Construction Equipment Requirements for 01 Pipeline Construction Spread (42" dia)
Construction
Equipment Requirements for 01 Construction Spread
to Achieve an
Anticipated Pipeline (42ӯ) Laying Progress of
01 Km per day
Kindly find detailed as under the requirement of machinery for carrying out various phases of pipeline construction activity mentioned against each
ROW Grading
·
01
No. Track Type Tractor D7 with LGP (Low Ground
Pressure) Track will be required for ROW clearance in water logged areas.
·
01 No. Track Type
Tractor D8 for ROW clearance.
·
01 No. Pick Up 4x4
Double Cabin to be used by the ROW Supervisor, Surveyors and for transportation
of ROW Markers.
·
01 No. Van 12-15 Seater
to be used by Dozer Operators and ROW crew.
·
01 No. Track Type
Tractor D9 for clearance / grading of sand dunes on the ROW. It is worth
mentioning here that shifting sand dunes of upto 150 ft height were observed on
the proposed ROW during an earlier pipeline laying operation.
Line Pipe Stringing
·
01
No. Crawler Crane (30-40 Tons) is to be used for
Loading Unloading of Line Pipe in the Pipeyard. Such a machine can be used for
Piling Work of overhead crossings as well.
·
06 No. Primemovers (6x4)
will be used for shifting of at least 05 No. 42” dia line pipes per trip. For
stringing of 1 km of Line Pipe a total of 17 trips will be required by such a crew
which works out to be 03 trips per Primemover. It is to be noted that Line Pipe
Stringing in certain desert and water logged areas is preceded by a towing operation
of upto 06 hours.
·
06 No. High Bed Semi
Trailers are to be hooked with above mentioned Primemovers.
·
01 No. Pipelayer 60 Ton
– 583 is to be used for line pipe stringing as well as towing loaded trailers
in desert and water logged areas on the ROW
·
01 No. Pick Up 4x4
Double Cabin for Stringing Supervisor and Pipelayer operators
·
01 No. Self Loader Truck
Crane 4x4 4 Tons is to be utilized for placing culvert pipes on ROW in
cultivated areas.
Main Line Welding
·
01
No. Mechanized Welding System Arrangement – Complete.
·
02
No. Welding Plants - Single Holder will be used for end
facing of line pipe and wire brush operation and are deployed at the forefront
of Mainline Welding Crew.
·
02 No. Pipelayers 40 Ton
– 572 are to be used for Line Pipe Handling, Removing Wooden Skids
·
01 No. Tong Clamp
42" dia is to be used for Line Pipe Handling
·
01 No. Internal
Pneumatic Clamp 42" dia is to be used during Root Pass phase of Main Line
welding.
·
01 No. Air Compressor 30
CFM 15-20 BAR is to be used for operating Internal Pneumatic Clamp
·
01 No. Bus 46 Seater will
be employed for moving Main Line Welding crew.
·
01 No. Coaster 23 Seater
will be used for transportation of labour.
·
01 No. Van 12-15 Seater will
be used for welders.
·
01
No. Pick Up 4x4 Double Cabin will be used by the Welding
Supervisor
·
01 No. Pick Up 4x4
Single Cabin will be used by the Welding Supervisor as well as for moving LPG
Cylinders employed for Pre Heating.
·
01 No. Truck 4x4 will be
used for handling and shifting of wooden skids, internal pneumatic line up
clamp, tong clamp (a farm tractor with trolley can also be used for the
purpose)
·
01 No. Farm Tractor will
be used for towing Single Holder Welding Plants which are moving in front of
the Main Line Welding Crew.
Air Pigging / Air Soap Testing
·
01
No. Air Compressor 1000 - 1300 CFM 25-30 BAR will be
used for PIGGING and Air Soap Testing (100 PSIG) of pipeline segments
containing more than 10 line pipes.
·
01
No. Welding Plant - Single Holder will be used for
welding Bull Plugs.
·
01 No. Farm Tractor will
be used for towing the Air Compressor / welding plant to the next testing point.
