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CHENNAI METROPOLITAN WATER SUPPLY AND

SEWERAGE BOARD

NATIONAL COMPETITIVE BIDDING (NCB)

CON No: CNT/SEW/NCB/TNUDP/039/2015-16

Design, Build and Operate (DBO) of 45 MLD Capacity Tertiary Treatment


Reverse Osmosis (TTRO) Plant at Kodungaiyur including Supply and
laying DI Transmission mains for conveyance of Product water to various
industries in Manali area, Chennai, Tamil Nadu, India

VOLUME II
TECHNICAL SPECIFICATION
Schedule9
TECHNICAL SPECIFICATIONS FOR CONSTRUCTION AND
OPERATION AND MAINTENANCE PHASE1

TO Design, Build and Operate (DBO) of 45 MLD Capacity Tertiary Treatment Reverse Osmosis
(TTRO) Plant at Kodungaiyur including Supply and laying DI Transmission mains for conveyance of
Product water to various industries in Manali area, Chennai, Tamil Nadu, India

1
Specifications pertaining to general civil works and the material requirements have been specified herewith. However the
specifications and the testing requirements shall be specified in accordance with the technology being selected by the
bidder and the detailed design submitted.
GENERAL

Chennai Metropolitan Water Supply and Sewerage Board (CMWSSB) has Sewage treatment plants in
Kodungaiyur, Koyambedu, Nesapakkam and Perungudi. The total capacity of these plants at present is 612
MLD and available as a source for alternate use. CMWSSB intend to install a 45 MLD capacity Tertiary
Treatment Reverse Osmosis Plant (TTROP) at Kodungaiyur, Chennai city, Tamilnadu, India in order to supply
the Tertiary treated water to the Industries in North Chennai. CMWSSB plans to reuse the sewage generated in
the city for Industrial applications thereby reducing the fresh water consumption by the industries operating in
the vicinity of the Chennai metro since there is no alternative reliable source of fresh water adjacent to the city.
This will provide a sustainable water source to the industry in the long run due to recycling of municipal waste
generated. At present CMWSSB is operating three STPs of capacities 80mld,80mld and 110mld at
Kodungaiyur. For the proposed TTRO plant it is proposed to utilize the secondary treated effluent of the
110mld STP. The 110mld STP was commissioned in August 2006 and is based on the conventional Activated
Sludge Process. Sewage in Kodungaiyur 110mld treatment plant undergoes Primary and secondary treatment.
The raw domestic sewage collected by the various sewage pumping stations are received in the Inlet chamber.
From the inlet chamber, the sewage is screened through Mechanical / Manual screens and taken to Detritors for
removal of sand etc. After detritors, the flow through Parshall flume reaches Primary clarifier, where settling
takes place and thereby about 60% of suspended solids and about 30% BOD are removed in the form of
Primary sludge. The overflow of Primary clarifiers are taken to Aeration tank, where surface aerators are used
for aeration of Mixed Liquor Suspended Solids (MLSS). The aeration tank has been designed for a hydraulic
detention time of 5 hours as a complete mix activated sludge plant. After aeration, the effluent is taken to
Secondary clarifiers for settling. Overflow from secondary clarifiers is let in to maturation pond (having a
detention time of 3 days) for reduction of coliforms before let into nearby Buckingham canal. A part of
secondary sludge from the secondary clarifiers are taken to Aeration tank as Activated sludge and the excess
sludge along with the Primary sludge are taken to Sludge thickener for thickening and then taken to Sludge
digesters (having a detention time of 15 days) for digestion. The sludge from digesters are taken to Centrifuges
for thickening and then disposed off in the form of landfill. The bio-gas produced during the digestion process,
after H2S scrubbing is taken to Bio-gas engines for production of power and is utilised to run the various units
of STP. About 80% to 85% of STPs power requirement are met from the Bio-gas power. The existing 110mld
STP is operating on Activated Sludge process based systems and designed for removal of Carbonaceous BOD
only and does not have integrated biological nutrient removal section as part of them. From the existing
110mld STPs Maturation pond, the Operator can draw about 65.3mld of Secondary treated effluent (at free of
cost) so as to produce, pump and transmit 45mld TTRO water.

The 45 MLD capacity TTRO plant to produce 45 MLD of tertiary treated Product water from about 65.3 MLD
secondary treated effluent supplied by the Owner, is to be Designed, Build, Tested, Commissioned and
Operated and Maintained for a total period of 15 years by the Operator. Operator shall comply with the
guidelines contained in Manual on Sewerage and Sewage Treatment Latest Edition published by the Central
Public Health & Environmental Engineering Organization (CPHEEO), Ministry of Urban Development,
Government of India. The Operator shall provide the basis and authority wherever CPHEEO guidelines are not
available. The Technical Standards and Specifications contained in this contract shall be read along with the
following standard specifications (latest versions) published by the Bureau of Indian Standard listed below:

The list is not exclusive and the operator shall be responsible to follow the appropriate standards:
i) IS 6280 1971 Sewage Screens

ii) IS 8413 1982 Biological Treatment Equipment Part II and its modifications

iii) IS 10037 Part I 1981 & Part II & III 1983 Sludge dewatering equipment

iv) IS 10261 Requirements for settling tank for waste water

v) IS 105533 Part I, II, III Chlorination Plants

vi) IS 5600 1970 - Sewage and Drainage Pumps

vii) IS 6279 1971 Grit Removal devices

Documents Comprising the Technical Standards Appendix


The Technical Standards Appendix consists of Technical Specification to be followed for during Construction
of Tertiary treatment Plant including Product water transmission main and other ancillary/ allied works for all
Civil, Mechanical, Electrical, Instrumentation required to be executed under this Contract. Notwithstanding to
the said specification, the bidder is instructed to adopt and follow necessary standard and approved Codes
/specification wherever required for fulfillment of all the works under this contract.

Supplementing the General Conditions and Design-Build or Operating Services Appendix

The Technical Standards Appendix shall be read along with the GCC / SCC and Design-Build and Operations
Services Appendices for the purpose of providing greater specificity of the technical standards which the
Bidder is required to meet.

Design-Build or Operations Services Appendix Description

The descriptions contained in the Technical Standards Appendix Chart entitled, Description of Service are
for the convenience of the Bidder and do not supersede the actual wording of the Design-Build and Operations
Services Appendices.

General Quality Standards

The term General Quality Standard means a standard of performance which,

(a) is competent, efficient, economical and in accordance with internationally accepted techniques
used in the sewage disposal and civil works construction industries;

(b) is in accordance with professional engineering, accounting and consulting standards, as


applicable, recognized by national or international professional bodies;

(c) is in accordance with sound management, commercial, technical, design and engineering
practices;

(d) employs appropriate technology and safe and effective equipment, machinery and methods;

(e) is in accordance with national and local standards and codes in the Owners Country;
(f) protects the interests of the Authorities;

(g) is in accordance with the Applicable Law;

(h) is in accordance with the technical specifications and design standards of the Owner as provided
to the Bidder;

(i) is in accordance with the applicable Environmental Assessment and Environmental Management
and Mitigation Plan; and

(j) is in accordance with the Design-Build Documents as approved by the Owner.

In the event of any conflict or inconsistency between any standards that comprise the General Quality Standard,
local and national standards in the Owners Country shall prevail over international standards.

The Operator shall, at all times, carry out the Services in accordance with the Technical Standards as specified
and, where a specific technical standard of quality of performance has not been specified, the Bidder shall
perform the Services to the standard of General Quality Standards set out in Section 2.2(1) of the Technical
Standards Appendix.

If the Owner is subjected to fines or penalties as a result of the operators breach of these Technical Standards,
such fines or penalties shall be paid by the Bidder

Design-Build Services

In respect of the Design-Build Services, the operator shall ensure that the design of the TTRO Plant including
Product water transmission main is prepared by qualified designers who are professionally recognized to design
the TTRO Plant and allied services.

The Operator warrants that the operator and its designers have the experience and capability necessary for the
design.

The offers shall be based on the operators own design and operating philosophy which is to be based on the
selected modern treatment technologies and should be within the overall framework and guidelines specified in
the bid document and its specifications. The bidders design for the entire facility shall be such that the project
shall

Require minimum land space


Require minimum energy for treatment of secondary treated Product water

Planning of the entire system should be done in such a manner so as to optimize capital and operational costs of
treatment of secondary treated Product water and maintenance of the Plant including Product water
transmission main on whole on sustainable basis.
Section 1. CIVIL WORKS

1 Specific Civil/Structural Work Requirement

1.1 Design Submissions:


Complete detailed design /hydraulic calculations & drawings of foundations and superstructure together with
general arrangement drawings and explanatory sketches shall be submitted to the Owner. Separate calculations
for foundations or superstructures submitted independent of each other shall be deemed to be incomplete and
will not be accepted. Though no GA drawings of all units are required along with the bid, a schematic layout
/GAD shall be submitted along with the bid. The design considerations described herewith establish the
minimum basic requirements of plain and reinforcement concrete structures, masonry structures and structural
steel works. However, any particular structure shall be designed for the satisfactory performance of the
functions for which the same is being constructed. The Operator shall also take care to check the stability of
partly completed structures.

1.2 Design Standards


All designs shall be based on the latest International or Indian Standard (IS) Specifications or Codes of
Practice. The design standards adopted shall follow the best modern engineering practice in the field based on
any other international standard or specialist literature subject to such standard reference or extract of such
literature in the English language being supplied to and approved by the Owner or Owners Representative. In
case of any variation or contradiction between the provision of the IS Standards or Code and the specifications
given with the submitted bid document, the provision given in the Specification shall be followed.

1.3 Design Loadings


All buildings and structures / underground structures shall be designed to resist the worst combination of the
following loads/stresses under test and working conditions these include dead load, live load, wind load,
seismic load, stresses due to temperature changes, shrinkage and creep in materials, dynamic loads and uplift
pressure.

i. Dead Load: This shall comprise all permanent construction including walls, floors, roofs, partitions,
stairways, fixed service equipment and other items of machinery. In estimating the loads of process
equipment all fixtures and attached piping shall be included, but excluding contents shall be considered.
The following minimum loads shall be considered in design of structures:

S.No Parameter Load

1 Weight of water 10.0 KN /m3

2 Weight of soil (irrespective of strata available at site and type of 20.0 KN/m3
soil used for filling etc.) However, for checking stability against
uplift, actual weight of soil as determined by field test shall be
considered

3 Weight of plain concrete 24.0 KN/m3

4 Weight of reinforced concrete 25.0 KN/m3

5 Weight of brickwork (exclusive of plaster) 22.0 KN/m3

6 Weight of plaster to masonry surface 18.0 KN/m3

7 Weight of granolithic terrazzo finish or rendering screed, etc. 24.0 KN/m3

8 Weight of sand (filter media) 25.0 KN/m3

ii. Live Load: Live loads shall be in general as per IS 875. However, the following minimum loads shall be
considered in the design of structures.

S.No Location Live Load

1 Floor supporting Pumping Machinery 1000 kg/sq.m

2 Storage, Maintenance Bay, Air Blower 750 kg/sq.m

3 Platform, Staircase, Corridors, Walkways 500 kg/sq.m

4 Toilet 200 kg/sq.m

5 Roof Slab 150 kg/sq.m

In the absence of any suitable provisions for live loads in IS Codes or as given above for any particular type of
floor or structure, assumptions made must receive the approval of the Owners Representative prior to starting
the design work. Apart from the specified live loads or any other loads due to material stored any other
equipment load or possible overloading during maintenance or erection/construction shall be considered and
shall be partial or full whichever causes the most critical condition.

iii. Wind Load: Wind loads shall be as per IS: 875- 2002 Part-III.
iv. Dynamic Load: Dynamic loads due to working of plant items such as pumps, blowers, compressors,
switchgears, traveling cranes, etc. shall be considered in the design of structures.
v. Other Loads: In addition to earth pressure and water pressure etc., the surcharge of 1 Ton/sq.m shall be
taken into account in the design for channels, tanks, pit etc.
vi. Earthquake Load: This shall be computed as per IS: 1893 2000.

1.4 Joints
Movement joints such as expansion joints, complete contraction joints, partial contraction joints and sliding
joints shall be designed to suit the structure as per relevant IS code provisions. Expansion joints of suitable gap
at intervals not more than 30 m shall be provided in walls, floors and roof slabs of water retaining structures.

Construction joints shall be provided at right angles to the general direction of the member. The locations of
construction joints shall be decided on convenience of construction. To avoid segregation of concrete in walls,
horizontal construction joints are normally to be provided at every 2 m height, GI 18 gauge/PVC water stops of
suitable type and minimum 230 mm width, 6 mm thick shall be used for walls and base slabs.

1.5 Water Retaining Structures


Liquid retaining/conveying structures including the members covering the same (such as roof of a chamber,
channel etc.) shall be designed by uncracked method of design as per BIS: 3370 and 6494. Basement RC walls
and slabs below ground shall also be designed by uncracked method of design as liquid retaining structures.
Shear shall be checked by working stress method as per BIS: 456. Minimum temperature and shrinkage
reinforcement shall be 0.3% in each direction.

All underground or partly underground liquid containing structures shall be designed for the following
conditions:

Liquid depth up to full height of wall including free board: no relief due to soil pressure from outside to be
considered.
Structure empty (i.e. empty of liquid, any material, etc.) full earth pressure including saturated condition
and surcharge pressure wherever applicable to be considered.
Partition wall between dry sump and wet sump : to be designed for full liquid depth up to full height of
wall including free board.
Partition wall between two compartments : to be designed as one compartment empty and other full
including free board;
Structures shall be designed for uplift in empty conditions as per water table at the level of ( + ) 1.700m.
No reduction factor for the uplift force shall be considered.
The dead weight of the empty structures should provide a safety factor of not less than 1.2 against uplift
pressures during construction and in service.
Wall shall be designed under operating conditions to resist earthquake forces from earth pressure
mobilization and dynamic water loads;
Underground or partially underground structures shall be checked against stresses developed due to any
combination of full and empty compartments with appropriate ground/uplift pressures from below to base
slab. The design shall be such that the minimum gravity weight (empty conditions) exceeds the uplift
pressure at least by 20%.
For design purpose, sub soil water level is to be considered at the level of (+) 1.700m.

Pressure Release Valve: Use of pressure release valves to reduce uplift pressure due to ground water table
shall not be allowed.
1.6 Foundation
The minimum depth of foundations for all structures, equipments buildings and frame foundations and
load bearing walls shall be as per IS: 1094.
The earth fill above virgin ground level till formation level shall be taken as a surcharge load and shall be
added in the loads coming on foundations appropriately
Care shall be taken to avoid the foundations of adjacent buildings or structure foundations, either existing
or not within the scope of this Contract. Suitable adjustments in depth, location and sizes may have to be
made depending on site conditions. No extra claims for such adjustments shall be accepted by the Owner.
Special attention is drawn to danger of uplift being caused by the ground water table
Plinth level of all structures/top of tanks shall be at least (600) mm above formation level high flood level.

Where there is level difference between the natural ground level and the foundations of structure or floor
slab, this difference shall be filled up in the following ways:-

a) In case of non-liquid retaining structures the natural top soil shall be removed till a firm strata is reached
(minimum depth of soil removed shall be 500 mm) and the level difference shall be made up by compacted
back fill as per specifications. However the thickness of each layer shall not exceed 150 mm. The area of
backfilling for floor slabs shall be confined to prevent soil from slipping out during compaction.

b) In case of liquid retaining structures, the natural top soil shall be removed as described above and the
level difference shall be made up with Plain Cement Concrete of M-10 grade.

Wherever the plinth level is above the ground level, a curtain wall shall have to be provided from plinth
level upto 300 mm below ground level, but not less than 1m in total height.

If pile foundations are used, the contractor shall conduct the initial routine test as per IS 2911 at his own
cost, to determine the safe load bearing capacity of piles. For pile foundations, the piles shall be bored cast-
in-situ piles only. To verify the load carrying capacity of the piles a minimum of two initial load tests shall
be conducted and routine load tests as required as per the relevant BIS code shall also be conducted. Under
reamed piles shall not be allowed.

Pump foundations, foundation of the equipment liable to generate vibrations shall be isolated from the main
building. Foundations/structures are not to transmit vibrations to the adjacent areas. Where common raft
foundations for building and column and pump foundations are used, isolation joint shall be provided
around the pedestal of such equipment at finished floor level.

1.7 Design Requirements


The following are the design requirements for all reinforced or plain concrete structures:
All blinding and leveling concrete shall be minimum 100 mm thick in concrete grade M15 for Building &
150 mm thick in concrete grade M20 for Water Retaining Structures as per IS -3370 (Part- 1)-2009 latest
version.
All structural reinforced concrete shall be with a maximum 25 mm aggregate size for footings and base
slabs and with a maximum 20 mm aggregate size for all the Water Retaining Structures & other structural
members.
All liquid retaining structures shall be designed as per IS: 3370. The minimum grade of concrete shall be
M30.
All Buildings, Pipe Pedestals, Thrust Block, Pump Foundation & other structures shall be designed as per
IS-456. The minimum grade of concrete shall be M25.
The maximum free water cement ratio shall not exceed 0.5 for all liquid retaining structures.
The amount of reinforcement in each of the two directions at right angles within each surface zone should
not be less than the minimum specified as per IS:3370 or IS:456 whichever is applicable for the type of
structure.
Use of pressure relief valves to reduce uplift pressure due to ground water table shall not be allowed.
All buildings shall have a minimum 1.0 m wide, 100mm thick plinth protection paving in M15 grade
concrete or stone slabs/tiles. All plinth protection shall be supported on well-compacted strata.

All buildings shall be provided with damp proofing for basement and floors and water proofing for roofs as
specified in specific requirements.

Any structure or pipeline crossing below roads shall be designed for Class AA of IRC loading or as
classified by the respective authority. NP3 RCC pipe (with encasing) shall be used below roads inside the
plant.

All pipes and conduits laid below the structural units shall be embedded in reinforced concrete of grade M30
of minimum thickness 150 mm.

The following minimum thickness shall be used for different reinforced concrete members irrespective of
design thickness.

S.No Civil Member Width(mm)


1 Walls for liquid retaining structures (except S.no 5) 200
2 Base Slab of liquid retaining structures 350
3 Wall foundation (At Junction of Base Slab & Wall) of liquid retaining 400
structures
4 Roof Slab of liquid retaining structures 150
5 Walls of Launders, Channels 150
6 Base slab of Launders, Channels 125
7 Floor slabs including roof slabs, walkways canopy slabs 100
8 Walls of cables/pipe trenches, underground pits, etc. 125
9 Footing Edge Thickness 250
10 Footing At the Face of Column 450
11 Column 230 (width) 300
S.No Civil Member Width(mm)
(depth)
12 Parapets, Sunshades 100
13 Precast trench cover 75
14 Beam 230 (width) 300
(depth)

1.8 MINIMUM COVER TO MAIN REINFORCEMENT

S.No. Member Details Cover (mm)


1 Slab Free Face 20

Face in contact with earth 30

2 Beam Top /Bottom 40

Side 30

Face in contact with earth 40

3 Column and pedestal Super Structure 40

Face in contact with earth 40

4 Retaining wall, Basement and Pit wall Free side 30

Face in contact with earth 30

5 Liquid Retaining Structure Face in contact with liquid 40

Face in contact with earth 40

Free face 40

6 Foundation Bottom 60

Top 60

1.9 Minimum Bar Diameter

S.No Member Diameter (mm)


1 Major Foundation 10
2 Block Foundation Main Bars 8
3 Block Foundation Tie Bars 8
S.No Member Diameter (mm)
4 Minor Foundation (Local Foundation etc.) 8
5 Column, Pedestal Main Bars 12
6 Column, Pedestal Ties 8
7 Beam Main Bars 12
8 Beam Anchor Bars 10
9 Beam Stirrups 8
10 Slab Main Bars 8
11 Slab Distribution Bars 8
12 Wall Main Bars 10
13 Wall Distribution Bars 8
14 Minor elements such as chajjas, Lintel Beams etc. 8

1.10 Bar Spacing

Minimum Maximum
S.No Member
(mm) (mm)
1 Foundations 125 200
2 Slabs 100 300
3 Stirrups for Beams 100 300
4 Ties for Columns, Pedestals 100 300
5 Walls 100 300
Bar spacing shall be provided in multiple of 25 mm.
The design submitted by the operator shall be proof checked from the nearest IIT / Engineering college
(Approved by the competent authority), for which the scrutiny charges shall be borne by the operator. The
delay in checking designs by the third party as above shall be treated as the delay on the part of the operator for
operation of the tender clause.

2 MATERIALS IN GENERAL
The term materials shall mean all materials, goods and articles of every kind whether raw, processed or
manufactured and equipment and plant of every kind to be supplied by the Bidder for incorporation in the
Works.

Expect as may be otherwise specified for particular parts of the works the provision of clauses in Materials
and Workmanship shall apply to materials and workmanship for any part of the works. All materials shall be
new and of the kinds and qualities described in the Contract and shall be at least equal to approved samples.
As soon as practicable after receiving the order to commence the works, the Bidder shall inform the Owners
Representative of the names of the suppliers from whom he proposes to obtain any materials but he shall not
place any order without the approval of the Owners Representative which may be withheld until samples have
been submitted and satisfactorily tested. The Bidder shall thereafter keep the Owners Representative informed
of orders for and delivery dates of all materials.

Materials shall be transported handled and stored in such a manner as to prevent deterioration damage or
contamination failing which such damaged materials will be rejected and shall not be used on any part of the
Works under this contract.

2.1 Cement
The cement procured by the Operator shall comply with the requirements of IS 269/ 1976 with the latest
revision thereof for 33 grade ordinary portland cement and IS 12330/ 2001 for sulphate resistance cement, IS
8112/1989 with the latest revision thereof for 43 grade ordinary portland cement; IS: 12269-1987 with the
latest revision thereof for 53 grade ordinary Portland cement. Manufacturers Test Certificate shall have to be
furnished. Minimum cement consumption for RCC M20 shall be considered as 350 kg/cum and for RCC M25
shall be 380 kg/cum. mixing of fly ash in the concrete shall not be considered. Approved Manufacturers of
Cement of reputed firm with ISO certification shall be used

2.2 Reinforcement Steel


Reinforcement Steel shall confirm to BIS Specification 432-1966 (with up to date revision) and B.I.S.
Specification 1786-1985 (with up to date revision). All Reinforcement Steel will be as specified in Section 4
Concrete (mentioned elsewhere in this Bid document).

2.3 Minimum Cement Content


The minimum cement content for each grade of concrete shall be as per table below.

Minimum Cement Content in Concrete


S.No. Grade of Concrete
(Kg/m3 of finished concrete)
1 M15 240
2 M20 300

3 M25 300
4 M30 320
Please refer clause no. 8.2.4 Table no: 5 for reinforced concrete of IS code 456 2000 (latest
version)
3 SAMPLES AND TESTS OF MATERIALS
The operator shall submit samples of such materials as may be required by the Owner and shall carry out the
specified tests directed at the site or at the suppliers premises or at the laboratory approved by the Owner or
the Owners Representative. Samples shall be submitted and tests carried out sufficiently early to enable further
samples to be submitted and tested if required by the Owner.
The operator shall give the Owner seven days notice in writing of the date on which any of the materials will
be ready for testing or inspection at the suppliers premises or at a laboratory approved by the Owner. Owner or
the Owners Representative shall attend the test at the appointed place within seven days of the said date on
which the materials are expected to be ready for testing or inspection according to the Bidder, failing which the
test may proceed in his absence unless instructed by the Owners Representative to carry out such a test on a
mutually agreed date in his presence.

The operator shall in any case submit to Owner within seven days of every test such number of certified copies
(3) of the test results as the Owners Representative may require.

Approval by the Owners Representative as to the placing of orders for materials or as to samples or tests shall
not prejudice any of the Owners Representative powers under the Contract. The provisions of this clause shall
also apply to materials supplied under any nominated sub-contract.

4 ORIENTATION
The works shall be laid out within the confines of the site in order to be compatible with the existing
infrastructural facilities, inlet and outlet pipe work/channels and nearby water bodies. Underground services
requiring to be relocated in order to accommodate the proposed site layout shall be relocated by the operator to
alignments approved by the Owners Representative.

4.1 Buildings and Structures


All the building and structure works shall generally comply with the following Owners Requirements unless
otherwise specified elsewhere:

All building works shall be of reinforced concrete framework.

All walls of buildings/Pumps Houses/Control Room etc. shall be provided with a 40 mm thick Damp Proof
Course (DPC) cement concrete 1:2:4 nominal mix with 10 mm downgraded stone metal with proportionate
quantity of water proof compound and bitumen coating as per I.S specifications (latest revision). The damp
proof course shall run without a break throughout the length of the wall, even under the door or other openings.

All external walls shall be in 230 mm thick brick masonry built in cement mortar (1:5). Transoms and mullions
of 115 mm x 230 mm size with four numbers 6 mm bars and 6 mm links at 150 mm c/c shall be provided to
form panels not exceeding 3,500 mm x 3,500 mm in size. All internal partition walls except for toilets shall be
in 230 mm thick brick masonry built in cement mortar 1:5 with transoms and mullions as mentioned above.
Toilet partition walls shall be in 115 mm thick brick masonry built in cement mortar 1:4 and shall have
transoms and mullions as mentioned above and shall form panels not exceeding 1,200 mm x 1,200 mm in size.

Finishes to concrete liquid retaining structures shall be:

a. F1 - External surfaces, buried


b. F2 - External surfaces exposed and up to 300 mm below ground level
c. F2 - Internal surfaces
Finishes to other concrete structures shall be:

a. F1 Buried
b. F1 - Exposed, where plastering is specified
c. F2 Exposed
All internal masonry surfaces finish shall have 12 mm thick plain faced cement plaster in cement mortar (1:4)
with neat cement finish on top. Over this, one coat of primer and two coats of plastic emulsion paint of
approved quality and shade shall be provided.

All external masonry and concrete with rough board finish shall have 20 mm thick sand faced cement plaster in
two coats, base coat 12 mm thick in cement mortar 1:4 and finishing coat 8 mm thick in cement mortar 1:4.
Waterproofing compound of approved make and quality shall be added to the cement mortar in proportions as
specified by the manufacturer.

The ceiling of the building shall be finished with 10 mm thick cement plaster 1:3 and shall be given three coats
of white wash to give an even shade. The faces of other R.C.C. work which will form part of the building work
e.g. columns, beams etc. shall be rendered/plastered and finished as specified. Junction of brick work and
R.C.C. to be provided with wire mesh 12mm groove to avoid cracks.

All external surfaces above ground level shall have one coat of primer and two coats of waterproof cement
based paint of approved quality and shade. A coat of silicone water repellent paint shall also be applied thereon.

Toilet areas, walls and ceilings, shall have one coat of primer and two coats of plastic emulsion paint. Toilet
floor slab shall be filled with brick bat coba (broken bricks in lime) and provided with waterproofing as per the
specifications of an approved specialist waterproofing company. The finished floor level in toilet areas shall be
25 mm below general finished floor level elsewhere in the building.

The flooring in all areas except toilets and staircases, pumping stations, chlorination building, workshop, store
room, D.G. room, Rapid sand filter house, UF house, RO house, Chemical house,Ozonation house shall be in
250 mm x 250 mm x 20 mm thick marble mosaic tiles of approved make unless otherwise specified, shade and
pattern and placed in cement mortar 1:4 to give overall thickness of 50 mm. Half tile skirting shall also be
provided in these areas.

The flooring in the pumping stations, chlorination building, workshop, D.G.room, Rapid sand filter house, UF
house, RO house, Chemical house, Ozonation house shall be 60mm thick cement flooring with metallic
concrete hardener topping, under layer of 42mm thick cement concrete 1:2:4 (1 cement : 2 coarse : 4 graded
stone aggregate 16mm thick nominal size) and top layer of 18mm thick metallic concrete hardener consisting
of mix 1:2 (1 cement : 2 stone aggregate 6mm nominal size) by volume & mixed with metallic hardening
compound of approved quality @ 3 kg/m2 including cement slurry and rounding off edges.

The flooring in Operators room, loading/unloading bay, MCC cum Panel room shall be in 25mm thick Kota
stone slab of approved shade and pattern and placed over 20 mm thick base of cement mortar 1:4 to give
overall thickness of 45 mm. Half tile skirting shall also be provided in these areas.

Toilet areas shall have 450 mm x 450 mm x 25 mm thick polished Kota stone tiles placed in cement mortar 1:4
to give an overall thickness of 50 mm. 2100 mm high dado, in 150 mm x 150 mm x 6 mm thick glazed tiles
(approved make, shade and pattern) placed in cement mortar 1:3 shall also be provided in these areas.
The flooring along with skirting in administration cum laboratory building shall be 20 mm thick mirror
polished, machine cut granite slab of approved shade and pattern placed in cement mortar (1:4). 150mm high
skirting shall be provided in these areas. Granite stone shall be provided for laboratory platforms fixed over
double sandwiched cuddappa support as directed and the edges of granite is to be embedded into the wall.

All floorings unless otherwise stated should be supported by 150 mm thick cement concrete base of nominal
mix of 1:3:6 (1 cement : 3 coarse sand : 6 grade stone aggregate of 20 mm size). The base concrete shall be laid
over a well compacted river sand filling. All the filling required to be done under the base concrete shall be
with river sand alone in layers of 150mm and confined and saturated with water to prevent any settlement of
floor at subsequent period.

The minimum required toilet facilities at convenient place attached to any of the Pumphouse / Substation
building / DG room / Administration building shall be:-

a) Common toilet for use of men workers shall be provided with urinals 2nos, water closet 1no and bath room
of minimum size (2.0m x 2.0 m) with washbasin ( 1no), mirror (1no) and towel rail (2no).

b) Common toilet for use of women workers shall be provided with water closet 2no and bath room of
minimum size (2.0m x 2.0 m) with washbasin ( 1no), mirror (1no) and towel rail (2no).

c) Common toilet for use of men operators and officers shall be provided with urinals 2nos, water closet 2no
and bath room of minimum size (2m x 2 m) fitted with washbasin ( 1no), mirror (1no) and towel rail (1no).

d) Common toilet for use of women operators and officers shall be provided with water closet 2no and bath
room of minimum size (2.0m x 2.0 m) with washbasin ( 1no), mirror (1no) and towel rail (1no).

The sewage from toilet blocks shall be disposed suitably through septic tanks or any other methods

All staircases shall have 25 mm thick chequered mosaic tiles for treads and 25 mm thick plain mosaic tiles for
risers of approved make and shade and half tile skirting set in cement mortar in 1:4 to give an overall thickness
of 50 mm.

All concrete stairs shall have aluminum nosing over 2 mm thick rubber strip of width same as nosing for the
full length of the tread. Nosing shall be fixed with countersunk screws. Stairways shall be provided to permit
access between different levels within buildings. Staircase shall be minimum 1000mm wide unless specified
otherwise. Staircases in general shall not be steeper than 40. Staircases having space constraints may be
steeper than 40. The maximum vertical run for a single flight of stairs shall be 3.0 M.

All roof tops and overhead tanks shall be made accessible with ladder provision. Vertical step ladders fitted
with landing point extensions will be permitted where considered appropriate by the Design-Build-Operations
Engineer to access areas not frequently visited.

The minimum height of hand railing shall be 1m. Hand railing shall be provided with minimum two numbers
of 40mm dia SS316 horizontal pipes and 40mm dia SS316 vertical pipes of atleast 1meter in height placed at
1m centre to centre.
The reinforced concrete roofs shall be made waterproof by application of an approved roof polythene / bitumen
membrane . The finished roof surface shall have adequate slope to drain quickly the rain water to R.W down
take inlet points. A coat of Blown Bitumen 85/25 shall be applied at suitable rate. A roll of Modified
Bituminous Membrane shall be unrolled over the primed surface and completely bonded to the substrate by
pressing down evenly for the full width of the roll using a wooden roller. Torching shall be done, where
recommended by the manufacturer and where directed by the Design Build Operate Engineer.

All roof floors shall have minimum 750 mm height solid concrete block parapet wall where accessible is
provided and shall have minimum 300 mm height solid concrete block parapet wall where accessible is not
provided.

For roofing drainage, cast iron or uPVC rainwater down takes with C.I. bell mouth or u PVC bend and C.I. or
uPVC grating at top shall be provided. For roof areas up to 40 sq. m minimum two nos. 100 mm diameter
down take pipes shall be provided. For every additional area of 40 sq. m or part thereof, at least one no. 100
mm dia. down take pipe shall be provided. All the rainwater down take pipes shall suitably connected to rain
water harvesting structures.

Top surfaces of chajjas and canopies shall be made waterproof by providing a screed layer of adequate slope or
application of an approved roof membrane and sloped to drain the rain water.

Building plinth shall be minimum 600 mm above finished formation

All doors, windows, rolling shutters shall have lintels above. Chajja protection to lintels on external walls shall
be such as to prevent the rain water splashing into the building. Chajja projection of minimum 750 mm for
rolling shutters, 600 mm for doors and 450 mm for windows ( but not less than half the width of the opening)
shall be provided to prevent the rain water splashing into the building. Chajja shall be projected 150 mm on
either side from size of doors/windows/rolling shutters. All windows and ventilators shall have 25 mm thick
Kota stone sills bedded in cement mortar (1:3).

All doors and windows shall be painted with two coats of synthetic enamel paint over a priming coat (ready
mixed Zinc Chromate Yellow primer of approved brand and manufacturer confirming to I.S.: 127-106, 341 and
340).

All doors, windows and ventilators shall be made of Aluminium confirming to latest version of IS: 1948. All
fixtures for doors, windows and ventilators shall also be of Aluminium. Aluminium grills shall be provided in
all the windows. Doors shall be in two panel and both panels shall be glazed/unglazed. Minimum weight of
aluminum doors & windows shall be as follows

1. Single Glazed Window : (Weights indicated shall be aluminum)


Open able Outer Frame: Weight 0.70 kg/m
Shutter Frame: Weight 0.97 kg/ m
Intermediate Mullion: Weight 0.97 kg/ m
Beading: Weight 0.31 kg/ m
Fixing Louvers windows/ventilators
Outer Frame: Weight 0.46 kg/ m
2. Double Glazed Window
Outer Frame: Weight 0.72 kg/ m
Shutter Frame: Weight 0.97 kg/ m
Intermediate Mullion: Weight 0.98 kg/ m
Beading: Weight 0.31 kg/ m
3. Sliding Windows
Bottom & Top Frame: Weight 0.70 kg/m
Shutter Frame: Weight 0.42 kg/m
Interlocking Section: Weight 0.47 kg/m
4. Aluminum Door
Outer Frame: Weight 2.508 kg/ m
Shutter Frame: Weight 2.508 kg/ m
Bottom Stile: Weight 2.508 kg/ m
Glazing shall be 5.5 mm thick glass.
a) Openings of the windows & ventilators shall be minimum 25% of the external wall area.
b) Ventilator shall be provided where height of floor is more than 3m.
c) All windows and ventilators shall have wire mesh. Frame of doors, windows and ventilators shall be of
aluminum of standard rolled section. Doors, Windows and Ventilators shall be of size as per schedule
to be submitted by the Operator for approval of Design-Build-Operations Engineer . The minimum size
shall be as per below:
a. Door of opening size 1.2m x 2.1m
b. Door of opening size 0.75m x 2.1m for toilets
c. Glazed widows of minimum size 1.2m x 1.2m
d. Ventilators of minimum size 0.6m x 0.6m
d) Rolling shutters shall be made of 80 x 1.25 mm MS laths. Rolling shutter shall be of minimum size 3m
wide x 3.0m high. Rolling shutter shall be provided in chlorination building, centrifuge building,
workshop, store room, D.G. room, Rapid sand filter house, UF house, RO house, Chemical
house,Ozonation house MCC cum panel room, , at entry and exit of the pump house for access to pumps,
motors, valves, panels and as wherever required.
e) All concrete channels and ducts used for conveying liquid shall have inside finish of type F2. A finishing
layer of screeding concrete of 50 mm average thick in cement concrete with nominal mix of 1:1.5:3 shall
be provided on top of floors, channels etc.The width of concrete channels shall not be less than 500 mm.
All open channels shall be provided with Stainless Steel Type 316 hand railings or concrete walls to a
minimum height of 1 m from the access surface elevation. All concrete surfaces of structures conveying
liquid shall be protected with Epoxy Coating as specified .
f) Kerbs to be provided below the hand railing on the catwalks/pathways should be as per relevant sections of
Factory Act. It shall not be less than 150mm.
g) All exposed surfaces of inserts embedded in concrete shall be painted with two coats of enamel paint over
one coat of red oxide zinc chrome primer. Surfaces in contact with concrete shall not be painted.
h) All structural steel members shall be painted with two coats of enamel paint over one shop and one field
coat of red oxide zinc chrome primer.
i) All rooms in the treatment plant buildings shall be provided with appropriate sign boards indicating the
function of the rooms involved written in Tamil and English Languages.
j) The design of buildings shall reflect the climatic conditions existing on site. Process buildings shall as far
as is possible permit the entry of natural light , and the use of glazed panelling shall be kept to a minimum
and preference given to wall openings protected by weather canopies.
k) Emergency exit doorways shall be provided from all buildings in order to comply with local and
international regulations .Stairways and paved areas shall be provided at the exit points.
l) Toilet blocks in process buildings and control blocks shall be provided with a sink with two drinking water
taps of 20 mm size with adequate inlet and outlet connections.
m) All the walkways in shall have minimum 1 m width and shall be covered with mosaic tiles.
n) Hand railing shall be provided with minimum two numbers of 40mm dia SS316 horizontal pipes and
40mm dia SS316 vertical pipes of atleast 1meter in height placed at 1m centre to centre.
o) For structures containing water or process liquid, the top of the wall shall be at least 0.5m higher than
the maximum water surface level . The top level of internal plant roads and approaches shall be at the
formation ground level.
p) If the High flood level is more than Ground Level then road shall be constructed on the earthen
embankment. Earthen embankment shall be constructed with side slope of at least 2 horizontal to 1
vertical. Stone pitching shall be provided at both sides of the embankment as per IS: 8237. Top width
of embankment shall be taken as 6.0m. Top level of embankment shall be 0.5m above high flood level.
Excavated earth from the plant can be used for embankment construction and if required, extra earth
can be borrowed from the borrow pit as approved by Design-Build-Operations Engineer .

4.2 Roadways, Pathways & Hard standings


a. Internal roads shall be provided around the treatment plant to link in with the existing units and the
approach road and permit access to the plant for necessary maintenance, delivery of consumables and
personnel access. All roads shall be of Cement concrete (as stated below) having 4 m wide carriage
way with 1 m wide flanks (shoulder) on either side of it, making a total roadway width of 6 m.
The road shall be given suitable camber and longitudinal slope. Vehicular access shall be provided
for all Plant structures and buildings. All roads shall be provided with drainage and shall be constructed
to prevent standing water.
b. The Operator should include preparation of sub-grade to the required level and camber, leveling
and dressing of the filling and consolidation by road roller.
c. For the road portion, 6m width of 0.3m consolidated thickness boulders should be placed as a sub
base.
d. Over the consolidated boulders, soling, with gravel ( which passes through 25mm sieve size )
153.3mm thick rolled down to a thickness of 115mm using 1.533 cum gravel for an area of 10 sqm
including spreading gravel, watering and consolidation by power roller etc complete should be
carried out. The width of this layer will be of 6m.
e. Water bound macadam to a thickness of 100mm using 1 cum of 40mm IRC size HBG metal with
0.33 cum of gravel ( which will passes through 10mm sieve size ) fine for blindage for an area of 10
sqm including spreading metal and gravel fine and packing to camber, consolidation by power roller
and including watering and keeping the surface moist for 15 days etc complete should be carried out.
The width of this layer will be of 6m.
f. Plain Cement concrete 1:3:6 to a consolidated thickness of 0.3m including necessary curing etc
complete should be carried out. The width of this layer will be of 4m.
g. Hard standing areas with shading facility shall be provided to permit the parking of vehicles involved
in the delivery of consumables from blocking site roadways during unloading or loading..
5 Site Drainage
The operator shall provide a site drainage system. The system shall comprise of the following:
Storm Water Drainage
Foul Drainage (if any)

5.1 Storm Water Drainage


(a) Storm water drains adjacent to the existing and proposed roads (under this Contract) shall be
sized for a rainfall intensity of 50 mm/hr, allowing for 100% runoff. Drains adjacent to roads
shall be in stone masonry in CM (1:4) of appropriate thickness, topped with 75 mm thick M10
concrete and internally flush pointed in cement mortar (1:4), 20 mm thick. The minimum width
of drain shall be 450mm.
(b) The storm water drainage system shall also be designed to cater the run-off from the existing plot
areas and structures, if necessary depending upon the site topography. Sedimentation tank for
settlement of suspended solids of storm water runoff shall be provided.
5.2 Foul Drainage
(a) The foul drainage system shall accept discharge from toilets, washrooms, offices and the
laboratory. The foul drainage system shall be disposed suitably through septic tanks or any other
methods
6 Cable and Pipe work Trenches
(a) Cable and pipe work trenches shall generally be constructed in reinforced concrete. However, 500 mm
x 500 mm size or smaller trenches, not on fill may be constructed in 200 mm thick solid cement
concrete blocks over 150mm thick M 15 PCC base. The trenches will be 20mm thick plastered
internally with cement mortar (1:4) and externally in cement mortar (1:3).

(b) All floor cut-outs and cable ducts, etc. shall be covered with M20 precast concrete covers (Heavy
Duty) as per direction of Design-Build-Operations Engineer in outdoor areas and SS316 M.S.
chequered plates of adequate thickness ( but not less than 7mm thick) in indoor areas. All uncovered
openings shall be protected with hand railing. The pipe, cable trenches shall be suitably sloped to drain
off rainwater to a suitable location.

(c) Layout of trenches outside the buildings shall allow space for construction of future trenches where
necessary with due consideration for planning for future developments. This aspect shall be brought to
the notice of the Design-Build-Operations Engineer while planning the works.

7 Pipes and Ducts


(a) R.C.C ducts for drainage shall have minimum 1 metre wide pre-cast cover (M20 concrete, Heavy duty)
while laid under roads. Access shafts of size not less than 600 mm x 1000 mm shall be provided.

(b) All drains (except storm water drains adjacent to roads) shall be covered and designed structurally for
appropriate loads.

8 Main Gate
(a) Proposed treatment plant shall have minimum one main gate to access the plant irrespective of existing
gate at the premises of existing plant site. Minimum width of main gate shall be 6m. Main gate shall
have 1.5m wide wicket gate. Main gate shall have as external framework of GI/CI pipes and internal
framework of MS flats. Gate shall be fixed on RCC columns. The design and pattern of gate with
drawing shall be submitted for approval of the Design-Build-Operations Engineer . The gate shall have
all necessary hinges, locking arrangement, rolling arrangement and painting complete, as approved by
the Design-Build-Operations Engineer Engineer.

9 Landscaping
(a) The site shall be landscaped once the works are substantially complete. Landscaping area shall be
marked in the layout plan of TTRO Plant.

