DETAILS OF MUMBAI – PUNE – SOLAPUR PIPELINE

Mumbai–Pune –Solapur Pipeline (MPPL) is HPCL's cross-country pipeline designed to transport

petroleum products like HSD, SKO & MS. The pipeline originates from Trombay, near HPCL
Refinery and traverses through seven districts viz. Mumbai, Thane, Raigad, Pune, Satara, Sangli
and Solapur. The pipeline is of 508 Kms length with 7 Pumping / Pumping cum receiving /
Receiving stations, 5 MOV stations and 9 Sectionalizing Valve stations.

The pipeline is protected against external corrosion by cold applied tape coating & impressed
current cathodic protection system. Protection against Internal corrosion is through injection of
corrosion inhibitor.

Details of sections to be surveyed are as follows

Loni – H’wadi section

Length : 183 KM
Size : 14 inch OD(6.4/9.5 mm WT)
Material : API 5 LX 56.
Coating : PE coating

HAZARWADI –PAKNI section

Length : 162 KM
Size : 12.75inch OD(6.4/8.7 mm WT)
Coating : PE coating
Material : API 5 LX 52

Details of CP stations and IJs

Sr. No. CP Station Location Chainage ( Km )

1 Loni Station 161.0 IJ (2 nos)

2 SV-1 185.2
3 SV-2 222.1
4 SV-3 260.2
5 SV-4 287.6
6 SV-5 325.2
7 Hazarwadi 346.0 IJ (2 nos)
8 SV-6 372.3
9 SV-7 (Hatid) 411.2
10 SV-8 (Wadhegaon) 443.0
11 SV-9 476.0
12 Pakni 508.2 IJ

Test stations are provided at a distance of approx.1.5 kms all along the pipeline route and at all
canal/road/rail/river crossings.

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 SCOPE OF JOB & TECHNICAL SPECIFICATIONS

“CLOSE INTERVAL POTENTIAL LOGGING (CIPL), CURRENT ATTENUATION TEST (CAT)

SURVEYS OF HPCL’S MUMBAI – PUNE – SOLAPUR PIPELINE. ”

M/s HPCL intends to carry out CIPL survey to assess the effectiveness of CP system of the
pipeline, and CAT / DCVG survey to assess the condition of the pipeline coating of Mumbai –
Pune – Solapur Pipeline. Length of the pipeline sections that needs to be surveyed are per the
tender schedule of quantities.

1. Main objectives of CIPL survey :

1.1. To know the effectiveness of C.P. system.

1.2. To identify Anodic and Cathodic regions of the Pipeline, as existing.

1.3. To study, whether the entire pipeline is cathodically protected.

1.4. To study the interference effect due to Tractions/Transmission lines & foreign
pipelines etc., and to provide mitigation measures for the same.

2. Main objectives of CAT survey:

2.1. To identity of pipeline sections where coating is good and bad

2.2. To pinpoint coating defect in pipeline sections where coating is bad with Use of ‘PCM’
A frame equipment

2.3. To give accurate coating defect locations for future coating repairs

2.4. To size the defects by standard method.

2.5. Classify defects as Anodic or Cathodic

3. CIPL SURVEY :

3.1. CIPL Survey spacing shall be at every 1 meter interval.

3.2. The Vendor shall use a standard make ‘MC MILLER’ or equivalent Microprocessor
based CIPL survey equipment Which is capable of taking CIPL and side gradient
simultaneously ie. the data logger shall have one channel of recording line half cell
reading and and another independent channel for recording lateral half cell reading.
Alternatively two single channel instruments may be used. Instrument shall be with
valid calibration. If calibration error exists and it cannot be adjusted in the instrument,
the error shall be duly taken care in final report generation / Documentation / CIPL
data graphs.

3.3. Party shall have master / standard reference cell at camp office for daily calibration of
half cells at site with calibration certificate. If calibration error exists and it can- not be
adjusted in the CIPL survey instrument, the error shall be duly taken care in final
report generation/Documentation/CIPL data graphs.

3.4. Half cells used for the day to day survey shall be reconditioned with fresh CuSO4
solution at least once in a week and checked with the standard reference cell.