(the Pipelayer / 4x4 Truck of Mainline Welding Crew
will be used for handling the PIG i.e., Pipeline Internal Gauge)
Coat & Wrap / Sleeving
·
02
No. Air Compressors 400 CFM 10 BAR will be used by 02
Coat & Wrap Teams to Sand Blast the weld joints before application of HSS
i.e., Heat Shirk Sleeves.
·
02 No. Trucks 4x4 will
be used by 02 Coat & Wrap Teams for transportation of above mentioned Air
Compressors as well as the Sand Blasting arrangement, LPG Cylinders and extra
slag to be employed for cleaning operation.
·
02 No. Coasters 23
Seater will be used for transportation of 02 Coat & Wrap teams to the site
from camp.
·
01 No. Pick Up 4x4
Double Cabin will be used for Coat & Wrap Supervisor and Operators.
·
01 No. Truck Mounted
Water Bowser 4x4 will be used for water spray on the ROW to suppress dust.
Trenching / Lowering / Backfilling
·
03
No. Crawler Excavators 25 Tons will be used for
Trenching Operation.
·
01 No. Crawler Excavator
25 Tons will be used for Backfilling of trench after lowering the welded
pipeline.
·
02 No. Pipelayers 60 Ton
583 will be used for Pipeline Lowering in the trench.
·
01 No. Pipelayer 80-100
Ton 587 will be used Pipeline Lowering in the trench.
·
01 No. Van 12-15 Seater will
be used for transportation of Machine Operators and Lowering Staff.
(Coat & Wrap / Sleeving Supervisor will look
after the Trenching / Lowering / Backfilling operation as well)
Tie ins / Crossings
(No. of Tie in crews is entirely
dependant on the quantity and category of Crossings as well as Horizontal Bends
encountered on the ROW. More Crews are recommended if there are a lot of
crossings on the planned ROW)
·
02
No. Welding Plants - Twin Holder will be used by 02
Teams of Tie ins Crossings.
·
02 No. Welding Plants -
Single Holder will be used for 02 Teams of Tie ins / Crossings for Line Pipe
end facing and wire brush operation.
·
02 No. External Clamps
42" dia with Hydraulic Jacks will be used by 02 Teams of Tie ins /
Crossings for lining up the pipe faces.
·
02 No. Pick Ups 4x4
Double Cabin will be used for transportation of 02 Supervisors and Welders of 02
Teams of Tie ins Crossings
·
02 No. Vans 12-15 Seater
will be used for transportation of 02 Teams of Tie ins / Crossings.
·
04 No. Pipelayers 60 Ton
– 583 will be used by 02 Teams of Tie ins / Crossings for handling the welded
pipe.
·
02 No. Crawler Excavators
25 Tons will be used by 02 Teams of Tie ins / Crossings for clearance of
trench.
·
02 No. Trucks 4x4 will
be used by 02 Teams of Tie ins / Crossings for shifting of tools, wooden skids,
LPG Cylinders etc.)
·
01 No. Crawler Excavator
30 Tons will be used by both the Tie ins / Crossings teams for tougher Tie ins)
Fabrication of Vas
(No. of Fabrication Welding crews is
entirely dependant on the quantum of work involved. More teams will be required
if Spool Fabrication of Compressor Stations and Modification of existing Valve
Assemblies is involved.)
·
02
No. Welding Plants - Twin Holder will be used by 02
Fabrication Teams.
·
02 No. Welding Plants - Single
Holder will be used by 02 Teams for end facing of line pipe, tacking of spools
and wire brushing operation.
·
02 No. External Clamps
42" dia with Hydraulic Jacks will be used by 02 Fabrication Teams.
·
02 No. Pick Ups 4x4
Double Cabin will be used for transportation of Supervisors and Welders of both
the teams.
·
02 No. Vans 12-15 Seater
will be used for transportation of 02 Fabrication Teams
·
02 No. Self Loader Truck
Cranes 6x4 8 Tons will be used by 02 Fabrication Teams for shifting / handling
of fittings / spools, wooden skids and welding plants from fabrication yard to
site locations.
Hydrostatic Testing
·
01
No. Centrifugal Pump will be used for filling of a
welded pipeline segment with water.
·
01
No. Reciprocating / Triplex Testing Pump will be used
for pressurizing the welded pipeline segment for Yo-Yo and 24 Hours Hold Up
Test.