(b) Landscaping shall include planting of suitable tree saplings trees and development of lawn/grassed
areas. Landscaping in general shall meet ecological and environmental conditions of the site. Road
widths shall determine the size of the tree height and spread to be selected for planting. Trees suitable
for local conditions shall be selected as approved by the Design-Build-Operations Engineer Engineer.
Medicinal and fruit trees shall be avoided. Landscaping shall be maintained in good condition till the
completion of the contract.

10 Tree Planting
(a) Pits dug a few days in advance of actual planting shall be allowed to weather and be filled with top soil
mixed with manure. Size of the pit shall be as per standard requirement. Only one tree sapling shall be
planted in each pit. A guard made of bamboo with wire mesh or bricks or M.S. ring as approved by
Design-Build-Operations Engineer Engineer, shall be provided.

11 EARTH WORK AND EXCAVATION


11.1 General
Applicable provisions of Conditions of contract shall govern work under this section. The Bidder shall report
any water conditions encountered and will be given directions as to the type of procedure to be adopted in such
cases. The Indian Standards wherever referred to herein shall be the latest edition of such Standards.

11.2 Excavation for Foundation, Trenches, Pits, etc.


All foundation trenches shall be excavated to the full-widths and depths shown on the drawings or to such
greater or smaller depths as may be found necessary or so ordered to him.

Should any excavation be taken down below the specified levels, the operator shall fill in such excavation at his
own cost with concrete as specified for foundations, well rammed in position until it is brought up to the level.
The operator shall notify to the Owner when the excavation is completed and no concrete or masonry shall be
laid until the Owner has approved of the soil for each individual footing, rafts, etc.

The operator shall keep the site clear of water at all times. To this end he shall provide arrangements for
building or pumping of water as required. All foundation pits shall be refilled to the original surface of the
ground with approved material, which shall be suitably consolidated. No extra will be paid for bailing out water
collected in excavation due to rains, ordinary springs etc.

11.3 Earth Filling


The space around the foundations in the trenches or sites shall be cleared of all trash and loose debris and filled
with approved excavated earth, all clods being broken. Filling shall be done in 200 mm layers; each layer to be
moistened and well rammed. This shall be done in step with the foundation masonry or foundation concrete
work the difference between the tops of masonry and filling not exceeding a days work. The top of filling shall
be finished off 150 mm above ground level to allow for settlement only, pit or depressions occurring during the
Construction and O&M period shall be filled up and rammed by the Bidder at or his own expense.

11.4 Shoring, Planking & Shuttering


Shoring shall be done when sides of excavation do not stand up by themselves and sloping or stepping is not
feasible or economical.

The shoring shall consist of vertical planks 38 mm to 50 mm thick and of Available width and required length.
The planks shall be held by walling, vertical places and struts, and this to form a frame. The struts shall be not
more than 1.5 m. apart, and the timber shall be sufficiently strong not to wrap. The planks shall be held tight by
means of wedges between them and walling. The planks shall be driven in by cutting the earth beneath their
toes or driving each plank separately after removing the wedges. The planks shall be driven in vertically and
shall be set touching one another.

The shoring shall be adequate to prevent caving in of the trench walls of subsidence of areas adjacent to the
trench. In narrow trenches of limited depth, a simple form of shoring shall consist of a pair of 40 to 50 mm
thick and 30 cm wide planks set vertically at intervals and firmly strutted. For wider and deeper trenches a
system of wall plates (Wales) and struts of heavy timber section is commonly used. Continuous sheeting shall
be provided outside the wall plates to maintain the stability of the trench walls. The number and the size of the
wall plates shall be fixed considering the depth of trench and type of soil. The cross struts shall be fixed in a
manner to maintain pressure against the wall plates which in turn shall be kept pressed against the timber
sheeting by means of timber wedges or dog spikes.

11.5 Wet Foundation:


As soon as water is encountered in foundations, a sump shall be dug for removing the water. The bottom level
of this sump shall be kept 500 mm or more below the lowest level of the excavation. The difference between
the levels of the bottom of the excavation and of the sump shall be kept constant as excavation depth is
increased. If the excavation is to be taken to a substantial depth and a large quantity of water is encountered,
two sumps shall be excavated and deepened alternatively so that the pump does not require to be stopped whilst
the sump is deepened.

11.6 Earthwork in Site Levelling


All materials required for the purpose of filling shall be taken from high areas and stockpile, which are to be
levelled to specified reduced level as required. Roots, sods, wood or other organic matter shall not be placed in
the fill. Before a new layer is laid the existing ruts or other unevenness in the surface of the layer shall be
removed and the surface of the layer shall be scarified and roughened by borrowing and ploughing to obtain
bond with the material to be placed. The materials shall be placed continuous horizontal layers not greater than
200 mm thickness. The earth fill shall be kept slightly sloping from center to the edges to avoid formation of
pools during the rain.
Section 2. CONCRETE
12 Concrete
12.1 General
Applicable provisions of Conditions of Contract shall govern work under this section.

All concrete work, plain or reinforced shall be carried out in strict accordance with this specification and any
working drawing or instructions given from time to time to the operator. The operators rates shall allow for
wastage in all materials as well as for all tests of materials and for concrete. No concrete shall be cast in the
absence of the Owners representative or any other person duly authorized by him. The operators Engineer
shall personally check that both the formwork and reinforcement have been correctly placed and fixed, and
shall satisfy himself that all work preparatory to the casting is completely ready, before calling the Owners
representative for final inspection and approval and for which purpose at least 24 hours notice shall be given
by the operator. The Indian Standards wherever referred to herein shall be the latest edition of such Standards.

12.2 Cement
The cement procured by the Operator shall comply with the requirements of IS 269/ 1976 with the latest
revision thereof for 33 grade ordinary portland cement and IS 12330/ 2001 for sulphate resistance cement, IS
8112/1989 with the latest revision thereof for 43 grade ordinary portland cement; IS: 12269-1987 with the
latest revision thereof for 53 grade ordinary Portland cement. Cement tests shall have to be carried out at
operators expense as and when directed.

12.3 Aggregate
The fine and coarse aggregate shall conform to IS: 383 & IS: 456. The necessary test indicated in IS 383 and
IS 456 shall have to be carried out to ensure the acceptability and shall meet prior approval of the Owner.

12.4 Reinforcement
Reinforcement Steel & Structural Steel All Reinforcement steel should be either of the following:-

a) Fusion Bonded Epoxy coated having not less than 175 microns thickness and upto 300 microns to
reinforcement of all diameters as per IS code 13620-1993for RTS rods for RCC works including testing of
coating at plant. The binding wire should be of PVC coated and the exposed portion if any after bar bending
work should be covered with the Epoxy paint supplied by the coating agency.

b)The contractor shall procure CTD of high strength deformed CRS steel reinforcement bars and structural
steel conforming to relevant BIS codes (Gr Fe 415, BIS code 1786-2008) from main producers such as SAIL,
TISCO, RATHI TOR, JSW, Shyam Steel or as approved by the Ministry of Steel.

The epoxy coated reinforcement conforming to IS 13620 or latest relevant Indian Standards shall be of tested
quality. It shall also comply with relevant part of IS. 456. All epoxy coated reinforcement shall be clean and
free from dirt, oil, paint, grease, mill scale or loose or thick rust at the time of placing. The reinforcement shall
be bent to the shapes shown on the drawings prior to placing and all bars must be bent cold. The Steel shall be
placed in such a way that it is rigidly held in position while concrete is being cast. The correct clearance from
the form shall be maintained by either precast mortar blocks or by metal supporting chairs to be supplied by the
operator free of charge. The intersections of rods crossing one another shall bound together with soft pliable
wire No. 16 S.W.G. at frequent intervals so that reinforcement will not be displaced during the process of
depositing concrete. The loops of binding wire should be tightened by pliers.

12.5 Water
Water shall conform to IS: 456, clean and free from alkali, oil or injurious amounts of deleterious material. As
far as possible, the water should be of such quality that is potable. If any chemical analysis of the water is
necessary and ordered the same shall be got done at approval laboratory at the operators expense.

12.6 Concrete Proportioning


The concrete proportion shall be as indicated on the approved drawings and shall conform to IS: 456.The
minimum cover to main reinforcement shall be as per Clause 1.8, Section 3 Civil works.

Type of joints, spacing of joints, use of all jointing materials and other features pertaining to the provision of
movement joints in liquid retaining structures shall be got approved prior to commencement of construction.
All reinforced concrete work shall be thoroughly and efficiently vibrated during laying by use of vibrators.

For liquid retaining structures M30 grade shall be used, the same shall be deemed to be satisfactorily watertight
if the external faces show no signs of leakage and remain apparently dry over the period of observation of 7
days after allowing a period of 7 days for absorption after filling. Covered tank, where all faces are not
accessible for inspection, shall be kept filled with water for 7 days and thereafter the drop of water over the
next 7 days shall not exceed totally a depth of 12.5 mm per day. Approved corrective measures, if necessary,
shall be undertaken by the Bidder at his own expense. The operator shall use appropriate water proofing
compound during the process of pouring of concrete in required proportion.

12.7 Workmanship
All concreting work shall be carried out according to the IS: 456 Indian Standard Code of Practice for Plain
and Reinforced Concrete for general Building Construction. It should, however, be note that for Over 60 m3 of
concrete placed or for every one days work a minimum of 6 (six) cubes shall be cast for test purposes and
tested at the operators expense in an approved laboratory.

12.8 Formwork
The formwork shall conform to IS: 456. Centering ; Only steel / plywood centering shall be used
12.9 Curing
The concrete shall be cured according to IS: 456 or as directed.
12.10 Concrete Finish:
The concrete surface on removal of form work shall be such that no finishing is necessary. If however the
surface is not satisfactory, the operator shall, if so instructed, remove unwanted projecting parts by chipping
and smoothening the surface with cement at his own expense and coated with corrosion resistance epoxy paint.
.

12.11 Construction Joints / Water Stops


These shall be in accordance with IS: 456 or as shown on the approved drawings.
The centering for forming, the construction joint shall be firmly fixed and adequately slotted for reinforcement
extending beyond the joint. If any concrete has set, care shall be taken not to disturb the reinforcing steel in
casting the second half of a member with a construction joint and thereby crack the concrete previously placed.
The PVC joints shall be of the rebated or keyed type and shall have a minimum width of 300 mm inclined
feather or straight joints shall not be permitted. The Joints/Water stops shall be got approved by the Design-
Build-Operations Engineer before their placement into the structure.

12.12 Expansion Joints


Expansion joints shall be provided at positions shown on the approved drawing or as directed and shall comply
strictly with the details shown on construction drawings. Reinforcement shall not extend across any expansion
joint and the break between the two sections MUST be complete. Unless otherwise specified, the gap shall be
filled with an elastic joint filler consisting of the following ingredients (by weight), preheated to a temperature
of 190 C(375 F).

a) Very find sand 60%


b) Hot bitumen emulsion 33%
c) Cement 5%
d) Fine chopped hemp 2%
12.13 Operators Supervision
The operator shall provide constant and strict supervision of all the item of construction during progress of
work, including the proportioning and mixing of the concrete and bending and placing of reinforcement. Before
any important operation such as concreting or stripping of formwork is begun, adequate notice shall be given.

12.14 Laying Cement Concrete in Foundations & Under Floors


Before laying the concrete, the bottom and sides of the trench up to the proposed height of the concrete shall be
moistened. The concrete shall be tamped immediately after laying.

12.15 Protective Epoxy Paint Treatment:


Epoxy Paint of standard specifications manufactured/purchased from a reputed firm approved by IS shall be
applied to the outside Concrete surface of R.C.C. Underground sump and all mild steel works within and near
the sump. The coverage capacity of layers shall be at 125 Microns D.F.T. 7.60 sq. mt. /Litre .( Exposed steel
inserts, embedded in concrete and ladders, submerged in water shall be provided with epoxy paint 360 microns)

12.16 Chases, Holes, Recesses and Inserts:


All chases, holes and recesses for foundation bolts, various services and other requirements must be formed as
shown on the drawings or as directed by the Owners Design-Build-Operations Engineer during the execution
of the work, without extra charge. The operator shall fix all necessary inserts in the concrete for support of
hangers for pipes and cables, ceiling clamps for lights and fans or for duct etc. If any of the inserts are to be
supplied by other agencies no extra payment will be made to the Bidder for placing the inserts position.

12.17 Load Testing of Structures


Load tests shall be carried out in accordance with IS: 456, if required by the Design-Build-Operations
Engineer.
Section 3. BRICK WORK
13 Brick Work
13.1 General
Applicable provisions of Conditions of Contract shall govern the work under this section. The operator shall
build the whole of brickwork shown on the drawings with first-class bricks in cement mortar. The Indian
Standard wherever referred to herein shall be the latest edition of such Standards. As a first preference, Burnt
clay fly ash building bricks conforming to IS 13757: 1993 shall be used in all brick masonry works. However,
when it is not available in the market, common burnt clay building bricks conforming to the requirements of IS
1077 and of quality not less than class 50 with moisture absorption rate not exceeding 15% as defined in IS :
1077 shall be used. The bricks shall be chamber burnt and shall not be damaged in any manner and sizes shall
conform to the works sizes specified with tolerance as given in 6.2 of IS:1077. (AS PER SUPREME COURT OF INDIA
DIRECTIVE ONLY FLYASH BRICKS SHALL BE USED FOR ALL GOVT CONSTRUCTION LOCATED WITHIN 100KM BELT OF A
THERMAL POWER STATION)

13.2 Materials

Bricks The bricks used shall generally conform to IS: 1077

Cement The cement used shall conform to IS: 269

Sand The sand used shall conform to IS: 1344

Water The water used shall be clean and free from injurious
amounts of deleterious materials. As far as possible, the
water should be of such quality that it is potable

13.3 Mortar Proportion


Unless otherwise specified, the proportions of cement-sand-mortar by volume for various classes of work
shall be as under:

Type of work Cement Sand

Ordinary brickwork for building 1 5

Brickwork in pillars 1 4

Half-brick thick or brick-on edge partition wall 1 4


13.4 Workmanship
The cement and sand shall be thoroughly mixed dry in specified proportions. Water shall then be added by a
sprinkler just sufficient to make a stiff and workable paste. The mortar shall be used within half an hour of
mixing. The mortar, which is unused within half an hour of mixing, shall be removed from the site.

13.5 Brick-work
All the bricks shall be kept in water till they are completely soaked & only thoroughly soaked bricks shall be
used in the work. The operator shall set out & build all brickwork to the respective dimensions, thickness and
height, as shown on the drawings.

The operator shall build all brickwork uniformly, no one portion being raised more than 1000mm above
another at one time. The operator shall keep wet all brickwork for at least 10 days after laying. The surface of
unfinished work shall be cleaned and thoroughly wetted before joining new work to it.

In curved brickwork, the bricks shall be dressed to shape obtain joints redial to the curve. The joints shall not
exceed 12 mm in thickness and should extend the full thickness of the curved brickwork.

13.6 Damp-proof Course


Damp-proof course shall be provided at positions where ever necessary. In masonry walls of buildings, it shall
normally be placed above the external ground level. It shall be laid for the full width of solid walls and shall be
prepared as specified.

A layer of cement concrete 1:2:4 (cement: sand: coarse aggregate) mix, and of specified thickness shall be
provided. If a damp-proof course requiring the use of bitumen felt is specified, bitumen used shall conform to
IS: 1322 and workmanship shall conform to IS: 1609. All exposed surface of the damp-proof course shall be
finished fair and smooth. The external edge shall be chamfered if specified, and shall be finished flush with
masonry surface.

Section 4. FLOORS AND PAVEMENTS


14 General
Applicable provisions of Conditions of Contract shall govern work under this section. The Indian Standards
wherever referred to herein shall be the latest edition of such standards.

14.1 Types of Floors and Pavements


The principal types of floors and pavements considered in this specification are as under:
a) Cast-in-situ artificial stone flooring (plain)
b) Natural stone slab flooring
c) Pre-cast artificial stone flooring (Plain/Textured)
14.2 Materials
Cement
Ordinary Portland cement and white and colored cement shall conform to IS: 269.

Lime
Where lime is required to be used, it shall conform to IS: 712 and slaking of lime shall be done
according to IS: 1635.

Aggregates
The aggregates shall conform to IS: 383. Fine aggregates shall range in size from 1.5 mm to 6 mm.
unless specified otherwise. Not more than 5 percent of grains shall pass IS sieve 15 (0.151 mm mesh)
and not more than 10 per cent shall pass IS sieve 30 (0.296 mm mesh). Coarse aggregate shall all pass
through 19 mm mesh, unless specified otherwise and shall be graded as directed. The coarse aggregate
for concrete pavements for approaches and driveways shall all pass through 25 mm ring and shall be
formed by mixing 80% of 25 mm to 12 mm size and 20% of 12 mm to 6 mm size. The above
proportion shall be altered to suit workability if so approved.

Natural Stone Slabs


The stone slabs if used shall be best quality obtainable from Neemuch, Kotah, Shahabad, Tandur or
other places as specified and shall be hard, even durable, uniform in color and free from cracks, flakes
and other defects. No stone shall be thinner at its thinnest part than 25 mm. unless otherwise specified;
the stones shall be 300 mm x 300 mm in size dressed square and with straight edges. The top surface of
stones shall be smooth or polished as specified and edges dressed to a true fit or chisel dressed as
directed.

Water
Water shall be clean and free from injurious amounts of deleterious materials. As far as possible, water
shall be of potable quality.

14.3 Cast in situ Artificial Stone Flooring

Grey and colored artificial stone is to be composed of 4 parts of fine stone chips 12 mm and below 2
parts of sand and properly screened to one part of cement. The topping in all cases and to consist of clean
and fine sand and cement (2:1) and sufficient skin thickness to be kept and finally toweled with neat
cement finish perfectly smooth to satisfaction. In the case of dados and skirting the total thickness is to be
19 mm of which the bottom layer is to be 12 mm and the topping 6 mm thick in all cases both the layers
are to be laid simultaneously without hiatus so that it will in effect be one complete layer; the mixing be
made in two different lots.

14.4 Natural stone slab flooring

The stone slabs shall be evenly and firmly bedded to the required level and slopes as directed. Unless
otherwise specified, the thickness of joints shall not exceed 6 mm for unpolished stone slabs and 1 mm
for polished stones. The joints shall be raked out to an adequate depth and pointed flush or slightly sunk,
as directed, with cement-sand mortar of 1:2 proportions. The stone slabs shall be laid to pattern which
shall be approved prior to ordering the stones. The flooring shall be kept wet with wet sand or water for
at least seven days. The flooring shall be well washed and shall be perfectly clean and free from all
mortar stains etc. when completed
Section 5. PLASTERING AND POINTING
15 General
Applicable provisions of Conditions of Contract shall govern work under this section. The Indian
Standards wherever referred to herein shall be the latest edition of such Standards.

15.1 Cement Plaster Materials


Cement shall confirm to IS: 269 and Sand shall confirm to IS: 1542.Other materials, tools and
Accessories, they shall confirm to relevant IS codes listed above and to the requirements specified in IS:
1661.
15.2 Proportioning and thickness of Cement Plasters:
The proportions of materials, number of coats and thickness of each coat shall be as a specified or as
directed.

15.3 Workmanship
Unless otherwise specified, all plasterwork shall be carried out as per IS: 1661 Code of Practice for
Cement and Cement-Lime Plaster Finished on Walls and Ceilings. Special finishing textures to the
plaster shall be executed according to Clause 16 of IS: 1661 and/or as directed.

15.4 Curing
After the completion of the work, the pointed face shall be kept well wetted for at least for 10 days in the
case of Cement Pointing.

Section 6. PAINTING AND GLAZING


16 General
Applicable provisions of Conditions of Contract shall govern work under this section. The Indian Standards
wherever referred to herein shall be the latest edition of such standards.
16.1 Painting of Iron and Steel Work
Painting of iron and steel work shall generally be carried out as per IS: 1447 (Part I).

16.2 Preparation of Surfaces:


The surface to be painted shall be cleaned free of dirt, oil rust, mill scale and be thoroughly dry before painting.
Cleaning, degreasing, and de scaling wherever necessary shall be carried out as specified in IS: 1477 (Part I)
and the method adopted for surface preparation shall have prior approval.

16.3 Primer Coat:


Unless otherwise specified, the primer coat for steel and iron work shall be of Red Lead paint, conforming to
IS: 102. The Red Lead primer shall be applied by means of approved brushes. The Red Lead paint shall be
allowed to dry sufficiently hard before the application of the succeeding coat A red lead painted surface shall
not however be left exposed permanently, as it is liable to heavy chalking. The primer coat shall be applied as
specified in IS: 1477 (Part-I) and the number of coats shall be as necessary for as directed.

16.4 Finish Coat


The type of intermediate and finish coat and the number of coats to be applied shall be as necessary or as
directed. Intermediate and finish coats may be oil bound bituminous, aluminum or other types of paints.
Aluminum conforms to IS: 165. The intermediate and finish coats for structural steel work, sheet metal work
and cast iron work shall be applied as specified in IS: 1477 (Part-I).

Section 7. Glazing Materials


17 Glass
All glass used in the work shall be best quality glass free from specks, bubbles, smokes, wanes, air holes and
other defects, Unless other-wise specified, sheet glass shall be transparent and of the following weights. For
panes up to 600 mm x 600 mm in size, glass weighing not less than 7.97 kg/sq.m. shall be used. For panes 750
mm x 750 mm to 900 mm x 900 mm size, the weight of glass shall be 9.76 kg/sq.m. Unless other-wise
specified, for sizes of glass above 900 mm x 900, plate glass shall be used.

17.1 Putty
Putty for use on wooden frames shall conform to IS: 419 and on metal frames to IS: 420.
17.2 Workmanship
All glass be cut according to the sizes required as per drawings. Glazing of metal doors, windows and
ventilators shall conform to IS: 1081 and glazing of timber doors, windows, and ventilators shall conform to IS:
1003, unless specified otherwise. For glazing wooden doors and windows, the wooden frame, particularly the
rebate, shall be well oiled to prevent oil from putty being sucked in by wood. The Bidder shall thoroughly clean
all glass and replace all putty or glass damaged during the work.

Section 8. MISCELLANEOUS STEEL AND IRON WORK


18 General
Applicable provisions of Conditions of Contract shall govern work under this section.

The Indian Standards wherever referred to herein shall be the latest edition of such Standard.

18.1 Iron Grills


As per Section 3 Clause 4.1 All doors, windows and ventilators shall be made of Aluminium confirming to latest
version of IS: 1948. All fixtures for doors, windows and ventilators shall also be of Aluminium. Aluminium grills shall
be provided in all the windows. Where ever Iron grills are used, it shall be of mild steel or wrought iron as specified for
the work. The design of grills and shapes and sizes of various components shall be as approved. The edges,
angles and corners shall be clean and true to shape. The joints shall be mechanically inter-locked and
overlapping areas spot welded in such a way that the grill is rigid.

Where moulded grills are specified, the moulded work shall be as approved, and shall have clean, straight and
sharply defined profiles. The operator shall do the necessary cutting, fitting, drilling, tapping, scribing etc.
required to fix grills to adjacent surfaces. The grills shall be fixed plumb, in line and level. Unless otherwise
specified, grills shall be painted with two coats of red lead paint conforming to IS: 102 before they are fixed.

18.2 Rolling Shutters


Rolling shutters, where specified shall be of the size to suit the openings and shall be positioned as shown on
the drawings and/or as directed.

The rolling shutter shall be fabricated from 18 B.G. Steel and machine rolled with 75 mm rolling contras with
effective bridge depth of 12 mm lath sections, interlocked with each other and ends locked with malleable cast
iron. The guides shall be either rolled or pressed deep channel sections 75 mm deep and 25 mm wide fitted
with necessary fittings and fixtures.

The suspension shaft shall be formed from solid drawn seamless tubes 60 mm O.D. of wall thickness of 25 mm
in 3 segments coupled 2 with 2 pairs C.I. dog-tailed flange coupling forming one complete unit eliminating
deflection in the center to a minimum.

The springs shall be imported high tensile English flat springs 50/60 mm breadth and 1.6/1.8 mm thickness
hardened and tempered. These shall be fitted inside the fabricated housing on either ends, which
counterbalance the shutter curtain. The ball bearings shall be double row self-aligning ball bearing fitted inside
C.I. housing fixed on side brackets holding the suspension shaft at either end

.The suspension of the curtain shall be belted in specially fabricated cages formed from MS flats, and plates all
are welded. The hood cover shall be made of 20 gauge G.P. sheets with necessary stiffeners and framework to
prevent sag, the bottom lock plate shall be made of 3 mm thick M.S. plate and 95 mm wide reinforced with
angle/T iron of suitable section with 6 mm dia. M.S.rivets interlocked with last stride of curtain.

The locking arrangement shall consist of hasp and staple on the bottom plate, lockable from both sides. Unless
otherwise specified, for overall area of rolling shutters up to 9 sq. m. pull and push type hand-operated shutters
shall be used, for area between 9 and 12 sq. m. Pull and Push type shutters shall be provided with ball bearings;
for area larger than 12 sq. m, Mechanical Gear type shutters shall be supplied.

18.3 Collapsible Gates


Collapsible gates shall be of the size and type as specified by the Owners Design-Build-Operations Engineer .
The gates shall be manufactured out of M.S. channel pickets of size 20 mm x 10 mm and flats 20 mm x 6 mm.
The top runner flat shall be at least 50 mm x 12 mm in section. The bottom guide shall consist of a channel or
two angles of specified size laid in the flooring to guide the free movement of the gate. The gate shall move in
the guide channel on rollers of adequate size fixed at the top and bottom of the gate as specified. The gate shall
be painted with one coat of red lead paint conforming to IS : 102 before fixing in position.

Section 9. WOODWORK AND JOINARY


This section is deleted as generally wood should not be used in Industrial buildings from the Fire safety point of vi

21 ILLUMINATION:
All internal and external areas shall be provided with lighting. The illumination levels to be achieved shall be
as follows:

AREA LUX
Office and labs 300 Lux

Switchgear Room 200 Lux

Control Room 300 Lux

Pump House 200 Lux

DG set room 200 Lux

Chemical and general store 150 Lux

Chemical Plant room 200 Lux

Other indoor areas 100 Lux

Outdoor plant from and 50 Lux

Building entrance 100 Lux

Indoor Plant Area 200 Lux

Outdoor Plant Area 50 Lux

Transformer Area 100 Lux

Roads 10 Lux

Fluorescent luminaries shall be used primarily for internal lighting. High pressure vapour or metal halide type
luminaries shall be used in indoor application where their use is appropriate. If mercury or metal halide is used
in indoor then they should be supplemented with fluorescent luminaries to assure that minimum illumination
levels are maintained following momentary power dips. All other internal areas shall be lit with fluorescent
luminaries. Where specific recommendations of lux level are not covered above, illumination level in such
areas shall be finalized in consultation with Owner.

Owner shall be required to measure levels of illumination after completion of lighting installation work and
short fall in illumination level shall be made good by the Bidder. Complete set of calculations showing, room,
index, copy MF shall be given during detailed engineering.

21.6.1 Switches / sockets of piano type shall be used in general and in offices of staff, control room, MMI
room, decorative modular switches shall be used. Suitable fans shall be provided in rooms/ plant areas
as per standards. For exhaust fans it must be provided in panel rooms, pump rooms, chemical rooms,
stores, toilets and at least 20 air changes per hour must be maintained.

21.6.2 The following type of lighting fixtures shall be proposed:


a) Decorative type 2x36W fixtures for fluorescent luminaries inside office/ administrative buildings
and control rooms.

b) Corrosion resistant fixture with canopy made of FRP for fluorescent luminaries for corrosive areas
like chlorine handling or chemical store or area with corrosive smell/gases etc.

c) Industrial type vitreous enameled fixture for fluorescent luminaries inside 415V switchgear, MCC
room and pump house.

d) In outdoor process areas, lighting fixtures shall be sodium vapour type subjected to minimum of IP
protection class.

e) All outside lights as plant field lights, building outside lights, flood lights etc. which are to be
switched on only during night hours should be controlled through photo cell/ clock switch installed
at a central place. All lights shall have minimum IP65 protection class.

f) Street lighting wiring shall be through buried underground.

g) All bulb fittings (except fluorescent lamps) will have screw type caps.

h) For outdoor lighting, the lighting feeder shall be operated through a contactor, controlled by
photocell/ clock switch and shall also have a manual by pass switch.

21.6.3 Luminaries shall be installed to permit ease of maintenance i.e. it shall not be necessary to shut down
plant in order to carryout maintenance or to access luminaries located over areas of water etc. The
Operator shall provide all equipment necessary to carryout maintenance on the lighting installation and
demonstrate its operation to the satisfaction of Owner
21.6.4 Indoor lighting circuit will be arranged in such a way that 50% lighting can be put off in each room
through switches. All lighting circuits will be wired with 2.5sq.mm. Stranded copper wire or through
2.5 sq.mm. armoured cable laid in cable trays. Sub circuit from switch to fixture could be wired
with1.5 sq.mm. stranded copper wire in MS conduits or armoured copper cable of similar size provided
total voltage drop in any lighting distribution board to last lighting point shall not exceed 2%. All
lighting circuits will have separate neutral, separate earth from Lighting Distribution Board. For
illumination of roads, outdoors areas where operation of equipment or units required and substation
area, lighting fixtures of appropriate type (such as street lighting type, flood lighting type, post top
lanterns etc.) incorporating high pressure sodium vapour lamps shall be proposed. Street light poles
shall not have less than 7500 mm height above the finished road level and the arm shall not project
more than 1200 mm along the road width. Poles of bigger heights may also be used if some outdoor
areas are to be illuminated. Poles of 4 / 4.5 Mtrs using post top lantern may be used in gate office walk
way or in front of office area. Complete area, streets, lanes, boundary shall be covered with street
lighting.
21.6.5 Receptacles (Lighting & Small Power) :
a) Decorative and industrial type units of above shall be proposed in all plant areas, offices,
stores, workshop, plant room and they shall be located at least two numbers in each room. Distance
between two receptacles shall not be more than 8 10 m. All small 5 amps 5 pin lighting & small
power sockets shall be wired by multi stranded copper wire of 2.5 sq. mm laid in rigid MS conduits
along with earth wire of 1.5 sq.mm flexible copper wire or equivalent size armoured cables. All wiring
shall be coded with Red, Yellow, Blue & Black as per the phase used. If required, wiring can be done
alternatively through armoured copper cables of similar size laid in MS perforated trays of minimum
2.0 mm thick.
b) Three phase power receptacles (convenience outlets) suitable for operation of 415V,3 Phase 4
wire, 50 Hz power supply shall be proposed. In indoor areas one such unit shall be provided to cover
areas of 20 meter radius (or at least one in each room housing plant items ) and in outdoors areas on
such unit shall be provided at 50 meter interval. Actual requirement of such units shall be finalized by
MMC during detailed engineering. One three phase receptacle shall be provided near entrance of each
building for utilities like welding.
c) Single phase 15 Amp 5 Pin / 6 Pin receptacles will be provided in each room and in halls they
will be provided in such a way that with 15 meter cord we should reach every place in building. These
shall be wired with 4 sq. mm copper earth wire in MS rigid conduits along with 2.5 sq. mm earth wire.
Not more than two sockets shall be looped in one circuit. Alternatively they can also be connected
through armoured cable of 4 sq. mm running in appropriate cable trays.
21.6.6 Separate lighting panels and lighting distribution boards shall be installed and they shall not take
tapping for power from motor control centers or power distribution boards.

Section 10. WOODWORK AND JOINARY


21.6.7 This section is deleted as generally wood should not be used in Industrial buildings from the Fire
safety point of view
19 Wood:
19.1 Jointing Materials:

Section 11. PIPING WORK


20 Cast Iron Pipes & Fittings

20.1 All protection and bedding of sewers work shall be carried out in strict accordance with the specification
and methods laid out in the CPHEEO manual.
20.2 Applicable Codes
The manufacturing, testing, supplying, jointing and testing at work sites of cast iron pipes and fittings shall
comply with all currently applicable statutes, regulations, standards and codes. In particular, the following
standards, unless otherwise specified herein, shall be referred. In all cases, the latest revision of the codes shall
be referred to. If requirements of this specification conflict with the requirements of the code of standards, this
specification shall govern.
IS:210 - Specification for grey iron casting
IS: 290 -Specification for coal tar black paint.
IS: 638 -Specification for sheet rubber jointing and rubber insertion jointing.
IS:782 -Specification for caulking lead
IS:1387 -General requirements for the supply of Metallurgical material
IS: 1537 -Specification for vertically cast iron pressure pipes for water, gas and sewage.
IS:1536 -Specification for centrifugally cast (spun) iron pressure pipes for water, gas and sewage
IS: 1538 -Specification for cast iron fittings for pressure pipes for Water, gas and sewage.
IS: 1500 -Method for Brinell hardness test for grey cast iron.
IS: 2078 -Method for tensile testing of grey cast iron.
IS:5382 -Specification for rubber sealing rings for gas mains, water mains, and sewers
IS: 6587 -Specification for spun hemp yarn.
IS: 3114 - Code of practice for laying of cast iron pipes.

21 Mild Steel ERW Pipe


The manufacturing, testing, supplying, jointing and testing at work sites of mild steel pipes and fittings shall
comply with all currently applicable status, regulations, standards and codes. In particular, the following
standards, unless otherwise specified herein, shall be referred. In all cases, the latest revision of the codes shall
be referred to. If requirements of this specification conflict with the requirements of the code standards,
Design-Build-Operations Engineer decision shall be final.
Materials
a. IS:226 : Specification for structural steel (standard quality).
b. IS: 2062 : Specification for structural steel (fusion welding quality).
c. IS: 6631 : Specification for steel pipes for hydraulic purposes.
d. IS:3589 : Specification for electrically welded steel pipes for water, gas and sewage (150 mm to
2000 mm nominal dia).
e. IS:6392 : Specification for steel pipe flanges
f. IS:814 : Specifications for electrodes for metal arc welding of structural steels: Part 2 welding
sheets.
Code of Practice
a. IS: 5822 : Code of practice for laying of electric welded steel pipes.
b. IS: 11906: Recommendations for cement mortar lining for mild steel pipes and fittings for
transportation of water.
c. IS:10221 : Code of practice for coating and wrapping of underground mild steel pipelines.
d. IS: 816 : Code of practice for use of metal arc welding for general construction in mild steel.

22 HDPE Pipes
These pipes shall meet specifications as per IS: 4984.
22.1 Jointing
HDPE pipe shall be jointed properly with HDPE socketed specials to get smooth inner side surface without any
extrusion to avoid any obstruction to the flow of wastewater. If in any particular case butt welding has to be
done, smooth inner surface of pipe without intrusion inside shall be ensured.
23 Glazed Stone Wares Pipes
. The GSW pipes to be provided should be of IS Specifications. They should be properly laid to proper gradient
and as per drawings and approved by Design-Build-Operations Engineer .
24 VALVES
24.1 Gate (Sluice) Valves
Gate Valves shall be either solid wedge or knife gate unless specifically defined on the drawings.
The materials used for the manufacture of each component shall be the best available for the specific purpose
and shall not, in any case be inferior to the following:
Cast Iron - IS. 210 Grade 20
Stainless Steel - IS. 1570 Grade, B.S. 970 Type EN, ASTM A 473.
Gun Metal - BS.1400-LG 2 -C or the equivalent Indian Standard.
Cast Steel - Plain Carbon Steel complying with IS. 1570 Grade, or BS: 970 Grade 431 S 29.
Valve Bodies shall be in cast steel for TTRO Plant unless otherwise stated , Spindle shall conform to Stainless
Steel and Valve Gates shall conform to Stainless Steel
25 Specifications Referred
The specifications contained herein are not exhaustive and for such items of works which may arise and which
are not covered by this specification, or by the relevant Indian Standards, the provisions in the C.P.W.D.
Handbook Vol. I and II (latest edition) shall apply. A list of few important Indian Standards is given below:
Wherever reference to the Indian Standards mentioned below or otherwise appears in this specification, it shall
be taken as a reference to the latest version of the standard.

IS No. Description
General
IS : 456 Code of Practice for Plain and Reinforced Concrete for
General Building Construction
IS 3764 Safety code for excavation
IS : 1200 Method of measurement of building and engineering (Part 1 to 28) works
IS : 3385 Code of practice for measurement of Civil Engineering works.
IS : 1642 Fire safety of buildings (General): Details of Construction Code of Practice.
IS : 4082 Recommendations on stacking and storing of construction materials at site.
Sand
IS: 2116 Sand for Masonry, Mortar
IS: 1542 Sand for Plaster
Aggregates
IS: 383 Aggregates, Coarse and fine from National Sources for Concrete.
IS: 515 Aggregates for use in Mass Concrete Natural and Manufactured.
Cement
IS : 12330 Specification for sulphate Resisting Portland cement.
IS : 1489 Specification for Portland pozzolana cement
IS : 12269 Specification for 53 grade ordinary Portland cement.
Concrete Plain &
Reinforced
IS : 457 Code of practice for general construction of plain and reinforced concrete for
dams and other massive structures.
IS: 3370 Concrete Structures for the Storage of liquids (Part I & Part II, III & IV)
IS : 432 Specification for mild steel and medium tensile steel
(Part 1 and 2) bars and hard drawn steel wires for concrete reinforcement
IS : 1786 Specification for high strength deformed steel bars and wires for concrete
reinforcement.
IS : 4326 Code of practice for earthquake resistant design and construction of building.
IS : 10262 Recommended guidelines for concrete mix design.
IS No. Description
Code for Construction
safety
IS : 3696 Safety code for scaffolds and ladders. (Parts I and III)
IS : 7969 Safety code for handling and storage of building materials.
IS : 8989 Safety code for erection of concrete framed structures.
Brickwork
IS : 1077 Common Burnt Clay Building Bricks.
Paving and Floor Finishes
IS : 1237 Flooring Tiles, Cement Concrete
IS : 1443 Cement Concrete Flooring Tiles, Laying and Finishing of
Plastering & Pointing
IS : 1661 Cement and Lime, Plaster Finishes on Walls and Ceilings
Roof Coverings
IS : 459 Asbestos Cement Sheets, Unreinforced Corrugated Sheets
IS : 730 Fixing Accessories for Corrugated Sheet Roofing
Steel & Iron Work
IS : 226 Structural Steel (Revised)
IS : 800 Use of Structural Steel in General Building Construction, code of Practice for
Pipes& Fittings Pipes
IS : 3486 Cast Iron Spigot & Socket Drain Pipes
IS : 1538 Cast Iron fittings for Pressure pipes for water, Gas & Sewage
IS : 1536 Centrifugally Cast Iron Pressure Pipes for water , Gas & Sewage.
IS : 458 Concrete pipes with or without reinforcement
IS : 783 Code of practice for laying Concrete pipes.
IS : 3114 Code of practice for laying of C.I. Pipes
IS : 1726 C.I. Manhole covers and frames intended for use in drainage works.

Chemical handling tanks


IS: 6164 Code of Safety for Hydrochloric Acid
IS: 4264 - Code of Safety for Caustic Soda

This list does not necessarily cover all the Standards referred to.
SECTION -12
Specifications for Electro mechanical and Electrical works shall be detailed specific to the
Technology being proposed and as per the detailed design submitted.
26 General Technical Specifications for Electrical Works
All works shall be carried out in accordance with the requirements of:
i. IE Rules
ii. State Electricity Board
iii. Rules and regulations of Local authorities, and
iv. The standards in this specification
The Operator is responsible for applying and obtaining necessary statutory approvals and shall ensure
workmanship of good quality and shall assign qualified supervisor / engineers and competent labour who are
skilled, careful and experienced in carrying out similar works.
Latest applicable standards specified below.

Code No. Title

IS 13118 / BS 5311 / IEC 56, 694 Circuit Breakers


IS 3427 / BSEN60298 / IEC298 Metal Enclosed switchgear
IS 2705 / BS 7626 Current Transformers
IS 3156/BS 7625/IEC 186
Voltage Transformers
IS 5578, 11353 Arrangement for Switchgear Busbars, Main
Connections and Auxiliary wiring
IS 2544 / BS 3297 / IEC 273 Busbar Support insulators
IS 13947 (Part 1) / IEC 947-1 / BSEN 60529 Degree of Protection
IS 3231, 3842 / BS 142 / Electrical Relays for Power system protection
IEC 255
IS 1248 / BS 89 / IEC 51 Electrical Indicating Instruments

IS 9385 / BS 2692 / IEC 282 High Voltage Fuses


IS 722, 8530 / BS 5685 / IEC 145, 211 AC Electricity Meters
IS 613 Specification for copper rods and bars for electrical
purposes
Code of practice for phosphating iron and steel
IS 6005 / BS 3189
IS 9920 / IEC 129, 265 & 298 Alternating current Switches for voltages above
1000 V
IS 13703 / BS 1362 / IEC 269 Low voltage fuses
IS 3452 / BS 3676 Toggle switches
IS 10118 Code of practice for selection, installation and
maintenance of switchgear and control gear
IS6875/BSEN 60947/IEC 947 Control switches
Title Code No.