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 SCOPE OF JOB & TECHNICAL SPECIFICATIONS

3.5. Data logger shall have downloading facility and shall have sufficiently high sampling
rate to Pick up PSP-OFF in 1 second duration.

3.6. A synchronization test shall be conducted lasting for 48 hours duration to check that
the timers stay in sync without error that shall subvert the purpose of the survey. This
test may be repeated at HPCL discretion thrice (at Loni, Hazarwadi and Pakni) during
survey period or anytime a new timer need to be introduced, if any timer is found
faulty at any point of survey

3.7. The survey shall be conducted with minimum 2 Sec OFF and 8 Sec ON
synchronization periods for the purpose of recording PSP-OFF and PSP-ON. Vendor
may choose at his discretion a higher ratio only upon specific permission from HPCL.
A lower ratio/timing shall not be accepted.

3.8. The surveyor for the purpose of survey is expected to stand still for duration longer
then PSP-OFF/ON cycle period after commencing the reading recording in
microprocessor based instrument at every 1 meter survey spacing.

3.9. The vendor shall use a Pipe locator, which can function with CP Station currents ON.

3.10. Pipeline alignment shall be fixed by pipeline locator at regular intervals not more than
5 meters apart, for accurate over the line survey. Both peak and null modes of
pipeline identification shall be used for accurate pipeline alignment fixation. A Rope
line shall be laid on the alignment which shall have knots at every 1 meter interval for
doing the CPL readings at 1 mtr interval.

3.11. Vendor shall download data into the PC / laptop on daily basis for analyzing
suspected Anodic locations and showing the anodic locations to HPCL engineer-in-
charge.
3.12. Vendor shall keep log of Daily calibration of reference electrodes, TR unit/ CPPSM
parameters, last recorded PSP values check before start of survey.

3.13. For the purpose of the CIPL survey results analysis the limits of PSP - ON potential
with respect CuCuSo4 (Half cell) shall be within the range – 0.95V & -1.50 V.

3.14. For the purpose of the CIPL survey results analysis the limits of PSP - OFF potential
shall be between –0.95V & -1.2V.

3.15. Abrupt Dip (potential drop) in both ON & OFF PSP values at any particular point
should be recorded with location coordinates.

3.16. At River crossings / water crossings, PSP shall be measured with reference to
Silver / Silver chloride or any other standard reference half cell, where ever
measurement by Cu/ CuSo4 is not practical. However the Cu / CuSo4 half-cell
should be recalibrated after completion of every submerged/under water survey.

3.17. The contractor has to organize for his own interrupters / switching devices (if required)
for putting ON and OFF of CP power supply units and TR / CPPSM units. CP system
can be switched OFF for a maximum of 8 to 10 HRS. Only during the daytime while
carrying out the survey. The CP system must be switched ON after survey work is
completed for the day. The switching ON / OFF of CP system shall be strictly adhered
to without fail by the contractor and all transportation of men and materials on this
account has to be arranged by the vendor.

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3.18. The CP system shall be switched OFF/ON only for the pipeline section from one
Insulation joint to another Insulation joint.

3.19. The progress and data report shall be submitted to HPCL on weekly basis. The daily
records shall get verified / signed by HPCL representatives on daily basis.

3.20. Analysis of the recorded data and submission of reports with necessary
recommendations and remedial measures shall be as per the following :

- ON/OFF potentials, side gradient potentials graphically and tabular Plotted with
respect to Pipeline chainage starting from Chainage 0km at Trombay dispatch
station.

- Physical route features like TLP locations/KM posts/Road crossings etc.

- C.P. power supply parameters

- Location of under protected pipeline sections

- Location of over protected pipeline sections

3.21. The calibration check of the equipment / instruments at a periodic interval

- Reference electrodes before start of survey - Daily

- Output voltage and current at ICCP stations - At least
once in two days
- Synchronization of current interrupter timers -At least once in
Two days
- Re-confirmation of PSP at the starting point to
Continue the survey - Daily
- Data transfer to the computer for - Daily

3.22. Data analysis for identifying Zones of under protection & over protection

3.23. Submission of the final report shall be in the form of 4 sets of hard copy in a
bound form along with 4 sets of CD’s. The final submitted report shall consist of data
generated by data recorder in tabular and graphical form (for PSPs, coating integrity
etc.) and analysis report and recommendations by the contractor.

