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

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.