Basic climatic and mechanical IS:9000


durability tests for components for
electronic and electrical equipment
Environmental tests for electronic and electrical IS:9000
equipment

Metal clad base material for printed circuits for use in IS:5921
electronic and telecommunication equipment
Transformers and inductors (power, audio, pulse and IS:6297
switching) for electronic equipment
Printed wiring boards IS:7405
Environmental requirements for IS 6553
semi-conductor devices and
integrated circuits
Terminals for electronic equipment IS:4007
Factory built assemblies of IS:8623/BS: 5486 /IEC:439
switchgear and control gear for voltages upto and
including 1000 V AC and 1200 V DC
Air break switches IS : 13947 (Part 3)BSEN60947-3
Miniature circuit breakers IS 8828/BSEN:60898
HRC cartridge fuses IS:9224/BS:88
Contactors IS:13947(Part3) /BS:775/ IEC:158-1
Control switches/push buttons IS:6875
Indicating instruments IS:1248/BC:89/ EC:51
Degree of Protection IS:13947-(Part1)/IEC:947-1
Climate-proofing of electrical equipment BSCP:1014
Code of practice for phosphating IS:6005/BS:3189
iron and steel
Semi-conductor converters IEC:146
Semi-conductor rectifier IS:6619
equipment safety code
Specification for copper rods IS : 613
and bars for electrical purposes
Code No. Title

IS2026/BS171/IEC76 Power Transformer


IS3639 Fittings and Accessories
IS1180 Auxiliary Transformer
IS6600/BSCP.1010/IEC354 Loading of oil immersed transformer
IS335/BS 148/IEC296 Transformer Oil
IS2099/BS223/IEC137 Bushings for > 1000V, AC
IS7421 Bushings for 1000V, AC
IS13947 (Part 1) / IEC947-1 Degree of Protection
IS3637 Buchholz Relay
IS 1271/BS2757/IEC85 Insulation Materials for Electrical Machinery
IS 3202/ BSCP1014/ IEC354 Climate Proofing
IS 1886 Installation & Maintenance of Transformers
IS 2705 Current Transformers

IS 375 Marking & arrangement for switchgear, busbars, main


connection and auxiliary wiring
IS 2147 Degree of Protection
IS 3202 Climate- proofing of electrical equipment
IS 5082 Aluminium Busbars
IS 8081 For Non-segregated phase bus-ducts.
IS 3202 Code of Practice for climate proofing of electrical equipment
IS 2516 Alternating current Circuit Breakers ( Relevant part/Section)
IS 3231 Electric Relays for Power System Protection
IS13947 Switchgear General Requirements
IS 3427 Metal Enclosed switchgear and control gear
IS 4237 General requirements for switch gear and control gear for
voltage not exceeding 1000 volts
IS 694 Part I & II PVC insulated cables ( for voltages up to 1100V with copper
and Aluminium conductors)
IS 8623 Factory Built Assemblies of SWGR and Control gear for
Voltages upto and including 1000V AC & 1200V DC
IS 13947-P3 Air Break Switches
IS 8828 Miniature Circuit Breakers
IS 13703 Low voltage Fuses
IS13947 Contactors
IS13947 Starters
IS 6875 Control Switches / Push buttons
IS 2705 Current Transformers
IS 3156 Voltage Transformers
IS 1248 Direct Acting Electrical Indicating instruments
IS 2147 Degree of protection provided by enclosures for low voltage
switch gears.
IS 2959 AC Contactors of voltage not exceeding 1000 volts
IS 11353 Marking and Identification of Conductors and Apparatus
Terminals
IS 722 A.C. Electricity Meters
IS 10118 Selection installation and maintenance of switchgear and control
gear
IS : 2834 Shunt capacitors for power systems
IS : 2544 Specification for Porcelain Post
Insulators (3.3 KV and above)
IS : 5553 Series Reactors (Part II)
IS : 12672 Internal fuses and internal overpressure disconnectors for shunt
capacitors
IS:7098 (Part-II) Cross linked polyethylene insulated PVC sheathed cables for
working voltages from 3.3 kV up to and including 33 kV

IS : 5831 PVC insulation and sheath of


Electric cables
IS : 6474 Polyethylene insulation and
sheath for electric cables
IS : 8130 Conductors for insulated electric
Cables
IS : 3975 Mild Steel wires, strips and tapes for armouring of cables
IS : 10810 Methods of test for cables
IS : 3961 (Part II) Recommended current ratings for cables PVC insulated and
PVC sheathed heavy duty cables
IS : 1753 Aluminium Conductors for insulated cables
IS : 10418 Specification for drums of Electric cables
IS : 2633 Methods of testing weight, thickness and uniformity of coating
on hot dipped galvanized articles
IS : 209 Specifications for Zinc
IS : 694 PVC insulated cables (for Voltage up to 1100 V)
IS : 1554 (Part I) PVC insulated heavy duty electric cables for working voltage up
to and including 1100 volts
IS : 5831 PVC insulation and sheath of Electric cables
IS : 6474 Polyethylene insulation and sheath for electric cables
IS : 8130 Conductors for insulated electric Cables
IS : 3975 Mild Steel wires, strips and tapes for armouring of cables
IS : 10810 Methods of test for cables
IS : 3961 (Part II) Recommended current ratings for cables PVC insulated and
PVC sheathed heavy duty cables
IS : 1753 Aluminium Conductors for insulated cables
IS : 10418 Specification for drums of Electric cables
IS : 2633 Methods of testing weight, thickness and uniformity of coating
on hot dipped galvanized articles
IS : 209 Specifications for Zinc

IS2026/BS171/IEC76 Power Transformer

IS3639 Fittings and Accessories

IS1180 Auxiliary Transformer

IS6600/BSCP.1010/IEC354 Loading of oil immersed transformer

IS335/BS 148/IEC296 Transformer Oil

IS2099/BS223/IEC137 Bushings for > 1000V, AC

IS7421 Bushings for 1000V, AC

IS13947 (Part 1) / IEC947-1 Degree of Protection

IS3637 Buchholz Relay

IS 1271/BS2757/IEC85 Insulation Materials for Electrical Machinery

IS 3202/ BSCP1014/ IEC354 Climate Proofing

IS 1886 Installation & Maintenance of Transformers


IS 2705 Current Transformers

I.S. 3043 1987. Earth Pits

27. Equipment List

The suggested Equipment List shall be as follows:-

S.No NAME OF THE QTY CAPACITY/ SPECIFICATIONS/ SIZE MOC


EQUIPMENT
1 Pre Chlorination 1 (with Total Effective Liquid Holdup Capacity = RCC EL
contact Tank / Rapid twin 1360 m3 (Each compartment 20 m x
sand filter feed sump compa 20 m x 1.7 m LD + 0.5 m FB)
rtments)
2 Rapid sand filter feed 4 (2W Each 1360 m3/h @ 10 m Head C & I: CS
pumps +
2SB)
3 ClO2 generator 2 (1W Each 10 kg/h As per
(Submerged/ + Manufacturer
Encapsulated 1SB) recommendation/
Underwater U tube standard
type)
4 ClO2 generator 1 During Detail Engineering RCC framed
Room structure + Brick
work
5 Pipeline between Pre 1 1000 mm dia C.I LA class
chlorination tank and
Rapid sand filter
house
6 Rapid sand filter 1 ( 4 3W + 1 SB beds of each 15.5m x 12m x RCC + Brick
house beds ) 3.7m total depth, housed in a suitable work
Filter house
7 Rapid sand Filter 1 Effective Liquid Holdup Capacity = 1120 RCC EL
Backwash Tank m3 (Minimum) ( To be provided over the
Rapid sand filter house)
8 Ultra filtration feed 1 Effective Liquid Holdup Capacity = 450 RCC EL
sump m3 (13 m dia x 3.4 m LD + 0.5 m FB)
9 Ultra filtration feed 4 (3W 890 m3/h @ 25 m Head C & I: CS
pumps +
1SB)
10 RSF Backwash tank 2 (1W 145 m3/h @ 15 m Head C & I: CS
filling pumps +
1SB)
11 Ultra-Filtration (UF) 7 (6W 7 skids x 392 m3/h permeate each skid, Membrane: Poly
Skids + Membrane Module /skid: 160 - 200 Nos, Ether Sulfone/
1SB) Each skid provided with a Pre filter / PVDF,
Manual strainer / basket filter Pressure Tube:
FRP/GRP / ABS/
PVC
12 UF Permeate Tank 1 Effective Liquid Holdup Capacity = 2750 CS EC
m3 (15.5 m Diameter x 14.6 LD + 1.4
FB)
13 UF Backwash Pumps 3 (2W 700 m3/ h @ 25 m Head C & I: SS316L
+ 1SB)
14 Cartridge Filters 5 (4W Each 588 m3/ h @ 25 m Head C & I: SS316L
Feed Pumps + 1SB)
15 Cartridge Filters 5 (4W 588 m3/ h per Cartridge Cartridge Filter
+ 1SB) Element: PP,
Shell / Housing:
SS 316L
16 RO High Pressure 5 (4W 588 m3/ h , Differential Head: During C & I: SS316L
Feed Pumps + 1SB) Detail Engineering
17 Brackish Water 5 (4W 471 m3/ h net permeate per skid Membranes:
Reverse Osmosis + 1SB) Polyamide,
Skids (BWRO) Pressure
Tubes: GRP/ FRP
18 Degasser Tower 7 (6W 2.45 m Diameter, Tower Height: During Tower: CSRL;
+ 1SB) Detail Engineering (1.5 m Minimum Packing: PP
Packing Height)

19 Degassed Air Blower 8 (6W 7000 m3/ h * @ 100 mm head Minimum C & R: CS; S:
+ 2SB) EN8
20 RO Permeate Tank/ 1 (with Total Effective Liquid Holdup Capacity = RCC EL
Activated carbon twin 938 m3 (Each compartment 12.5 m x
filter feed sump compa 12.5 m x 1.8 m LD + 0.5 m FB)
rtments)
21 Activated carbon 4 (3W Each 625 m3/h @ 25 m Head C & I: CS
filtration feed pumps + 1SB)
22 Activated carbon 4 (3W Each handling 625 m3/h flow ( Each 5m CS EC or FRP or
filters + 1SB) dia x 2.7m side depth) Equivalent
23 Treated water storage 1 (with Total Effective Liquid Holdup Capacity = RCC EL
Tank twin 10000 m3 (Each compartment 41 m x
compa 41 m x 3.0 m LD + 0.5 m FB)
rtments)
24 Ozone treatment 1 Lot To disinfect a flow of 45mld i.e 10 kg/ As per suppliers
hour @ 10% concentration wt/wt recommendation
25 Treated Product 4 (2W 950 m3/h @ 35.00 m Head C & I: CS
water pumps + 2 SB)
26 Caustic Lye Storage 2 (Total Effective Liquid Hold-up CS (PWHT)
Tank combined capacity equivalent to 20 days
total requirements of Caustic in TTRO
plant or 15 m3, whichever is more)
27 Caustic Lye 2 (1W 15 m3/ h Differential Head: During
C & I: SS316L
Unloading/ Transfer +1SB) Detailed Engineering
Pumps
28 Caustic Solution 2 (1W Capacity & Differential Head: During C: PP/PVDF & D:
Dosing Pumps + 1SB) Detailed Engineering TEFLON

29 Sodium Chlorite 2 (Total Effective Liquid Hold-up Solid FRP with


Storage Tank combined capacity equivalent to 20 days UV Protection
total requirements of Sodium Chlorite in
TTRO plant or 15 m3, whichever is
more)
30 NaClO2 Unloading/ 2 (1W 15 m3/ h Differential Head: During C: PP/PVDF & I:
Transfer Pumps + 1SB) Detailed Engineering TEFLON

31 NaClO2 Dosing 2 (1W Capacity & Differential Head: During C: PP/PVDF & D:
Pumps + 1SB) Detailed Engineering TEFLON

32 Chemical Enhanced 1 Capacity & Size: During Detail Solid FRP


Backwash Tank-I Engineering
(HCl)
33 Chemical Enhanced 1 Capacity & Size: During Detail CS PWHT
Backwash Tank-II Engineering
(NaOH)
34 Chemical Enhanced 1 Capacity & Size: During Detail Solid FRP
Backwash Tank-III Engineering
(NaOCl)
35 Chemical Enhanced 2 (1W Capacity & Differential Head: During Casing: PP/PVDF,
Backwash Pumps I + 1SB) Detailed Engineering Diaphragm:
(HCl) Teflon
36 Chemical Enhanced 2 (1W Capacity & Differential Head: During Casing: PP/PVDF,
Backwash Pumps II + 1SB) Detailed Engineering Diaphragm:
(NaOH) Teflon
37 Chemical Enhanced 2 (1W Capacity & Differential Head: During Casing: PP/PVDF,
Backwash Pumps + 1SB) Detailed Engineering Diaphragm:
III (NaOCl) Teflon
38 Disposal Blending 1 (with Effective Liquid Holdup Capacity of each RCC with PPG
Tank twin compartment: 775 m3 Minimum * Lining
compa
rtments)
39 Disposal Pumps 4 (3W 300 m3/ h , Differential Head: 15 m To C & I: SS 316L
+ 1SB) be confirmed during detail engineering

40 Suck Back Tank 1 Capacity & Size: During Detail Solid FRP
Engineering
41 Anti Scalant Dosing 2 Capacity & Size: During Detail Solid FRP
Tank Engineering
42 Anti Scalant Dosing 2 To suit Tank I & S: SS 316L
Tank Agitators
43 Anti Scalant Dosing 2 (1W Capacity & Differential Head: During Casing: PP/PVDF,
Pumps + 1SB) Detailed Engineering Diaphragm:
Teflon

44 Sodium Bi Sulphite 2 Capacity & Size: During Detail Solid FRP


Dosing Tank Engineering

45 Sodium Bi Sulphite 2 To suit Tank I & S: SS 316L


Dosing
Tank Agitators

46 SBS Dosing Pumps 2 (1W Capacity & Differential Head: During Casing: PP/PVDF,
+ 1SB) Detailed Engineering Diaphragm:
Teflon

47 HCl Bulk Storage 2 (Total Effective Liquid Hold-up Solid FRP with
Tank combined capacity equivalent to 20 days UV Protection
total requirements of Acid in TTRO plant
or 85 m3, whichever is more)
48 HCl Unloading/ 2 (1W 15 m3/ h Differential Head: During C: PP/PVDF & I:
Transfer Pumps + 1SB) Detailed Engineering TEFLON

49 HCl Dosing Pumps 2 (1W Capacity & Differential Head: During C: PP/PVDF & D:
(for Dosing at RO + 1SB) Detailed Engineering TEFLON
Inlet)
50
HCl Dosing Pumps 2 (1W Capacity & Differential Head: During C: PP/PVDF & D:
(for ClO2 + 1SB) Detailed Engineering TEFLON
generation)
51 RO Cleaning 1 Capacity & Size: During Detail Solid FRP
Solution Tank Engineering
52 RO Cleaning
2 (1W Capacity & Differential Head: During C & I: SS 316L
Solution Pumps
+ 1SB) Detailed Engineering

53 RO Cleaning 1 Capacity: During Detail Engineering Cartridge Filter


Solution Cartridge Element: PP,
Filters Shell / Housing:
SS 316L
54 RO Cleaning 1 To suit Tank I & S: SS 304
Solution Tank with FRP lining
Agitators

55 Chemical House 1 20 m x 15 m * (Minimum & Indicative) RCC framed


Building Chemical House Building shall be sized structure + Brick
for requirements of a 60 MLD TTRO work
Plant

56 UF Shed 1 During Detail Engineering (Shall be sized As per


for requirements of a 60 MLD TTRO Engineering
Plant) Specifications

57 RO Shed 1 During Detail Engineering (Shall be sized As per


for requirements of a 60 MLD TTRO Engineering
Plant) Specifications

58 Substation and 1 During Detail Engineering (Shall be sized RCC framed


Control Room for requirements of a 60 MLD TTRO structure + Brick
Plant) work

59 Administration cum 1 Each floor 20m x 10m x 3.5m ht (GF + RCC framed
Laboratory Building FF) structure + Brick
work

60 Air blower house 1 Suitable size to house all the air blowers RCC framed
required for the TTROP structure + Brick
work

61 UF Air Blowers During Detail Engineering based on UF


system suppliers recommendations.
62 Rapid sand filters Air During Detail Engineering
Blowers
63 Transformer cum DG 1 Suitable size to house the Transformers RCC framed
room and DG sets required for the TTROP structure + Brick
work

64 Pipeline between 1 As per Treated Product water main Bill DI K9 class


Treated Product of Quantities
water pump house
and usage point
65 Reject/ disposal 1 Suitable dia between disposal blending DI K7 class
water pumping main tank and disposal point
for conveying reject
water from the
Disposal water sump
to the disposal point
66 Disposal blending 1 Suitable dia between 110mld Maturation DI K7 class
pipe pond and disposal blending tank

ABBREVIATION
LD: Liquid Depth CS: Carbon Steel SS: Stainless Steel
FRP: Fibre Reinforced Plastic RL: Rubber lining (min. 4.5 mm thk) PWHT: Post Weld Heat
Treatment
EC/ EL: Epoxy Coating/ Epoxy Lining PP: Poly Propylene C: Casing
I: Impeller D: Diaphragm RCC: Reinforced Cement Concrete
R: Rotor S: Shaft FB: Free Board
PVDF: Poly Vinylidene Fluoride DVD: Dead Volume Depth GRP: Glass Reinforced Plastic
PVC: Poly Vinyl Chloride ABS: Acrylonitrile Butadiene Styrene PPG: Plastic Polypropylene
Glass (Acid / Alkali Resistant Lining)
NOTES
1. In addition to above, all other equipment necessary for completeness but not listed above shall
also be deemed to have been included in Operators scope.
2. Data marked as * has to be furnished/ confirmed by the Operator.
3. All other works including civil, mechanical, electrical, piping, instrumentation, construction,
erection, testing, painting works, etc., shall be provided.
4. All the Sizes/Specifications as specified above in the Equipment List are Minimum
Requirements Operator shall confirm these sizes/specifications and shall provide adequate
sizes/specifications not less than the above or more as required to make the plant complete
from process & engineering point of view including trouble free safe operation of the plant.
5. Pump houses, Dewatering Pumps, Static Mixers, Weighing Machines, Monorails, Safety
Showers & Eyewash, Drinking Water Cooler, Fume absorbers etc. shall be provided as per
requirements. Details to be reviewed during detail engineering.
6. Liquid Depth (LD) excludes FB & DVD.
7. Process Datasheet for ClO2 generator system & UF Air blowers shall be prepared and submitted
by the system supplier during detail engineering.
8. Operator may include in their scope any additional requirements, if so warranted by them for
safe and trouble free operation of the plant.

The required details for the various Process units shall be as follows:-

15.1 Pre Chlorination Contact Tank / Rapid Sand Filter Feed


Sump
Service : To receive secondary treated effluent from
the Maturation Pond of the Owners STP and
to be used as a Pre chlorination tank cum
Rapid sand filter feed sump
PROCESS DATA
Inlet flow (max.) (m3/hr) 2720
Nominal capacity (m3) *
Effective liquid storage volume of tank (m3) 1360
Storage temperature (oC) Ambient
Design temperature (0C) NA
Sp. gr. of liquid at storage temperature (oC) ~1.0

Storage pressure (kg/cm2 .a) Atm. + liquid column


UNIT DESCRIPTION
No. of tanks 1
Type Rectangular, above and below ground and
open tank
No. of. Compartments 2
Inter connection between compartments With overflow cut out
Length of each compartment of the tank (m) 20.0 (suggested, Bidder can vary)
Width of each compartment of the tank (m) 20.0(suggested, Bidder can vary)
Liquid depth (m) (of each compartment) 1.7 (suggested, Bidder can vary)
Free board above TWL (m) of each compartment 0.5
Size of suction channel (m x m) *x*
Total height (m) *
Residence time (hrs) / tank (@ normal flow) 0.5
Slope for tank bottom Yes, provided as per specs / as per
requirement.
Overflow arrangement required (yes / no) Yes
Bottom drain required (yes / no) Yes
Any baffle arrangement required (yes / no) Yes (so as to have a length of travel of
90m)
Vent NA
Level indication required (yes / no) Yes
Level transmitter & level alarm(yes / no) Yes
Level transmitter platform (yes/no) Yes
MATERIAL OF CONSTRUCTION
Tank RCC
Painting / lining Epoxy lining
Operating platform, access stairs, hand railings Yes, provided as per specs / as per
requirement.
Rungs Yes, provided as per specs / as per
requirement.
Manholes NA
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
2.The tank shall be provided with inlet sump arrangement connected to each compartment of the tank through
sluice gates. Submerged, underwater chlorine dioxide generators shall be located in this inlet sump with
diffuser assembly.
15.2 Rapid Sand Filter Feed Pumps
Service : Feed water to Rapid sand filtration system
Type : Submersible or Centrifugal, Horizontal
PROPERTIES OF LIQUID
Liquid handled Secondary Treated water from STP and
Pre Chlorinated
o
Pumping temp. ( C) AMB.
Viscosity at pumping temp. (cP) 1.0
Liquid density (kg/m3) 1000
Presence of corrosive / toxic components No
Solids in suspension (yes/no) Yes
Size of solid particles (mm) (max) 3 to 5 mm
OPERATING CONDITIONS
Flow rate - Normal (m3/h) 1360
Flow rate - Max/ Rated (m3/h) *

Flow rate - Min. (m3/h) *


Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (m) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 4 (2W+2SB)
MECHANICAL DATA
Design pressure (kg/cm2.g) *

Design temperature (oC) 65


Material Code Casing CS
Material Code Impeller CS
Seal type (Mechanical/Packing) Packing
Line rating In/Out */*
Driver Electrical Motor
NOTES :
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. The minimum requirement head may be indicated in the Bidding stage and the Bidder shall
increase pump head (if required) as per actual pressure drop calculations of the pump during detail
Engineering.
3.The pump shall be capable of auto start / auto stop operation.
4.The pump motor shall be sized for open discharge conditions and parallel operations.
5. The pumps shall be able to meet minimum continuous flow (MCF) requirement.
15.3 Rapid Sand Filters
Service : Filtration of Pre Chlorinated water
Type Vertical down flow
PROCESS DATA

Inlet flow (max.) (m3/hr) 2720


INLET CHARACTERISTICS
TSS (mg/l) 30
Turbidity (NTU) 25
Specific gravity of feed water 1.0
OUTLET CHARACTERISTICS
TSS (mg/l) The outlet water quality from Rapid
filtration system shall meet the Ultra
filtration system suppliers inlet water
quality requirements
Turbidity (NTU) The outlet water quality from Rapid
filtration system shall meet the Ultra
filtration system suppliers inlet water
quality requirements
OPERATING CONDITIONS
Temperature (oC) Ambient
Pressure (kg/cm2.g) *
Pressure drop across bed (kg/cm2) *
FILTER SPECIFICATIONS
Number of beds to be constructed 3 W + 1 SB
Design flow to each bed (m3/hr) 906.67
Rate of filtration (4.8 to 6) cum/sqm/hr 5 (suggested)
Length of each Bed (m) 15.5 (suggested, Bidder can vary)
Width of each Bed (m) 12.0(suggested, Bidder can vary)
Depth of gravel (m) 0.45 (suggested, Bidder can vary)
Size of gravel at Bottom (mm) 25 (suggested, Bidder can vary)
Size of gravel at top (mm) 2 to 5 (suggested, Bidder can vary)
Depth of sand (0.6 to 0.75) (m) 0.75 (suggested, Bidder can vary)
Effective size of sand (0.45 to 0.70) (mm) 0.50 (suggested, Bidder can vary)
Uniformity coefficient of sand (1.30 to 1.70) (mm) 1.50 (suggested, Bidder can vary)
Depth of water above sand surface (1.00 to 2.00) m 2.00 (suggested, Bidder can vary)
Free board (m) 0.50
Backwash Provision Yes
Rate of wash water (cum/sqm/hr) 36 (suggested, Bidder can vary)
Rate of Air scour (36 to 45 ) (cum/sqm/hr) 40 (suggested, Bidder can vary)
Back wash time per Filter bed (minutes) 10 (suggested, Bidder can vary)
MATERIAL OF CONSTRUCTION
Tank RCC
Painting / lining Epoxy lining
Operating platform, access stairs, hand railings Yes, provided as per specs / as per
requirement.
Rungs Yes, provided as per specs / as per
requirement.
Manholes NA
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
15.4 Rapid Sand Filter Backwash Tank
Service: To store back wash water for
Rapid sand filtration system
PROCESS DATA

Inlet flow (max.) (m3/hr) *


Nominal capacity (m3) *
Effective liquid storage volume of tank (m3) 1120
Storage temperature (oC) Ambient
Design temperature (0C) NA
Sp. gr. of liquid at storage temperature (oC) ~1.0

Storage pressure (kg/cm2 .a) Atm. + liquid column


UNIT DESCRIPTION
No. of tanks 1
Type Rectangular, above Rapid sand filter house,
open tank
No. of. Compartments 1
Inter connection between compartments NA
Length of each compartment of the tank (m) *
Width of each compartment of the tank (m) *
Liquid depth (m) (of each compartment) *
Free board above TWL (m) of each compartment 0.5
Size of suction channel (m x m) NA
Total height (m) *
Residence time (hrs) / tank (@ normal flow) *
Slope for tank bottom *
Overflow arrangement required (yes / no) Yes
Bottom drain required (yes / no) Yes
Any baffle arrangement required (yes / no) No
Vent NA
Level indication required (yes / no) Yes
Level transmitter & level alarm(yes / no) Yes
Level transmitter platform (yes/no) Yes
MATERIAL OF CONSTRUCTION
Tank RCC
Painting / lining Epoxy lining
Operating platform, access stairs, hand railings *
Rungs *
Manholes NA
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
15.5 Ultra Filtration Feed Sump
Service : To store Rapid sand filtered water and
transfer for UF Feed and Rapid sand filter
back wash tank filling
PROCESS DATA
Inlet flow (max.) (m3/hr) 2666
Nominal capacity (m3) *
Effective liquid storage volume of tank (m3) 450
Storage temperature (oC) Ambient
Design temperature (0C) NA

Sp. gr. of liquid at storage temperature (oC) ~1.0


Storage pressure (kg/cm2 .a) Atm. + liquid column
UNIT DESCRIPTION
No. of tanks 1
Type Circular, Conical roof with vents
No. of. Compartments 1
Inter connection between compartments NA
Diameter of each compartment of the tank (m) 13 (suggested, Bidder can vary)

Liquid depth (m) (of each compartment) 3.4 (suggested, Bidder can vary)
Free board above TWL (m) of each compartment 0.5
Total height (m) *
Residence time (hrs) / tank (@ normal flow) 0.166
Slope for tank bottom Yes, provided as per specs / as per
requirement.
Overflow arrangement required (yes / no) Yes
Bottom drain required (yes / no) Yes
Any baffle arrangement required (yes / no) No
Vent Yes, the tank vent shall be goose neck
type and be provided with wire mesh
Level indication required (yes / no) Yes
Level transmitter & level alarm(yes / no) Yes
Level transmitter platform (yes/no) Yes
MATERIAL OF CONSTRUCTION
Tank RCC
Painting / lining Epoxy lining
Operating platform, access stairs, hand railings, Manholes Yes, provided as per specs / as per
requirement.
Rungs N.A
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
15.6 Ultra Filtration Feed Pumps
Service : Feed water to Ultra filtration system
Type : Submersible or Centrifugal, Horizontal
PROPERTIES OF LIQUID
Liquid handled Treated water from Rapid sand filter
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cP) 1.0
Liquid density (kg/m3) 1000
Presence of corrosive / toxic components No
Solids in suspension (yes/no) Fine suspended solids
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (m3/h) 890
Flow rate - Max/ Rated (m3/h) *

Flow rate - Min. (m3/h) *


Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (m) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 4 (3W+1SB)
MECHANICAL DATA
Design pressure (kg/cm2.g) *
Design temperature (oC) 65
Material Code Casing SS 316 L
Material Code Impeller SS 316 L
Seal type (Mechanical/Packing) Mechanical
Line rating In/Out */*
Driver Electrical Motor
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
2.The bidder shall provide pump head as per pressure drop
calculations of the pump as per tender requirements during
detail engineering
3. The pump shall be capable of auto start / auto stop operation.
4. The pump motor shall be sized for open discharge conditions.
5. The pump motor shall be designed for pressure requirement
of UF Membranes at the end of third year and at 15 deg C water
temperature.
6.The pumps shall be able to meet minimum continuous flow
(MCF) requirement.
7. Pump to be provided with variable frequency drive motors in
order to meet variable pressure requirement. The VFD shall be
provided for all the installed pumps (04 nos.)
15.7 Rapid Sand Filter Backwash Tank Filling Pumps
Service : To fill backwash tank required for Rapid
sand filtration backwashing system
Type : Submersible or Centrifugal, Horizontal
PROPERTIES OF LIQUID
Liquid handled Treated water from Rapid sand filter
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cP) 1.0
Liquid density (kg/m3) 1000
Presence of corrosive / toxic components No
Solids in suspension (yes/no) Fine suspended solids
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (m3/h) 145 (suggested, Bidder can vary)
Flow rate - Max/ Rated (m3/h) 145 (suggested, Bidder can vary)
Flow rate - Min. (m3/h) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) 1.5 (suggested, Bidder can vary)
Differential pressure (kg/cm2) *
Differential head (m) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
MECHANICAL DATA
Design pressure (kg/cm2.g) *
Design temperature (oC) 65
Material Code Casing CS
Material Code Impeller CS
Seal type (Mechanical/Packing) Packing
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. The minimum requirement head may be indicated in the
Bidding stage and the Bidder shall increase pump head (if
required) as per actual pressure drop calculations of the pump
during detail Engineering.
3.The pump shall be capable of auto start / auto stop operation.
15.8 Ultra Filtration System
Service : Filtration of Fine suspended solids
PROCESS DATA
Liquid handled Water/Cleaning fluids
Viscosity of liquid (cP) 1.0
Liquid density (kg/m3) 1000
Operating temperature (oC) AMB.
Mechanical design temperature (0C) 65
Operating pressure / design pressure (kg/cm2.g) 5.0/ 7.0 * (suggested, Bidder can vary)
Pre-filtration (m) 100 to 200 (suggested, Bidder can vary)
ULTRA FILTRATION MEMBRANES
Total flow rate in each skid (m3/h) 445
Number of skids 7 (6W+1SB)

UF net permeate flow rate (m3/h)/skid 392 (Minimum)

UF gross feed flow rate (m3/h) ~2670


Water required for backwash and cleaning(m3/d) *
Flow reversibility *

Backflush Flux (GFD) *

Backflush frequency *

Chemical enhance backwash frequency *

Cleaning In Place (CIP) frequency *

Normal backflush pressure *

Max backflush pressure *

Recovery (%) 88 % (Minimum)

Mode of operation Dead end/Cross flow

Diameter of membrane (inch/mm) *


Length of membrane (inch/mm) *

Filtration area per membrane (m2) *


Flow direction Inside out /Outside in
Gross flux (rate) (GFD) 25 (UK gallons)

Total membrane surface filtration area m2 min *


Type of membrane Hollow fibre / Single layered

Lumen fibre inner diameter (mm) *

Designed to remove molecular weight < 1,50,000 Daltons

Mode of operation Auto

Guaranteed life of membranes 5 Years (2 year flat & 3 years on


pro-rata)

Make of membrane suppliers GE / HYDRANAUTICS /


HYFLUX / INGE / KOCH/
MANN & HUMMEL/ MEMCOR/
NORIT/ OSMONICS / PALL/
TORAY/ Or Equivalent

Make of pressure tube suppliers ADVANCED COMPOSITE / BEL-


ISRAEL/ CODELINE/ PHOENIX/
PROTEC/ORLITE/ KANOPPE/
WAVE CYBER/ Or Equivalent

MOC of process & permeate piping PE (suggested, Bidder can vary)


MOC of drain & vent piping PVC SCHEDULE 80 (ASTM-
D1784,1785) *(suggested, Bidder can
vary)

MOC of flange joints & victaulic connections */*

MOC of frames *

Gaskets & Elastomers EPDM/BUNA*

Bolts & Washers *

MATERIAL OF CONSTRUCTION

Material of construction of membrane Poly Ether Sulfone/ PVDF

Material of construction of pressure tube FRP/ GRP/ ABS/ PVC

Applicable design code ASME

PARAMETERS UF Inlet *(after


UF OUTLET *
Pre treatment)
445 / Skid 392 / Skid of net
permeate flow
Flow, cum / h after water losses
during various back
wash steps
Ph * *

Temperature (oC) * AMB

Total Suspended Solids (TSS), mg/l * Nil

Total Dissolved Solids (TDS), mg/l * *

Salt Rejection of Membranes, % * *

Conductivity, micro mho/cm * *


Oil & Grease, mg/l * *
BOD, mg/l * *
COD, mg/l * *
Total Hardness, mg/l as CaCO3 * *
Calcium Hardness, mg/l as CaCO3 * *
Magnesium Hardness, mg/l as CaCO3 * *
Chlorides as Cl, mg/l * *

Sulphates as SO4, mg/l * *


Sodium as Na, mg/l * *

Phosphates as PO4, mg/l * *

Ammoniacal N, mg/l * *
Kejaldahl N, mg/l * *
Reactive Silica as SiO2 / Colloidal Silica, mg/l * *

Turbidity, NTU * *

Silt Density Index (SDI) * <3 #

Iron as Fe, mg/l * *

Alkalinity,mg/l * *

All other metals * *

# Included in guaranteed parameters besides recoveries in UF


(shall be based on 25 oC water temperature)
Notes
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. Bidder to provide process parameter guarantee as per data
sheet & tender specs
3. Bidder to provide separate data sheets for various valves in
the skid with tag nos. containing information on type, MOC,
Service etc. It should also include block and bleed valves,
integrity check valve, isolation valves, etc.
4.Bidder to give backup process calculations for all the data
marked as * in the data sheet. Calculations should include all the
water lost due to backflush, fast flush and time lost.
5.Bidder to design the system such a way that minimum
recovery from UF skids is obtained even at the end of third year.
6. A platform of suitable size shall be provided for maintenance
of UF system.
7.For leak detection, one no. of ultrasonic leak detection
instrument shall be provided in addition to membrane suppliers
recommendations.
8.The calculation for the flux rate shall be done considering UK
gallon as reference unit
15.9 UF Permeate Tank
Service : To store UF permeate water and
transfer for RO feed/ UF backwash
requirements

PROCESS DATA
Inlet flow (max.) (m3/hr) 2352
Nominal capacity (m3) *
Effective liquid storage volume of tank (m3) 2750
Storage temperature (oC) Ambient
Design temperature (0C) NA

Sp. gr. of liquid at storage temperature (oC) ~1.0


Storage pressure (kg/cm2 .a) Atm. + liquid column
o
Design Temperature ( C) 65
UNIT DESCRIPTION
No. of tanks 1
Type Circular, Conical roof with vents
No. of. Compartments 1
Inter connection between compartments NA
Diameter of each compartment of the tank (m) 15.5 (suggested, Bidder can vary)

Liquid depth (m) (of each compartment) 14.6 (suggested, Bidder can vary)
Free board above TWL (m) of each compartment 1.4
Total height (m) *
Residence time (hrs) / tank (@ normal flow) *
Slope for tank bottom 1:100
Overflow arrangement required (yes / no) Yes
Bottom drain required (yes / no) Yes
Any baffle arrangement required (yes / no) No
Vent Yes, the tank vent shall be goose neck
type and be provided with wire mesh
Level indication required (yes / no) Yes
Level transmitter & level alarm(yes / no) Yes
Level transmitter platform (yes/no) Yes
MATERIAL OF CONSTRUCTION
Tank CS
Painting / lining Epoxy Painting
Corrosion Allowance (mm) (Shell/Bottom/Roof) 3.0/3.0/1.5
Minimum thickness (mm) (Shell/Bottom/Roof) 12.0/10.0/6.0
Operating platform, access stairs, hand railings, Manholes Yes, provided as per specs / as per
requirement.
Rungs N.A
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
15.10 UF backwash Pumps
Service : To backwash Ultra Filtration system
Type : Submersible or Centrifugal, Horizontal
PROPERTIES OF LIQUID
Liquid handled UF Permeate water
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cP) 1.0
Liquid density (kg/m3) 1000
Presence of corrosive / toxic components No
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (m3/h) 700 (suggested, Bidder can vary)
Flow rate - Max/ Rated (m3/h) 700 (suggested, Bidder can vary)
Flow rate - Min. (m3/h) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) 2.5 (suggested, Bidder can vary)
Differential pressure (kg/cm2) 2.5 (suggested, Bidder can vary)
Differential head (m) 25 (suggested, Bidder can vary)
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 3 (2W+1SB)
MECHANICAL DATA
Design pressure (kg/cm2.g) *
Design temperature (oC) 65
Material Code Casing SS316L
Material Code Impeller SS316L
Seal type (Mechanical/Packing) Packing
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. The capacity and head of the pumps are indicative and shall
be finalised during Detail Engineering as per UF system
suppliers recommendation. Capacity of pumps shall be
selected considering Backwash/CEB/CIP of 2 skids of UF
simultaneously.
3.The pump shall be capable of auto start / auto stop operation.
4.This datasheet shall be vetted by Ultra Filtration system
supplier.
15.11 Cartridge Filter feed Pumps
Service : To feed Cartridge Filtration system
Type : Submersible or Centrifugal, Horizontal
PROPERTIES OF LIQUID
Liquid handled UF Permeate water
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cP) 1.0
Liquid density (kg/m3) 1000
Presence of corrosive / toxic components No
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (m3/h) 588 (suggested, Bidder can vary)
Flow rate - Max/ Rated (m3/h) 588 (suggested, Bidder can vary)
Flow rate - Min. (m3/h) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (m) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 5 (4W+1SB)
MECHANICAL DATA
Design pressure (kg/cm2.g) 4.5 (suggested, Bidder can vary)
Design temperature (oC) 65
Material Code Casing SS316L
Material Code Impeller SS316L
Seal type (Mechanical/Packing) Packing
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. The head indicated is minimum requirement and the bidder
shall increase pump head (if required) as per actual pressure
drop calculations of the pump during detail engineering.
3.The pump shall be capable of auto start / auto stop operation.
4. The pump motor shall be sized for open discharge
conditions and parallel operations.
5.The pumps shall be able to meet minimum continuous flow
(MCF) requirements.
15.12 Cartridge Filter
Service : Filtration of RO feed water
PROPERTIES OF LIQUID
Liquid handled UF Permeate water
Operating temp. (oC) AMB.
Viscosity of Liquid. (cs) 1.0
Liquid density (kg/m3) 1000
Design Temperature (0C) 65
Design pressure (kg/cm2.g) * As per shut off pressure of the
Cartridge Filter Feed Pumps OR 4.5
kg/cm2.g, whichever is higher
Operating pressure (kg/cm2.a) 3.5 (suggested, Bidder can vary)
CARTRIDGE FILTERS
Rated flow (m3/h) 588 per cartridge housing
Total flow(m3/h) 2352 (4W filter + 1SB filter)
Micron rating (microns) 5 ( Nominal)
Flow per element(m3/h) *
No of element per housing *
Size of element *
Pressure drop across system (clean/dirty) (kg/cm2) *
Filtration area per cartridge *
Pressure relief valve *
Flow per element(m3/h) *
MATERIAL OF CONSTRUCTION
Cartridge filter membrane PP
Shell SS316L
Design code As per ASME standards
Type of cartridge PP wound
Ends caps *
Notes:
Data marked as "*" to be furnished / confirmed by the bidder.
15.13 RO High Pressure Feed Pumps
Service : To feed Reverse Osmosis Skids
Type : Submersible or Centrifugal, Horizontal
PROPERTIES OF LIQUID
Liquid handled UF Permeate water after cartridge filters
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cP) 1.0
Liquid density (kg/m3) 1000
Presence of corrosive / toxic components No
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (m3/h) 588 (suggested, Bidder can vary)
Flow rate - Max/ Rated (m3/h) 588 (suggested, Bidder can vary)
Flow rate - Min. (m3/h) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (m) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 5 (4W+1SB)
MECHANICAL DATA
Design pressure (kg/cm2.g) *

Design temperature (oC) 65


Material Code Casing SS316L
Material Code Impeller SS316L
Seal type (Mechanical/Packing) Mechanical
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2.The bidder shall provide pump head as per pressure drop
calculations of the pump as per tender requirements during
detail engineering.
3. The pump shall be capable of auto start / auto stop operation.
4. The pump motor shall be sized for open discharge conditions.
5. The pump motor shall be designed for pressure requirement
of RO Membranes at the end of third year and at 15 deg C
water temperature.
6.The pumps shall be able to meet minimum continuous flow
(MCF) requirement.
7. Pump to be provided with variable frequency drive motors in
order to meet variable pressure requirement. The VFD shall be
provided for all the installed pumps (05 nos.)
15.14 Brackish Water Reverse Osmosis Skid
Service : Removal of total dissolved solids
PROCESS DATA
Liquid handled Water/Antiscalant/ Acid/ Alkali/ SBS
solution
Viscosity of liquid (cP) 1.0
Liquid density (kg/m3) 1000
Operating temperature (oC) AMB.
Mechanical design temperature (0C) 65
Operating pressure / design pressure (kg/cm2.a) *
REVERSE OSMOSIS MEMBRANES
No. of RO streams (nos.) (net permeate) 4 * 471 m3/h
Average flux (rate) 10 GFD/ 17 LMH (MAX.)
Net reject capacity (m3/h) *
Reject stream pressure (kg/cm2.a) *
No of stages *
Array configuration *
Max no of elements in each pressure tube 7*
Max length of each membrane (inch)/ max dia 40/8
Max element area (m2) 40
Max pressure across each element *
RO permeate recovery (%) 80 (Minimum)
Fouling allowance (min) 15% per year (Total 45% )
Inlet flow required for rated output (m3/h) *
Salt rejection percentage 1st year 3rdyear (min) 99.6%- 99.3%
Permeate pressure (kg/cm2.a) *
Make of membrane suppliers DOW / KOCH/ HYDRANAUTICS/ GE-
OSMONICS/ TORAY/ MEMCOR/
ROCHEM/ PALL /Hyflux / Equivalent
Make of pressure tube suppliers CODELINE/ ADVANCED
COMPOSITE / PHOENIX/
PROTEC/ORLITE/ KANOPPE/ WAVE
CYBER/ BEL-ISRAEL/Equivalent
Material of construction of membrane Composite Polyamide
Type of membrane Fouling resistant membrane
Overall efficiency (%) *
Guaranteed life of membrane 3 Years (1 year flat & 2 years on pro-rata)
MATERIAL OF CONSTRUCTION
Membrane Polyamide
Tube FRP/ GRP (ASME standards) side entry*
High pressure piping in RO skid As per specs / as per requirement.
Low pressure piping in RO skid As per specs / as per requirement.
MOC of process & permeate piping As per specs / as per requirement.
MOC of drain & vent piping PVC schedule 80 (ASTM standards 10-
1A)
MOC of flange joints & victaulic connections */*

MOC of frames CS (with powder coated paint)


Gaskets & elastomers EPDM/BUNA*
Bolts & washers *
PARAMETERS RO Inlet * UF OUTLET *
Flow, cum / h 588 / Skid 471 / Skid #
Ph 7.5
Temperature (oC) AMB AMB
Total Suspended Solids (TSS), mg/l Nil Nil
Total Dissolved Solids (TDS), mg/l 1500 70 Max #
Salt Rejection of Membranes, % * *
Conductivity, micro mho/cm * *
Oil & Grease, mg/l Nil *
BOD, mg/l 5* BDL*
COD, mg/l 25* BDL*
Total Hardness, mg/l as CaCO3 430 *
Calcium Hardness, mg/l as CaCO3 130 *
Magnesium Hardness, mg/l as CaCO3 300 *
Chlorides as Cl, mg/l 370 *
Sulphates as SO4, mg/l 170 *
Sodium as Na, mg/l 238.7 *
Phosphates as PO4, mg/l 0.3 *
Ammoniacal N, mg/l * *
Kejaldahl N, mg/l Note 11 *
Total Silica as SiO2, mg/l <50 <5.0#
Turbidity, NTU BDL BDL
Silt Density Index (SDI) <3 <3
Iron as Fe, mg/l 0.5 BDL
Alkalinity,mg/l 404
All other metals Trace BDL
# included in guaranteed parameters besides recoveries in RO skid (shall be based on 30oc water
temperature & third year projections)
NOTES:
1.Data marked as "*" to be furnished/confirmed by the bidder.
2.Bidder to give projection of recovery and operating pressure requirement from first year to end of third year.
Pump and other system are to be sized accordingly. Also indicate SP increase per year, Flux decline coefficient.
Bidder to also provide RO design programs and normalising program in a soft copy form.
3.RO cleaning shall be done stagewise. All elements in one stage shall be cleaned at a time. Isolation valves to
isolate each stage shall be provided. Cleaning system including tank & pump shall be sized accordingly.
4. Bidder to provide process parameter guarantee as per process design basis of the tender document and tender
specs
5.Design temp. for pressure tubes of RO shall be 65 deg C.
6.Bidder to furnish individual housing permeates conc., flow and interstage pressure requirement.
7.Bidder to give backup process calculations for all the data marked as * in the data sheet. Calculations should
include all the water lost due to cleaning and time lost.
8.Permanent RO cleaning arrangement by rigid piping from RO cleaning pump are to be provided to clean each
stage separately.
9.Bidder to provide probe test apparatus to evaluate the performance of each element in the pressure
vessel.
10.RO to be designed for varying feed conditions as per tender specifications.
11.Kjeldahl nitrogen value shall be suitable considered by the bidder based on equivalent values of other
forms of nitrogen given in the analysis in process design basis.
15.15 Degasser Tower
Service : Degassification of RO permeate
Type: Forced draft- gravity down flow
PROPERTIES OF LIQUID
HCO3 / CO2 concentration at inlet (mg/l) */*
CO2 conc. in outlet (design max.) ( ppm) 5
OPERATING CONDITIONS
Liquid Flow rate - Normal (m3/h) 314 (suggested, Bidder can vary)
Liquid Flow rate - Rated (m3/h) *
Liquid Flow rate - Min. (m3/h) *
Air Flow rate - Normal (m3/h) 7000 * (suggested, Bidder can vary)
Air Flow rate - Rated (m3/h) *
Air Flow rate - Min. (m3/h) *