3.24. Zinc grounding cells are provided along MPSPL with Spark gap surge diverter in
series, for the purpose of mitigating the AC interference. For the purpose of survey
same shall generally be not disconnected as spark gap surge diverter keeps the Zinc
grounding cells decoupled during normal course survey excepting when Short term
interference occurs for duration of 1 sec (approx).

4. CAT SURVEY :

4.1. Vendor shall carryout Pipeline current mapping followed by A frame survey at pipeline
sections where coating is suspected to be damaged. Vendor shall also make coating
defect co-ordinates drawing for subsequent coating repairs.

4.2. The survey need to be carried out by the Instrument “Pipeline Current Mapper” of M/s
Radio detection, U.K. (OR) any other equivalent equipment.

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4.3. The method and procedure of survey shall be mutually accepted by contractor and
HPCL inline with Equipment manufacturer’s operating instructions but as minimum
shall involve the following activities.

4.4. The survey along the pipeline should be carried out after duly identifying the pipeline
alignment using the instrument’s peak and null modes of operation. The pipeline
alignment should be identified using temporary markers, at defined distance intervals.
This shall facilitate retracing back high current attenuation locations for PCM-’A’ frame
survey.

4.5. Distance of survey traverse - survey Chainage shall be accurately measured with
tape for accurate demarcation of the coating fault. The same shall be re matched with
Pipeline marker Chainage /TLP Chainage, at regular intervals to avoid accumulation
of error of measurement.

4.6. The current mapping/depth measurement shall be done at an interval of 50 meters

4.7. The contractor has to arrange for field computer for downloading data from the
instrument.

4.8. Field data analysis should be done at every 500 - 1000 meter interval to identify
places of high current attenuation, by plotting Pipeline Map current v/s Distance on
graph sheets / Field computer for immediate on site review to undertake the PCM/’A’
frame survey at close intervals.

4.9. In sections of high current attenuation, current mapping at closer intervals using the
PCM and accessory ‘A’ frame should be done to demarcate the coating damages and
pipeline shorts accurately and precisely.

4.10. Accurate location identification drawings should be prepared for each and every
coating fault located with suitable survey equipment and permanent markers available
around that area for subsequent coating repair activity along with details of nearest
pipeline marker/TLP and Chainage. Prior approval from HPCL should be taken for a
typical location identification drawing.

4.11. The CP system shall be switched off for pipeline sections from one Insulation Joint to
insulation Joint for the purpose of the survey.

4.12. The progress and data report shall be submitted to HPCL on weekly basis

4.13. After PCM survey of every 500 meter interval and identification of suspected sections
of coating damage, the field data report shall be submitted to HPCL for approval
before proceeding ahead with accurate identification of coating damage location. The
field data report submitted shall consist of data generated by PCM in tabular and
graphical form as part of field data analysis by contractor for conducting PCM / ‘A’
frame survey at closer intervals.

4.14. All coating defects shall be peg marked on surface using temporary markers

4.15. The final report documentation of PCM survey as a minimum shall involve the
following:

- Each PCM transmitter setup shall have its unique serial no. along with the
Pipeline current measured for easy identification. The serial no. shall be
uniquely identified for each IJ-IJ section. For example A-1 shall indicate the first
PCM transmitter setup in the first IJ-IJ section.

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- System conditions: shall indicate the CP stations that were switched off, Date
of survey, PCM transmitter power source details like set current and mode of
operation and location of PCM transmitter.

- Results of survey: Shall indicate Survey Chainage, Pipeline Chainage, Map

current, Depth and Remarks column which shall indicate the pipeline features
like TLP/KM marker/Road/Canal/River/Power line crossings etc.

- Graph: Shall indicate as a minimum Pipeline current with respect to survey

Chainage and Pipeline Chainage

- PCM - ‘A’ survey: shall have unique serial no.of PCM Transmitter setup, Pipe
current measured along with Chainage on either side of the Fault/ ‘A’ frame
survey location, Exact fault Chainage, Fault dB along the pipeline &
perpendicular to the pipeline and percentage loss of Pipeline current loss in the
section where Fault is detected/’A’ frame survey was done

- Summary of survey: shall consist of comments of coating condition along the

pipeline for each PCM transmitter section.