·
01
No. Pick Up 4x4 Double Cabin will be used for
transportation of Testing Supervisor, Staff as well as for PIG Tracking on the
ROW.
·
01 No. Welding Plant -
Single Holder will be used for welding of filling / drain lines as well as for lighting
arrangement on the Testing Point
(Air Compressor 1000 - 1300 CFM 25-30 BAR as
mentioned above will be used for Flushing Operation, Foam Pigging as well)
Civil Works
(more resources will be
required in case civil works on the compressor stations are to be carried out
by Projects)
·
03
No. Concrete Mixer Machines
·
01
No. Pick Up 4x4 Double Cabin will be used for transporting
the Civil Supervisor and Staff
·
01 No. Truck 4x4 will be
used for shifting of civil material and Mixer Machines to the sites
Workshop
·
01
No. Mobile Workshop Truck 4x4 will be used for
onsite maintenance of construction equipment
·
01 No. Pick Up 4x4
Double Cabin will be used by the Workshop Incharge and Workshop Supervisor for
attending out of order machinery onsite.
·
01 No. Pick Up 4x4
Single Cabin will be used by the Maintenance Supervisor and Mechanics to attend
out of order machinery.
·
02 No, Primemovers (6x4)
will be used for shifting / relocation of construction equipment.
·
02 No. Low Bed Semi
Trailers will be used hooked to the said Primemovers for shifting / relocation of
construction equipment.
·
02 No. High Bed Semi
Trailers at least 11 ft wide will be hooked to the above mentioned Primemovers
for Line Pipe Stringing when no shifting of construction equipment is underway.
Camp Setup
·
01
No. Power Generator 200 - 250 kVA will be used for
electricity supply to the residential area / offices in the camp.
·
02 No. Mobile Hydraulic
Crane 6x4 20 Tons will be used for shifting / handling of fittings / spools / field
bends / welding plants / thrust boring machine / boring augers / air
compressors / testing pumps from fabrication yard / camp to site locations.
·
01 No. Pick Up 4x4
Double Cabin will be used for site visits of EIC
·
02 No. Pick Ups 4x4
Double Cabin will be used for supervision of construction activities by 02 Site
Engineers.
·
01 No. Pick Up 4x4
Double Cabin will be used by Accounts / Land Acquisition Staff for processing /
dispersing payments.
·
01 No. Pick Up 4x2
Double Cabin will be used by the Admin Officer and his Staff based in the camp.
·
01 No. Pick Up 4x2
Double Cabin will be used by the Store / Audit Officers and their Staff
·
01 No. Pick Up 4x2
Single Cabin will be used for Purchase Duty
·
01 No. Ambulance will be
used in case of emergencies
·
01 No. Truck Mounted
Fuel Bowser 4x4 will be used for dispensing fuel
Specialized Equipment
(this specialized
equipment will be used by All the Construction Spreads working on the project)
·
01 No. Rough Terrain Hydraulic Crane 4x4 25 - 30 Tons will be used for shifting / handling of fittings / spools / field bends /
welding plants / thrust boring machine / boring augers / air compressors /
testing pumps from fabrication yard / camp to site locations.
·
01 No. Thrust Boring Machine 48" - 56"
dia with tracks and Boring Augers.
·
01 No. Pipe Bending Machine 42" - 56" dia (to be procured if the No.
and cost of factory bends required is more than the cost of this machine)
·
01 No. Air Compressor Booster, 1000 PSIG for resolving PIGGING issues.
·
01 Trencher with Side
Cutters to avoid collapsing during operation in water logged, desert areas.
However, it is worth mentioning here that this machine is very expensive and a
backfiller and a crawler excavator will still be required translating in to
more cost for completing the trenching and backfilling operation. On the other
hand, approximately 15 Crawler Excavators 25 Tons can be procured in place of
this machine. Doing so will mitigate the breakdown issues as well.
·
01 No. Backfiller for backfilling operation after lowering of welded pipeline.
·
01 No. Wheel Loader for loading the dump truck with sand / mud if construction
activity involves work in Rock Terrain.
02 No. Dump Trucks, 6x4 for unloading
sand / mud along the trench in Rocky Terrain before backfilling.