Operating temperature (0c) Ambient


Design water temperature (0c) 15
Liquid surface flow rate (m3/m2/h) 60
TOWER
Type & make Forced draft
Number 7 (6W + 1SB)
Diameter (mm) 2450 (suggested, Bidder can vary)
Tower height (mm) *
Packing
Packing volume (m3) *
Packing height (m) 1.5 *
Packing material & type / make & size (mm) PP pall rings or raschig rings/ *
MECHANICAL DATA
Design pressure (kg/cm2.a) ATM

Design temperature (0C) 65


MATERIAL OF CONSTRUCTION
Tower CSRL (As per specs / as per
requirement.)
Internal protection & thickness of lining Rubber lining 4.5 mm thick
External finish Painting (as per specs / as per
requirement).
Packing material PP
NOTES:
1. Data marked as "*" to be furnished/confirmed by the bidder.
2.Degasser towers along with degasser blowers shall be
placed on an elevated RCC platform with hand railings and
approach stair case. The size of the platform shall be suitable
for ease of operation and maintenance of the tower and
blowers. The platform height shall be as required based on
height of RO permeate water storage tanks.
15.16 Degasser Air Blower
Service : Air supply for degassification
Type: Centrifugal- turbo blower
PROPERTIES OF GAS
Gas handled Air
Composition (% by vol.) 79% N2, 21% O2
Molecular weight 29
Ratio of specific heats (K = Cp/Cv) 1.4
Compressibility factor (Z) 1.0
OPERATING CONDITIONS
Flow rate - Normal (Nm3/h) * (7000 / or as per manufacturers
recommendation)
Flow rate - Rated (Nm3/h) * (NOTE 3)

Flow rate - Min. (Nm3/h) *


Suction temperature (0C) (MAX/NOR/MIN) 45 / 25 / 5
Suction pressure (kg/cm2 abs) ATM. (@ sea level)
Discharge pressure (kg/cm2.g) *
Discharge head (mm WC) * (100 Minimum)
Compression ratio *
No. of blowers 8 (6 W + 2 S)
Type of blower Centrifugal
CAPACITY CONTROL
Continuous/Discontinuous/Manual/Automatic Manual Type
Range (%) *
Precision at specified range (%) *
MECHANICAL DATA
Design pressure (kg/cm2.g) * (1.25 MINIMUM)
Design Temperature (0c) 65
Material Casing CS
Material Rotor CS
Material Shaft EN-8
Line Rating In/Out */*
Driver Electric Motor
Location Outdoor
Notes
1.Data marked as * to be furnished by the bidder.
2.Blower to be provided with suction filter, throttle valve, etc.
3.Each blower is to be designed for catering to one degasser
tower requirement.
15.17 RO Permeate Tank / Activated carbon filter feed sump
Service : To store RO permeate, degasified water
and to pump water to Activated carbon
filters
PROCESS DATA
Inlet flow (max.) (m3/hr) 1875
Nominal capacity (m3) *
Effective liquid storage volume of tank (m3) 938
Storage temperature (oC) Ambient
Design temperature (0C) NA
Sp. gr. of liquid at storage temperature (oC) ~1.0

Storage pressure (kg/cm2 .a) Atm. + liquid column


UNIT DESCRIPTION
No. of tanks 1
Type Rectangular, above and below ground and
covered with vents
No. of. Compartments 2
Inter connection between compartments With overflow cut out
Length of each compartment of the tank (m) 12.5 (suggested, Bidder can vary)
Width of each compartment of the tank (m) 12.5(suggested, Bidder can vary)
Liquid depth (m) (of each compartment) 3.0 (suggested, Bidder can vary)
Free board above TWL (m) of each compartment 0.5
Size of suction channel (m x m) *x*
Total height (m) *
Residence time (hrs) / tank (@ normal flow) 0.5
Slope for tank bottom Yes, provided as per specs / as per
requirement.
Overflow arrangement required (yes / no) Yes
Bottom drain required (yes / no) Yes
Any baffle arrangement required (yes / no) No
Vent Yes
Level indication required (yes / no) Yes
Level transmitter & level alarm(yes / no) Yes
Level transmitter platform (yes/no) Yes
MATERIAL OF CONSTRUCTION
Tank RCC
Painting / lining Epoxy lining
Operating platform, access stairs, hand railings Yes, provided as per specs / as per
requirement.
Rungs Yes, provided as per specs / as per
requirement.
Manholes Yes
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
15.18 Activated Carbon Filter feed Pumps
Service : To feed Activated carbon Filtration system
Type : Submersible or Centrifugal, Horizontal
PROPERTIES OF LIQUID
Liquid handled RO permeate, degasified water
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cP) 1.0
Liquid density (kg/m3) 1000
Presence of corrosive / toxic components No
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (m3/h) 625 (suggested, Bidder can vary)
Flow rate - Max/ Rated (m3/h) 625 (suggested, Bidder can vary)
Flow rate - Min. (m3/h) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) 2.5 (suggested, Bidder can vary)
Differential pressure (kg/cm2) 2.5 (suggested, Bidder can vary)
Differential head (m) 25 (suggested, Bidder can vary)
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 4 (3W+1SB)
MECHANICAL DATA
Design pressure (kg/cm2.g) *

Design temperature (oC) 65


Material Code Casing SS316L
Material Code Impeller SS316L
Seal type (Mechanical/Packing) Packing
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. The head indicated is minimum requirement and the bidder
shall increase pump head (if required) as per actual pressure
drop calculations of the pump during detail engineering.
3.The pump shall be capable of auto start / auto stop operation.
4. The pump motor shall be sized for open discharge
conditions and parallel operations.
5.The pumps shall be able to meet minimum continuous flow
(MCF) requirements.
15.19 Activated Carbon Filters
Service : Filtration of RO feed water
PROPERTIES OF LIQUID
Liquid handled RO permeate, degasified water
Operating temp. (oC) AMB.
Viscosity of Liquid. (cs) 1.0
Liquid density (kg/m3) 1000

Design Temperature (0C) 65


ACTIVATED CARBON FILTERS
Rated flow (m3/h) 625 per Activated carbon Filter
Total flow(m3/h) 1875 (3W Filter + 1SB Filter)
Operating Pressure (kg/sqcm) * (0.5 to 2.5 / or as per manufacturers
recommendation)
Pressure drop at design flow should not exceed (kg/sqcm) *(0.08 / or as per manufacturers
recommendation)
Back wash Pressure (kg/sqcm) *(0.5 to 2.5 / or as per manufacturers
recommendation)
Empty Bed Contact time (minutes) *(Not less than 5)
Filter media Pebbles, Silux & Carbon IV 900
Carbon Liquid Phase activated carbon
Carbon usage ( kg / ML of treated water) * (6 to 120 / or as per manufacturers
recommendation)
Weight of carbon not less than (kg) *

Construction Carbon Steel Epoxy coated tank of


adequate shell thickness or Fibre
Reinforced Plastic (FRP) / Equivalent
Tank diameter (m) 5 (suggested, Bidder can vary)
Height of Side (m) 2.7 (suggested, Bidder can vary)
Inlet / Outlet *
Connection sizes Inlet / Outlet side *
Connection sizes Carbon Fill / Cleanout (Top) (m) * (0.45/ or as per manufacturers
recommendation)
Connection sizes Carbon Drain (m) * (0.15 / or as per manufacturers
recommendation)
Connection sizes Water Drain (m) * (0.05 / or as per manufacturers
recommendation)
15.20 Treated Water Storage Tank
Service : To hold treated water from TTRO Plant
PROCESS DATA
Inlet flow (max.) (m3/hr) 1875
Nominal capacity (m3) *
Effective liquid storage volume of tank (m3) 10000
Storage temperature (oC) Ambient
Design temperature (0C) NA

Sp. gr. of liquid at storage temperature (oC) ~1.0


Storage pressure (kg/cm2 .a) Atm. + liquid column
UNIT DESCRIPTION
No. of tanks 1
Type Rectangular, above and below ground and
covered with vents
No. of. Compartments 2
Inter connection between compartments With overflow cut out
Length of each compartment of the tank (m) 41.0 (suggested, Bidder can vary)
Width of each compartment of the tank (m) 41.0(suggested, Bidder can vary)
Liquid depth (m) (of each compartment) 3.0 (suggested, Bidder can vary)
Free board above TWL (m) of each compartment 0.5
Size of suction channel (m x m) *x*
Total height (m) *
Residence time (hrs) / tank (@ normal flow) 5.34
Slope for tank bottom Yes, provided as per specs / as per
requirement.
Overflow arrangement required (yes / no) Yes
Bottom drain required (yes / no) Yes
Any baffle arrangement required (yes / no) No
Vent Yes
Level indication required (yes / no) Yes
Level transmitter & level alarm(yes / no) Yes
Level transmitter platform (yes/no) Yes
MATERIAL OF CONSTRUCTION
Tank RCC
Painting / lining Epoxy lining
Operating platform, access stairs, hand railings Yes, provided as per specs / as per
requirement.
Rungs Yes, provided as per specs / as per
requirement.
Manholes Yes
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
15.21 Treated Product water Pumps
Service : To pump TTRO water to the usage point
Type : Submersible or Centrifugal, Horizontal
PROPERTIES OF LIQUID
Liquid handled TTRO water
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cP) 1.0
Liquid density (kg/m3) 1000
Presence of corrosive / toxic components No
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) No
OPERATING CONDITIONS
Flow rate - Normal (m3/h) 950
Flow rate - Max/ Rated (m3/h) 950

Flow rate - Min. (m3/h) *


Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (m) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 4 (2W+2SB)
MECHANICAL DATA
Design pressure (kg/cm2.g) *

Design temperature (oC) 65


Material Code Casing CS
Material Code Impeller CS
Seal type (Mechanical/Packing) Packing
Line rating In/Out */*
Driver Electrical Motor
NOTES :
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. The minimum requirement head may be indicated in
the Bidding stage and the Bidder shall increase pump
head (if required) as per actual pressure drop
calculations of the pump during detail Engineering.
3.The pump shall be capable of auto start / auto stop operation.
4.The pump motor shall be sized for open
discharge conditions and parallel operations.
5. The pumps shall be able to meet minimum
continuous flow (MCF) requirement.
6.Pump to be provided with variable frequency drive motors in
order to meet variable pressure requirement. The VFD shall be
provided for all the installed pumps (04nos.).
15.22 Caustic Lye Storage Tank

Service : Storage Of Caustic Lye Solution


PROCESS DATA
Liquid stored Caustic Lye
Nominal capacity of each tank (m3) *
Liquid hold-up capacity of each tank (m3) (LAH-LAL) * (Note-4)
Storage temperature (oc) Ambient
Sp. gr. of liquid at storage temperature (oc) ~1.48
Viscosity at 25c (cp) *
Design pressure (kg/cm2.a) ATM+Full of liquid+50 mm WC & 50
mm WC Vacuum
Design temperature (0c) 65
MECHANICAL DATA
No. of tanks 2
Type Fixed Cone Roof
Diameter (m) * (Note-4)
Liquid Depth + Free Board + DVD (m) * + 0.5 + * (Note-4)
Total Height (m) *
Corrosion Allowance (mm) 3.0
Minimum thickness (mm) Shell/Roof/Bottom 10.0/8.0/10.0
Shape Circular
Heating Coil (Yes/No) No
Insulation (Yes/No) No
Breather Valve (Yes/No) *
Overflow Line (Yes/No) * (If Provided, Water Seal arrangement
shall also be provided)
Level Indication Required (Yes / No) Yes
Level Transmitter (Yes / No) Yes
Level Transmitter Platform (Yes/No) Yes
Level Alarm (Yes/No) Yes
Flame Arrestor (Yes/No) No
Vent (Yes/No) Yes
Gauging And Sampling Hatch (Yes/No) No
Manhole (yes/no) Yes, provided as per specs / as per
requirement.
Operating plat form with hand railing & ladder (yes/no) Yes, provided as per specs / as per
requirement.
MATERIAL OF CONSTRUCTION
Tank CS PWHT
Lining NIL
Steam Coil NA
NOTES :
1. Data marked as * to be furnished/ confirmed by the bidder.
2.The tank shall be checked for maximum positive pressure and
vacuum conditions due to CO2 absorber on the vent.
3.Tank shall be located within the Dyked area suitably lined
(floor, inside dyke wall and all structures inside the Dyked area)
with acid/alkali proof PPG lining. Bidder shall also provide
neutralisation facility for neutralization of chemical spill inside
dyke.
4.These tanks shall have total effective liquid hold-up (excluding
dead storage & free- board) combined capacity equivalent to 20
days total requirements of caustic in TTRO plant or 15 m3
effective liquid hold-up in each tank, whichever is more.
5.Provision to dose caustic to disposal blending tank by gravity
shall be made by the bidder.
6. All nozzles in the tank shall be provided on the top of shell
side of the tank to the maximum extent possible to avoid
direct contact with bulk chemical except pump suction and
drain nozzles.
15.23 Caustic Lye Unloading/ Transfer Pumps
Service : To unload/transfer alkali
Type : Centrifugal, Horizontal
PROPERTIES OF LIQUID
Liquid handled 40 ~ 50 wt% Alkali (NaOH)
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cs) *
V.PR. at pumping temp. (kg/cm2 abs) *
Liquid density (kg/m3) @ 15 Deg C ~1480
Presence of corrosive / toxic components 40 ~ 50 wt% Alkali
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate Normal (m3/h) 15 (suggested, Bidder can vary)
Flow rate Max/ Rated (m3/h) 15 (suggested, Bidder can vary)
Flow rate Min. (m3/h) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (m) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
MECHANICAL DATA
Design pressure (kg/cm2.g) 5.0 (suggested, Bidder can vary)
Design temperature (oC) 65
Material Code Casing SS316L
Material Code Impeller SS316L
Seal type (Mechanical/Packing) Mechanical
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as * to be furnished/confirmed by the bidder.
2. The pump shall be sized for open discharge condition.
3. Pump auto cut-off at tank high level to be provided.
4. Two numbers of unloading bays to be provided for alkali
unloading.
15.24 Caustic Solution Dosing Pumps

Service : Caustic dosing at the inlet of RO section


for pH correction
Type : Positive Displacement, Diaphragm

PROPERTIES OF LIQUID
Liquid handled 40 ~ 50 wt% Alkali (NaOH)
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cs) *
V.PR. at pumping temp. (kg/cm2 abs) *

Liquid density (kg/m3) @ 15 Deg C ~1480


Presence of corrosive / toxic components 40 ~ 50 wt% Alkali
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate Normal (lph) *
Flow rate Max (lph) *
Flow rate Min. (lph) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (mLC) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
Capacity Control For Volumetric Pumps

Continuous / Discontinuous / Manual / Automatic Manual


Type Stroke Adjustment
Range (%) 10-100
Precision at min. rate (%) *
MECHANICAL DATA
Design pressure (kg/cm2.g) * (minimum 2 kg/cm2g more than the
differential pressure)
Design temperature (oC) 65
Material Code Casing PP/PVDF (POLY VINYLIDENE
FLUORIDE)
Material Code Diaphragm TEFLON (Poly Tetra Fluoro Ethylene)
Seal type Glandless
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as * to be furnished/confirmed by the bidder.
2. Pump shall be capable of auto start/stop.
3. Pumps shall be provided with external PSV, if not
provided internally. Set pressure of the PSV shall be 10%
over discharge pressure or 1 kg/cm2g, whichever is higher.
15.25 Sodium Chlorite Storage Tank

Service : Bulk storage of Sodium Chlorite


PROCESS DATA
Liquid stored Sodium Chlorite (commercial
concentration)
Nominal total capacity (m3) *
Effective liquid hold-up (m3) (LAH-LAL) * (NOTE-2)
Operating temperature (oC) AMBIENT
SP. GR. Of liquid at storage temperature (oC) *
Viscosity at storage temperature (cp) *
Operating pressure (kg/cm2.abs) Atm+Full Of Liquid
Design positive pressure (kg/cm2.abs) Atm+Full Of Liquid+50 mm WC

Design vacuum pressure (kg/cm2.abs) 50 mm WC Vacuum


Design temperature (0c) 65
MECHANICAL DATA
No. of tanks 2
Type Circular Fixed Roof
Diameter (m) * (NOTE-2)
Liquid Depth + Free Board + DVD (m) * + 0.5 + * (NOTE-2)
Total Height (m) *
Corrosion Allowance Shell/Bottom /Roof (mm) * (As per specs / as per requirement)
Shape Circular
Heating Coil (Yes/No) No
Insulation (Yes/No) No
Breather Valve (Yes/No) *
Level Indication Required (Yes / No) Yes
Level Transmitter (Yes / No) Yes
Fume Absorber (Yes/No) *
Silica Gel Breather With Vent Nozzle (Yes/No) No
Gauging And Sampling Hatch (Yes/No) No
Manhole (Yes/No) Yes, provided as per specs / as per
requirement.
Operating Platform With Hand Railing & Ladder (Yes/No) Yes, provided as per specs / as per
requirement.
MATERIAL OF CONSTRUCTION
Tank FRP (WITH UV PROTECTION ),
DESIGN CODE : BS EN 13121 (Latest
corrigendum)
Internal Lining& External Lining NIL
Steam Coil NA
NOTES :
1. Data marked as * to be furnished/ confirmed by the bidder.
2.These tanks shall have total effective liquid hold-up (excluding
dead storage & free- board) combined capacity equivalent to 20
days total requirements of Sodium Chlorite in TTRO plant or 15
m3 effective liquid hold-up in each tank, whichever is more.
3.Tank shall be located within the dyked area suitably lined
(floor, inside dyke wall and all structures inside the dyked area)
with acid/alkali proof ppg lining. Bidder shall also provide
neutralizatyion facility for neutralization of chemical spill inside
dyke.
4. All nozzles in the tank shall be provided on the top of shell
side of the tank to the maximum extent possible to avoid
direct contaxct with bulk chemical except pump suction and
drain nozzles.
15.26 Sodium Chlorite (NaClO2) Unloading/ Transfer
Pumps
Service : To Unload/Transfer Sodium Chlorite
Type : Centrifugal, Horizontal
PROPERTIES OF LIQUID
Liquid handled 25 ~ 31 wt% Sodium Chlorite
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cs) *
V.PR. AT PUMPING TEMP. (kg/cm2 abs) *

Liquid density (kg/m3) @ 20 Deg C ~1280 (Max)*


Presence of corrosive / toxic components 25 ~ 31 wt% Sodium Chlorite
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate Normal (m3/h) 15 (suggested, Bidder can vary)
Flow rate Max/ Rated (m3/h) 15 (suggested, Bidder can vary)
Flow rate Min. (m3/h) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (m) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
MECHANICAL DATA
Design pressure (kg/cm2.g) 5.0 (suggested, Bidder can vary)

Design temperature (oC) 65


Material Code Casing PP/ PVDF (Poly Vinylidene Fluoride)
Material Code Impeller Teflon (Poly Tetra Fluoro Ethylene)
Seal type (Mechanical/Packing) Mechanical
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as * to be furnished/confirmed by the bidder.
2. The pump shall be sized for open discharge condition.
3. Pump auto cut-off at tank high level to be provided.
4. Two numbers of unloading bays to be provided for Sodium
Chlorite unloading.
15.27 Sodium Chlorite (NaClO2) dosing pumps
Service : NACLO2 dosing for Chlorine dioxide
generation skid
Type : Positive Displacement, Diaphragm
PROPERTIES OF LIQUID
Liquid handled 25 ~ 31 wt% Sodium Chlorite
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cs) *
V.PR. AT PUMPING TEMP. (kg/cm2 abs) *

Liquid density (kg/m3) @ 20 Deg C ~1280


Presence of corrosive / toxic components 25 ~ 31 wt% Sodium Chlorite
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate Normal (lph) *
Flow rate Max (lph) *
Flow rate Min. (lph) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (mLC) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
CAPACITY CONTROL FOR VOLUMETRIC PUMPS

Continuous / Discontinuous / Manual / Automatic Manual


Type Stroke Adjustment
Range (%) 10-100
Precision At Min. Rate (%) *
MECHANICAL DATA
Design pressure (kg/cm2.g) * (minimum 2 kg/cm2g more than the
differential pressure)
Design temperature (oC) 65
Material Code Casing PP/PVDF (Poly Vinylidene Fluoride)
Material Code DIAPHRAGM TEFLON (Poly Tetra Fluoro Ethylene)
Seal type Glandless
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as * to be furnished/confirmed by the bidder.
2. Pump shall be capable of auto start/stop.
3.The head indicated is minimum requirement and the bidder
shall increase pump head (if required) as per actual ressure
drop calculations of the pump during detail engineering.
4. Pumps shall be provided with external PSV, if not
provided internally. Set pressure of the PSV shall be 10%
over discharge pressure or 1 kg/cm2g, whichever is higher.
15.28 Chemical Enhance Backwash Tank-I

Service : Dosing of Hydrochloric acid to UF


backwash
PROCESS DATA
Liquid stored 33% HCL*
Viscosity of liquid (cP) *
Vapour pressure *
Liquid Density (kg/m3) 1162
Operating Temperature (oC) AMBIENT
Design Temperature (0C) 65
Operating Pressure (kg/cm2.a) ATM.
Design pressure (kg/cm2.a) ATM. + LIQUID COLUMN
Nature Of Liquid (Toxic/Corrosive) Corrosive
HCL required (100%) at design flow rate (kg/Bank) *
Purity of commercially available chemical 33%
Holding period of each tank (hrs) (Minimum) *
MECHANICAL DATA
No. of tanks 2
Type Closed with removable lids
Diameter (m) *
Liquid depth (m) *
Free board (m) *
Total height (m) *
Liquid hold-up capacity of each tank (m3) *
Total capacity of each tank (m3) *
Level Indication Required Yes
Type Of Level Indicator Through Level Transmitter
Service Water Connection Yes
Overflow Connection Yes
Draining Arrangement Yes
Dosing Arrangement Dosing Pump
Agitator Required No
Baffle Arrangement No
Size Of Baffles Na
Corrosion allowance (mm) Nil
Heating Coil No
Insulation (Yes/No) No
Breather Valve (Yes/No) No
Gauging And Sampling Hatch (Yes/No) No
Vent (Yes/No) Yes
Flame Arrestor (Yes/No) No
Calibration Of Tank (Yes/No) No
MATERIAL OF CONSTRUCTION
Tank Solid FRP
Lining NA
NOTES :
1. Data marked as * to be furnished/ confirmed by the bidder.
2.The tank size shall be based on the recommendations of Ultra
Filtration system supplier.
15.29 Chemical Enhance Backwash Tank-II

Service : Dosing of NaOH to UF backwash


PROCESS DATA
Liquid stored BULK CAUSTIC
Viscosity of liquid (cP) *
Vapour pressure *
Liquid Density (kg/m3) *
Operating Temperature (oC) Ambient
Design Temperature (0C) 65
Operating Pressure (kg/cm2.a) ATM.
Design pressure (kg/cm2.a) ATM. + Liquid column
Nature Of Liquid (Toxic/Corrosive) CORROSIVE
NaOH required (100%) at design flow rate (kg/Bank) *
Purity of commercially available chemical 40 to 50%
Holding period of each tank (hrs) (minimum) *
MECHANICAL DATA
No. of tanks 1
Type Closed with removable lids
Diameter (m) *
Liquid depth (m) *
Free board (m) *
Total height (m) *
Liquid hold-up capacity of each tank (m3) *
Total capacity of each tank (m3) *
Level Indication Reuqired Yes
Type Of Level Indicator Through Level Transmitter
Service Water Connection Yes
Overflow Connection Yes
Draining Arrangement Yes
Dosing Arrangement Dosing Pump
Agitator Required No
Baffle Arrangement No
Size Of Baffles NA
Corrosion Allowance (mm) 3
Minimum thickness (mm) Shell/Bottom 8.0/10.0
Heating Coil No
Insulation (Yes/No) No
Breather Valve (Yes/No) No
Gauging And Sampling Hatch (Yes/No) No
Vent (Yes/No) Yes
Flame Arrestor (Yes/No) No
Calibration Of Tank (Yes/No) Yes
MATERIAL OF CONSTRUCTION
Tank CS (PWHT)
Lining NA
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
2.The tank size shall be based on the recommendations of Ultra
Filtration System Supplier.
15.30 Chemical Enhance Backwash Tank-III
Service : Dosing of NaOCl to UF backwash
PROCESS DATA
Liquid stored NaOCl
Viscosity of liquid (cP) *
VAPOUR PRESSURE *
Liquid density (kg/m3) *
Operating temperature (oC) AMBIENT
Design temperature (0C) 65
Operating pressure (kg/cm2.a) ATM.
Design pressure (kg/cm2.a) ATM. + Liquid Column
Nature Of Liquid (Toxic/Corrosive) Corrosive
NaOCl required (100%) at design flow rate (kg/Bank) *
Purity Of Commercially Available Chemical *
Holding period of each tank (hrs) (Minimum) *
MECHANICAL DATA
No. of tanks 1
Type Closed with removable lids
Diameter (m) *
Liquid Depth (m) *
Free Board (m) *
Total Height (m) *
Liquid hold-up capacity of each tank (m3) *
Total capacity of each tank (m3) *
Level Indication Reuqired Yes
Type Of Level Indicator Through Level Transmitter
Service Water Connection Yes
Overflow Connection Yes
Draining Arrangement Yes
Dosing Arrangement Dosing Pump
Agitator Required *
Baffle Arrangement *
Size Of Baffles *
Corrosion allowance (mm) Nil
Heating Coil No
Insulation (Yes/No) No
Breather Valve (Yes/No) No
Gauging And Sampling Hatch (Yes/No) No
Vent (Yes/No) Yes
Flame Arrestor (Yes/No) No
Calibration Of Tank (Yes/No) Yes
MATERIAL OF CONSTRUCTION
Tank Solid FRP
Lining NA
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
2.The tank size shall be based on the recommendations of Ultra
Filtration System Supplier.
15.31 Chemical Enhanced Backwash Pumps I
Service : To dose CEB-I chemical during
chemical enhanced backwash of UF
Type : Positive Displacement, Diaphragm
PROPERTIES OF LIQUID
Liquid handled 33 wt% HCL
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cs) *
V.PR. AT PUMPING TEMP. (kg/cm2 abs) *

Liquid density (kg/m3) @ 20 Deg C ~1140


Presence of corrosive / toxic components 33 wt% HCL
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (lph) *
Flow rate Max (lph) *
Flow rate - Min. (lph) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (mLC) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
CAPACITY CONTROL FOR VOLUMETRIC PUMPS

Continuous / Discontinuous / Manual / Automatic Manual


Type Stroke Adjustment
Range (%) 10-100
Precision At Min. Rate (%) *
MECHANICAL DATA
Design pressure (kg/cm2.g) * (minimum 2 kg/cm2g more than the
differential pressure)
Design temperature (oC) 65
Material Code Casing PP/PVDF (Poly Vinylidene Fluoride)
Material Code Diaphragm TEFLON (Poly Tetra Fluoro Ethylene)
Seal type GLANDLESS
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. Pump shall be capable of auto start/stop.
3. The pump capacity shall be based on the
recommendations of Ultra Filtration System Supplier.
4. Pumps shall be provided with external PSV, if not
provided internally. Set pressure of the PSV shall be 10%
over discharge pressure or 1 kg/cm2g, whichever is higher.
15.32 Chemical Enhanced Backwash Pumps II
Service : To dose CEB-II chemical during
chemical enhanced backwash of UF
Type : Positive Displacement, Diaphragm
PROPERTIES OF LIQUID
Liquid handled 40-50 wt% Caustic
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cs) *
V.PR. at pumping temp. (kg/cm2 abs) *

Liquid density (kg/m3) @ 15 Deg C ~1480


Presence of corrosive / toxic components 40-50 wt% Caustic
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (lph) *
Flow rate Max (lph) *
Flow rate - Min. (lph) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (mLC) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
CAPACITY CONTROL FOR VOLUMETRIC PUMPS

Continuous / Discontinuous / Manual / Automatic Manual


Type Stroke Adjustment
Range (%) 10-100
Precision At Min. Rate (%) *
MECHANICAL DATA
Design pressure (kg/cm2.g) * (minimum 2 kg/cm2g more than the
differential pressure)
Design temperature (oC) 65
Material Code Casing PP/PVDF (Poly Vinylidene Fluoride)
Material Code DIAPHRAGM TEFLON (Poly Tetra Fluoro Ethylene)
Seal type Glandless
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. Pump shall be capable of auto start/stop.
3. The pump capacity shall be based on the
recommendations of Ultra Filtration System Supplier.
4. Pumps shall be provided with external PSV, if not
provided internally. Set pressure of the PSV shall be 10%
over discharge pressure or 1 kg/cm2g, whichever is higher.
15.33 Chemical Enhanced Backwash Pumps - III
Service : To dose CEB-III chemical during
chemical enhanced backwash of UF
Type : Positive Displacement, Diaphragm
PROPERTIES OF LIQUID
Liquid handled 6 wt% NAOCL *
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cs) *
V.PR. AT PUMPING TEMP. (kg/cm2 abs) *
Liquid density (kg/m3) ~1000 *
Presence of corrosive / toxic components 6 wt% NAOCL *
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (lph) *
Flow rate Max (lph) *
Flow rate - Min. (lph) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (mLC) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
CAPACITY CONTROL FOR VOLUMETRIC PUMPS

Continuous / Discontinuous / Manual / Automatic Manual


Type Stroke Adjustment
Range (%) 10-100
Precision At Min. Rate (%) *
MECHANICAL DATA
Design pressure (kg/cm2.g) * (minimum 2 kg/cm2g more than the
differential pressure)
Design temperature (oC) 65
Material Code Casing PP/PVDF (Poly Vinylidene Fluoride)
Material Code Diaphragm TEFLON (Poly Tetra Fluoro Ethylene)
Seal type Glandless
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. Pump shall be capable of auto start/stop.
3. The pump capacity shall be based on the
recommendations of Ultra Filtration System Supplier.
4. Pumps shall be provided with external PSV, if not
provided internally. Set pressure of the PSV shall be 10%
over discharge pressure or 1 kg/cm2g, whichever is higher.
15.34 Antiscalant Dosing Tanks

Service : Preparation Of Antiscalant Solution


PROCESS DATA
Liquid handled Antiscalant Soln
Viscosity Of Liquid (cP) *
Vapour Pressure NA
Liquid Density (kg/m3) *
Operating Temperature (oC) Ambient
Design Temperature (0C) 65
Operating Pressure (kg/cm2.a) Atm.
Design Pressure (kg/cm2.a) Atm. + Liquid Column
Nature Of Liquid (Toxic/Corrosive) Corrosive
Antiscalant Solution Required (100%) At Design Flow Rate *
(Kg/Bank)
Purity Of Commercially Available Chemical *
Holding Period Of Each Tank (Hrs) (Minimum) 24
MECHANICAL DATA
No. of tanks 2
Type Closed With Removable Lids
Diameter (m) *
Liquid depth (m) *
Free board (m) *
Total height (m) *
3
Liquid hold-up capacity of each tank (m ) *
Total capacity of each tank (m3) *
Level Indication Reuqired Yes
Type Of Level Indicator Through Level Transmitter
Service Water Connection Na
Overflow Connection Yes
Draining Arrangement Yes
Dosing Arrangement Through Metering Pumps
Agitator Required Yes *
Baffle Arrangement 4 nos. diametrically opposite *
Size Of Baffles 10% of tank dia along its ht*
Corrosion allowance (mm) Nil
Heating Coil No
Insulation (Yes/No) No
Breather Valve (Yes/No) No
Gauging And Sampling Hatch (Yes/No) No
Vent (Yes/No) Yes
Flame Arrestor (Yes/No) No
Calibration Of Tank (Yes/No) Yes
MATERIAL OF CONSTRUCTION
Tank Solid FRP
Lining NA
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
2.The sizes shall be as per the recommendations of the RO system
supplier based on actual requirement of Antiscalant for RO
Membranes.
15.35 Antiscalant Solution Dosing Agitators

Service : Anti Scalant Solution Preparation


PROCESS DATA
Purpose Mixing
Operation (Batch/Continuous) Batch
Flow Rate Through Vessel (m3/h) N.A.
Operating pressure (kg/cm2.a) Atm.
Operating temperature (0C) Ambient
Solids Present (Yes/No, Type & Size) No
Foam Tendency (Yes/No) *
Solubility (High/Medium/Low/Nil) *
Abrasion (High/Medium/Low/Nil) *
Settling (High/Medium/Low/Nil, Velocity) *
Degree Of Agitation (Mild/Medium/Violent) Medium
Corrosive Products (Yes/No, Type) Yes
Process Limitation (None/HP/Tip Speed/Space) Tip Speed
Component Percent Composition Viscosity Cp Sp Gravity
BY VOL. BY WT.
Anti Scalant * * * *2
Water * * 1.0 1.0
Average Properties Of Mix * *
MECHANICAL DATA
Impeller - Type (Turbine / Propeller) Propeller
Impeller Number 2 (One / Tank)
Impeller -diameter (mm) *
Impeller -speed (rpm) *
Impeller -M.O.C. SS-316 L
Blades Type *
Blades Number *
Blades Pitch SQUARE
Blades - width (mm) *
Blades - M.O.C. SS-316 L
Shaft - M.O.C. SS-316 L
Power No. Used *
Mounting Space Available ( Ample/Restricted) Ample
Mixer Entry (Top/Side/Bottom/Portable) Top
Mounting (Clamped/Flanged, Mounting Angle) *
Shaft Seal N.A.
(Mechanical/Stuffing Box/Labyrinth Seal/Vapour Seal)
Drive Type Electrical Motor
Drive Unit Transmission Type (Gear/Belt/Direct) *
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
15.36 Anti Scalant Dosing Pumps
Service : To dose Anti Scalant at upstream of RO
system
Type : Positive Displacement, Diaphragm
PROPERTIES OF LIQUID
Liquid handled 10 Wt% Anti Scalant *
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cs) *
V.PR. AT PUMPING TEMP. (kg/cm2 abs) *

Liquid density (kg/m3) ~1100 *


Presence of corrosive / toxic components 10 Wt% Anti Scalant *
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (lph) *
Flow rate Max (lph) *
Flow rate - Min. (lph) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (mLC) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
CAPACITY CONTROL FOR VOLUMETRIC PUMPS

Continuous / Discontinuous / Manual / Automatic Manual


Type Stroke Adjustment
Range (%) 10-100
Precision At Min. Rate (%) *
MECHANICAL DATA
Design pressure (kg/cm2.g) * (minimum 2 kg/cm2g more than the
differential pressure)
Design temperature (oC) 65
Material Code Casing PP/PVDF (Poly Vinylidene Fluoride)
Material Code Diaphragm TEFLON (Poly Tetra Fluoro Ethylene)
Seal type Glandless
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. Pump shall be capable of auto start/stop.
3. The pump capacity shall be based on the
recommendations on actual anti scalant requirement by RO
system supplier.
4. Pumps shall be provided with external PSV, if not
provided internally. Set pressure of the psv shall be 10%
over discharge pressure or 1 kg/cm2g, whichever is higher.
15.37 Sodium Bi Sulphite Dosing Tanks

Service : Preparation of Sodium Bi-Sulphite


solution
PROCESS DATA
Liquid Handled SBS SOLN
Viscosity Of Liquid (cP) *
Vapour Pressure *
Liquid Density (kg/m3) *
Operating Temperature (oC) Ambient
Design Temperature (0C) 65
Operating Pressure (kg/cm2.a) Atm.
Design Pressure (kg/cm2.a) Atm. + Liquid Column
Nature Of Liquid (Toxic/Corrosive) Corrosive
Sodium bi-sulphite solution required (100%) at design flow rate *
(kg/bank)
Purity Of Commercially Available Chemical *
Holding Period Of Each Tank (Hrs) (Minimum) 24
MECHANICAL DATA
No. of tanks 2
Type Closed With Removable Lids
Diameter (m) *
Liquid Depth (m) *
Free Board (m) *
Total Height (m) *
Liquid Hold-Up Capacity Of Each Tank (m3) *
Total capacity of each tank (m3) *
Level Indication Reuqired Yes
Type Of Level Indicator Through Level Transmitter
Service Water Connection Na
Overflow Connection Yes
Draining Arrangement Yes
Dosing Arrangement Through Metering Pumps
Agitator Required Yes *
Baffle Arrangement 4 Nos. Diametrically Opposite *
Size Of Baffles 10% Of Tank Dia Along Its Ht*
Corrosion allowance (mm) Nil
Heating Coil No
Insulation (Yes/No) No
Breather Valve (Yes/No) No
Gauging And Sampling Hatch (Yes/No) No
Vent (Yes/No) Yes
Flame Arrestor (Yes/No) No
Calibration Of Tank (Yes/No) Yes
MATERIAL OF CONSTRUCTION
Tank Solid FRP
Lining NA
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
2.The sizes shall be as per the recommendations of the RO system
supplier based on actual requirement for RO membranes.
15.38 Sodium Bi Sulphite Solution Dosing Agitators

Service : Sodium Bi Sulphite Solution Preparation


Process Data
Purpose Mixing
Operation (Batch/Continuous) Batch
Flow Rate Through Vessel (m3/h) N.A.
Operating pressure (kg/cm2.a) ATM.
Operating temperature (0C) AMBIENT
Solids Present (Yes/No, Type & Size) No
Foam Tendency (Yes/No) *
Solubility (High/Medium/Low/Nil) *
Abrasion (High/Medium/Low/Nil) *
Settling (High/Medium/Low/Nil, Velocity) *
Degree Of Agitation (Mild/Medium/Violent) Medium
Corrosive Products (Yes/No, Type) Yes
Process Limitation (None/HP/Tip Speed/Space) Tip Speed
Component Percent Composition Viscosity Cp Sp Gravity
BY VOL. BY WT.
SBS * * * *
Water * * 1.0 1.0
Average Properties Of Mix * *
Mechanical Data
Impeller - Type (Turbine / Propeller) Propeller
Impeller Number 2 (One / Tank)
Impeller -diameter (mm) *
Impeller -speed (RPM) *
Impeller -M.O.C. SS-316 L
Blades Type *
Blades Number *
Blades Pitch Square
Blades - Width (mm) *
Blades - M.O.C. SS-316 L
Shaft - M.O.C. SS-316 L
Power No. Used *
Mounting Space Available ( Ample/Restricted) Ample
Mixer Entry (Top/Side/Bottom/Portable) Top
Mounting (Clamped/Flanged, Mounting Angle) *
Shaft Seal(Mechanical /Stuffing Box/Labyrinth Seal/Vapour N.A.
Seal)
Drive Type Electrical Motor
Drive Unit Transmission Type (Gear/Belt/Direct) *
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
15.39 Sodium Bi Sulphite Dosing Pumps
Service : To dose Sodium bi sulphite at upstream
of RO system
Type : Positive Displacement, Diaphragm
PROPERTIES OF LIQUID
Liquid handled 10 wt% SODIUM BI SULPHITE *
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cs) *
V.PR. AT PUMPING TEMP. (kg/cm2 abs) *

Liquid density (kg/m3) ~1100 *


Presence of corrosive / toxic components 10 wt% SODIUM BI SULPHITE *
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (lph) *
Flow rate Max (lph) *
Flow rate - Min. (lph) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (mLC) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
CAPACITY CONTROL FOR VOLUMETRIC PUMPS

Continuous / Discontinuous / Manual / Automatic Manual


Type Stroke Adjustment
Range (%) 10-100
Precision At Min. Rate (%) *
MECHANICAL DATA
Design pressure (kg/cm2.g) * (minimum 2 kg/cm2g more than the
differential pressure)
Design temperature (oC) 65
Material Code Casing PP/PVDF (Poly Vinylidene Fluoride)
Material Code Diaphragm TEFLON (Poly Tetra Fluoro Ethylene)
Seal type Glandless
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. Pump shall be capable of auto start/stop.
3. The pump capacity shall be based on the
recommendations on actual Sodium bi sulphite requirement
by RO system supplier.
4. Pumps shall be provided with external PSV, if not
provided internally. Set pressure of the PSV shall be 10%
over discharge pressure or 1 kg/cm2g, whichever is higher.
15.40 HCL Bulk Storage Tank

Service : Bulk storage of 33% Hydrochloric acid


PROCESS DATA
Liquid stored 33% Hydrochloric acid
Nominal total capacity (m3) *
Effective liquid hold-up (m3) (LAH-LAL) * (Note-2)
Operating temperature (oC) Ambient
SP. GR. of liquid at storage temperature (oC) 1.1376 *
Viscosity at storage temperature (cP) *
Operating pressure (kg/cm2.abs) ATM