5. SURVEY VALIDATION

The contractor shall arrange for excavation at 10 nos of random coating defect
locations decided by HPCL, along the pipeline length to verify the survey results as per
Engineer-in-charge’s direction. If the results of the survey were found not matching with
the actual pipe coating condition, at 80% of trial excavation locations, then the
contractor has to re-carry out the survey of that section of the pipeline and reverify
the coating condition at no extra cost.

6. CAT/PCM survey need not be conducted in streams/rivers/canals where flowing water

makes it difficult to conduct the survey.

7. REPORTS

Final report shall be submitted in the form of 4 sets of hard copies in bound form along
with 4 CD’s for CIPL, CAT/PCM surveys.

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 SPECIAL TERMS & CONDITIONS

1. Special Conditions of Contract shall be read in conjunction with the General

Conditions of Contract, Scope and Technical specifications of work and any other
document forming part of this contract wherever the context so requires.

2. The contractor will depute only experienced and competent personnel on this job.
Experience certificates of the personnel shall be submitted along with the bid

3. Party shall submit technical brochure of the Survey, Survey Equipment, Model no. And Job
completion time schedule along with the bid. HPCL will review the method, equipment to be
used for survey and format of report. The changes suggested by HPCL shall be binding on
the contractor.

4. Mock Test: Party should demonstrate the use / performance of survey equipment at one of
the sites as per owner’s instruction at the cost of bidders to ascertain the integrity of the
equipment and survey team. During mock test (CIP/CAT survey) all documents like
purchase papers, data sheet formats etc are required to be submitted.

5. In the CIP Mock survey party shall demonstrate the synchronization of the data-logger with
the on/off cycle of the TR units / CPPSMs

6. All the above exercise to be carried out during review and accordingly HPCL will carry out
of technical evaluation of the bids.

7. All men, material, equipment, tools & tackles required for carrying out the surveys,
transportation to worksite, boarding and lodging is in the scope of contractor.

8. Clearing of survey route along the pipeline shall be carried out by contractor to suit his
requirements.

9. Party has to take necessary measures so that any external disturbance in the congested
areas or near overhead HT lines does not affect determining the exact location /defect in
the pipeline. If not satisfied with the outcome of survey at any particular section, party has
to re do the survey of particular section till satisfactory results are obtained.

10. Party shall be whole responsible for safety and protection of all their equipment deployed
for the survey at site.

11. The entire job shall be carried out in the presence of HPCL’s representative. Survey
progress and coating defects observed shall be reported to Officer-In-Charge HPCL, on
daily basis. Party has to make daily reports with all the data obtained, distance covered and
sketches.

12. Any damage done knowingly or unknowingly to Pipeline / its CP system etc. shall be made
good by the contractor without any cost and time Implications to HPCL.

13. After completion of survey and identification of suspected sections of coating defects,
preliminary report shall be submitted to HPCL for approval. Report shall consist of data
generated in tabular and graphical form and analysis of report by the contractor.

14. If so decided by HPCL, the contractor shall carry out the survey in selected sections on
priority over other sections.

15. Deviation List : Any deviation from the “scope of job” shall be clearly indicated by vendor in
separate “deviation list”.

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 SPECIAL TERMS & CONDITIONS

16. Quantities mentioned in the tender enquiry are approximate and payment shall be made as
per actual measurement and as certified by HPCL’s representative/site engineer.

17. Job Completion Period: Time is the essence of this contract.

17.1. The job shall be commenced / the contractor shall mobilize at site within 4 weeks
(mobilization period) from the date of receipt of FOI/PO.

17.2. The job shall be completed within 4 months including the mobilization period, from
date of receipt of FOI/PO. Vendor is required to mobilize the required number of
teams to complete the job within this period.

18. PAYMENT TERMS: Payment shall be released in the following stages for respective
surveys

Payment stage CIPL CAT

Completion of Survey 40% 30%
Preliminary report & Survey
Not Applicable 20%
Validation
Final Survey report 60% 50%

19. A maximum of 4 Running bills @ 1 running bill per month + 1 final bill shall be allowed.

20. Vendor cannot subcontract or sublet any part of the contract to any third party and sub
contracting is strictly not allowed.

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