Design positive pressure (kg/cm2.abs) ATM+Full of liquid+50 mm WC

Design vacuum pressure (kg/cm2.abs) 50 mm WC Vacuum

Design temperature (0C) 65


MECHANICAL DATA
No. of tanks 2
Type Conical Fixed Roof
Diameter (m) * (NOTE-2)
Liquid Depth + Free Board + DVD (m) * + 0.5 + * (NOTE-2)
Total height (m) *
Corrosion Allowance Shell/Bottom /Roof (mm) * (As Per Specs / As Per Requirement)
Shape Circular
Heating Coil (Yes/No) No
Insulation (Yes/No) No
Breather Valve (Yes/No) *
Level Indication Required (Yes / No) Yes
Level Transmitter (Yes / No) Yes
Fume Absorber (Yes/No) * Yes
Silica Gel Breather With Vent Nozzle (Yes/No) No
Gauging And Sampling Hatch (Yes/No) No
Manhole (Yes/No) Yes, provided as per specs / as per
requirement.
Operating Plat Form With Hand Railing & Ladder (Yes/No) Yes, provided as per specs / as per
requirement.
MATERIAL OF CONSTRUCTION
Tank Solid FRP (with UV protection )
Internal Lining& External Lining Nil
Steam Coil NA
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
2.These tanks shall have total effective liquid hold-up (excluding
dead storage & free- board) combined capacity equivalent to 20
days total requirements of acid in TTRO plant or 85 m3
effective liquid hold-up in each tank, whichever is more.
3.Tank shall be located within the dyked area suitably lined
(floor, inside dyke wall and all structures inside the dyked area)
with acid/alkali proof ppg lining. bidder shall also provide
neutralizatyion facility for neutralization of chemical spill inside
dyke.
4. All nozzles in the tank shall be provided on the top of shell
side of the tank to the maximum extent possible to avoid
direct contact with bulk chemical except pump suction and
drain nozzles.
5.Each tank shall be provided with suitable system for vapour
collection, neutralisation & safe disposal.
6.The tank shall be checked for maximum positive pressure and
vaccum conditions due to fume absorber on vent/ overflow line.
7.Provision to dose acid to disposal blending tank by gravity
shall be made by the bidder.
15.41 HCl Unloading/ Transfer Pumps
Service : To Unload/transfer HCl
Type : Centrifugal, Horizontal
PROPERTIES OF LIQUID
Liquid handled 33 wt% HCl
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cs) *
V.PR. at pumping temp. (kg/cm2 abs) *
Liquid density (kg/m3) @ 20 Deg C ~1140 (Max)*
Presence of corrosive / toxic components 33 wt% HCl
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (m3/h) 15 (suggested, Bidder can vary)
Flow rate - Max/ Rated (m3/h) 15 (suggested, Bidder can vary)
Flow rate - Min. (m3/h) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (m) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
MECHANICAL DATA
Design pressure (kg/cm2.g) 5.0 (suggested, Bidder can vary)
Design temperature (oC) 65
Material Code Casing PP/ PVDF (Poly Vinylidene Fluoride)
Material Code Impeller TEFLON (Poly Tetra Fluoro Ethylene)
Seal type (Mechanical/Packing) Mechanical
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. The pump shall be sized for open discharge condition.
3. Pump auto cut-off at tank high level to be provided.
4. Two numbers of unloading bays to be provided for acid
unloading.
15.42 HCl Dosing Pumps (For Dosing At RO Inlet)
Service : To dose hcl at inlet of RO system
Type : Positive Displacement, Diaphragm
PROPERTIES OF LIQUID
Liquid handled 33 wt% HCl *
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cs) *
V.PR. at pumping temp. (kg/cm2 abs) *

Liquid density (kg/m3) ~1140 *


Presence of corrosive / toxic components 33 wt% HCl *
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (lph) *
Flow rate Max (lph) *
Flow rate - Min. (lph) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (mLC) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
CAPACITY CONTROL FOR VOLUMETRIC PUMPS

Continuous / Discontinuous / Manual / Automatic Manual


Type Stroke Adjustment
Range (%) 10-100
Precision At Min. Rate (%) *
MECHANICAL DATA
Design pressure (kg/cm2.g) * (minimum 2 kg/cm2g more than the
differential pressure)
Design temperature (oC) 65
Material Code Casing PP/PVDF (Poly Vinylidene Fluoride)
Material Code Diaphragm TEFLON (Poly Tetra Fluoro Ethylene)
Seal type Glandless
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. Pump shall be capable of auto start/stop.
3. The pump capacity shall be based on the
recommendations on actual HCL requirement by RO system
supplier.
4. Pumps shall be provided with external PSV, if not
provided internally. Set pressure of the PSV shall be 10%
over discharge pressure or 1 kg/cm2g, whichever is higher.
15.43 Hcl Dosing Pumps (For Clo2 Generation)
Service : Hcl dosing for ClO2 generation
Type : Positive Displacement, Diaphragm
PROPERTIES OF LIQUID
Liquid handled 33 wt% HCl *
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cs) *
V.PR. AT PUMPING TEMP. (kg/cm2 abs) *

Liquid density (kg/m3) ~1140 *


Presence of corrosive / toxic components 33 wt% HCl *
Solids in suspension (yes/no) No
Size of solid particles (mm) (max) NA
OPERATING CONDITIONS
Flow rate - Normal (lph) *
Flow rate Max (lph) *
Flow rate - Min. (lph) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (mLC) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
CAPACITY CONTROL FOR VOLUMETRIC PUMPS

Continuous / Discontinuous / Manual / Automatic Manual


Type Stroke Adjustment
Range (%) 10-100
Precision At Min. Rate (%) *
MECHANICAL DATA
Design pressure (kg/cm2.g) * (minimum 2 kg/cm2g more than the
differential pressure)
Design temperature (oC) 65
Material Code Casing PP/PVDF (Poly Vinylidene Fluoride)
Material Code Diaphragm TEFLON (Poly Tetra Fluoro Ethylene)
Seal type Glandless
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. Pump shall be capable of auto start/stop.
3. The pump capacity shall be based on the
recommendations on actual HCL requirement by ClO2
system supplier.
4. Pumps shall be provided with external PSV, if not
provided internally. Set pressure of the PSV shall be 10%
over discharge pressure or 1 kg/cm2g, whichever is higher.
15.44 Disposal Blending Tank
Service : To hold and blend different waste
streams from TTRO plant
PROCESS DATA
Fluid Handled Waste Water
Influent temperature (oC) Ambient
Inlet flow (avg.) (m3/hr) (Design) 775 *
Presence Of Corrosive/Toxic Components Yes
Total Nominal capacity (Overall volume) (m3) *
Residence Time At Peak Flow (minimum) 60 minutes in each compartment
UNIT DESCRIPTION
No. of tanks 1
Type Rectangular, covered by removable
MSEP chequered plates with vents
No. of. Compartments 2
Inter connection between compartments With overflow cut out
Length of each compartment of the tank (m) 20.0 (suggested, Bidder can vary)
Width of each compartment of the tank (m) 9.7(suggested, Bidder can vary)
Liquid depth (m) (of each compartment) 4.0 (suggested, Bidder can vary)
Free board above TWL (m) of each compartment 0.5
Size of suction channel (m x m) *x*
Total height (m) *
Residence time (hrs) / tank (@ normal flow) *
Slope for tank bottom Yes, provided as per specs / as per
requirement.
Overflow arrangement required (yes / no) Yes
Bottom drain required (yes / no) Yes
Any baffle arrangement required (yes / no) No
Vent Yes
Level indication required (yes / no) Yes
Level transmitter & level alarm(yes / no) Yes
Level transmitter platform (yes/no) Yes
MATERIAL OF CONSTRUCTION
Tank RCC
Painting / lining Acid/Alkali Proof PPG Lining
Operating platform, access stairs, hand railings Yes, provided as per specs / as per
requirement.
Rungs Yes, provided as per specs / as per
requirement.
Manholes Yes
NOTES :

1. Data marked as " * " to be furnished/ confirmed by the bidder.


Tank shall be lined with acid/alkali proof PPG lining from
inside. specifications of PPG lining shall be submitted by the
bidder for review during detail engineering.
15.45 Waste Water Disposal Pumps
Service : To pump waste/Reject water generated in
the Plant area to the disposal point
Type : Submersible or Centrifugal, Horizontal
PROPERTIES OF LIQUID
Liquid handled Waste/Reject water generated in the Plant
area
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cP) 1.0
Liquid density (kg/m3) 1000
Presence of corrosive / toxic components Yes
Solids in suspension (yes/no) Yes
Size of solid particles (mm) (max) 3 to 5
OPERATING CONDITIONS
Flow rate - Normal (m3/h) 300 *
Flow rate - Max/ Rated (m3/h) 300 *
Flow rate - Min. (m3/h) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (m) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 4 (2W+2SB)
MECHANICAL DATA
Design pressure (kg/cm2.g) *
Design temperature (oC) 65
Material Code Casing SS316L
Material Code Impeller SS316L
Seal type (Mechanical/Packing) Packing
Line rating In/Out */*
Driver Electrical Motor
NOTES :
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. The minimum requirement head may be indicated in the
Bidding stage and the Bidder shall increase pump head (if
required) as per actual pressure drop calculations of the pump
during detail Engineering.
3.The pump shall be capable of auto start / auto stop operation.
4.The pump motor shall be sized for open discharge
conditions and parallel operations.
5. The pumps shall be able to meet minimum continuous flow
(MCF) requirement.
15.46 RO Cleaning Solution Tank

Service : Preparation of RO cleaning solution


PROCESS DATA
Liquid Handled Ro Cleaning Soln
Viscosity of liquid (Cp) *
Vapour Pressure *
Liquid density (kg/m3) *
Operating temperature (oC) *
Design temperature (0C) 65
Operating pressure (kg/cm2.a) ATM.
Design Pressure (kg/cm2.a) Atm. + Liquid Column
Nature Of Liquid (Toxic/Corrosive) Corrosive
RO cleaning solution required (100%) at design flow rate *
(kg/wash)
Purity of commercially available chemical *
Holding period of each tank (hrs) (minimum) To hold chemical for cleaning maximum
pressure tubes in any one of the arrays of
RO skids.
MECHANICAL DATA
No. of tanks 1
Type Closed with removable lids
Diameter (m) *
Liquid depth (m) *
Free board (m) 0.5 (minimum) *
Total height (m) *
3
Liquid hold-up capacity of each tank (m ) *
Total capacity of each tank (m3) *
Level Indication Reuqired Yes
Type Of Level Indicator Level Gauge + Level Transmitter
Service Water Connection NA
Overflow Connection Yes
Draining Arrangement Yes
Dosing Arrangement Through Pumps
Agitator Required Yes *
Baffle Arrangement 4 Nos. Diametrically Opposite *
Size Of Baffles 10% of tank dia along its ht*
Corrosion allowance (mm) Nil
Heating coil * (if required, bidder to consider an
additional electrical heater in their scope)
Insulation (Yes/No) *
Breather Valve (Yes/No) No
Gauging And Sampling Hatch (Yes/No) No
Vent (Yes/No) Yes
Flame Arrestor (Yes/No) No
Calibration Of Tank (Yes/No) No
MATERIAL OF CONSTRUCTION
Tank Solid FRP
Lining NA
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
2.The sizes shall be as per the recommendations of the RO system
supplier based on actual requirement for RO membranes.
15.47 RO Cleaning Solution Pumps
Service : To transfer RO cleaning chemical to RO
skids
Type : Submersible or Centrifugal, Horizontal
PROPERTIES OF LIQUID
Liquid handled RO cleaning chemical
Pumping temp. (oC) AMB.
Viscosity at pumping temp. (cs) *
V.PR. at pumping temp. (kg/cm2 abs) NA

Liquid density (kg/m3) *


Presence of corrosive / toxic components Yes
Solids in suspension (yes/no) *
Size of solid particles (mm) (max) *
OPERATING CONDITIONS
Flow rate - Normal (m3ph) *
Flow rate Max (m3ph) *
Flow rate - Min. (m3ph) *
Suction pressure (kg/cm2.g) ATM
Discharge pressure (kg/cm2.g) *
Differential pressure (kg/cm2) *
Differential head (mLC) *
NPSH Available (m) Minimum Flooded suction (bidder to indicate the
exact value)
No. of pumps 2 (1W+1SB)
CAPACITY CONTROL FOR VOLUMETRIC PUMPS

Continuous / Discontinuous / Manual / Automatic N.A


Type N.A
Range (%) N.A
Precision At Min. Rate (%) N.A
MECHANICAL DATA
Design pressure (kg/cm2.g) * (minimum 2 kg/cm2g more than the
differential pressure)
Design temperature (oC) 65
Material Code Casing SS316L
Material Code Impeller SS316L
Seal type Mechanical
Line rating In/Out */*
Driver Electrical Motor
1. Data marked as "*" to be furnished/confirmed by the bidder.
2. Pump shall be capable of auto start/stop.
3. The pump capacity shall be based on the
recommendations of the RO system supplier.
4. The pump motor shall be sized for open discharge
conditions and parallel operations.
15.48 RO Cleaning Solution Cartridge Filter
Service : Filtration of RO cleaning chemical
PROPERTIES OF LIQUID
Liquid handled RO cleaning chemical
Operating temp. (oC) AMB.
Viscosity of Liquid. (cs) *
Liquid density (kg/m3) *
Design Temperature (0C) 65
Design pressure (kg/cm2.g) * As per shut off pressure of the RO
Cleaning Solution Pumps OR minimum
2 kg/cm2g more than its differential
pressure, whichever is more
Operating pressure (kg/cm2.a) *
CARTRIDGE FILTERS
Rated flow (m3/h) *
Total flow(m3/h) *
Micron rating (microns) 5 ( Nominal)
Flow per element(m3/h) *
No of element per housing *
Size of element *
Pressure drop across system (clean/dirty) (kg/cm2) *
Filtration area per cartridge *
Pressure relief valve *
MATERIAL OF CONSTRUCTION
Cartridge Filter Membrane PP
Shell SS316L
Design Code As per ASME standards
Type Of Cartridge PP wound
Ends Caps *
NOTES:
Data marked as "*" to be furished / confirmed by the bidder.
The cartridge filter capacity shall be as per RO
system suppliers recommendations.
15.49 RO Cleaning Solution Tank Agitators

Service : RO cleaning chemical solution


preparation
Process Data
Purpose Mixing
Operation (Batch/Continuous) Batch
Flow rate through vessel (m3/h) N.A.
Operating Pressure (kg/cm2.a) ATM.
Operating Temperature (0C) Ambient
Solids Present (Yes/No, Type & Size) No
Foam Tendency (Yes/No) *
Solubility (High/Medium/Low/Nil) *
Abrasion (High/Medium/Low/Nil) *
Settling (High/Medium/Low/Nil, Velocity) *
Degree Of Agitation (Mild/Medium/Violent) *
Corrosive Products (Yes/No, Type) Yes
Process Limitation (None/HP/Tip Speed/Space) Tip Speed
Component Percent Composition Viscosity Cp Sp Gravity
BY VOL. BY WT.
Ro Cleaning * * * *
Chemical
Water * * 1.0 1.0
Average Properties Of Mix * *
Mechanical Data
Impeller - Type (Turbine / Propeller) Propeller
Impeller Number 1
Impeller -diameter (mm) *
Impeller -speed (RPM) *
Impeller -M.O.C. SS-304 FRP Lined
Blades Type *
Blades Number *
Blades Pitch Square
Blades - Width (mm) *
Blades - M.O.C. SS-304 FRP Lined
Shaft - M.O.C. SS-304 FRP Lined
Power No. Used *
Mounting Space Available ( Ample/Restricted) Ample
Mixer Entry (Top/Side/Bottom/Portable) Top
Mounting (Clamped/Flanged, Mounting Angle) *
Shaft Seal (Mechanical /Stuffing Box/Labyrinth Seal /Vapour N.A.
Seal)
Drive Type Electrical Motor
Drive Unit Transmission Type (Gear/Belt/Direct) *
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
15.50 Suck Back Tank

Service : To fill up RO membrane pressure tubes


with permeate water
PROCESS DATA
Liquid Handled RO permeate
Viscosity of liquid (cP) *
Vapour pressure *
Liquid density (kg/m3) 1000
Operating Temperature (oC) AMB
Design Temperature (0C) 65
Operating Pressure (kg/cm2.a) ATM.
Design pressure (kg/cm2.a) ATM. + LIQUID COLUMN
Nature Of Liquid (Toxic/Corrosive) NA
Holdup Volume Of Tank (Hrs) (Min) * For wetting all membranes of RO
MECHANICAL DATA
No. of tanks 1
Type Cylindrical, covered with vent
Diameter (m) *
Liquid depth (m) *
Free board (m) 0.5 (MINIMUM) *
Total height (m) *
Liquid hold-up capacity of each tank (m3) *
Total capacity of each tank (m3) *
Level Indication Reuqired Yes
Type Of Level Indicator Level Gauge
Service Water Connection NA
Overflow Connection Yes
Draining Arrangement Yes
Dosing Arrangement *
Agitator Required No
Baffle Arrangement NA
Size Of Baffles NA
Corrosion allowance (mm) Nil
Minimum thickness (mm) Shell/Roof/Bottom 8.0/6.0/8.0
Heating Coil NA
Insulation (Yes/No) No
Breather Valve (Yes/No) No
Gauging And Sampling Hatch (Yes/No) No
Vent (Yes/No) Yes
Flame Arrestor (Yes/No) No
Calibration Of Tank (Yes/No) No
MATERIAL OF CONSTRUCTION
Tank CS
Lining Epoxy
NOTES :
1. Data marked as " * " to be furnished/ confirmed by the bidder.
2.The sizes shall be as per the recommendations of the RO system
supplier based on actual requirement for RO membranes.
15.51 Chemical House
Service : To house chemical storage inventory,
some of the solution preparation tanks,
office etc. (as detailed below)
Type RCC framed structure
Over All Size (Indicative) (L X B) (Note-9) 20 m x 15 m (Minimum) *
Ground floor area (m2) (Indicative) (Note-9) 20 m x 15 m (Minimum) *
First floor area (m2) (Indicative) 20 m x 15 m (Minimum) *
Details Of Area Usage (Minimum Area) Ground Floor (mxm) First Floor (mxm)
Chemical Storage *
Maintenance-Cum-Store Room (Note-5) 5x5
Check & Change Room 4x5
MCC (as applicable / specifications) Separate Building
Laboratory Room 5x5
Toilet (10 m2 minimum) 2 no 3x4 3x4
Space For Water Cooler * *
Chemical Solution Preparation & Dosing *
Area
Bulk Acid / Alkali Storage Area To be provided outside chemical house
Space Requirement Minimum 20 days storage for chemicals used daily
based on chemical solution strength and dose rates in
data sheets, otherwise as per process requirement and
shelf life
No. Of Chemicals To Be Dosed Yes, provided as per specs / as per requirement.
No. Of Soln. Preparation Tanks Yes, provided as per specs / as per requirement.
Width Of Platform Yes, provided as per specs / as per requirement.
Stairs/Handrails To Approach Platform Yes, provided as per specs / as per requirement.
Chemical Lifting Arrangement Electrically O
Block Hoist & Monorail (1.0 Ton Capacity)
Type Of Cradle Provided *
Size Of Cutout (Minimum) 1.2 m X 1.2 m
Safety Shower & Eyewash Minimum 2 no in chemical house (1 near dry chemical
handling area and 1 near chemical solution preparation
area) *
Exhaust Fans Yes, provided as per specs / as per requirement.
Lime Pit Details *
Overhead Tank Capacity 5.0 m3 minimum *
Capacity of weighing machine 100 kg
Drinking water loft tank capacity Yes, provided as per specs / as per requirement.
Details of soak-pit & septic tank Yes, provided as per specs / as per requirement.
Water cooler Yes, provided as per specs / as per requirement.

1.List of chemicals to be dosed shall be as per design basis/process requirements.


2. Number of chemical solution tanks: refer respective data sheets for the chemical solution preparation
and dosing tanks for further details.
3.Data marked as "*" to be provided by the bidder.
4.The area should be indicated by bidder, any increase in the area during detailed engg. shall not have
any commercial implications whatsoever.
5.Maintenance room shall be provided for electrical, mechanical & instrumentation, which shall be used
for storing tools and spares, etc.
6.Separate building to be provided for Substation/MCC room
7. Details of area usage to be reviewed & approved by owner during detail engineering.
8. The complete chemical storage area on the ground floor and chemical solution preparation/dosing
area on the first floor shall be provided with acid/alkali resistant PPG lining on floors and up to 2.0
m high skirting on walls/partitions. However, acidic/alkaline material shall never be stored together.
9. The minimum area indicated does not include ClO2 generator equipment room (for skid/ submerged/
encapsulated generator location). Adequate additional area as per ClO2 system suppliers
recommendations to be considered by the bidder. These rooms shall be part of chemical house building or
shall be kept adjacent to chemical house/ bulk chemical handling area.
All mechanical equipment which comes into contact with liquid shall be fabricated in non corrosive materials and metallic parts in contact with liquid shall
conform to Stainless steel SS316L unless otherwise stated. All walkways shall be in RCC or stainless steel with stainless steel handrails SS316 unless otherwise
stated.
Tertiary Treated water shall be disinfected

The tertiary treated Product water shall be pumped and conveyed to the usage point and the rejects to the final disposal to canal leading to Buckingham canal for
final disposal.

15 Process Instrumentation, Control. and SCADA System -General


The instrumentation shall include online measurement of influent and Product water parameters Process Instrumentation, Control. and SCADA System shall
include continuous monitoring the process parameters, process flow, tank level and other equipment protection devices. These measurements shall be connected
to a network of Programmable Logic Control (PLC) based unit process controllers that will generate pre-programmed monitoring and control actions for
process, equipment and other control devices.

A Supervisory Control and Data Acquisition (SCADA) system, networked to the PLC unit process controllers shall acquire and display process parameters,
process flow, tank level, etc., monitor and issue remote control actions for maintaining process control. The SCADA system shall also achieve pre-
determined process parameters and originate custom performance reports for management reporting.

17.Recommended process for the proposed TTRO Plant:

Secondary Treated effluent will be made available by the Owner at the existing 110 mld STPs Maturation pond ( Invert level: 0.75 m, Maximum water level:
2.00 m & Near by ground level: 2.713 m). The Operator has to tap the flow from the Maturation Pond to the proposed TTRO Plant. The conveying pipeline
between the existing Maturation pond and the proposed Pre Chlorination contact Tank / Rapid sand filter feed sump will be in the scope of the Operator.

Three stages of treatment are required. These are broadly classified as: Pre-treatment Stage (to control suspended impurities), Secondary Treatment Stage (to
control Silt Density Index),Tertiary Treatment Stage (to reduce Total Dissolved Solids & Disinfection).

17.1 Pre Chlorination contact Tank / Rapid sand filter feed sump
The feed water received under gravity is routed to Pre Chlorination contact Tank / Rapid sand filter feed sump These are twin compartment tanks having a
common inlet sump. For effective Prechlorination the tank will have a 30minutes detention time on the inlet flow of 65.3mld. The tank shall be provided with
inlet sump arrangement connected to each compartment of the tank through sluice gates. Submerged, underwater chlorine dioxide generators shall be located in
this inlet sump with diffuser assembly. The floor level and top water level shall be so arranged so as receive influent by gravity from the existing Maturation
pond.
Pre-treatment: Pre-treatment block is the first stage of treatment and consists of removal of settable suspended particulate matters and removal of impurities
like residual BOD and COD which may be harmful to the UF/ RO membranes. This stage is achieved with the help of organics reduction through Chlorine
Dioxide dosing followed by Rapid gravity filtration .
Organics Reduction through Chlorine Dioxide Dosing: Chlorine Dioxide is generated on-site and is dosed at the inlet sump of Pre Chlorination contact Tank /
Rapid sand filter feed sump Equalization tanks to eliminate micro biological growth and also to reduce the organics load of the feed water. Submerged/
encapsulated underwater U-tube type onsite chlorine dioxide generators are envisaged to generate chlorine dioxide at the dosing point, i.e., at the Pre
Chlorination contact Tank / Rapid sand filter feed sump Equalization tanks inlet sump with diffuser arrangement. Chlorine dioxide dosing shall be controlled
based on the residual chlorine dioxide level in water, which is measured by means of online analyzer located at the discharge of the Filter Feed Pumps. The
Chlorinated equalized effluent is then routed to Rapid sand Disc Filtration system through Rapid sand Filter Feed Pumps located at the Pre Chlorination contact
Tank / Rapid sand filter feed sump thorough a 1000mm dia CI LA class pipe.
17.2 Rapid gravity sand Filtration Arrangements
The filtration system proposed is the conventional Rapid gravity sand filters to trap the suspended solids present in the feed water to UF system. Filtration is a
process for separating suspended and colloidal impurities from the effluent by passage through a porous media. The Rapid sand filter comprises of a bed of sand
serving as a single medium granular matrix supported on gravel overlying an underdrainage system. The features of Rapid sand filtration include use of high
filtration rates and coarser but more uniform filter media to utilize greater depths of filter media to trap influent solids without excessive head loss and
backwashing of filter bed by reversing the flow direction to clean the entire depth of filter.
The Operator should provide a Rapid gravity filter house of suitable size to house the required filter beds as indicated in the Equipment list, with the suggested
rate of filtration of 5 cum/sqm/hour. Filter sand is defined in terms of effective size and uniformity coefficient. Filter sand to a depth of 0.75m having an effective
size of 0.50mm and uniformity coefficient of 1.50 is suggested. Filter gravel to a depth of 0.45m having a size of 2 to 5 mm at the top portion and a size of 25
mm at the bottom portion is suggested. The suggested depth of water is 2.00m with a free board of 0.50m. For taking the filtered water through the Under
drainage system suitable orifices, laterals and manifolds shall be provided. Suitable back wash water troughs and gullets shall be provided for back washing of
filters. For backwash air scouring suitable number of air blowers with 50% standby shall be provided. For back wash water requirement a tank of capacity as
indicated in the Equipment list, shall be provided over the roof of the Filter house. For filling backwash water requirement tank suitable pumpsets with 100%
standby shall be provided. The filtered water will be taken to the Ultrafiltration feed sump. The backwash water will be taken to the Disposal blending tank for
final disposal. The sizes mentioned here are only suggested sizes and the Operator can adopt his own size based on the design adopted. The Rapid sand filtration
system shall work at a minimum recovery of 98%.
17.3 Ultrafiltration feed Sump.
A Ultrafiltration feed sump of liquid capacity as indicated in the Equipment list, shall be provided so as to receive the effluent from Rapid sand filters and from
where it will be pumped to the Ultrafiltration through Pre filter / Manual Strainer / Basket filter for further treatment. Suitable high pressure pumps as indicated
in the Equipment list, as Ultrafiltration feed pumps and suitable pumps as indicated in the Equipment list, for filling Rapid sand filters wash water storage tank
shall be provided.
17.4 Ultra filtration System:
The Ultra Filtration system shall be either dead end or cross flow arrangement meeting minimum recovery guarantees of 88% . The UF treated water is stored in
a UF Permeate storage tank to provide hold up and store water required during UF back flush and chemical enhanced backwash steps. The UF system shall also
have Chemical Enhanced Backwash provision along with the normal back-flushing arrangement for cleaning of the UF membranes. The UF system shall be
designed to have a minimum net permeate recovery of 88%. Suitable UF skids as indicated in the Equipment list, shall be provided. Total flow rate and the
permeate expected from each skid shall be as indicated in the Equipment list. The Backwash / Back-flush effluent from the UF system shall be routed and
collected in the Disposal Blending tank for mixing with other waste water streams of TTRO plant and further disposal outside battery limit. Dedicated UF
Backwash pumps as indicated in the Equipment list, shall be are provided to Backwash UF membranes during normal back flush steps and during Chemical
Enhanced Backwash steps. Air scouring arrangement shall be provided for UF system, if required to meet the guarantees from UF system. The TTRO Plant
contractor shall additionally provide Air blowers for UF Air scouring and any other TTRO Plant internal requirement as per recommendation by the UF system
supplier. The design of UF system shall ensure that the downstream units are not starved of the required quantity of water so as to ensure net treated water
production capacity from the TTRO Plant. The sizes mentioned here are only suggested sizes and the Operator can adopt his own size based on the design
adopted
17.5 Reverse Osmosis System:
The UF outlet water from UF permeate tank is then pumped to cartridge filters through Cartridge Filter Feed pumps as indicated in the Equipment list. The
Cartridge Filters envisaged shall be of disposable type. Rated flow to each cartridge filter shall be as indicated in the Equipment list. Minimum numbers as
indicated in the Equipment list, shall be provided. The outlet of Cartridge Filters is connected to suction of RO high pressure Feed pumps. RO high pressure
Feed pump is provided with VFD on the individual drive motor. Minimum numbers as indicated in the Equipment list, shall be provided. Individual RO skids
as indicated in the Equipment list, fed with high pressure feed water, produce a permeate water stream of very low Dissolved solids and a reject water stream
of high Dissolved solids content. The Reject stream shall be throttled in such a way to provide sufficient pressure to permeate stream for routing it to Degasser
tower, which is kept at an elevation above the RO permeate tank . Necessary piping and valve arrangements shall be provided to route a part of permeate
stream to Suck Back tank in order to avoid keeping the membranes in dry conditions during standby operation of RO skids as well as during plant shutdown.
Reverse Osmosis unit shall remove TDS & Silica. The outlet from RO shall be followed by Degasser Tower. The degasser tower design shall be based on the
highest CO2 achieved in any of the computational analysis of feed quality provided. After degassing the effluent is taken to RO permeate tank. From RO
Permeate tank, the water is pumped to the Treated water storage tank through Activated carbon filter. The Activated carbon filter shall be provided for
polishing of water. Minimum numbers as indicated in the Equipment list, shall be provided.The Treated water is then stored in a storage tank with pump out
facilities for distribution of the treated water to various industries through a pipeline.
The reject/backwash effluents from the TTRO Plant (RO reject, UF & Filter backwashes, etc.) shall be collected in a Disposal Blending Tank within plant
boundary limit blended with secondary effluent to be taken from the Owners STPs Maturation pond and then pumped to the nearby Buckingham canal for
disposal.

17.6Transfer of Treated Water:


The Treated Water from Activated carbon filter is collected in Treated Water storage tank . Ozonisation shall be done in the Treated water storage tank to make
the water completely sterilized. This treated water stream is further transferred to the pipeline network for routing it to various industrial parks through Treated
Water transfer pumps.

17.7 Ozonation System


To prevent the pipeline network from microbiological growth, ozonation system shall be provided at the Treated water storage tank.
17.7.1 Scope of Supply/Work
The scope of work for the Ozonation system for pipeline network shall be, but not limited to as given herein:
The scope shall include Design, Engineering, Procurement, Supply, Manufacture, Construction and Erection of Civil and Structural, Mechanical, Electrical,
Piping, Painting and Instrumentation works, Storage at site, Commissioning and testing of Ozonation system, Training of owners personnel, trial runs after
commissioning and performance guarantee test run for continuous operation, guaranteeing, and handing over the Ozonation systems to the Owner at the end of
the O&M period.

All works required to meet requirements given in design /process /operation requirements defined elsewhere in the tender document shall also be deemed to have
been included in Contractors scope.

All the applicable safety codes, national laws and local regulations shall be followed by the successful bidder for the design engineering, fabrication, erection,
commissioning of the Ozonation system and necessary approvals shall be obtained from the concerned statutory authorities by the contractor. It is to be ensured
that all activities from detailed engineering up to handing over of the Plant should accommodate statutory requirement during the execution of the contract and
this also forms part of the scope. Documents as required for taking statutory approvals will be generated and submitted to the statutory
authorities by the contractor through Owner. Follow up and obtaining clearances (wherever applicable), shall be the responsibility of the contractor. Statutory
bodies from which approvals may have to be taken include State Pollution Control Board, Factory Inspectorate, Labour Authorities etc. The contractor shall
ascertain requirement of approvals as applicable in such Plants and initiation of action as required shall be in contractor's scope.

All safety procedures for different types of work as per the safety rules from time to time by owner shall be binding and adhered to by the contractor. Safety
report generation for different situations as per the rules and required by owner are to be adhered to.
The ozonation system suppliers scope of supply shall include but not limited to the
following equipment:
Oxygen Generation system
Ozone Generation system
Cooling Water system
Power Supply Unit
Inline Ozone dosing system with Static Mixers
Measuring & Monitoring Devices
PLC based Control Panel

In addition to the above, the contractor shall supply other necessary accessories to
ensure safety of the plant as well as for a smooth and trouble free operation of the plant.

17.7.2 Supply of Consumables & Chemicals


Supply of all chemicals, spares and consumables required for the operation and maintenance of the ozonation system during start-up, pre-commissioning,
commissioning, trial runs, successful performance guarantee test run and during the O&M period shall be in the scope of the contractor.

Special chemicals required, if any, shall be clearly defined by the bidder during tender stage with respect to quality & quantity. Minimum two Nos. of
manufacturers/ supplier shall be specified by the bidder for these special chemicals.
17.7.3 Process Description
Continuous Ozone generation and dosing system is envisaged for the Project. The system shall have oxygen generation/ air preparation system (as required),
ozone generators, venture injector with suitable backflow prevention, etc, as applicable to ensure safe, smooth and trouble free operation of the system.

The system shall also have proper ozone leak detection and automatic shutdown
provision in addition to over current protection, over/ under voltage protection, etc. The
system shall also be provided with manual shut down from a safe distance in the event
of ozone leakage and instrumentation failure case. The vents of the ozonation system
shall be routed to a safe height. Requirement of the air as well as cooling water
requirement for the Ozonation system shall also be provided by the contractor.

17.7.4 Guidelines and System Description/ Specifications


Ozonation plant as defined by these specifications includes ozone generating plant as a
whole including mixing device, its feed gas preparation device & its controls. The
ozonation system must be capable of producing the required quantities & concentration
of ozone & injecting it to pipeline on continuous basis.

17.7.5 Design criteria


The capacity of ozonation system shall be a function of the total ozone demand of the
treated water for disinfection application. The ozone generation plant shall be designed
to generate & deliver to the injection points, an ozone solution @ 5 ppm.

The ozone generator proposed shall provide maximum production efficiency with
minimum power consumption. Ozone shall be generated using a dry filtered gas
containing oxygen, which is fed through an electrical discharge created between the two electrodes. These electrodes are separated by the discharge gap & a
single dielectric.

The electrode shall be maintained at high voltage & the vessel is connected to the earth.
The discharge, known as silent corona discharge causes the dissociation of some of
the oxygen molecules resulting into the formation of ozone.

The ozone content, or ozone concentration, shall be expressed by the ratio of ozone in
the outlet gas (% by weight) or the weight of ozone produced per volume of the outlet
gas (g/Nm3). The quantity of ozone produced & the ozone concentration shall be
controlled by adjusting the feed gas flow rate & the power applied to the discharge.
17.7.6 Ozonator System Arrangement
The electrodes (called H.T. electrode) are inserted in dielectric tubes. The outside
stainless steel tube forms water-cooled grounded electrode. Several of them are
installed inside the production vessel forming the design of classical heat exchanger.
The portion of the electric energy necessary for ozone generation is transformed into
heat. This heat is effectively removed by the cooling water passing through the vessel.
Suitable tap-off/ provision inside the TTRO plant/ intermediate storage tanks shall be
made for supply of cooling water requirement for the ozonation system.

The ozone production elements design shall provide low dielectric stress & a high
dielectric tube breakdown safety. The main factors which influence ozone generators
efficiency, reliability and agility are electric parameter and mechanical strength.

17.7.7 Markings
The marking of the plant & parts shall be as per the Technical rules of pressure vessel. The supplier shall clearly indicate the same.Tubings carrying ozone
gases shall be marked in accordance to with DIN 2403 identification of pipelines according to the fluid conveyed.

17.7.8 Choice of Material


Ozone proof materials shall be used for all parts & components of the ozonation plant
that come in contact with ozone gas. The ozone electrode material shall be confirming
to DIN 19627 part 2 (i.e., SS 1.4571), H.T. element (i.e., aluminum) according to DIN
17007 part 4, PVC according to DIN 8061 (i.e. Un-plasticized polyvinyl chloride pipes) and general quality requirement including testing & overall ozone
generator as per DIN19627.

17.7.9 Design data


Design treated water flow rate 1875 cum/ hour, Suggested Ozone dose - 5 ppm or mg/lit, Ozone required 10 kg/ hour @ 10% concentration wt/wt

17.7.10 Oxygen Generation System


The purpose of this system is to feed desired quantity of feed gas to Ozonator at a
specified quality.
Compressor with electrical motor of suitable capacity shall be provided as part of this
system. The compressor shall be of Non-lubricating type.
Air drying unit of suitable capacity with a heatless type regenerative system to
achieve dew point of 40/60 Celsius with no purge loss shall be provided.
The system shall be any of PSA or Cryogenic type.
Oxygen generator/ concentrator of suitable capacity shall be designed to achieve
oxygen purity up to 92% by volume & dew point at -60 Celsius. The feed gas shall
be filtered to 0.1 m and the hydrocarbon content shall be less than <15 mg/lit.
Online measurement & monitoring facilities of oxygen purity & dew point shall be
provided as part of the system.

Ozone Generation System


Ozone Generation plant of capacity shall not be less than the capacity indicated earlier
in this document and the system shall be with single inline dosing system in the pipeline after respective transfer pumps.

Ozone electrode
Ozone generating modules of shall be of SS316Ti grade material & should comply
with DIN 19627 standards.
Cooling waterside shall be pressure proof up to 6 bar minimum or higher as per
system requirements.
Thermal isolation against condensate water shall be provided.
Indirectly cooled dielectric of high graded borosilicate glass free of mechanical or
heat generated tensions shall be provided.
High voltage electrodes with individual fuses without inside mesh shall be provided.
Ozonator Modules
The system supplier shall provide Ozonation system in modules of same capacity with
minimum of one standby module of equal capacity.

Gas / Cooling ends


Water inlet & outlet connection of Heat Exchanger shall be of SS 316 Ti grade where as ozone inlet & outlet connection should also be of SS 316 Ti grade.

17.7.11 Cooling Water (chiller) System


Chiller system of suitable capacity shall be provided for removal of excess heat
generated during ozone generation from ozone producing cells. It shall consist of compressor, cooler, condenser, refrigerant circuit, control center, pump, chilled
water
piping, condenser water piping, electrical panel, power & control cabling.

17.7.12 Ozone Dosing System

Ozone dosing system shall be defined as part of the plant where the ozone gas that
exits the generator mixes water. It shall consist of the following:

Venturi Injector of Ozone resistant MOC with backflow prevention arrangement. With
flap trap design with suitable booster pumps (1Working + 1Stand by minimum) on
assessing the dosing point location at site.

All pipelines, valves, fittings & other metallic parts involved in oxygen concentrator &
ozone generator up to dosing point shall be of suitable non-corrosive/ ozone
resistant metallurgy.

Suitable inline static mixers to avoid gas phase separation.

17.7.13 Measuring & Monitoring Devices

The outlet ozone gas of each ozone-generating module shall be measured by a


common ozone analyzer (common for all ozone generating modules), of digital
display model in gm / Nm3 (range 0 to 400) having accuracy of 0.1 gm/Nm3 based on
UV adsorption technique.
Ambient ozone leak detector shall be provided and is placed in the ozone generator
room to detect ozone leakage with alarm and cut-off signal on set value.

The above measuring / monitoring devices shall be of standard make.

17.7.14 Lighting and Ventilation system

Ozonation system shall be erected in closed building (that can be locked) and the
building/ rooms where ozone might be emitted/ leaked in case of failure shall be
effectively monitored by gas detectors with alarms that stop the generation of ozone
when activated. Sensors shall be triggered at an ozone concentration level of 1.0
mg/m3. The building/ rooms shall be equipped with ventilation at floor level actuated
automatically by the gas detectors and shall comprise a suction device. Ventilation shall guarantee minimum three complete changes of air per hour. All lighting
fixtures, window ACs, ventilation systems along with MCC, SLDBs, cables (power, control &
Instrument) etc., shall be provided as part of the system. There shall be no permanent
work stations in rooms with ozonation system. Ozone rooms shall be marked with the
signs in accordance to applicable international standards. They shall be clearly visible & durable.
17.7.15 Commissioning Spares

For successful pre-commissioning, commissioning and performance testing,


requirements of spares are to be provided by the contractor within quoted lump sum
price and are to be listed in the bid. Any additional spares used shall be to Contractors
account.

17.7.16 Instrumentation and Control Philosophy


Contractor shall also provide one number local control panel (PC-PLC based) for operation and monitoring of ozonation system. The PLC system shall control
the complete system and required data can be recorded for reference. Both auto & manual mode of operations for the ozonation system shall be provided. Control
& monitoring of all important / critical system parameters shall be carried out through PLC.

Alarms and Safety Features


Ozone vessel gas pressure shall be precisely regulated using transducers and PID
control. A water back flow prevention device suitable for ozone use shall be installed on the ozone gas out piping. Any electrical cabinet that has a door shall
have electrical and mechanical interlocks on that door.
Alarm list
The system supplier shall provide necessary safety alarms & trips and instrumentation
required but not limited to the following:
High gas exit temperature
High or low gas pressure
Low chilled water flow
High chilled water exit temperature
Frequency drive failure
Loss of phase detect
High inverter current trip
Low feed gas flow
Door interlock trip
Ozone concentration
Oxygen purity
Dew point
Ozone suction
Pump failures
For Power Supply Unit :- Instantaneous over current protection, over/ under voltage protection, Inverter over heat, Earth fault protection, Control and regulated
power supply failure protection.

17.8 Chemical handling:


An integrated and centralized system shall be provided for chemical solutions preparation in Chemical House and dosing at various points. Chemical dosing
system shall be suitably located on first floor of the chemical house; whereas provision for chemicals storage shall be made on the ground floor. Bulk liquid
chemicals such as conc. Hydrochloric acid, Sodium Chlorite & Caustic lye shall be stored outside the Chemical house in a dyked area. Transfer (loading from the
supply tankers and unloading to solution preparation tanks in TTRO plant) of these chemicals shall be done by their respective unloading pumps and transfer
pumps. These tanks shall be provided with dyke wall. HCl, NaClO2 and Caustic Lye bulk storage tanks shall be provided with a separate dyke wall and located
within TTRO plant battery limit with the required facilities. Suck back tank provided shall be of appropriate capacity and shall be housed at adequate elevation.
The elevation shall be more than the top pressure tube of RO skids. Analyzers (as per suppliers recommendations) shall be put in an analyzer room with AC
environment located under common shed of TTRO Plant.
17.9 Other works:
The Bidder has to provide all infrastructural facilities such as inner roads, storm water drains, Tower lights, rain water harvesting, Land scapping with pathways,
water supply facilities, substation yard etc., as per the requirements.
18.0 Specifications for RO Plant:

18.1 General Design requirements: It may be noted that all the pumps which are to be located below FGL shall have a suitable pump house building having
RCC construction below FGL and RCC lintel and brick masonry work above FGL except if indicated specifically about its non-requirement.
For pumps/blowers to be located on grade level, the motors shall be protected by canopies. The pavement and pedestal minimum levels shall be as per
requirements. The interspacing/ clearances between wet sump and pump pedestal, pump pedestal to side/ back walls shall be same as applicable for pumps to
be located in a pump house/ dry well below FGL.
The specifications / requirements specified are bare minimum only; the DBO contractor shall follow Good engineering practices and incorporate maximum
operational flexibility in the system.
RO membrane winding are an integral part of membranes and are supplied along with the membrane by membrane supplier. The guarantee/warrantee for RO
membranes shall extend to their respective winding also. Pressure tube is a protective cover, wherein membrane elements are re housed. RO pressure tubes
shall be as per applicable ASME standards.
Head of RO feed pumps should be designed such that it is suitable for all approved makes of membranes at design condition. Adequate margins over & above
design calculations shall be considered for capacity & head so that quality & quantity of water always assured from the plant.
Chain pulley blocks with monorail shall be provided for maintenance of pumps, blowers, cartridge filters, RO skids, chemicals, etc.
Draining arrangement shall be provided for all units, as necessary.
All effluent holdup tanks shall be provided with overflow lines, Sampling and gauging hatches etc.
Adequate number of sampling points shall be provided at the inlet and outlet of each treatment sections.
Piping class shall be as per Process requirements.

Velocity in pipes shall be as given below. The same shall form the governing criteria for the contractor for Line Sizing:

i. Pump suction lines shall not exceed 1.2 m /s

ii. Gravity lines shall not exceed 0.8 m /s

iii. Discharge headers and all pressure lines, it shall not exceed 2.0 m/s.

iv. However, in no case minimum diameter of pipe shall be less than 40mm (1.5).
18.2 GENERAL ENGINEERING SPECIFICATIONS
NOTE: Bidders to refer clauses relevant to respective units/equipment in the Tender document.
a) All pumps shall be flooded suction type, unless otherwise specified, fully primed under Low Liquid Level in the suction sump/ tank. Low Liquid
Level shall be above the top of pump casing. The sump floor shall slope towards suction pit/channel.
b) Motors of all pumps and blowers shall be covered with canopy.
c) Mixers in chemical solution tanks (without baffle) shall be located off-centre to avoid vortex.
d) All drains from chemical house to be routed to a waste disposal tank of appropriate capacity and suitable neutralization arrangement before
connecting the outlet to the disposal blending tank.
e) All dosing pumps shall have external pressure safety valves (if not provided internally).
f) HCl storage tank(s) shall be provided with Fume absorber system.
g) Caustic storage tank(s) shall be provided with CO2 absorber on vent. Overflow shall have water seal.
18.3 CONTROL PHILOSOPHY
The TTRO plant shall be a PLC based control system as per Process requirements. Since feed analysis is important for the safety and efficiency of
the plant, on line TOC analyser is envisaged at a preset value for the measurement of organics in the feed water and at the inlet of UF system. The analyser at UF
inlet shall be having high level alarm beyond which feed cannot be taken for further processing. Provision shall be provided for auto drain/auto shut down of the
inlet valve in case of off specifications of feed water.
The instrument control philosophy for the building blocks shall be as applicable to the smooth operation of filtration/UF/RO blocks and shall be
defined in detail in Process/ Job specifications. Similarly on line analysers for ORP (Oxidation-Reduction Potential), pH, Conductivity, Silica, shall be installed
at appropriate locations for smooth & trouble free operation of TTRO plant.

18.4 Unit of Measurement: All engineering specifications shall be issued in the MKS system of measurement, with the exception of piping/tubing sizes, which
shall be reported in inches.

Parameter Unit
o
Temperature C
Pressure (Gauge) Kg/cm2.g
Pressure (absolute) Kg/cm2.a
Mass Kg
Length m, mm
Relative density (Sp. gravity) -
Density Kg/m3 or g/l
Vacuum mmH2O or mmHg
Flowing mass Kg/hr
Flowing liquid m3/hr
Flowing vapour/ gas Nm3/hr or kg/hr
Heat rate K Cal/hr
Viscosity cP
Kinematic viscosity Cst
Level %
Storage Tank Pressure mm of WC
Volume m3
Composition Vol %
Power KWHR

Chlorination System: Chlorine dioxide generation and dosing system shall comprise but not limited to the following shall be provided:
Required numbersof automatic Chlorine-di-oxide generators (submerged type / Encapsulated underwater U-tube type) as per Equipment listshall be
provided.
1 (one) No. of on-line free residual chlorine dioxide analyzer with controller and recorder to start, stop and to control the Chlorine Dioxide dosage rate
shall be provided. The Chlorine Dioxide dosage rate shall be controlled automatically based on residual analyzer feedback through dosing pump flow
control.
Tapping for dilution water supply shall be taken by the contractor from inside the TTRO plant at a suitable location.
Required numbers (as per Equipment list of 33% HCl dosing pumps shall be provided.
One (1) number of Sodium Chlorite Storage Tank (25-31% NaClO2) with nozzles, vents, density indicator and neutralization system, drains, overflows
etc. all complete shall be provided.
Required numbers (as per Equipment list of 25-31% Sodium Chlorite (NaClO2) unloading pumps shall be provided.
NaClO2 tank shall have 2 numbers of non contact radar type Level transmitters, one for high level and low level alarms in control room and the other for
unloading pump trip at high level and Dosing pump trip at low level shall be provided. Level transmitters shall also be provided with indication both in
field and in control room.
In case of water supply to the Chlorine-dioxide generator stops, the chemical dosing pumps shall also stop automatically.
Chlorine-dioxide Generators must be equipped with systems of dosing and/ or measurement for reagents and diluting water. These systems must be
able to shut down the operation of the Chlorine-dioxide generator in case any of the supplies is cut off.
ClO2 leak sensor with detector shall be installed at ClO2 generator room. The least count of sensor shall be 0.1 ppm and Chlorine-dioxide generator
shall stop automatically.
All other instruments like pressure gauges, pressure relief valves, level indicators, compound gauges, etc. as required for safe & trouble free operation
of the system shall be provided.
Complete piping with diffusers from Chlorine-di-oxide generator room to the dosage point (as applicable based on the type of Chlorine-dioxide
generator encapsulated or submerged) with flow control valves, drain valves, Y-strainers, vents, ejector, etc., shall be provided. The diffuser shall be
of HDPE (A1Z).
Complete piping (including interconnecting), all fittings, bends, tees, reducers, valves, flanges, bolts, gaskets, specials, isolation valves, permanent
strainers, etc., including pipe racks and supports, jointing, etc., and any other work as required for the system shall be provided.
ClO2 generator equipment room (for skid/ encapsulated generator location) and control room shall be provided. These rooms shall be part of Chemical
house building or shall be kept adjacent to chemical house/ Bulk Chemical handling area.
1 (One) No. Safety shower and eye wash facility (located just outside the Chlorine-dioxide generator room) shall be provided.
Pressure indicator and flow meter with controller shall be provided on water inlet pipe to Chlorine-dioxide generator.
Any other item(s) if required for completeness of the system, safety requirements and to make the system operational shall be provided.
Painting of exposed pipelines, steel structures, equipment operating platforms, ladders, stairs, hand railing, etc., as required and as per specification
shall be carried out by the contractor.
Complete Civil & structural, mechanical, electrical and instrumentation works for the system shall be carried out by the DBO contractor.
Approvals, if any, from any regulatory/ statutory body shall be in the scope of DBO Contractor.
Safety equipment: - Chlorine institute approved 2 (Two) numbers of respiratory equipment (pressure demand type air masks-full face for working
in leak area), 2 (Two) numbers of canister type gas mask, 2 (Two) numbers of ammonia torches, 2 (Two) numbers of emergency repair kit, One
number of Weather sock provided at a suitable location on the building, 2 (Two) each of Safety helmets, goggles, rubber boots, gloves and colored
vests (aprons), Display charts of PFD, Safety checks, maintenance procedure, Emergency Action Plan, etc.
Supply of all chemicals and consumables including lubricants, neutralization chemicals etc. actually consumed during pre-commissioning,
commissioning and during operation and maintenance for a period of 15 years shall be in the scope of DBO Contractor.
Datasheet for ClO2 generator system shall be prepared and submitted by the system supplier during detail engineering for Owner s review & approval. Capacity
indicated is minimum requirement. In case higher capacity is envisaged by the bidder, the same to be considered & provided by the bidder.
18.5 Inherent Design of TTRO Plant:
During the finalization of configuration of the TTRO Plant, due consideration has to be given to the presence of nutrients which cause biological fouling of the
UF/RO systems of TTRO Plant and hence it was envisaged to provide Chlorine Dioxide dosing at the inlet to control biological fouling in the TTRO plant.
18.6 Bio-fouling control precautions in TTRO Plant:
The TTRO Plant shall have effective ClO2 dosing at the inlet to control the microbiological growth in the system thereby reducing the chance of organic fouling
in membranes. The plant design shall also have effective residual chlorine dioxide level monitoring and thereby ensurings that residual levels of chlorine dioxide
is maintained in the feed water stream thereby arresting the biological growth in the pipeline as well as treatment systems. It shall further be ensured by the
Bidder that the membranes envisaged in RO skids shall be of Low fouling RO membranes thereby further reducing the chance of membrane fouling. As the RO
membranes are not tolerant to the presence of Chlorine/ Chlorine Dioxide in the feed water, the TTRO Plant shall be provided with required Anti-Oxidant
dosing at the inlet of RO membranes for de-chlorination purpose. In an extreme eventuality, if organic fouling occurs in membranes, it shall only result in slight
increase in frequency of membrane cleaning operation and shall not affect the overall process performance of the plant. Further it shall be ensured by the Bidder
that adequate standby skids are provided for UF & RO systems in order to ensure continuous production of Treated Water in the eventuality of taking out any
skid due to maintenance activity arising out of biological fouling. As the RO membranes also reject the Nitrogen and phosphorus contents present in the feed
water, adequate design margins shall be considered as well as precautions shall be taken in the TTRO Plant and its design to control the biological fouling in
TTRO Plant and the TTRO plant performance shall not be hampered because of the feed quality.
18.7 Commissioning:
For successful pre-commissioning, commissioning and performance testing, requirements of spares for operation and maintenance period of fifteen years shall
be provided by the DBO contractor within quoted lump sum price and shall be listed in the tender. Any additional spares used shall be to Contractors account.
The plant shall be PLC based system as given in job specifications for instrumentation works. The PLC shall be located in the control room. The control room
shall be housed in the TTRO plant substation building. All works for instrumentation and control shall be as per Instrumentation Job Specifications.
Instrumentation works specified in this section are minimum requirements and shall be considered by the contractor in his scope of work. All other
instrumentation works requirements required for safe and trouble free operation of the plant shall also be included in the DBO Contractors scope of work.
For each tank/sump/pit, Non Contact type SMART Radar type Level Transmitter (including the interface level) shall be provided as primary level
measurement device and for secondary level measurement, servo type local level indicator shall be provided.
No level switch shall be used unless specified otherwise. Switching action shall be in PLC. No displacer type level measurement shall be considered.
Level transmitter shall be used for local & control room level indication and for tripping purposes (including low & high levels alarms in the control room).
Since feed analysis is important for the safety and efficiency of the plant, on line TOC analyzer is envisaged at a preset value for the measurement of
organics in the feed water and at the inlet of UF system. The analyzer at UF inlet shall be having high level alarm beyond which feed cannot be taken for further
processing. Provision shall be provided for auto drain/auto shut down of the inlet valve in case of off specifications of feed water.
Incoming and Outgoing Lines: Suitable type flow measurement systems (orifice type for fluids without solid particles and magnetic type for fluid with solid
particles, annubar for lines with large diameter) with local and control room indication along with recording and totalizing facilities (in Control Room) shall be
provided on all incoming effluent feed (pressure lines) and outgoing lines. All incoming and outgoing lines shall be provided with PG and double block and
bleed valves arrangement with a spectacle blind provision at TTRO Plant battery limit. RO reject line shall also be provided with local and control room flow
indications including recorder and totalizer.

Sumps / Tanks and Transfer Pumps: Each of the sumps / tanks shall be provided with one level transmitter for high and low alarm in control room and for
interlocking purpose to auto start/ trip the respective operating pumps and a local level indicator as per process requirements. All the operating pumps shall auto
trip at level low. This logic shall be generally applicable to all tanks / sumps, unless otherwise specified. Level Transmitter shall have level indication in both
local as well as in control room. The local level indication shall be readable from grade/ platform.

Ultra Filtration (UF): Each UF skid shall have a flow control valve at the inlet. Each skid shall have a PT at the inlet and outlet. A pH analyzer for indication
and control shall also be provided on backwash line downstream of static mixer. A flow element with transmitter, indicator, integrator / totalizer and recorder at
the out let of each UF skid. PSV shall be provided at inlet to UF. The entire operation of ultra filtration, including backwashing, fast flush shall be completely
automatic (PLC based). Timer setting shall be done prior to each type of cleaning. Alarm for end of cycle shall be provided.

UF Permeate Tank: The UF permeate Feed Tank shall receive the UF outlet water. The UF Permeate tank shall be equipped with one level transmitter for high
and low alarm in control room and for interlocking purpose to autos start/ trip the respective operating pumps and a local level indicator as per process
requirements. Level Transmitter shall have level indication in both local as well as in control room. The local level indication shall be readable from grade/
platform.

Cartridge Filters: Differential pressure transmitter across each cartridge filter module shall be provided with high alarm in control room. The high alarm
indicates the requirement of cartridge change in these filters.
Reverse Osmosis (RO) Skids:
Each stream of RO shall have Flow indicators, Pressure Indicators on feed, permeate and reject lines and Conductivity & multi-channel Silica analyzers at outlet.
Conductivity, silica, ORP and pH analyzers at the common inlet header of RO skids shall also be provided.
A Differential Pressure transmitter shall also be provided across each RO skids
Conductivity & silica analyzer shall also be provided at the common outlet header of RO skids.
Flow element with transmitter, indicator, integrator/totaliser and recorder at the out let of each RO skid shall be provided.
The entire operation of RO system shall be completely automatic (PLC based). Only the cleaning of RO membrane shall be manual and the cleaning operation
shall be under operators supervision.
Treated Water Storage Tank and transfer pumps: The Treated Water Storage Tank shall receive the RO permeate after passing through Degasser tower and
Activated carbon filter . Each compartment of the treated Water Storage shall be equipped with one level transmitter for high and low alarm in control room and
for interlocking purpose to auto start/ trip the respective operating pumps and a local level indicator as per process requirements. Level Transmitter shall have
level indication in both local as well as in control room. The local level indication shall be readable from grade/ platform.
All Chemical Solution preparation / Dosing Tanks and Pumps: Each of the bulk chemical tanks shall be provided with two level transmitters, one for low
alarm and the other for auto tripping of the corresponding unloading/ transfer pump at high level during tanker unloading operation. Each of the chemical
solution preparation/ dosing tanks shall be provided with two level transmitters, one for low alarm and the other for auto tripping of the corresponding dosing
pumps and agitators at low level. Level Transmitters shall have level indication in both local as well as in control room. The local level indication shall be
readable from grade/ platform.
All tripping and alarms shall be configured on the PLC for the TTRO plant. All the dosing pumps (Diaphragm type) shall have pressure safety relief valves at
their respective discharge lines (if not provided internally). Local flow indicators shall be provided on the discharge line on the dosing pumps. If the same pumps
are dosing a chemical at more than one place, then those lines shall be provided with individual local flow indicators.

18.8 General

All pumps shall have Pressure Gauge (PG) on their discharge lines. The PG on all chemical services shall be of diaphragm type.
All motors shall have their running indication in the Control Room.
All motors shall have local start / stop facility. The motors having interlock facility shall have local / remote selector switch (local), auto / manual switch,
start / stop push buttons and main / standby switch in Control Room to facilitate remote operation.
All required start/stop push buttons, selectors, etc. for operation of various equipment shall be through soft keys in the PLC Console.
In case a motor is already running, there should not be a stoppage due to mode change over from local to remote and vice-versa. This is equally
applicable for mode change over from auto to manual and vice-versa.
For all pumps/blowers acting on interlocks/program, if the running pump/blower fails, the standby pump/blower shall start automatically provided it is in
Auto mode. However, manual override arrangement for the same shall also be available. All pumps/blowers are interchangeable.
Under no point of time both the operating and standby pumps/blowers shall run together in auto mode. However the same is not applicable for manual
mode.
In case of more than two pumps, provision of alarm shall be made only for the highest cut-in level and not for intermediate cut-in levels, unless otherwise
specified. In auto mode removal of high level signal should not cause stoppage of the running pump. All pumps are interchangeable and start to depend
on the liquid level in the sump, i.e. as the level in the sump rises, pumps to correspondingly get activated.
Effective Liquid Depth of units shall be considered between levels corresponding to Lowest Water Level and Highest Water Level. Flooded suction
requires that lowest level of the sump shall not be lower than the elevation of discharge flange of pump or top of pump casing, whichever is at higher
elevation.
All sumps and pumps shall be provided with appropriate instrumentation for alarms and auto operation (start/stop) of pumps with respect to preset levels.
No direct level switches shall be used in the TTRO Plant. Instead level transmitters shall be used for all sumps and tanks. These transmitters shall be
connected to PLC system and software switches shall be generated for interlock/alarm.
No direct process switches shall be used in the TTRO Plant. For Pressure, Diff. pressure, Flow, Temperature, Level, etc., transmitters shall be used and
switching action shall be carried out in PLC.
All instrumentation as required for monitoring and control of process and operating parameters in the TTRO Plant system to be provided. Also to be
provided are suitable instruments to measure the consumption of various chemicals and utilities for establishing the system performance during
performance guarantee test run.
Type of all instruments shall be as per requirement
Selection of RO membranes shall be subject to approval by the Owner based on the technical details/projection reports for the selected membranes for
the type of effluent envisaged for this project.
On line analyzers and other instruments with corresponding panel display in control room for the plant shall be as per requirement .
VFD for line pump (linked to flow transmitter in pump discharge) shall be provided. Flow change should be possible through PLC. HCl, SMBS &
Antiscalant dosing pumps control also shall be automatic (through PLC).
18.9 On-line analyzers
On line analyzers with corresponding panel display in control room on different lines as given below shall be provided as minimum requirements:
TOC analyzer on incoming influent treated TTRO Plant water line.
Residual Chlorine Dioxide analyzer in the discharge header of Filter Feed Pumps.
TOC & Turbidity analyzer at common inlet header of Ultra Filtration system.
Turbidity analyzer at individual outlet of UF skids.
pH analyzer at the common outlet header of UF Backwash Pumps (After static mixer).
pH, ORP, Conductivity & Silica analyzer at common inlet header of RO skids.
Conductivity analyzer & Multi-channel Silica analyzer at individual permeate outlet of RO skids.
Silica, Conductivity & pH analyzer at common outlet header of RO skids.
Conductivity analyzer at outlet header of Treated Water Transfer Pumps.
pH analyzer at the Outlet header line of Disposal pumps.
All other analyzers as required for smooth & trouble free operation & control of the plant shall also be included in the DBO contractors scope of work.
The detailed Instrumentation specifications are specified elsewhere in this present Bid document.
19.0 Specifications for Product water Transmission main:

19.1 Standards for Ductile Iron Pipes


IS: 8329 2000 Centrifugally cast (spun) Ductile Iron pressure pipes for water, gas and sewage - Specification
IS: 5382 - 1985 Specification for Rubber sealing rings for gas mains, water mains and sewers.
IS: 3400 Methods of test for vulcanized rubbers (Part 1 23 - latest revisions)
IS: 13655 1993 Guidelines for Heat Treatment of Cast Iron.
IS: 1500 2005 Methods for brinell hardness test for metallic materials.
IS: 9523 2000 Ductile Iron fittings for pressure pipes for Water, Gas & Sewage Specification.
IS: 12288 1987 Code of practice for use and laying of Ductile Iron Pipes.
IS: 2062 1999 Steel for General Structural purposes Specification.

19.2 Standards for Sluice Valves


IS: 1364 Hexagon Head Bolts, Screws and Nuts of product Grade A and B (Part 1 6 latest revision)
IS: 638 1979 Specification for sheet rubber jointing and rubber insertion jointing.
IS: 2685 1971 Code of practice for selection, installation and maintenance of sluice valves.
IS: 14846 2000 Sluice valve for water works purposes (50 to 1200mm size) Specification
19.3 SPECIAL CONDITIONS
19.3.1 CONSTRUCTION WATER:
The Contractor shall make his own arrangement for the fresh water required for construction of civil works and testing of pipeline and hydraulic structures as
well as for the potable water required for his labour camps.

19.3.2 CONSTRUCTION POWER:

The Contractor shall make his own arrangement for supply of electrical energy required at his sites and the works.

19.3.3 TEMPORARY FENCING:

The Contractor shall, at his own expense, erect and maintain in good condition temporary fences and gates along the boundaries of the areas assigned, if any, to
him by the Owner for the purpose of the execution of the works.

The Contractor shall, except when authorised by the Design-Build-Operations Engineer or his representative, confine his men, materials and plant within the site
of which he is given possession. The Contractor shall not use any part of the site for purposes not connected with the works unless prior written consent of the
Design-Build-Operations Engineer or his representative has been obtained. Access shall be made to such areas only by way of approved gateways.

19.3.4 SANITARY FACILITIES:

The Contractor shall provide and maintain in clean and sanitary condition adequate W.C.s and wash places, which may be required on the various parts of the
site or use of his employees, to the satisfaction of the Design-Build-Operations Engineer or his representative. The Contractor shall make all arrangements for
the disposal of sewage/drainage in accordance with the directions of the Design-Build-Operations Engineer or his representative.

19.3.5 RESTRICTED ENTRY TO SITE:


The Contractor shall get the prior permission of the Design-Build-Operations Engineer or his representative before any person not directly connected with the
works to visit the site.

19.3.6 EXISTING SERVICES:

Drains, pipes, cables, overhead electric wires and similar services encountered in the course of the works shall be guarded from injury by the Contractor at his
own cost, so that they may continue in full and uninterrupted use to the satisfaction of the Owner and the Contractor shall not store materials or otherwise occupy
any part of the site in a manner likely to hinder the operation of such services. The Contractor must make good or bear the cost of making good, the damage
done by him on any mains, pipes, cables or lines (whether above or below ground), whether shown or not shown in the drawings, without delay to the satisfaction
of the Design-Build-Operations Engineer or his representative.

19.3.7 ELECTRIC POWER SUPPLY:

1.The Electrical Power required has to be obtained by the Contractor from the Tamil Nadu Generation and Distribution Corporation Limited (TANGEDCO).

2. The Contractor is forewarned that there can be interruptions in power supply for reasons beyond the control of the TANGEDCO and therefore the contractor is
advised to make his standby arrangement to provide and maintain all essential power supply for his work area at his expense. The contractor shall not be entitled
to any compensation for any loss or damage to his machinery or any equipment or any consequential loss in progress of work and idle labour as a result of any
interruptions in Power supply.

19.3.8 NOTICE TO TELEPHONE, RAILWAYS & ELECTRICITY SUPPLY UNDER TAKING:

Before commencing operations the contractor has to obtain permission from local bodies / Highways Department when he wants to cut any section of the road.
The Owner will give necessary assistance such as sending letters and attending meetings if required. The Owner will also pay necessary charges towards
restoration of roads to the Corporation of Chennai / State Highways and National Highways. Any delay in getting the permission from the Corporation /
Panchayats / Municipalities, State Highways Department, National Highways Department, Railway Department, Electricity Board, Telegraphs Department,
Traffic Department attached to the police and other departments or companies for carrying out the work will be to the account of contractor.
The contractor before taking up operations, which involve cutting of roads, shifting utilities etc., during the progress of the work, shall give notice to the
concerned authorities viz. the Corporation / Panchayats / Municipalities, State Highways Department, National Highways Department, Railway Department,
Electricity Board, Telegraphs Department, Traffic Department attached to the police and other departments or companies as may be affected by the work. The
notice should identify the specific details so that the necessary diversion of traffic may be arranged and permissions obtained. The contractor shall co-operate
with the department concerned and provide for necessary barricading of roads, protection to existing underground cables etc., met with during the excavation of
trenches. The contractor shall provide at his own expenses watching and lighting arrangements during day and night and erect required notice board such as
Caution Road closed for Traffic etc.,. He should also provide and maintain at his own cost the necessary supports for underground cables etc., to afford best
protection to them in consultation with the authorities in charge of the properties and to their best satisfaction. The contractor has to make necessary
arrangements to get supply of electricity from TANGEDCO for operating the machinery and equipment. The Owner will pay the necessary service connection
and S.D charges. The contractor should obtain all approvals for installation and commissioning of machinery and accessories offered by them from the respective
inspecting authorities such as CEIG or CEFG etc., Fees if any, to be paid to the inspecting authorities will be reimbursed by the Owner.

19.3.9 PERMISSION FOR ROAD CUTS:

Wherever the Contractor considers that it is necessary to cut through an existing road or track he shall submit details to the Design-Build-Operations Engineer or
his representative for approval, a minimum of seven days before such work commences.

In the event of cutting a road by the Contractor without the written permission from the Design-Build-Operations Engineer or his representative, the Contractor
shall be responsible for the cost of reinstating the road as undertaken by the Municipal Road Department or the Highways Department, as the case may be.
Where all permissions are correctly obtained the cost of such reinstatement will be paid directly by the Owner.

19.3.10 TEMPORARY DIVERSION OF ROADS:

During the execution of the work the Contractor shall make at his cost all necessary provision for the temporary diversion of roads, cart-tracks, footpaths, drains,
water courses, channels etc., if he fail to do so, the same shall be done by the Design-Build-Operations Engineer or his representative and the cost thereof will be
recovered from the Contractor.

19.3.11 BARRICADING:
The manhole / trench shall be barricaded (Iron Barricading arrangements) on all four sides. The Contractor who has dug up the trench shall be responsible for
any mishap, which may occur. Non-barricading of trenches by the Contractor shall be liable for a fine of Rs.500/- per day, per location from the interim payment
bills. Such deduction will not relieve the Contractor of any liability or duty under the Contract.

19.3.12 FILLING IN HOLES AND TRENCHES ETC.:

The Contractor immediately upon completion of the Works shall fill up holes and trenches which may have been made or dug, level the mounds, or heaps or
earth that may have been raised or made, and clear away all rubbish which may have become superfluous or have been occasioned or made in the execution of
the works, and the Contractor shall bear and pay all costs, charges etc.

19.3.13 ACCIDENTS:

It shall be the duty of the Contractor to arrange for the execution of the works in such a manner as to avoid the possibility of the accidents to persons or damage
to the properties at any state of the progress of work. Nevertheless he shall be held wholly responsible for any injury or damage to persons and properties, which
may occur irrespective of any precautions he may take during the execution of the works. The Contractor shall make good all claims and loss arising out of such
accidents and indemnify the Owner from all such claims and expenses on account thereof.

19.3.14 WATER AND LIGHTING:

The Contractor shall pay all fees and provide water and light as required from Municipal mains or other sources and shall pay all charges, thereof (including
storage tanks, meters etc.) for the use of the works and workmen, unless otherwise arranged and decided on by writing with Design-Build-Operations Engineer or
his representative. The water used for the works shall be free from earthy vegetable or organic matter and from salts or other substances likely to interfere with
the setting of mortar or otherwise prove harmful to the work and conform to relevant standards.

19.3.15 PAYMENT TO LABOURERS:

The Contractor should note, that in the event of emergency, he shall pay all labourers every day and if this is not done, the Owner shall make requisite payment
and recover the cost from the Contractor. The Contractor shall not employ any labourer below age of 15 years.

19.3.16 EQUIVALENCE OF STANDARDS AND CODES:


Whenever reference is made in the contract to the respective standards and codes in accordance with which plant, equipment or materials are to be furnished and
work is to be performed or tested the provisions of the latest current edition or revision of the relevant standards and codes in effect shall apply, unless otherwise
expressly set forth in the contract. Where such standards and codes are national in character, or relate to a particular country or region, other authoritative
standards which ensure equal or higher quality than the standards and codes specified will be accepted subject to the prior review and written approval by the
Design-Build-Operations Engineer or his representative. Difference between the standards specified and the proposed authoritative standards must be fully
described in writing by the Contractor and submitted to the Design-Build-Operations Engineer or his representative well in advance for approval. If on the prior
review, the Design-Build-Operations Engineer or his representative determines that such proposed deviations do not ensure equal or higher quality; the
Contractor shall comply with the standards set forth in the contract documents.

The Contractor should use only accepted makes of materials and plant and should construct the entire Works according to Specifications, Standards, data sheets,
drawings etc. If no makes are specified then only manufacturers of Plant and materials corresponding to the state of the Art technology and / or confirming to the
latest Indian / International standards shall be used. Providing materials of approved quality and confirming to the standards does not relieve the Contractor from
being responsible for the successful performance of all system components.

19.3.17 SAFETY PROVISION:

19.3.17.1General Requirements for Health and Safety:

The safety provision shall be brought to the notice of all concerned by displaying on a notice board at a prominent place at the work spot, persons responsible for
ensuring compliance with the safety provision shall be named therein by the Contractor.

To ensure effective enforcement of the rules and regulations relating to safety precautions, arrangements made by the Contractor shall be open to inspection by
the Design-Build-Operations Engineer or his representative and the inspecting officer.

Notwithstanding the above provision Contractor is not exempted from the operation of any other Act or rules in force relating to safety provisions.

19.3.17.2 Protection of the Public:


No material on any of the sites shall be so stocked or placed as to cause danger or inconvenience to any person or to the public. The Contractor shall provide all
necessary fencing and lights to protect public from accidents and shall be bound to bear expenses of defense of every suit, action or proceedings of law that may
be brought by any person for injury sustaining, owing to neglect the above precautions and to any such suit, action or proceedings to any such person or which
may with the consent of the Contractor be paid to compromise any claim by any such person.

19.3.17.3 Scaffolding and Ladders:

The Contractor shall ensure that suitable scaffolds are being provided for workers for all the works, which cannot safely be done from the ground or from solid
construction, except such short period work, as can be done safely from ladders.

When a ladder is used an extra labour shall be engaged for holding the ladder and if the ladder is used for carrying materials as well, suitable footholds and
handholds shall be provided on the ladder and the ladder shall be given an inclination not steeper than to 1 ( horizontal to 1 vertical). IS code for scaffolding
and ladders, IS: 3696 Part I and Part II and its latest revision is to be followed. Every ladder shall be securely fixed. No portable single ladder shall be over
7000 mm in length. Width between side rails in rung ladders shall in no case be less than 300 mm. for ladders; this width shall be increased by atleast 6mm for
each additional 300 mm length. Uniform steps spacing shall not exceed 300 mm.

Scaffolding or staging more than 3250 mm above the ground or floor swung or suspended from an overhead support or erection with stationary support shall
have guard rail properly attached bolted, braced or otherwise secured atleast at 1000 mm high above the floor or platform and the scaffolding of staging and
extending along the entire length of the outside and ends thereof with only such openings as may be necessary for the delivery of materials. Such scaffolding or
staging shall be so fastened as to prevent it from swaying from the building or the structure.

All scaffolds, ladders and other safety devices mentioned or described herein shall be maintained in a safe condition and no scaffold, ladder of equipment shall be
altered or removed while it is in use.

19.3.17.4 Working Platforms:

Working platform, gangways and stairways shall be so constructed that they do not sag unduly or unequally and if height of a platform or gangways or stairway
is more than 3250 mm above ground level, it shall be closely boarded having adequate width and be suitably fenced as described above. Every opening in the
floor of a building or in a working platform shall be provided with suitable means to prevent fall of persons or materials by providing suitable fencing or railing
with a minimum height of 1000 mm. Safe means of access shall be provided to all working platforms and other working places.

19.3.17.5 Precautions when using Electrical Equipments:

Adequate precautions shall be taken to prevent danger from electrical equipment. When workers are employed on electrical installations, which are already
energised, insulating mats, wearing apparel such as gloves, sleeves and boots, as may be necessary shall be provided. Workers shall not wear any rings, watches
and carry keys or other materials, which are good conductors of electricity.

19.3.18 DEMOLITION:

Before commencing any demolition work and also during the process of the work, safety code for demolition of building IS: 4130 of the latest revision shall be
followed:

a) All roads and open areas adjacent to the work site shall either be closed or suitably protected.

b) No electric cable or apparatus, which is liable to be a source of danger for a cable or apparatus used by operator, shall remain electrically charged.

c) All practical steps shall be taken to prevent danger to persons employed from risk or fire or explosion or flooding. No floor, roof or other part of a building
shall be so overloaded with debris or materials as to render it unsafe.

19.3.19 SAFETY EQUIPMENT:

19.3.19.1 General Requirements:

All necessary personal safety equipment as considered adequate by the Design-Build-Operations Engineer or his representative shall be available for use of
persons employed on the site and maintained in a condition suitable for immediate use and the Contractor shall take adequate steps to ensure proper use of
equipment by those concerned.

a) Workers employed on mixing asphaltic materials, cement and lime mortars / concrete shall be provided with protective footwear, hand gloves and goggles.

b) Those engaged in handling any materials which is injurious to eyes shall be provided with protective goggles.
c) Stone breakers shall be provided with protective goggles and protective clothing.

d) When workers are employed in confined spaces (sewers, manholes etc.), which are in use, the Contractor shall ensure that manhole covers are opened and
manholes are ventilated atleast for an hour before workers are allowed to get into them. Manholes so opened shall be cordoned-off with suitable railing and
warning signals of boards provided to prevent accident to public. Before entry by any worker the Contractor shall ensure that a gas detector is lowered into the
confined space and the atmosphere is shown to be safe.

e) The Contractor shall not employ men below the age of 15 and women on the work of painting with products containing lead in any form. Whenever men
above the age of 18 are employed on the work of lead painting the following precautions shall be taken:

i) No paint containing lead or lead products shall be used except in the form of paste of ready-made paint.

ii) Suitable face mask shall be supplied for use by workers when paint is applied in the form of spray or a surface having lead paints dry rubbed and scraped.

iii) Contractor shall supply overalls to workmen and adequate facilities shall be provided to enable working painters to wash during and on cessation of working
periods.

19.3.19.2 Working near water:

When the work is done near any place where there is risk of drowning, all necessary equipment shall be provided and kept ready for use and all necessary steps
taken for prompt rescue of any person in danger and adequate provisions made for prompt first aid treatment of all injuries likely to be sustained during the
course of the work. 19.3.19.3 Hoisting Machines:

Use of hoisting machines and tacks including their attachments, anchorage and supports shall conform to the following:

a) i) These shall be of good mechanical construction, sound material and adequate strength and free from patent defects and shall be kept in good repair and
in good working order.

ii)Every rope used in hoisting or lowering materials or as a means of suspension shall be of durable quality and adequate strength, and free from patent
defects.
b)Every crane driver or hoisting appliance operator shall be properly qualified and no person under the age of 21 years shall be in-charge of an hoisting machine,
including any scaffold winch or giving signals to operator.

c) In case of every hoisting machine and of every chain ring hook, shackle, swivel and pulley block used in hoisting machine or lowering or as means of
suspension, safe working load shall be ascertained by adequate means. Every hoisting machine and all gear referred to above shall be plainly marked with safe
working load in case of hoisting with safe working load. In case of hoisting machine having a variable safe working load and the conditions under which it is
applicable shall be clearly indicated. No part of any machine or of any gear referred to above in this paragraph shall be loaded beyond safe working load except
for the purpose to testing.

d) Design-Build-Operations Engineer shall notify the safe working load of the machine in case of Owners machine. As regards Contractors machine, the
Contractor shall notify safe working load of each machine to the Design-Build-Operations Engineer or his representative. Whenever he brings to the site of work
and get it verified by the Design-Build-Operations Engineer or his representative. Motors, gearing, transmission, electrical wiring and other dangerous parts or
hoisting appliance shall be provided with such means so as to reduce to the minimum risk and accident descend of load; adequate precautions shall be taken to
reduce to the minimum risk of any part of a suspended load becoming accidentally displaced.

19.3.20 WORKING WITH EXPLOSIVES:

The Contractor shall obtain prior permission of the competent authority such as Chief of Fire services for the site, manner and method of storing explosives near
the site of work. All handling of explosives including storage, transport shall be carried out under the rules approved by the Explosive Department of the
Government.

19.3.21ENVIRONMENTAL PROTECTION WORK:

The Contractor have to take following measures during construction and commissioning of works for protection of environment as to avoid environmental
impacts on air, water and land.

19.3.21.1 Site Clearance:

The site clearance shall be done with minimum damage to existing structures flora and fauna, electricity and telephone lines and other infrastructure service.
19.3.21.2 Earthwork and Excavation:

The Contractor shall inform the local authorities / government if any fossils, coins artifacts of value or antiquity, structures and other remains of geological or
archaeological interests and excavation shall be stopped until identification of cultural relics by the authorized institution is complete.

The Contractor shall dispose off surplus / waste material at identified sites approved by the Design-Build-Operations Engineer or his representative. The
Contractor shall ensure that there is minimum hindrance to normal activities and business. The Contractor shall avoid damage to permanent structures and shall
avoid loss of standing crops along the road.

19.3.21.3 Replanting of Trees and Bushes:

The Contractor shall carry out replantation on areas / on the periphery of construction sites to minimize visual impact and soil erosion. The Contractor shall pay
special attention to the type of trees to be replanted to prevent fouling of water through falling leaves and bird droppings. A list showing the type of trees to be
replanted shall be submitted to the Design-Build-Operations Engineer or his representative for approval prior for undertaking any replantation.

19.3.21.4 Soil Erosion and Water Quality:

The Contractor shall ensure that earth and stone do not silt up existing irrigation / drainage systems. The Contractor shall take suitable measures to prevent direct
discharge of polluted waters from construction activity into lakes / rivers / irrigation channels.

The Contractor shall minimize exposure of soil types susceptible to wind and water erosion. The Contractor shall control run-off and erosion through proper
drainage channels and structures.

19.3.21.5 Soil Compaction:

The Contractor shall restrict traffic movements and use low ground pressure machines. The Contractor shall preserve topsoil to be replaced after completion of
construction activity. The Contractor shall avoid wet soils as far as possible.

19.3.21.6 Social Disruption:


The Contractor shall minimize interruptions to utility services through proper planning and scheduling of activities. The Contractor shall provide temporary roads
and diversions as may be necessary for smooth flow of traffic and people.

19.3.21.7 Dust / Air Pollution:

The Contractor shall provide effective dust control through sprinkling / washing of construction sites and access roads. The Contractor shall cover / water
stockpiles and storage areas to prevent dust pollution. The Contractor shall cover trucks transporting construction materials to minimize spills. The Contractor
shall have a preventive maintenance programme for construction equipment and vehicles to meet emission standards. Oil shall not be used to control dust.

19.3.21.8 Noise Pollution:

The Contractor shall normally undertake construction work during daytime only (between 7.30 to 18.00 hrs.) and when authorised to work beyond these hours
adopt suitable noise control methods during such works. The Contractor shall maintain machines and trucks to keep them with low noise. The Contractor shall
install sound barriers and plant tree as appropriate during construction. The Contractor shall monitor the level of noise near the construction site, factory sites and
sensitive areas with the following frequency:

a) During construction period: 12 times a year each time including day and night.

b) During commissioning period:4 times ad hoc monitoring.

19.3.21.9 Construction Camps:

The Contractor shall take adequate measures such as provision of septic tank / pit latrines at construction site / camps. The Contractor shall provide crches to
working women labour. The Contractor shall provide drinking water conforming to IS: 10500 1991.

The Contractor shall provide garbage can at suitable fixed place and the garbage shall be disposed off regularly.

19.3.21.10 Aesthetic Improvement:

The Contractor shall through proper house keeping enhance aesthetic appearance of construction sites. The Contractor shall dispose-off construction wastes at
approved disposal sites. The Contractor shall repair pavements immediately following construction of pipeline and appurtenant structures.
The Contractor shall remove after completion of construction, all temporary structures and restore the project and surrounding areas nearest possible to the
reconstruction condition.

19.3.21.11 Conservation of Ecological Resources:

The Contractor shall not use farmland and forest belts as materials borrow sites. The Contractor shall not select arable land as material borrow site. In case
excavation in arable land is unavoidable, topsoil layer (30cms depth) shall be saved and returned after construction work is completed so as to minimize impacts
on ecosystem, agriculture and animal husbandry. The Contractor shall educate construction workers to protect natural resources, wild plants and animals.

19.3.22 Use of Trade Names:

Wherever reference is made in the contract to specific manufacturers or trade names the Contractor shall be entitled to substitute Plant and materials supplied by
other manufacturers or producers. Such substitution shall be to the approvals of the Design-Build-Operations Engineer or his representative, which will not be
unreasonably withheld. At the request of the Design-Build-Operations Engineer or his representative the Contractor shall provide information to establish that
the substituted Plant and materials are equivalent or better than those referred to.

19.3.23 Direction by the Design-Build-Operations Engineer:

The Contractor is responsible for all activities relating to the construction of the works. Any reference in this Specification to the Design-Build-Operations
Engineer or his representative directing or ordering, prescribing etc. the Contractor shall be deemed to mean Contractor to propose a methodology of
construction and to submit to the Design-Build-Operations Engineer or his representative for approval. Any such approval by the Design-Build-Operations
Engineer or his representative shall not limit the Contractors responsibilities relating to construction of the Works. Notwithstanding this clause the Design-
Build-Operations Engineer or his representative shall be entitled to instruct the Contractor whenever the Design-Build-Operations Engineer or his representative
considers it necessary to do so. Where such an instruction is considered by the Contractor to represent additional work he shall inform the Design-Build-
Operations Engineer or his representative of his opinion before undertaking the work. No claim for additional work on the basis of an instruction by the Design-
Build-Operations Engineer or his representative can be considered where the Contractor has failed to provide such prior notification.

19.3.24 Special requirements:


Before commencing the execution, the contractor shall conduct detailed survey of the project area, soil investigation tests/ geotechnical investigations, study the
earthquake/ seismological data specific to the region/project area and based on the study results, entire structural design has to be rechecked and vetted with a
reputed Institution / Structural Engineer as directed by the Design-Build-Operations Engineer or his representative. The contractor shall be responsible for the
safety of the structures, correctness of the design and drawing, even after the approval of the Design-Build-Operations Engineer or his representative.

19.4 SUBMITTALS FOR PRODUCT WATER TRANSMISSION MAIN

19.4.1 DESCRIPTION:

This section covers additional requirements for submission of schedules, samples, certificates, etc., and forms a part of all other sections in which submittals are
required. It is subjected to General Conditions of Contract.

Requirements of submissions to be included:

1. PERT / CPM Progress Schedule

2. Samples of all materials pertaining to this work

3. Material lists and equipment

4. Factory test reports

5. Certificates

6. Laboratory test reports

19.4.2 REQUIREMENTS:

CPM Progress Schedule:

Within 30 days of award of the tender, the Contractor shall submit a critical path method analysis for construction progress control and make such revisions as
are required for approval. He shall clearly indicate all construction activities, sub activities and mileposts on a time-oriented basis, with the critical path fully
identified for all activities. He shall update and resubmit the charts monthly, flag all slippages and mileposts and attach a narrative description of the proposed
corrective actions to the resubmitted charts. The Contractor shall include the following minimum information for each activity and critical path item:

i. Date and initial submittal, as applicable.

ii. Ordering dates for long lead time items.

iii. Dates for materials on site.

iv. Testing and clean up.

v. Final completion and handing over.

19.4.3 SAMPLES:

The Contractor has to submit samples of all materials used for the work prior to start of the works and get the approval of the Design-Build-Operations Engineer
or his representative. He shall label or tag each sample or set of samples, identifying the manufacturers name and address, brand name, catalogue number,
project title he intends use.

19.4.4 MATERIAL LISTS AND EQUIPMENT DATA:

The Contractor has to submit all material lists, equipment lists etc. well in advance before starting the work and get the approval of the Design-Build-Operations
Engineer or his representative.

19.5 - SITE PREPARATION

19.5.1 CLEARING SITE:

Preliminary work are required to be done before laying of pipes including pegging out, clearing and disposal of shrubs, grasses, bushes, hedges, boulders, debris
from the route.
This shall also include the removal of stumps, etc. or parts thereof lying along the alignment of pipe. The Contractor should inform the Design-Build-Operations
Engineer or his representative before removing shrubs, grasses, etc. well in advance. The alignment of the mains shall be so fixed as to avoid cutting of any trees
as far as possible.

19.5.2 REMOVAL OF TOP SOIL, SHRUBS AND OTHER VEGETATION:

All shrubs, vegetation and other plants shall be removed and cleared from the selected stretch of the site. All debris and unsuitable material upto a depth of 300
mm between ground level or road level shall be removed. All debris and unsuitable material shall be carted away from the site as per the direction of Design-
Build-Operations Engineer or his representative up to a distance of 10 km.

19.5.3 UTILITIES PROTECTION:

All utility lines and structures, whether indicated on the drawings or not, which are to remain in service shall be protected by the contractor from any damage
likely to result from his operations. Relocation wherever necessary will be done by the respective Service Departments on payment by the Owner separately. No
extra payment will be made for minor relocation, which does not require dislocation from existing condition and shifting to other location. In such a condition,
the service lines shall be pushed slightly to facilitate laying of main and brought back to original position after the work is completed wherever necessary. The
service lines should be supported at bottom with planks, posts, etc. and tied with ropes properly. Any damage to any utility resulting from the Contractor's
operations shall be repaired at the Contractor's expense.

19.5.4 PAVEMENT REMOVAL:

The Contractor must inform the other concerned departments well in advance before starting the work. The Contractor must provide and maintain proper and
efficient traffic control system such as safety lamps, sign boards etc. operating day and night for the full duration of work. The Owner shall not be responsible
under any circumstances for any mishappenings therefore. For the purpose of payment for removal of pavement, steel tapes are to be used and the Design-Build-
Operations Engineer or his representatives representative and Contractor or his representative shall take the measurement jointly. The width of trenches shall be
as per the specification and only such widths shall be taken into account for computing quantities for payment. The Contractor has to pay restoration charges for
width excavated in excess of prescribed width. For other elements of work such as making cross connections, fixing other appurtenances etc. the Design-Build-
Operations Engineer or his representative shall prescribe the dimensions for removal of pavement from time to time.
19.5.5 MAINTENANCE OF TRAFFIC AND CLOSING OF STREETS:

The work shall be carried out in such a manner, which will cause the least interruption to traffic, and road / street may be closed in such a manner that it causes
the least interruption to traffic. Where it is necessary for traffic to cross open trenches, suitable bridges shall be provided. Suitable signs indicating that a street is
closed shall be placed and necessary detour signs for the proper maintenance of traffic shall be provided.

19.5.6 INTERRUPTION TO SERVICE:

No valve or other control of the existing services shall be operated with out the permission of the authority.

19.5.7 WORK DURING NIGHTS:

No extra payment will be made for doing the work in the nights. The Contractor shall get prior approval from the Design-Build-Operations Engineer or his
representative before starting the work during nights.

19.6 DISMANTLING

19.6.1 DISMANTLING OF EXISTING STRUCTURES:

The structure shall be dismantled carefully and materials removed without causing damage to the serviceable material to be salvaged, the part of the structure to
be retained and any properties of structures nearby. Any avoidable damage to the articles to be salvaged and part of the structure shall be made good by the
Contractor without extra claims. The Contractor shall be responsible for any injury to the onlookers or the public.

Structure should be removed 450 mm below Ground and portion which in any way comes within new construction shall be removed entirely. Contractor shall
maintain register or the salvaged material, which shall have signature of the Design-Build-Operations Engineer or his representative on entries made.

All the material obtained from the removed structure shall be the property of Owner. Serviceable materials shall be stacked neatly in such a manner as to avoid
deterioration at site or at other places. Non-serviceable materials shall be disposed off by the Contractor without causing any inconvenience.

All rubbish shall be cleared off the site and the Ground let clean and clear and Rubbish and non-serviceable materials shall be carted away upto a distance of
10km as per the direction of Design-Build-Operations Engineer or his representative.
19.6.2 MEASUREMENT AND PAYMENT:

The measurements of work shall be exact length and width and height of the dismantled structure. It shall be priced per unit of the Cubic metre. Any excavation
that may be necessary for dismantling the structure below 450 mm from ground level shall be paid under the item of Excavation and shall include labour for
refilling, watering and ramming, spreading on site if required and for disposal of surplus earth. 19.7 - EARTH WORK

19.7.1 DESCRIPTION:

The work specified in this section includes the provision of all labour, machinery, construction equipment and other appliances required to perform all earthwork
specified or required, in a sound, workmanlike manner.

19.7.2 GENERAL:

Excavation shall be required to be done for the following works:

a) Excavation for underground pipelines.

b) Excavations for valve chambers, Thrust blocks and Special structure.

No separate payment shall be made for removal of shrubs, which are less than 100mm in diameter at breast height, grass, small bushes and stumps. The
alignment of the main shall be so fixed as to avoid cutting of any trees as far as possible.

No extra payment shall be made to the Contractor for working in a confined space.

19.7.3 CLASSIFICATION:

The excavation work shall be classified into the following categories by inspection of faces of cutting:

i) Loamy, clayey soils like black cotton soils, red earth, hard gravel, mixture of gravel and soft disintegrated rock like shale, ordinary gravel, stony earth and earth
mixed with fair sized boulders, except rock requiring blasting, chiselling, wedging etc.

ii) Hard rock and boulders to be removed by benching, chipping, chiselling, wedging, barring and by controlled blasting wherever permissible.
19.7.4 TRENCH EXCAVATION:

General:

Trench excavation means excavation of trenches into which the pipe is to be laid. Before commencing trench excavation, the route of the trenches shall be
pegged out accurately and the natural ground levels and the alignment shall be agreed with the Design-Build-Operations Engineer or his representative. The
Contractor shall dig probing pits of appropriate size and depth including cutting the road at every 100m interval or as directed by Design-Build-Operations
Engineer or his representative. The quantity of excavation beyond the normal dimensions will be paid under relevant items of excavations in various stratas.

Stripping Surface Materials:

Before the surface of any part of the site is disturbed or the works there on are started, the Contractor shall take and record levels in the presence of the Design-
Build-Operations Engineer or his representative. Before commencing the excavation, the surface materials shall be carefully stripped and set aside for reuse as
directed by the Design-Build-Operations Engineer or his representative.

19.7.5 WIDTH OF TRENCH:

The width of the trench at bottom between the faces of sheeting shall be Nominal diameter of the pipe plus 300mm clearance on either side of the pipe. Trenches
shall be of such extra width, when required as will permit the convenient placing of timber supports, strutting and planking and handling of specials.

The width of trenches measured at the crown of the pipe shall permit adequate working space. The trenches shall be widened at sockets and other structures as
may be found necessary. Payment for excavation shall be made on quantity basis as per width given in the Table.

Care should be taken to avoid excessive trench width and thereby increasing the load on the pipes.

19.7.6 DEPTH OF EXCAVATION OF TRENCHES:

The depths for the trenches will be calculated from the surface to the bed of the pipes and in case when a layer of bedding is to be placed below the pipeline, the
depth to the bottom of the bedding will be paid.
The trench shall be so dug that the pipeline may be laid to the required gradient and to the required depth, mentioned in the Table below. A minimum cover of
1.0 m is to be provided above the crown level of pipe upto the Ground level / Road level.

TABLE SHOWING DETAILS OF TRENCH SIZE

Diameter (mm) Trench width (m)

100 0.50

150 0.55

200 0.60

250 0.65

300 0.70

350 0.75

400 0.80

450 0.85

500 1.20

600 1.30

700 1.40

750 1.45

800 1.50

900 1.60
Diameter (mm) Trench width (m)

1000 1.70

1100 1.80

1200 1.90

1300 2.00

1400 2.10

1500 2.20

1600 2.30

19.7.7 MAXIMUM LENGTH OF OPEN TRENCH:

Except by special permission of the Design-Build-Operations Engineer or his representative, only that length of trench excavation shall be permitted in advance
of the pipe jointing, such that laying and jointing of pipes can reasonably be expected to be completed and the trench refilled not later than 3 days after
excavation of the trench. The Contractor will not be permitted to keep trenches open for unduly long periods, creating public hazards. The Design-Build-
Operations Engineer or his representative 's decision in this respect shall be final.

19.7.8 WIDENING TRENCH AT JOINTS, ETC.

Any widening or deepening of the trench, whether in ordinary soil or rock, necessary to accommodate curves, joints or bends as shown on the drawings or
ordered by the Design-Build-Operations Engineer or his representative shall be carried out by the Contractor, after taking all the necessary safety measures.

19.7.9 OVER-EXCAVATION OF TRENCH BOTTOMS:

All excavation carried below the grades shown on drawings or bottom of the bedding shall be refilled with sand / concrete at the Contractor's expense.
19.7.10 EXCAVATED MATERIAL:

The material from the excavation shall be deposited on either side of the trench leaving clear berm on one side at least 400 mm wide or at such further distance
from the edges of the trench as may be necessary to prevent the weight of materials from causing the side of the trench to slip or fall, or at such a distance and
such a manner as to avoid any wall or structure or causing inconvenience to the public or other persons or otherwise as the Design-Build-Operations Engineer or
his representative may direct, till it is carted away.

The excavated soil should be so placed and handled as not to inconvenience the usual traffic, till it is carted away. The Contractor should also provide necessary
bridging over the excavated trenches for the house-holders and pedestrians to cross over and vehicular crossings if and where required at no extra cost; if the
Design-Build-Operations Engineer or his representative decides that there is no hindrance to traffic due to not carting away the excavated earth, he will give
instructions to that effect. The Contractor shall be responsible for making all arrangements for the disposal of surplus excavated material upto a distance of 10km.

19.7.11 PIPE BEDDING:

Sand Bedding:

Where specified, the river sand bedding the required thickness and level shall be provided below pipe prior to laying the pipe in trenches. It shall be compacted
with a light hand hammer. Any reduction in compaction shall be made up by adding sand during ramming. For the purpose of bedding under this item, only
screened fine sand of grain size not larger than 2mm shall be used. The sand shall be clean, uncoated and free from clay lumps, injurious amount of dust, soft
particles, organic matter, loam or other deleterious substances.

If the sand supplied is unclean, it shall be washed. In no case shall sand containing more than 3.5% by dry volume or 5% by wet volume of clay, loam or silt be
accepted. Tests specified for determining silt in sand and organic impurities described in IS: 383 shall apply. Sieved and washed sand shall be stored on the
works in such a manner as to prevent intrusion of any foreign matter, including coarser particle of sand or any clay or metal or chips. Tests as indicated above
shall be performed if called for by the Design-Build-Operations Engineer or his representative at the expense of the Contractor.

Concrete Bedding:
This type of bedding is to be provided at locations wherever warranted or as specified by the Design-Build-Operations Engineer or his representative. A concrete
bedding using M15 grade is to be adopted. The concrete work related to this specification is detailed in the specifications of concrete and allied works.

19.7.12 EXCAVATION FOR APPURTENANCES:

Excavation in trenches for foundation of valve chambers, pedestals etc. shall be as per the requirement or as directed by the Design-Build-Operations Engineer or
his representative. The dimensions of the excavation shall be measured as the projection in plan of the outermost edges of the structure.

19.7.13 KEEP EXCAVATION CLEAR OF WATER:

Where ground water is encountered or anticipated, the Contractor shall provide sufficient pumps to handle the ingress of water and must provide and maintain in
working order. Standby pumping units are to be made available and employed in the event of mechanical failure. The Contractor must also arrange for night and
day operation of the pumps wherever necessary to ensure that the work proceeds at all times.

19.7.14 DEWATERING IN AREAS OF HIGH WATER TABLE:

The Contractor shall perform dewatering as required so that all works of the contract are installed on dry areas and excavations, including without limitation the
construction of all structures and underground piping. The Contractor shall ensure that dewatering is carried out only to a depth sufficient for the required
excavation. The Contractor shall also ensure that, at all times, during construction, no groundwater shall come into contact with any concrete surface or
reinforcement and that any structure shall be capable of withstanding any hydrostatic pressure to which it may be subjected during construction and until
completed.

The Contractor shall be deemed to have included in the tender price for maintaining all works in a dry condition during construction. Any water removed from
excavations shall wherever practicable, be pumped directly to the natural drainage channel or to storm sewers if approved via an efficient system of discharge
lines. No water may be discharged into the sewerage system or onto open spaces.

The Contractor shall include for the diversion of all water courses encountered in the work until the scheme is completed and put into operation.

Notwithstanding any previous approval, the Contractor shall be fully responsible for maintaining dry excavations.
Where deemed necessary by the Design-Build-Operations Engineer or his representative, working drawings and data shall be submitted for review or approval
showing the intended plan for dewatering operations. Details of locations and capacities of dewatering wells, well points, pumps, sumps, collection and
discharge lines, standby units, water disposal methods, monitoring and settlement shall be included. These shall be submitted not less than 30 days prior to start
of dewatering operations.

The static water level shall be drawn down to a minimum of 300mm below the bottom of the excavation so as to maintain the undisturbed state of the foundation
soils and allow the placement of any fill or backfill to the required density. The dewatering system shall be installed and operated so that the groundwater level
outside the excavation is not reduced to the extent that would damage or endanger adjacent structures or property.

19.7.15 UNSOUND FOUNDATIONS, SOFT SPOTS:

When the specified levels of trench or structure are reached, the Design-Build-Operations Engineer or his representative will inspect the ground exposed and if he
considers that any part of the ground is by its nature unsuitable, he may direct the Contractor to excavate further and the further excavation shall be filled with
concrete M-10 or river sand. Should the bottom of any trench or structure excavation, while acceptable to the Design-Build-Operations Engineer or his
representative at the time of his inspection subsequently become unacceptable due to exposure to weather conditions or due to flooding or have become puddled,
soft or loose during the progress of the works, the Contractor shall remove such damaged, softened or loosened material and excavate further by hand. In this
case, the cost of the extra excavation and of the additional foundation materials required will be the Contractor's responsibility if necessitated by his negligence.

The omission by the Design-Build-Operations Engineer or his representative to give an instruction under this Clause shall not relieve the Contractor from any
responsibility for defect in the works due to the construction being placed upon an unsuitable formation if prior to the construction of the work the Contractor
shall have failed to call the attention of the Design-Build-Operations Engineer or his representative thereto in writing.

If in the opinion of the Design-Build-Operations Engineer or his representative, a formation is unsound as a result of the Contractor failing to keep the excavation
free from water, the Design-Build-Operations Engineer or his representative will order the removal and disposal of the unsound material and filling of the
resulting void. The Contractor shall execute the work as directed and shall have no claim against the Owner for any costs thus incurred.

19.7.16 CAUTION CUM INFORMATION BOARDS:


Before commencing an excavation, "Caution-Cum-Information" board shall be installed at site by the Contractor. Such board shall remain at site as long as the
trench remains open. The board shall be installed at both the ends of the trench atleast 100m before the approach to the area, if the trench is less than 600m in
length. Additional boards at every 300m shall be installed, if the length of the trench exceeds 600m. If the streetlight is inadequate, lettering with fluorescent
paint shall be used for these boards. The boards shall also contain information regarding dates of commencement and completion of the work, name and phone
number of the Design-Build-Operations Engineer or his representative in charge of the work. See also Clause 19.7.19 REFILLING TRENCHES. The size of
lettering shall be adequate to be read by passing vehicles.

19.7.17 BARRICADING:

To prevent persons from injury and to avoid damage to the property, adequate barricades, construction sign, torches, red lanterns and guards as required shall be
provided and maintained during the progress of the construction work and until it is safe for traffic to use the roadways. The pipe laying trenches, manhole
trench shall be barricaded on all four sides. Barricading arrangements consists of Providing Iron Barricading of size 6 feet (1830 mm) width and 3.5 feet (1070
mm) height using 1.5 inch (38mm) dia MS Square tubular pipe for outer frame supports, inch (20mm) size small MS tubular square pipe for inner frame
supports and 3 x 2 (900 mm x 600 mm) size MS sheet for name board (as per requirement) including fabrication, painting, indication sticker and necessary
interlocking arrangements with adjoining units. Barricading work also includes watching during night, fixing danger flags, danger lights / reflector and painting
in different colours. The Contractor who has dug up the trench shall be responsible for any mishap, which may occur.

19.7.18 FENCING, WATCHING, LIGHTING:

The parts of the fencing shall be of timber, securely fixed in the ground not more than 2500 mm apart, they shall not be less than 100 mm in dia. or not less than
1250 mm above the surface of the ground. There shall be two rails, one near the top of the posts and the other about 500 mm above the ground and each shall be
of 50 mm to 100 mm in diameter and sufficiently long to run from post to post to which they shall be tied with strong ropes. The method of projecting rails
beyond the posts and tying together where they meet will not be allowed on any account. All along the edges of the excavated trenches, a bund of earth about
1000 mm high shall be formed when so required by the Design-Build-Operations Engineer or his representative for further protection. Proper provision shall be
made for lighting at night and watchmen shall be kept to see that this is properly done and maintained. In addition to the normal lighting arrangements, the
Contractor shall provide, whenever such work is in progress, battery operated blinking lights (6 volts) in the beginning and end of a trench with a view to
provide suitable indication to the vehicular traffic. The Contractor shall also provide and display special boards printed with fluorescent prints indicating the
progress of work along the road. In the event of the Contractor not complying with the provisions of the clause, it may be carried out by the Design-Build-
Operations Engineer or his representative and the cost recovered from the Contractor besides claiming liquidity damages from the Contractor. In all such cases
the work may be carried out by the Owner. The Contractor shall be held responsible for all claims for compensation as a result of accident or injury to persons /
non-provision of red flags.

The Contractor shall at his own cost provide all notice boards before opening of roads as directed by the Design-Build-Operations Engineer or his representative.

Arrangements shall be made by the Contractor to obtain permission from Police / Traffic authorities for working and to direct traffic when work is in progress.
No separate payment shall be paid for this item of work.

19.7.19 REFILLING TRENCHES:

a) With a view to restrict the length of open trenches, on completion of the pipe laying operations, refilling of trenches shall be started immediately by the
Contractor. Pipe laying and testing shall follow closely upon the progress of trench excavation and the Contractor shall not be permitted more than 500 metres of
trench excavation to remain open while awaiting testing of the pipe line.

b) Care shall be taken while back filling, not to injure or disturb the pipe. Back fill material shall be free from lumps, organic and other foreign material. Filling
shall be carried out simultaneously on both the sides of the pipes so that unequal pressure does not occur.

c) Walking or working on the completed pipelines shall not be permitted unless the trench has been filled to a height of at least 300 mm over the top of the pipe
except as may be necessary for tamping etc., during back filling work.

d) Filling-in shall be done in layers not exceeding 150mm in thickness accompanied by adequate watering, ramming etc. so as to get good compaction upto
300mm above the top of the pipe.

e) The trench shall be refilled so as to build up to the original ground level, keeping due allowance for subsequent settlement likely to take place.

f) Before and during the backfilling of the trench, precautions shall be taken against the floatation of the pipeline due to the entry of large quantities of water into
the trench causing an uplift of the empty or the partly filled pipeline.
19.7.20 MEASUREMENT AND PAYMENT:

The payment of excavation shall be made on quantity basis as per the actual dimensions of the trench excavated limited to the width as per specification.

a) Trench Excavation:

The length of the trench excavation shall be measured along the center line of pipe at various depths stated in the Bill of Quantities, the total length being
segregated into stretches according to the various depths of excavation contained in the Bill of Quantities to fall into the specified categories. Within each
stretch, the depth applicable shall be within the range specified in Bill of Quantities.

The depth of excavation shall be measured from the top of the trench at the center before excavation upto the bottom of the bedding under the pipe. If no
bedding is provided, the measurement shall be to the top level of the bottom of the pipeline. The width of the trench shall be measured on the basis of the
specification. No additional payment shall be made for the deepening and widening at sockets specials, hunching or surrounds beyond the dimensions mentioned
in the specification. For excess width excavated the road cutting charges to be paid by the Contractor.

The measurement of depth and width of trench shall be taken at every 20 metres along the alignment and at every change in direction and diameter of the pipe.

b) Structure:

Measurement for structure excavation shall be made as per the projection in plan of the outermost edges of the structure as per the plan at the bottom.

c) Rock excavation:

The depth of rock excavation measured for payment shall not exceed the corresponding depth in ordinary excavation plus 150mm both for structure and trench
excavations.

The maximum trench widths measured for payment in rock excavations will be as per specification.

In all above cases, no payment will be made for additional selected fill, lean concrete, bedding cradling or hunching concrete that may be specified or ordered by
the Design-Build-Operations Engineer or his representative as a consequence of excavating beyond the limits specified in the contract documents or ordered by
the Design-Build-Operations Engineer or his representative.
d) Disposal of excavated material:

All the excavated material shall be carted away and the contractor shall be paid in the following manner for disposal of the same. An item is provided in the bill
of quantities and it includes loading, unloading, transporting to a site upto a distance of 10km as directed by the Design-Build-Operations Engineer or his
representative.

e) For excess width of excavation than specified, no payment will be made and the Contractor has to bear the cost of restoration.

19.7.21 PERMANENT REINSTATEMENT:

a) Highways:

Restoration and re-instatement of Highways head and sidewalk surface shall be done by Highway Department and Owner will pay the cost.

b) Municipal Roads:

The reinstatement of the Municipal roads, i.e. Asphalt and WBM roads and side walk surface will be carried out by the Municipal Roads Department of the
Chennai Municipal Corporation or by the Highways Department and Owner will pay the cost.

c) Private properties:

However, any damages to the private properties such as compound wall, fencing, etc. during the execution or immediately afterwards due to contractor
carelessness, the same has to be restored by the Contractor to the original shape at Contractor's own cost.

19.7.22 SHORING AND STRUTTING:

Open cuttings and trenches shall be suitably shored, sheeted and braced, if required by the Design-Build-Operations Engineer or his representative or by site
conditions or to meet local laws, for protecting life, property of the work.

Adequate shoring and strutting shall be provided by the Contractors at their own cost. Warped or deformed timber shall not be used. The shoring shall project at
least 150mm above ground level and shall extend to a suitable depth below the bottom of the trench. Wherever necessary, the planks or struts shall be driven by
compressed air pile drivers. The planks shall be fixed close enough to avoid any running in of sand earth through the joints. The shoring material shall not be of
sizes less than those specified below, unless steel sheet piling is used or unless approved by the Design-Build-Operations Engineer or his representative in
writing.

a) Planks : 38mm thick

b) Walling pieces : 1000 mm x 1000 mm

c) Struts : 150 mm x 200 mm

For walling pieces round timber shall not be allowed. In a vertical plane, there shall be at least three struts or more as directed by the Design-Build-Operations
Engineer or his representative. They shall rest on walling pieces. The spacing of the struts shall be as per the requirement of the design. At the bottom, extra
struts shall have to be provided if ordered by the Design-Build-Operations Engineer or his representative. The rates for excavation do not include the cost of
shoring, which shall be paid for separately as per relevant item of the Bill of Quantities. The Contractors shall be held responsible for providing secure shoring,
and for adopting every other precaution, which may be necessary for protecting nearby structures, which are likely to be damaged as a result of excavation. The
Contractors shall design the shoring required for actual site conditions and shall provide shoring accordingly. The design shall be submitted to the Design-Build-
Operations Engineer or his representative on demand. The shoring shall be so designed that lowering of pipe of normal length or any other pipe laying operation
does not necessitate the removal of any strut or any other member of shoring. If the Design-Build-Operations Engineer or his representative requires the
adoption of any special measures or precautions, the Contractor will comply with the same immediately. If any part of a nearby structure is cut out or removed
for facility of work, the same shall be made good on completion of the work by the Contractors at their cost.

In the event of the Contractors not complying with the provisions of this contract in respect of shoring the Design-Build-Operations Engineer or his
representative may, with or without notice to the Contractors, put up shoring or improve shoring already put up or adopt such other measures as he may deem
necessary, the cost of which shall be recovered from the Contractors. Such action on the part of the Design-Build-Operations Engineer or his representative,
shall not, however absolve the Contractors of their responsibilities under this contract.

No part of the shoring shall, at any time, be removed by the Contractors without obtaining permission from the Design-Build-Operations Engineer or his
representative. While taking out shoring planks, the hollows formed shall be simultaneously filled in with soft earth and shall be well compacted as directed.
No payment will be made if the Contractors leave shoring material in the trench on his own or merely to suit their own convenience. The work of providing
shoring shall be measured and paid for one the basis of areas of planks provided upto ground level and no separate payment will be made for providing and
fixing of walling pieces, struts, dog spikes etc. the cost of which shall be deemed to have been covered by the rate for shoring.

The planks shall project at least 150mm above the ground level. For the purpose of payment, however, measurements shall be taken up to ground level only and
no payment will be made for planking above ground level.

19.8 - BRICK WORK

19.8.1 Masonry Mortars:

Proportioning:

Mix proportion of cement sand mortar shall be as indicated. The mixes specified are by volume. 50 kg. of cement shall be taken as equal to 0.035 cum. to
determine bulk. The quantity of water to be added to cement sand mortar shall be such that working consistency is obtained. Excess water shall be avoided.

Preparation of Cement Mortar:

Mixing shall be done preferably in a mechanical mixer. If done by hand, mixing operation shall be carried out on a clean watertight platform. Cement and sand
shall be mixed dry in the required proportion to obtain a uniform colour. The required quantity of water shall then be added and the mortar hoed back and forth
for 5 to 10 minutes with additions of water to a workable consistency. In the case of mechanical mixing, the mortar shall be mixed for atleast three minutes after
addition of water. Cement mortar shall be freshly mixed for immediate use. Any mortar, which has commenced to set, shall be discarded and removed from the
site.

Time of use of Mortar:

Mortars with cement as an ingredient shall be used as early as possible after mixing, preferably within 30 minutes from the time water is added to the mix or at
the latest within one hour of its mixing.

Workability of Masonry Mortar:


The working consistency of the mortar is usually judged by the work during application. The water used shall be enough to maintain the fluidity of the mortar
during application, but at the same time it shall not be excessive leading to segregation of aggregates from the cement.

19.8.2 Brick Masonry:

a) Manufacture:

Common burnt clay building bricks shall conform to the requirements of IS: 1077 and shall be of quality not less than class 20 with moisture absorption rate not
exceeding 15 percent as defined in IS:1077. The bricks shall be chamber burnt and shall have sharp corners and smooth faces and shall not be damaged in any
manner and sizes shall conform to the works sizes specified with tolerances as given in 6.2 IS: 1077.

b) Samples:

The Contractor shall deliver samples of each type of brick to the Design-Build-Operations Engineer or his representative, and no orders shall be placed without
the written approval of the Design-Build-Operations Engineer or his representative. All the bricks used in the works shall be of the same standard as the
approved samples. The samples shall be preserved on site, and subsequent deliveries shall be checked for uniformity of shape, colour and texture against the
samples. If in the opinion of the Design-Build-Operations Engineer or his representative any deliveries vary from the standard of the samples, such bricks shall
be rejected and removed from the site. Samples of bricks shall be tested in accordance with IS: 3495 by the Contractor.

c) Uniformity:

The bricks selected for exposed pointed brickwork walls shall be of uniform colour, deep cherry red or copper colour, and uniform texture. Only such bricks as
are permitted by the Design-Build-Operations Engineer or his representative shall be used.

19.8.3 SETTING OUT:

All brickworks shall be set out and built to the respective dimensions, thickness and heights as indicated.

19.8.4 SCAFFOLDING:
Scaffolding shall be strong to withstand all dead, live and impact loads, which are likely to come on them. Scaffolding shall be provided to allow easy approach
to every part of the work, overhand work shall not be allowed.

For exposed brick facing double scaffolding having two sets of vertical supports shall be provided. For brickwork, which is to be plastered over, single
scaffolding may be provided. In single scaffolding one end of the putlogs shall rest in the hole provided in the header course of brick masonry. Not more than
one header for each putlog shall be left out. Such holes shall not be allowed in the case of pillars of narrow masonry portions between openings, which are less
than one metre in width or are immediately under or near the structural member supported by the walls. The holes left shall be made good on removal of
scaffolding to match with the face work / surrounding area.

Timber or bamboo scaffolds shall be erected in accordance with the provisions contained in IS: 3696 (Part I) - 1987. Safety code for scaffolds and ladders, Part I
- Scaffolds, to ensure safety of workmen and others. Steel scaffolding shall be erected in accordance with the provisions contained in IS: 2750-1964.
Specifications for steel scaffolding and relevant provisions of IS: 3696 (Part I) - 1987 for safety code for scaffolds (Parts I & II) and ladders shall be followed.

19.8.5 SOAKING OF BRICKS:

Bricks shall be soaked in water before use for a period of the water to just penetrate the whole depth of the bricks. Alternatively bricks may be adequately soaked
in stacks by profusely spraying with clean water at regular intervals for a period not less than six hours. The bricks required for masonry work using mud mortar
shall not be soaked. When bricks are soaked, they shall be removed from the tank sufficiently early so that at the time of laying they are skin-dry. Such soaked
bricks shall be stacked-on clean place, where they are not again spoiled by dirt, earth, etc.

19.8.6 LAYING:

All loose materials, dirt and set lumps of mortar which may be laying over the surface on which brickwork is to be freshly started, shall be removed with a wire
brush and surface wetted slightly. Bricks shall be laid on a full bed of mortar. When laying, the bricks shall be properly bedded and slightly pressed with handle
of trowel so that the mortar can get into all the pores of the brick surface to ensure proper adhesion. All the joints shall be properly flushed and packed with
mortar so that no hollow spaces are left. Care shall be taken to see that the required quantity of water is added to the mortar at the mixing platform to obtain
required consistency. Addition of water during laying of the course shall not be permitted. In the case of walls two bricks thick and over, the joints shall be
grouted at every course in addition to bedding and flushing with mortar.
Bricks shall be laid with frog up. However if the top course is exposed, bricks shall be laid with frog down. Care shall be taken to fill the frogs with mortar
before embedding the bricks in position.

All quoins shall be accurately constructed and the height of courses checked with storey rods as the work proceeds. Acute and obtuse quoins shall be bonded,
where practicable, in the same way square quoins; obtuse quoins shall be formed with squint showing a three quarter brick on one face and quarter brick on the
other.

19.8.7 BOND:

All brickwork shall be built in English Bond, unless otherwise indicated. Half brick walls shall be built in stretcher bond. Header bond shall be used for walls
curved on plan for better alignment. Header bond shall also be used in foundation footings, stretchers may be used when the thickness of wall renders use of
headers impracticable. Where the thickness of footings is uniform for a number of course of the footings shall be headers.

Half or cut bricks shall not be used except where necessary to complete the bond.

Overlap in stretcher bond is usually half brick and is obtained by commencing each alternate course with a half brick. The overlap in header bond which is
usually half the width of the brick is obtained by introducing a three quarter brick in each alternate course at quoins. In general, the cross joints in any course of
brickwork shall not be nearer than a quarter of brick length from those in the course below or above it.

19.8.8 UNIFORMITY:

The brickwork shall be built in uniform layers; corners and other advanced work shall be raked back. No part of a wall during its construction shall be raised
more than one meter above the general construction level, to avoid unequal settlement. Parts of walls left at different levels shall be properly raked back.
Toothing may be done where future extension is contemplated but shall not be used as an alternative to raking back.

For half brick partition to be keyed into main walls, indents shall be left in the main walls.

19.8.9 THICKNESS OF JOINTS:


The thickness of joints shall be 10mm + 3 or 3mm, unless otherwise specified. Thickness of joints shall be kept uniform. Slight difference to thickness of
bricks shall be adjusted within joint thickness. Where brickwork is to match the existing work, the joints shall be of the same thickness as in the existing work.

19.8.10 STRIKING JOINTS:

Where no pointing, plastering or other finish is indicated, the green mortar shall be neatly struck flush. Where pointing, plastering or other finish is indicated, the
joints shall be squarely raked out to a depth not less than 10mm for plastering and 15mm for pointing.

19.8.11 CURING:

The brickwork shall be constantly kept wet for atleast 7 days.

19.8.12 FACING:

In case of walls one brick thick and under, atleast one face shall be kept even and in proper plane, while the other face may be slightly rough. In case of walls
more than one brick thick, both the face shall be kept even and in proper plane.

For exposed brickwork selected bricks of the specified class and sub-class shall be used for the face work, where however, use of facing bricks is indicated, brick
walls shall be faced with facing bricks. No rubbing down of brickwork shall be allowed.

Brick walls shall be plastered pointed or otherwise finished, as indicated. Joints of external faces of brick walls in foundation upto 150 mm below ground level
and of internal faces of brick walls in foundation and plinth below sub-floor level shall be struck flush when the mortar is green, as the work proceeds.

19.8.13 CLEANING:

Face of brickwork shall be cleaned on the same day it is laid and all mortar droppings removed.

19.8.14 CONSTRUCTION DETAILS:

Holes for Pipes etc.

All necessary holes for pipes, air flues, ventilators, etc. shall be cut or formed as work proceeds and grouted in cement and sand mortar 1:3 or cement concrete
1:2:4 as required and directed by the Design-Build-Operations Engineer or his representative and made good.
19.9 - CONCRETE WORKS

19.9.1 CONCRETE:

General:

a. The quality of materials and method and control of manufacture and transportation of all concrete work irrespective of mix whether reinforced or
otherwise, shall conform to the applicable portions of this Specification.

b. The Design-Build-Operations Engineer or his representative shall have the right to inspect the source/s of materials, the layout and operation of
procurement and storage of materials, the concrete batching and mixing equipment, and the quality control system. Such an inspection shall be arranged and
Design-Build-Operations Engineer or his representatives approval obtained, prior to starting of concrete work.

19.9.2 MATERIALS FOR STANDARD CONCRETE:

The ingredients to be used in the manufacture of concrete shall consist solely of Portland cement, clean sand, natural coarse aggregate, clean water, and
admixtures, if Specifically called for and conditions at site warrant its use.

a. Cement: Cement shall conform to IS: 12269 1987/2013.

b.Aggregates: Aggregates shall comply with the requirements of IS: 383 1970.

i. General

a) Aggregate in general designates both fine and coarse inert materials used in the manufacture of concrete.

b) Coarse Aggregate is aggregate most of which is not passed through on 4.75mm IS sieve.

c)Fine aggregate is aggregate most of which is passed through on 4.75mm IS sieve.

d) All fine and coarse aggregate proposed for use in the works shall be subject to the Design-Build-Operations Engineer or his representatives approval and after
specific materials have been accepted, the source of supply of such materials shall not be changed without prior approval of the Design-Build-Operations
Engineer or his representative.
e) Aggregates shall, except as noted above, consist of natural sands, crushed stone from a source known to produce satisfactory aggregate for concrete and shall
be chemically inert, strong, hard, durable against weathering, of limited porosity and free from deleterious materials that may cause corrosion of the
reinforcement or may impair the strength and or durability of concrete. The grading of aggregates shall be such as to produce a dense concrete of specified
strength and consistency that will work readily into position without segregation and shall be based on the mix design and preliminary tests on concrete
specified later.

f) Aggregates having a specific gravity below 2.6 (saturated surface dry basis) shall not be used without the special permission of the Design-Build-Operations
Engineer or his representative.

ii. Fine Aggregate:

a) General:

Fine aggregate shall consist of natural or crushed sand conforming to IS: 383. The sand shall be clean, sharp, hard, strong and durable and shall be free from
dust, vegetable substances, adherent coating, clay, alkali, organic matter, mica, salt or other deleterious substances, which can be injurious to the setting qualities
/ strength / durability of concrete.

(i)Machine-made Sand: Machine-made sand will be acceptable, provided the constituent rock-gravel composition shall be sound, hard, dense, non-organic,
uncoated and durable against weathering.

(ii) Screening and Washing: Sand shall be prepared for use by such screening or washing, or both, as necessary, to remove all objectionable foreign matter
while separating the sand grains to the required size fraction.

(iii) Foreign material limitations: The percentage of deleterious substances in sand delivered to the mixer shall not exceed the following:

Percent by weight:

Uncrushed Crushed

(A) Material finer than 75 micron I.S. Sieve 3.00 15.00


(B) Shale 1.00 --

(C) Coal and lignite 1.00 1.00

(D) Clay lumps -- --

(E) Total of all above substances including items (A) 5.00 1.00
to (D) for uncrushed sand and items (C) and (D)
for crushed sand

b) Gradation:

(I) Unless otherwise directed or approved by the Design-Build-Operations Engineer or his representative, the grading of sand shall be within the limits indicated
under here:

IS Sieve Percentage passing for

Grading Grading Grading Grading

Designation Zone I Zone II Zone III Zone AVE

10mm 100 100 100 100

4.75mm 90 100 90 100 90 100 95 100

2.36mm 60 95 75 100 85 100 95 100

1.18mm 30 70 55 90 75 100 90 100

600micron 15 34 35 59 60 79 80 100

300micron 5 20 8 30 12 40 15 50
150micron 0 10 0 10 0 10 0 - 15

(II) Where the grading falls outside the limits of any particular grading zone of sieves, other than 600 micron I.S. sieve, by total amount not exceeding 5
percent, it shall be regarded as falling within that grading zone. This tolerance shall not be applied to percentage passing the 600 micron I.S. sieve or to
percentage passing any other sieve size on the coarser limit of Grading Zone I or the finer limit of Grading Zone AVE. Fine aggregates conforming to Grading
Zone AVE shall be used. Mix designs and preliminary tests shall show its suitability for producing concrete of specified strength and workability.

c) Fineness Modulus:

The sand shall have a fineness modulus of not less than 2.2 or more than 4.2. The fineness modulus is determined by adding the cumulative percentages retained
on the following I.S. sieve sizes (4.75mm, 2.36mm, 1.18mm, 600micron, 300micron and 150micron) and dividing the sum by 100.

(III) Coarse Aggregate:

a) Coarse aggregate for concrete, except as noted above, shall conform to IS: 383. This shall consist of crushed stone and shall be hard, strong, durable clean and
free from elongated, flaky or laminated pieces, adhering coatings, clay lumps, coal residue, clinkers, slag, alkali, mica, organic matter or other deleterious matter.

b)Screening and Washing:

Crushed rock shall be screened and or washed for the removal of dirt or dust coating, if so requested by the Design-Build-Operations Engineer or his
representative.

c) Grading:

Coarse aggregate shall be either in single size or graded, in both cases the grading shall be within the following limits.

Percentage passing for single sized Percentage passing for


aggregate of normal size graded aggregate of
IS Sieve Desig-
normal size
nation
40 20 16 12.5 10 40 20 16 12.5
mm mm mm mm mm mm mm mm mm

63 mm 100 -- -- -- -- 100 -- -- --

40 mm 85 100 -- -- -- 95 -- -- --
100 100

20 mm 0 85 100 -- -- 30 95 100 --
20 100 70 100

16 mm -- -- 85 100 -- -- -- 90 --
100 100

12.5 mm -- -- -- 85 100 -- -- -- 90
100 100

10 mm 0 0 0 0 85 10 25 30 40
5 20 30 45 100 35 35 70 85

d) Water:

Water for mixing concrete, mortar or grout shall conform to IS:456 2000. If required to do so by the Design-Build-Operations Engineer or his representative,
the Contractor shall take samples of the water and test them for quality.

19.9.3 TRANSPORTING AND DEPOSITING CONCRETE:


Mixing plant shall be located as close as possible to the point of placement. Concrete shall be placed within 30 minutes after mixing and shall be transported
from the mixer to its final placement as rapidly as practicable, taking care to see that no segregation or loss of ingredients take place. It shall also be ensured that
the concrete is of the required workability at the point and time of placing.

Dropping of concrete from an excessive height or running or working it along forms will not be permitted. Any concrete which, before placement has begun to
set and has become stiff shall be rejected.

Concrete shall not be disturbed after it has been placed in the form and has begun to set. Concrete shall be carefully placed in horizontal layers which shall be
kept at an even height throughout the work. Concrete shall not be allowed to slide or flow down sloping surfaces directly into its final position but shall be
placed in its final position form the skips, trucks, barrows, down pipes or other placing machines or device or, if this is impossible it shall be shovelled into
position, care being taken to avoid separation of the constituent materials. Concrete placed in horizontal slabs from barrows or other tipping vehicles shall be
tipped into the face of the previously placed concrete.

Concrete dropped into place in the work shall be dropped vertically. It shall not strike the formwork between the point of its discharge and its final place in the
work and except by approval of the Design-Build-Operations Engineer or his representative, it shall not be dropped freely through a height greater than 1.5
metres. Chutes & Conveyor belts shall be so designed that there is no segregation or loss of mortar and shall be provided with a vertical tapered down pipe or
other device to ensure that concrete is discharged vertically into place.

Where a lift of concrete is built up in layers each layer shall be properly merged into the proceeding layer before initial set takes place.

19.9.4. QUALITY ASSURANCE

General Procedure:

A. General:

In order to achieve the required strength and associated properties of concrete, proper control of the Water / Cement ratio by weight need be enforced. The
strength shall be prime consideration and W.C. ratio as prescribed by Design-Build-Operations Engineer or his representative shall have to be observed.

B. Operators:
At no time whatsoever will the mixer operator or those supervising or inspecting the works be permitted to alter the quantity of water specified by the Design-
Build-Operations Engineer or his representative for mixing the concrete. Batching shall be accurate and as specified by the Design-Build-Operations Engineer or
his representative.

C. Water / Cement Ratio:

The Water / Cement ratio will be determined after mix trials by the Contractor in the presence of the Design-Build-Operations Engineer or his representative. If
batching is by volume, the Contractor shall be required to fabricate such volumetric batches and water containers as the Design-Build-Operations Engineer or his
representative may determine and require so as to simulate the ideals of the trial mix without recourse to assessments by site staff and workmen.

D. Weighing:

The Contractor shall make available always a weighing machine if so required, guaranteed by the Contractor for its accuracy, for weighing cement and batches of
aggregate as and when the Design-Build-Operations Engineer or his representative or his assistant may require. The machine shall be capable of weighing upto
75 Kilograms and shall be accurate to half (0.5) Kilogram.

E. Compaction:

All concrete shall be thoroughly compacted and fully worked round the reinforcement by vibration just sufficiently so that the appearance of laitance is kept to a
minimum and in such manner as directed by the Design-Build-Operations Engineer or his representatives Representative. Under no circumstances shall
concrete be compacted by trowels or the like.

F. Transport and Placing:

Fresh concrete from the mixer shall be transported where required by the quickest and most efficient means so as to prevent pre-set or segregation or any loss of
ingredients and shall maintain required workability. Any laitance from previous mixes shall be removed.

19.9.5 SAMPLING, TESTING AND STORAGE OF MATERIALS:


Samples of aggregates for mix design and determination of suitability shall be taken under the supervision of Design-Build-Operations Engineer or his
representative and delivered to the laboratory well in advance of the scheduled placing of concrete. Records of tests made on proposed aggregates and on
concrete made from this source of aggregates shall be furnished to the Design-Build-Operations Engineer or his representative in advance of the work for use in
determining aggregate suitability. The cost of all such tests, sampling etc. shall be borne by the Contractor.

Materials shall be tested as hereinafter specified and unless specified otherwise, all sampling and testing shall be performed by Testing Laboratory approved by
Owner at the Contractors expense.

A. Cement:

Cement shall comply with the requirements of IS: 8041, IS: 455, IS: 8043, IS: 6909, IS: 1489, IS: 12269. The testing laboratory at the discretion by the Design-
Build-Operations Engineer or his representative, shall perform such tests as are deemed necessary. Cement bags or bulk silos shall be tagged for identification at
location of sampling. Tests will include tensile tests and weighing the cement supply to check for net weight received at site and used in the works.

1. On arrival at site, cement shall be stored in weatherproof silos designed for the purpose or in dry weather-tight and properly ventilated structures with floors
raised 150 to 200 mm above ground level, 300 mm away from walls and with adequate provision to prevent absorption of moisture or flooding. All storage
facilities shall be subject to approval by the Design-Build-Operations Engineer or his representative and shall be such as to permit easy access for inspection and
identification. Each consignment of cement shall be kept separately and the Contractor shall use the consignments in the order in which they are received. Any
cement in drums or bags, which have been opened, shall be used immediately. Different types of cement shall be kept in clearly marked separate storage
facilities. Not more than 15 bags shall be stacked vertically in one pile. Cement shall be stored in double locking arrangement, so that cement transactions can
be with the knowledge of supervisory staff. Daily account of cement shall be maintained by the Contractor in the prescribed register and shall be made available
to inspecting authorities for store verification.

2.The Contractor shall provide from each consignment of cement delivered to the site such samples as the Design-Build-Operations Engineer or his
representative may require for testing. Any cement which is, in the opinion of the Design-Build-Operations Engineer or his representative, lumpy or partially set
shall be rejected and the Contractor shall promptly remove such cement from the site.
3.Cement which has been stored on the site for more than ninety (90) days and cement which in the opinion of the Design-Build-Operations Engineer or his
representative is of doubtful quality shall not be used in the works until it has been retested and test sheets showing that it complies in all respects with the
relevant standard have been delivered to the Design-Build-Operations Engineer or his representative.

B. Water for Concrete Mixing & Curing:

Water shall be clean, clear and free from injurious quantities of salt, traces of oil, acids, alkalis, organic matter and other deleterious materials. The sources of
water shall be approved by the Design-Build-Operations Engineer or his representative and the containers for conveyance; storage and handling shall be clean. If
necessary, standard cement tests shall be conducted using the water intended to be used, in comparison with those adding distilled water to check quality of
water.

Water shall meet the requirement of 4.3 of IS: 456 2000. Generally potable water is fit for mixing and curing.

C. Aggregates:

Aggregate will be tested before and after concrete mix is established and whenever character or source of material is changed. Tests will include a sieve analysis
to determine conformity with limits of gradation.

1. Samples of aggregates 50 kg. in weight will be taken by the Contractor at source of supply and submitted to the Design-Build-Operations Engineer or his
representative before placing orders. These samples if approved shall remain preserved in the Design-Build-Operations Engineer or his representatives care for
reference and the type of aggregate used in the works may not be altered without Design-Build-Operations Engineer or his representatives prior approval.

2. Aggregate shall be obtained from an approved source and shall conform to the requirements of IS: 383.

For the aggregate grading, in table of IS: 383 1970 shall be applicable. Aggregate shall not be flaky or elongated particles, defined as particles having a
maximum dimension greater than five times the minimum dimension. Aggregate shall have water absorption not exceeding two percent when tested in
accordance with IS 383.

3. The Contractor shall sample and carry out analysis in the presence of the Design-Build-Operations Engineers representative, or the fine aggregate and each
nominal size of coarse aggregate in use employing the methods described in IS: 383 and 2386 at least once in each week when concreting is in progress and such
more frequent intervals as the Design-Build-Operations Engineer or his representative may require. The grading of all aggregates shall be within the respective
limits specified in the codes. For aggregates, which vary more than the approved fineness modulus, the Design-Build-Operations Engineer or his representative
may instruct the Contractor to alter the relative proportions of the aggregate in the mix to allow for such difference, or may require further trial mixes.

4. Storage of aggregates shall be provided at each point where concrete is made such that each nominal size of coarse aggregate and the fine aggregate shall be
kept separated at all times. Contamination of the aggregates by the ground or other foreign matter shall be effectively prevented at all times, and each heap of
aggregate shall be capable of draining freely. The Contractor shall ensure that graded coarse aggregates are dumped, stored and removed from store in manner
that does not cause segregation.

Coarse aggregate shall be piled in layers not exceeding 1.2m in height to prevent coning or segregation. The aggregates must be of specified quality not only at
the time of receiving at site but more so as the time of loading into mixer.

Wet fine aggregate shall not be used until, in the opinion of the Design-Build-Operations Engineer or his representative, it has drained to a constant and uniform
moisture content, unless the Contractor with the knowledge of the Design-Build-Operations Engineer or his representative measures the moisture content of fine
aggregate and adds water in each batch of concrete mixed to allow for the water contained in the fine aggregate.

19.9.6 MIX DESIGN:

Mix design is normally a prerequisite to any concreting job and will be required on all major works. If so required, an approved testing laboratory shall, at the
Contractors expense, design a mix for each class of concrete and shall submit full details of the mix designs to the Design-Build-Operations Engineer or his
representative for his approval. The Design-Build-Operations Engineers representative and the Contractor shall clearly code each approved mix with a number
and date, and file all details for identifying and reproducing exactly the same mix.

A. General:

Each mix design shall be such that the aggregate shall comprise fine aggregate and coarse aggregate of the size specified and the combined aggregate grading
shall be continuous. Aggregate shall be calculated by weight, and batching procedures shall be established. The cement content by weight shall not be outside
the minimum and maximum limits calculated from the minimum and maximum dry aggregate to cement ratios specified. The mixes shall be designed to produce
average concrete cube strength at twenty eighth day after manufacture not less than the trail mix test strength specified. The water / Cement ratio shall be in the
region of 0.45 to 0.55 and shall never exceed 0.60.

B. Preliminary Mix:

The proportions of cement, aggregate and water determined by the Contractor in his mix design shall be used in preliminary mix of concrete made and tested for
strength and workability under laboratory conditions observing the appropriate requirements. These preliminary mixes shall be repeated with adjusted
proportions as necessary until concrete mixes meeting the requirements of the preliminary and trial mix tests specified and with the workability defined herein
have been produced. If at any time during construction of the works, the source of cement or aggregates is changed, or the grading of the aggregate alters, then
further preliminary mixes shall be undertaken.

C. Trials:

After the Design-Build-Operations Engineer or his representatives approval of the preliminary concrete mix design for each class of concrete and during or
following the carrying out of the preliminary tests, the Contractor shall prepare a trial mix of each class in the presence of the Design-Build-Operations Engineer
or his representative. The trial mixes shall be mixed for the same time and handled by means of the same plant that the Contractor propose to use in the works.
The proportion of cement, aggregates and water shall be carefully determined by weight in accordance with the approved mix design (or modified mix design
after preliminary tests) and sieve analyses shall be made, by approved methods of the fine aggregate and each nominal size of coarse aggregate used.

D. Admixtures:

Admixtures shall mean material added to the concrete materials during mixing for the purpose of altering the properties of normal concrete mixes. If the
Contractor wishes to use admixtures, otherwise than as expressly ordered by the Design-Build-Operations Engineer or his representative, he shall first obtain the
Design-Build-Operations Engineer or his representatives written permission. The methods of use and the quantities of admixture used shall be subject to the
Design-Build-Operations Engineer or his representatives approval, which approval or otherwise shall in no way limit the Contractors obligations under the
contract to produce concrete with the specified strength and workability. Concrete of any class containing an admixture shall be separately designed and have
separate preliminary tests and trial mixes made and tested for approval by the Design-Build-Operations Engineer or his representative as if it were a separate
class of concrete.
Waiver of Mix Design and Weigh Batching:

On certain works, the Design-Build-Operations Engineer or his representative may waive the requirement of designing mixes and may allow the use of
established nominal mix proportion, provided always that preliminary trials are made to establish the volumetric batching procedure and mix strengths. The
Contractor will ensure that any established procedure approved by the Design-Build-Operations Engineer or his representative is strictly adhered to, so as to
achieve consistent strength, durability and economy of the concrete while ensuring approved workability of the mix. Any waiver of mix design or weigh
batching will not relieve the Contractor of his obligations to consistently produce concrete of the specified and approved strength and durability as determined by
works tests. However in any particular work / part of work, the Design-Build-Operations Engineer or his representative may decide to adopt mix design (mix)
concrete.

Workability:

The workability of each class of concrete shall be such that satisfactory compaction can be obtained when the concrete is placed and vibrated in the works. There
shall be no tendency to segregate when it is handled, transported and compacted by the methods, which the Contractor proposes to use when handling,
transporting and compacting that class of concrete in the works.

Grades of concrete:

The concrete shall be in grades designed in Table 2 IS: 456 2000. All the water retaining structures shall be of grade as specified in IS 3370 (Part-1): 2009,
Code of practice for Concrete structures for storage of liquids.

Concrete Mix Design:

Procedure for designing concrete mixes shall be as per IS: 10262 2009. Guidelines for concrete mix design proportioning.

19.9.7 BATCHING:

Cement:
All cement used in making concrete shall be measured by weight either with an approved weighing machine or by making the size of each batch of concrete such
as to require an integral number of complete bags of cement of weight consistent with the requirements of CI 9 of IS: 12269 - 1987. In case of ordinary mixes,
the cement bag shall be taken to be 50 kg. (35 litres).

Aggregate:

The fine and coarse aggregate shall be measured separately either by volume in gauge boxes or by weight using machines with weigh batching attachments. For
high grade concrete, the fine aggregate shall be measured singly or cumulatively by weight. The Design-Build-Operations Engineer or his representative will
rule on this requirement.

Gauge Boxes:

Gauge boxes shall be soundly constructed by the Contractor, with the approval of the Design-Build-Operations Engineer or his representative and shall be of
timber or of steel to contain exactly the volume of the various aggregates required for one batch of each mix. Each gauge shall be clearly marked with the mix
code and the aggregate for which it is intended. When calculating the size of the gauge box for fine aggregate, allowance shall be made for the bulking of the
fine aggregate due to the average amount of moisture contained in the stockpiles on the site. Before the Contractor shall put any gauge box into use on the site,
he shall obtain the approval of the Design-Build-Operations Engineer or his representative of the size and construction of such gauge box.

Water Container:

Containers for measuring water shall be soundly constructed of metal to contain the exact quantity of water required for a batch of mix, due allowance having
been made for the moisture content of the aggregates, or such fractions of the quantity as are approved by the Design-Build-Operations Engineer or his
representative. Containers shall have spouts, the pill levels of which determine the quantity. Fixed containers shall be elevated and have overflow pipes, which
determine the quantity held in the container, and shall have an outlet valve and hose fixed to the bottom of the container. Before any container is put into use, the
approval of the Design-Build-Operations Engineer or his representative shall be obtained.

Weigh-Batching:
Weigh batching machines shall provide facilities for the accurate control and measurement of the materials either singly or cumulatively and shall be capable of
immediate adjustment by operators in order to permit variations if ordered by the Design-Build-Operations Engineer or his representative. All weight dials shall
be easily visible from the place at which filling and emptying of the hoppers are controlled.

Addition of Water and Mixing:

A. Water:

The addition of water to a mixer shall be controlled such that between five and ten percent of the water enters the mixer before the cement and aggregate and a
further five to ten percent of water enters the mixer after the said materials have been batched. The remainder of the water shall be added at a uniform rate with
the said materials. The water-measuring device shall also be readily adjustable so that the quantity of water added to the mixer can, if necessary in the opinion of
the witnessing Design-Build-Operations Engineers representative be varied. The natural moisture contents of the aggregates shall be determined before the
commencement of concreting or at such intervals as may be necessary or as required by the Design-Build-Operations Engineer or his representative. The
Contractor shall make due allowance for the water contained in the aggregate when determining in consultation with the Design-Build-Operations Engineers
representative, the quantity of water to be added to each mix, and shall adjust the amount of water added to each mix to maintain consistently the approved water
/ cement ratio of the mixed concrete. All important concrete shall be machine mixed to give complete coating of cement mortar on each coarse aggregate particle
and to produce uniform coloured concrete with uniform distribution of materials. The mixer shall be run minimum 1 minutes. In case, for a minor job, hand
mixing is permitted by the Design-Build-Operations Engineer or his representative, it shall be done on smooth watertight platform not allowing the added water
to flow out. The fine aggregate shall be spread in uniform thickness layer over which cement as required shall be placed and they shall be mixed thoroughly to
give dry mortar. Water is then added gradually in required proportion, turning the mass, to give desired consistency mortar. The required quantity of coarse
aggregate is then placed on mixing platform, wetted and mortar added. The entire mass is turned and returned to give uniform concrete of required consistency.
5% additional cement shall be used for hand mixed concrete.

B. Admixtures:

Any admixtures approved by the Design-Build-Operations Engineer or his representative, which may be used, shall be measured separately in calibrated
dispensers and shall be added to the mixture together with the water.
C. Uniformity of Mix:

Concrete shall be mixed in batches in plant capable of mixing the aggregates, cement and water (including admixtures, if any) into a mixture of uniform in colour
and consistency and of discharging the mixture without segregation.

D. Contractors Returns:

The Contractor shall render to the Design-Build-Operations Engineer or his representative, daily return for each class of concrete of the number of batches
mixed, and total volume of concrete placed, the number of batches wasted or rejected and the weight of cement used. In case of ordinary mixes, where permitted,
the cement bags consumed for quantities of various classes of concrete shall be furnished. In addition daily details of time of starting concrete, closure, No. of
batches through mixer, W.C. ratio, slump, date of striking form works etc. shall be maintained. This day-to-day record shall be authenticated by responsible
supervisory staff.

E. Plant and Equipment - General:

All mixing and batching plants boxes, containers and other equipment shall be maintained free of defects or of set concrete or cement and shall be cleaned before
commencing mixing. At such intervals as may be directed by the Design-Build-Operations Engineer or his representative, the Contractor shall provide weights,
containers and equipment necessary for testing the accuracy of the weighting plant, water measuring plant and admixture dispenser.

19.9.8 CONCRETING:

Preparation:

The Contractor shall clear from the surface of the foundations or previously placed concrete all oil, loose fragments of rock, earth, mud, timber and any other
foreign matter and shall clear standing water and wash the surface of a previous lift of concrete to the satisfaction of the Design-Build-Operations Engineer or his
representative.

a. Laitance:
Where laitance on a lift of concrete is evident or if a substantial bond between this lift or bay or concrete and the next is required, in the opinion of the Design-
Build-Operations Engineers representative, the Contractor shall have the surface wire brushed after initial set of the concrete or have it bush-hammered at no
extra cost to the Owner. Any reinforcing bars covered in laitance shall be wire brushed to clean the surface of the metal.

b. Blinding:

As ordered by the Design-Build-Operations Engineer or his representative, or as shown on the drawings the formation surfaces on which concrete is to be placed
shall be covered with either blinding concrete not less than 75mm thick, or waterproof, building paper, or polythene sheeting immediately after completion of the
final trimming of the excavation.

19.9.9 INSPECTION:

Concrete shall not be placed until the Design-Build-Operations Engineer or his representative has inspected the formwork and the reinforcing steel, and taken
necessary measurements of the latter, and has approved the surface upon which the concrete is to be placed.

a. Transporting:

Fresh concrete shall be transported from the mixer to its place in the works as quickly and as efficiently as possible by methods, which will prevent pre-set or
segregation. If segregation has nevertheless occurred in any instance, the materials shall be remixed or discarded at the opinion of the Design-Build-Operations
Engineer or his representative.

b. Placing:

Fresh concrete shall be placed and compacted before initial set has occurred and in any event, not later than thirty minutes from the time of mixing. Concrete
shall be carefully placed in horizontal layers which shall not be allowed to slide or flow down sloping surfaces but shall be placed in its final position from skips,
or similar devices. If this is impracticable, it shall be shoveled into position care being taken to avoid segregation. No concrete shall be dropped more than 1.5m.
If greater drops are necessary approved chutes may be used. If the concrete abuts against earth or any other material liable to become loose or to slip, care shall
be taken to avoid falls of materials on the surface of the wet concrete.

As far as possible concrete for any particular portion shall be done in one continuous operation leaving construction joints, if specified by drawing.
Before commencing subsequent concrete on the one left incomplete, all the loose particles, laitance etc. shall be removed and surface shall be covered with thick
cement slurry. The concrete compacted manually shall be laid in layers not more than 150 to 200 mm. The successive layer shall follow within 30 minutes or
earlier.

19.9.10 COMPACTION:

All concrete placed in-situ shall be compacted with power driven or pneumatic internal type vibrators unless otherwise approved by the Design-Build-Operations
Engineer or his representative in writing, and shall be supplemented by hand spading and tamping where required. Vibrating by screed type vibrators may be
used for thin slabs. There shall be sufficient and spare vibrators of adequate capacity to compact the work in hand.

a. Vibration:

Vibrators shall be inserted into the uncompacted concrete vertically and at regular intervals. Where the uncompacted concrete is in a layer above freshly
compacted concrete, the vibrator shall be allowed to penetrate vertically for about 75mm into the previous freshly compacted layer. The vibrators shall not be
allowed to come into contact with the reinforcement or formwork nor shall they be withdrawn quickly from the mass of concrete but shall be drawn back slowly
while in motion so as to leave no voids. Internal type vibrators shall not be placed in the concrete in any arbitrary manner nor shall concrete be moved from one
part of the work to another by means of the vibrators. The vibrators shall have minimum 3600 (preferably 5000) impulses per minute.

b. Duration:

The duration of vibration shall be limited to that required to produce satisfactory compaction of the concrete without causing segregation. Vibration shall on no
account be continued after the appearance of water or grout on the surface.

c. Hand compaction:

This shall be permitted exceptionally for small jobs by the Design-Build-Operations Engineer or his representative. In such cases, compaction shall be attained
by means of rodding, tamping, ramming and slicing with suitable tools. The thickness of concrete layers will also be suitably reduced when hand compaction is
resorted to.

19.9.11 UNDER WATER CONCRETING:


No concrete shall be placed in water without the Design-Build-Operations Engineer or his representatives written permission, which may only be granted if in
his opinion it is not practicable to place the concrete in the dry. Concrete shall not be placed is running water nor shall concrete be allowed to fall through water.
Any water entering the area where concrete is being placed shall, at the Contractors expense, be kept clear of the concreting works. If under water concreting is
permitted, the specified mix of concrete shall be strengthened by increasing the cement content by atleast 10.0% and reducing the water / cement ratio to no more
than 0.45, and the placing shall be only through a tremmie approved by the Design-Build-Operations Engineer or his representative. The volume or mass of the
coarse aggregate shall not be less than 1 times not more than twice that of the fine aggregate. The material shall be so proportioned as to produce a concrete
having a slump of not less than 100mm and not more than 180mm.

19.9.12 CURING:

All concrete shall be protected from the effects of sunshine, rain, running water or mechanical damage and cured by covering with jute, hessian or similar
absorbent material kept constantly wet or a layer of sand kept covered with water is also permissible for a continuous period of fourteen days at least from the
date of placement. Should the Contractor fail to water concrete continuously, the Design-Build-Operations Engineer or his representative may provide labour
and materials required for curing and recover the cost from the Contractor.

19.9.13 FINISHING:

Immediately after removal of forms, any undulations, depressions, cavities, honey combing, broken edges or corners, high spots and defects shall be made good
and finished with C.M. 1:2, but the necessity of such finishing must be exceptional and total surface requiring finishing shall not exceed 1%. Where concrete
surface is to receive plaster, the surface shall be roughened immediately after removal of forms and within a day thereof to secure a hold for the plaster. The rate
of concrete is inclusive of this roughening and finishing. Concrete after finishing shall be cured for the full period.

19.9.14 JOINTS:

Construction Joints:

Construction joints are defined as joints in the concrete introduced for convenience in construction at which special measures are taken at to achieve subsequent
continuity without provision for further relative movement.
a. Submittal:

No concreting shall be started until the Design-Build-Operations Engineer or his representative has approved the methods of placing, the positions and form of
the construction joints and the size of lifts.

b. Jointing:

The face of a construction joint shall have all laitance removed and the aggregate exposed prior to the placing of fresh concrete. The laitance shall wherever
practicable be removed by spraying the concrete surface with water under pressure and brushing whilst the concrete is still green. Where the laitance cannot be
removed whilst the concrete is green, the whole of the concrete surface forming part of the joint shall be hacked to expose the aggregate. Where aggregate is
damaged during hacking, it shall be removed from the concrete face by further hacking. All loose matter shall be removed and the exposed surface thoroughly
cleaned by wire brushing, and washing down, and the surface to which fresh concrete is applied shall be clean and damp.

Expansion Joints:

Expansion joints are defined as joints intended to accommodate relative movement between adjoining parts of a structure, special provision being made where
necessary for maintaining the water tightness of the joint.

a. The joint location and type will be as indicated in the drawings.

1. The Contractor shall comply with the instructions of manufacturers of proprietary jointing materials and shall, if required by the Design-Build-Operations
Engineer or his representative, demonstrate that the jointing materials can be applied satisfactorily and will last the life of the structure.

2. Flexible water stops shall be fully supported in the formwork, free of nails and clear of reinforcement and other fixtures. Damaged water stops shall be
replaced and during concreting care shall be taken to place the concrete so that water stops do not bend or distort.

b. Jointing:

The surface of set concrete shall not be disturbed and concrete shall be placed against the dry finished surface.
3. If ingress of water or corrosive agents in the joint is possible, the steel, where such steel is continued, shall be cleaned and coated with two coats of an
approved bituminous paint to a distance not exceeding 10mm.

4. Where specified, the surface of the set concrete shall be painted with two coats of an approved bituminous paint, which shall be allowed to dry before placing
new concrete against it. Care shall be taken to prevent paint getting on the water stop, if any.

5. Expansion joints shall be formed by a separating strip of pre-formed compressible imperishable joint filler, to be approved by the Design-Build-Operations
Engineer or his representative.

19.9.15 TESTING OF CONCRETE:

Sampling and strength test of concrete shall be as per 14 of IS: 456 2000.

19.9.16 TESTING CONCRETE STRUCTURES FOR LEAKAGE

The Contractor shall take special care for concrete for liquid retaining structures, underground structures and those others specifically called for to guarantee the
finish and water tightness.

The Contractor shall make all arrangements for hydro-testing of structure as per BIS: 3370 part I, all arrangements for testing such as temporary bulk heads,
pressure gauges, pumps, pipe lines etc.

Any leakage that may occur during the hydro-test or subsequently during the O&M period shall be effectively stopped either by cement/epoxy pressure grouting,
guniting or such other methods as may be approved by the Design-Build-Operations Engineer or his representative. All such rectification shall be done by the
contractor to the entire satisfaction of the Design-Build-Operations Engineer or his representative at no extra cost to the department.

Hydrostatic test for water tightness shall be done at full storage level including free board as may be directed by the Design-Build-Operations Engineer or his
representative, as described below:
In the case of structures whose external faces are exposed, the requirements of the test shall be deemed to be satisfied if the external faces show no sign of
leakage or sweating and remain completely dry during the period of observation of seven days after allowing a seven day period for absorption after filling with
water.

In the case of structures whose external faces are buried and are not accessible for inspection, such as underground tanks, the structures shall be filled with water
and after the expiry of seven days after the filling; the level of the surface of the water shall be recorded. The level of water shall be recorded again at subsequent
intervals of 24 hrs over a period of seven days. The total drop in surface level over a period for seven days shall be taken as an indication of water tightness of
the structure. The Design-Build-Operations Engineer or his representative shall decide on the actual permissible nature of this drop in the surface level, taking
into account whether the structures are open or closed and the corresponding effect it has on evaporation losses. Unless specified otherwise, a structure whose top
is covered shall be deemed to be water tight if the total drop in the surface level over a period of seven days does not exceed 40 mm.

Each compartment/segment of the structure shall be tested individually and then all together.

For structures such as pipes, tunnels etc. the hydrostatic test shall be carried out by filling with water, after curing as specified, and subjecting to the specified test
pressure for specified period. If during this period the loss of water does not exceed the equivalent of the specified rate, the structure shall be considered to have
successfully passed the test.

19.10 - FORM WORK

19.10.1 MATERIAL:

All formwork for concrete work shall be mostly of M.S. Plates. The plates shall be free from wrinkles, lumps or other imperfections. Steel plates shall have
sufficient thickness to withstand the construction loads and the pressure exerted by the wet concrete as well as vibration during placing of concrete. Normally the
thickness shall not be less than 18 gauge for M.S. Plates.

The formwork may also be constructed of timber, or other approved material. It shall be firmly supported, adequately strutted, braced and tied to withstand the
placing and vibrating of concrete and the effects of weather. One copy of the Contractors shoring and formwork drawings shall be submitted to the Owner for
record purpose only and not for review or approval. Forms, shoring and false work shall be adequate for imposed live and dead loads including equipment and
men, height of concrete drop, concrete and foundation pressures and stresses, wind pressures, lateral stability, and other safety factors during construction. The
Contractor shall be responsible for the calculations and designs for the formwork. The Contractor shall be held solely responsible for any failure and for the
safety of work and workmen. He shall pay necessary compensation, if need be, for damages to work, property and injuries to persons. The scaffolding, hoisting
arrangements and ladders shall have easy approach to work spot and afford easy inspection.

All formwork shall be fabricated in compliance with the best modern practice, so that the finished surface is even, unblemished free of fins and true to line, level
and shape as shown in the drawings. The forms shall comply with the requirements of IS: 456.

19.10.2 ARRANGEMENTS:

All formwork shall conform to the shape, lines, dimensions as shown on the plans of the concrete members. The formwork shall include all wedging, bracing, the
rod, clamps, stop off boards and other devices necessary to mould the concrete to the desired shape. The formwork shall be constructed as to remain sufficiently
rigid during the placing and compacting of the concrete and shall withstand the necessary pressure, ramming and vibrations without any deflection from the
prescribed lines and curves. It shall be properly strutted and braced in at least two directions. It shall be sufficiently tight to prevent loss of liquid slurry from the
concrete. It shall be strongly and firmly erected. The moulds shall be free from holes, open joints, and other imperfections. The formwork shall be so arranged
as to permit easy erection initially and easy removal without jarring or disturbing the concrete finally. Wedges and clamps shall be used wherever practicable
instead of nails.

Where the depth of formwork exceeds 1.5 metres, the Contractors shall keep one side partly open, from which the concrete could be placed and the planking on
the open side could be raised as the work proceeds. This will avoid segregation of material in concrete and also facilitate its proper vibration.

Before concrete is placed, all rubbish shall be removed from the interior of the form and the surfaces of the formwork in contact with concrete shall be cleaned
and thoroughly wetted. The inside surface of the formwork shall be treated with a coat of lime, oil or any other material approved by the Design-Build-
Operations Engineer or his representative. Care shall be taken to see that the above approved composition is kept out of contact with the reinforcement. The slab
centering shall be covered with Double Wax water proofing paper or tar paper or polythene sheet as directed by the Design-Build-Operations Engineer or his
representative.
Where no special finish is desired and where form finish is acceptable, the formwork may be prepared out of water proof black board, which shall give a good
finish to the concrete surface and thus there will be no necessity of providing cement plaster finish. For work, which are of repetitive nature, such as column
footings, pedestals for pipes, pedestal footings; the formwork shall be fabricated out of steel plates and structurals to obtain uniform finish throughout the work.
In all cases the formwork shall be inspected and approved by the Design-Build-Operations Engineer or his representative, before any concreting is started. The
Contractor shall, however, be solely responsible for the proper design, adequacy and stability of the formwork. If at any time, in the opinion of the Design-Build-
Operations Engineer or his representative, the formwork provided is not considered sufficiently rigid and / or is defective, the Contractor shall improve or
strengthen the same in such manner as the Design-Build-Operations Engineer or his representative may direct. In no circumstances shall form be struck off until
the concrete attains adequate strength as required or without obtaining permission of the Design-Build-Operations Engineer or his representative. All formwork
shall be removed without such shock or vibration as would damage the concrete. Before the soffit and the struts are removed, the concrete surface shall be
exposed where necessary in order to ascertain that the concrete has hardened sufficiently. The responsibility for the removal of the formwork whether whole or
part, shall rest, entirely with the Contractor who must nevertheless be guided by the opinion of the Design-Build-Operations Engineer or his representative in this
regard. The work of striking and the removal of formwork shall be conducted in the presence of the Design-Build-Operations Engineer or his representative and
under personal supervision of a competent foreman in the employment of the Contractor.

19.10.3 REMOVAL OF FORMS AND SHORING:

Formwork shall be so designed as to permit easy removal without resorting to hammering or levering against the surface of the concrete. The periods of time
elapsing between the placing of the concrete and the removal of the formwork shall be as approved by the Design-Build-Operations Engineer or his
representative after consideration of the loads likely to be imposed on the concrete and shall be in any case be not less than the periods shown below, depending
on the ambient temperature.

1. Vertical surfaces of wall 1 day

2. Columns & vertical sides of beams 2 days

3. Slab bottoms with props left under 7 days

4. Beam bottom with props left under 7 days


5. Removal of props under slabs

Span upto 4.5 m 7 days

Span over 4.5 m 14 days

6. Removal of props to beam and arches

Span upto 6.0 m 14 days

Span over 6.0 m 21 days

Sequence of striking formwork shall be approved by the Design-Build-Operations Engineer or his representative.

Not withstanding the foregoing, the Contractor shall be held responsible for any damage arising from removal of formwork before the structure is capable of
carrying its own weight and any incidental loading. The Contractor shall be wholly responsible for repairing or reconstruction as directed by the Design-Build-
Operations Engineer or his representative the section of the works so affected.

1. Shoring and False work Removal:

In retaining wall construction shoring and false work shall not be removed until 21 days after concrete placement or until concrete has attained at least 90 percent
of the 28 days design compressive strength as demonstrated by control test cylinders, whichever is earlier.

2. Restriction:

Construction equipment, or permanent loads shall not be imposed on columns, supported slabs, or supported beams until concrete has attained the 28 days design
compressive strength as demonstrated by control test cylinders.

3. Concrete Curing during removals:

Concrete shall be thoroughly wetted as soon as forms are first loosened and shall be kept wet during the removal operations and until curing media or sacking is
applied. Portable water supply with hoses or buckets shall be ready at each removal location before removal operations are commenced.
19.10.4 SURFACE TREATMENT & FINISH:

When the formwork is struck, all the faces of concrete shall be smooth and sound, free from voids and air holes. Any roughness or irregularity on the exposed
surfaces shall be immediately filled up while the concrete is still green with cement grout, cement wash and / or 1:1 mortar properly trowelled and finished. Such
patching of the concrete face shall be carried only with the permission of the Design-Build-Operations Engineer or his representative. If the concrete is found
honey-combed, the honeycombed portion and whatever surrounding concrete that may be considered unsatisfactory by the Design-Build-Operations Engineer or
his representative shall be dismantled and fresh concrete of proper quality shall be provided at Contractors cost.

19.11 REINFORCEMENT

19.11.1 GENERAL:

Reinforcement shall be either plain round mild steel bars Grade I as per IS: 432 (Part - I) or medium tensile steel bars as per IS: 432 (Part I) or high strength
deformed bars as per IS: 1786. Wire mesh or fabric shall be in accordance with IS: 1566. Substitution of reinforcement will not be permitted except upon
written approval from the Design-Build-Operations Engineer or his representative.

19.11.2 STORAGE:

The reinforcement shall not be kept in direct contact with the ground but stacked on top of an arrangement of timber sleepers or the like. If the reinforcing rods
have to be stored for a long duration, they shall be coated with cement wash before stacking and / or be kept under cover or stored as directed by the Design-
Build-Operations Engineer or his representative. Fabricated reinforcement shall be carefully stored to prevent damage, distortion, corrosion and deterioration.

19.11.3 QUALITY:

a. All steel shall be of Grade I quality unless specifically permitted by the Design-Build-Operations Engineer or his representative. No re-rolled material will be
accepted. If requested by the Design-Build-Operations Engineer or his representative, the Contractor shall submit the manufacturers test certificate for the steel.
Random tests on steel supplied by the Contractor may be performed by the Design-Build-Operations Engineer or his representative as per relevant Indian
Standards. All costs incidental to such tests shall be at the Contractors expense. Steel not conforming to specifications shall be rejected.
b. All reinforcements shall be clean, free from grease, oil, paint, dirt, loose mill scale, loose rust, dust, bituminous material or any other substances that will
destroy or reduce the bond. All rods shall be thoroughly cleaned before being fabricated. Pitted and defective rods shall not be used. No welding of rods to
obtain continuity shall be allowed unless approved by the Design-Build-Operations Engineer or his representative. If welding is approved, the work shall be
carried out as per IS: 2751 according to the best modern practices and as directed by the Design-Build-Operations Engineer or his representative. In all cases of
important connections, tests shall be made to prove that the joints are of full strength of bars welded. Special precautions, as specified by the Design-Build-
Operations Engineer or his representative, shall be taken in the welding of cold worked reinforcing bars and bars other than mid steel.

19.11.4 SUBMITAL OF DRAWINGS AND SAMPLES:

Drawings:

The detailed drawings, Working drawings and bar bending schedules of reinforced concrete works shall be prepared by the Contractor.

Samples:

At least one month in advance of placing an order by him, the Contractor shall submit four samples of reinforcing bars which he intends ordering in case, the
steel is to be supplied by the Contractor.

The samples shall conform to IS: 10790 Part 2 1984. The Design-Build-Operations Engineer or his representative may carry out any test he may require to
satisfy that the steel to be brought by the Contractor complies with the test Specifications.

19.11.5 LAPS AND SPLICES:

Laps and splices for reinforcement shall be as per IS: 456 2000. Splices in adjacent bars shall be staggered and the locations of all splices, except those
specified on the approved Drawings, shall be only as approved by the Design-Build-Operations Engineer or his representative. The bars shall not be lapped
unless the length required exceeds the maximum available lengths of bars at site.

19.11.6 DOWELS:

Where and as designated on the drawings, steel bar dowels shall be provided for anchorage to previously cast concrete.
For anchorage where shown or required to existing construction, an approved non-shrink epoxy type grout or approved bolting devices shall be used.

19.11.7 BENDING:

a. Reinforcement bars supplied bent or in coils, shall be straightened before they are cut to size. Straightening of bars shall be done cold and without damaging
the bars.

b. All bars shall be accurately bent according to the sizes and shapes shown on the approved detailed working drawings / bar bending schedules. They shall be
bent gradually by machine or other approved means. Reinforcing bars shall not be straightened and in a manner that will injure the material; bars containing
cracks or splits shall be rejected. They shall be bend cold, except bars of over 25mm in diameter which may be bent hot if specifically approved by the Design-
Build-Operations Engineer or his representative. Bars, which depend for their strength on cold working, shall not be bent hot. Bars bent hot shall not be treated
beyond cherry red colour (not exceeding 845 degree C) and after bending shall be allowed to cool slowly without quenching. Bars incorrectly bent shall be used
only if the means used for straightening and rebending be such as shall not, in the opinion of the Design-Build-Operations Engineer or his representative, injure
the material. No reinforcement shall be bent when in position in the work without approval, whether or not it is partially embedded in hardened concrete. Bars
having kinks or bends other than those required by design shall not be used.

19.11.8 FIXING:

Reinforcement shall be accurately fixed by any approved means and maintained in the correct position by the use of blocks, spacers and chairs, as per IS: 2502,
to prevent displacement during placing and compaction of concrete. Bars intended to be in contact at crossing points shall be securely bound together at all such
points with number 16 gauge annealed soft iron wire. The vertical distances required between successive layers of bars in beams or similar members shall be
maintained by the provision of mild steel spacer bars at such intervals that the main bars do not perceptibly sag between adjacent spacer bars.

The Contractor shall ensure that all reinforcing bars are thoroughly wire brushed and cleaned free of loose mill scale, loose rust, coats and paints, oils, mud or
other coating.

Mesh reinforcement, where specified shall conform to IS: 1566 1982.

Binding wire shall be annealed wire conforming to IS: 280.


19.11.9 COVER:

Unless indicated otherwise, clear concrete cover for reinforcement (exclusive of plaster or other decorative finish) shall be as follows:

i) At each end of a reinforcement bar, not less than 25mm nor less than twice the diameter of the bar.

ii) For a longitudinal reinforcing bar in a column not less than 40mm, nor less than the diameter of the bar. In case of columns of minimum dimension of 200
mm or under with reinforcing bars of 12mm and less in dia. a cover of 25mm may be used.

iii) For longitudinal reinforcing bars in a beam, not less than 25mm nor less than the diameter of the bar.

iv) For tensile, compressive, shear or other reinforcement in a slab, or wall, not less than 15mm, nor less than the diameter of such reinforcement.

v) For any other reinforcement, not less than 15mm, nor less than the diameter of such reinforcement.

vi) For footing and other principal structural members in which the concrete is poured on a layer of lean concrete, the bottom cover shall be minimum of 50mm.

vii) For concrete surfaces exposed to the weather or the ground after removal of forms, such as retaining walls, grade beams, footing sides and tops, etc. not less
than 50mm for bars larger than 16mm diameter and not less than 40mm for bars 16mm diameter or smaller.

viii) Increased Cover thickness shall be provided for surfaces exposed to the action of harmful chemicals or exposed to earth contaminated by such chemicals
acids, alkalis, saline atmosphere, sulphurous smoke etc. and such increase of cover may be between 15mm and 50mm beyond the figures mentioned here as may
be specified by the Design-Build-Operations Engineer or his representative.

ix) For liquid retaining structures, the minimum cover to all steel shall be 40mm or the diameter of the main bar, whichever is greater. In the presence of soils
and waters of a corrosive character, the cover shall be increased by 10mm.

x) The correct cover shall be maintained by cement mortar cubes or other approved means. Reinforcement for footing, grade beams and slabs on sub grade shall
be supported on precast concrete blocks as approved by the Design-Build-Operations Engineer or his representative. The use of pebbles or stones shall not be
permitted.
xi) The 28 day crushing strength of cement mortar cubes / precast concrete cover blocks shall be at least equal to the specified strength of concrete in which these
cubes / blocks are embedded.

xii) The minimum clear distance between reinforcing bars shall be in accordance with IS: 456.

19.11.10 INSPECTION:

All continuous inspections shall be performed by the Design-Build-Operations Engineers Representative. Erected and secured reinforcement shall be inspected
and approved by the Design-Build-Operations Engineer or his representative prior to placement of concrete.

19.11.11 REINFORCEMENT BARS PROCUREMENT:

All reinforcement steel (TMT) should be procured as per IS 1786:2008 Grade Fe415/Fe500. Steel to be procured only from Primary steel producers/ Integrated
Steel Plants such as TATA / SAIL / RINL / JSW / SHYAM STEEL using iron ore as the basic raw material and having in-house iron making facilities followed
by production of liquid steel and crude steel with in-house rolling, adopting Blast Furnace to Basic Oxygen Furnace (BF-BOF) route or Direct Reduced Iron
Electric Arc Furnace (DRI-EAF) technology as per Ministry of Steel, Government of India guidelines. No Re-rolled material/secondary steel will be accepted or
allowed for any structural works.

As per IS.1786:2008, under clause 4.2.3, Low-alloyed/Micro alloyed/CRS steel can also be used by adding alloying elements like Cr, Cu, Ni, Mo and P, either
individually or in combination to improve allied product properties. However the total content of these elements shall not be less than 0.40%. In such alloy steels
when phosphorous is used, it shall not exceed 0.12% and carbon shall be restricted to a maximum of 0.15%.

The steel manufacturing company should have latest ISO accreditation for Quality Management System.

Every lot of supply shall require to be accompanied by manufacturers test certificate for establishing correlation with TMT/CRS bars supplied.

Every lot shall be tested in the independent laboratory to assess whether the properties are confirming to IS.1786:2008.

The Contractor shall arrange for transport, loading, unloading and storage at the work sites. The Contractor should plan the procurement of steel in such a way
that at least required quantity of steel of specified sizes is available at site for 3 months period.
Reinforcement shall be transported stacked and stored at site away from soil contact and protected from rain so as not to damage or rust the material. The bars
shall be stored above ground surface upon platforms or supports to avoid distortion and sags of long length.

The rate quoted for steel reinforcement shall be inclusive of taxes, transport, incidental charges etc., apart from labour component as specified in the respective
item in the Bill of Quantities.

Steel brought on site shall be stored in a proper manner as approved by the Design-Build-Operations Engineer or his representative so as to avoid distortion,
deterioration and corrosion. The Contractor shall maintain proper registers for the steel account, showing the steel received at site, steel used, and the balance
stock on site, to the entire satisfaction of the Design-Build-Operations Engineer or his representative. Further, it shall be obligatory on the part of the Contractor
to submit monthly, quarterly and yearly statements giving the full account of steel on the works and the balance on hand.

19.11.12 ANTI CORROSIVE TREATMENT FOR REINFORCEMENT:

The item covers providing fusion bonded epoxy coating not less than 175 microns thickness and upto 300 microns to reinforcement steels bars of all diameters as
per IS Code 13620-1993 for RTS rods for RCC works including testing of coating at plant.

19.12 PLASTERING

19.12.1 DEFINITIONS:

a) The term plastering shall cover all types of rough or fair finished plastering, rendering, floating and setting coat or finishing coat, screed, etc., in mud, lime,
cement lime or cement mortar.

b) Dubbing out shall mean filling in hollows in the surface of wall and roughly levelling up irregular or out of plumb surfaces, prior to rendering.

c) Rendering or rendering coat shall mean the plaster coat, which is applied following the Dubbing out or the final coat in case of one coat work.

d) Floating coat shall mean the second coat in a three-coat plasterwork, to bring the rendering coat to a true and even surface before the setting or finishing coat
is applied.

e)Setting of finishing coat shall mean final coat in a two or three coat plaster work.
f)Thickness of plaster shall mean the minimum thickness at any point on a surface. This does not include thickness of dubbing out.

g) The term even and fair as referred to finishing of the plastered surface shall mean a surface finished with a wooden float.

h) The term even and smooth as referred to finishing of the plastered surface shall mean a surface levelled with wooden float and subsequently smoothened
with a steel trowel.

19.12.2 SCAFFOLDING:

Where possible, independent scaffolding shall be used to obviate the subsequent restoration of masonry in putlog and other breaks in the work. Stage scaffolding
shall be provided for ceiling plaster.

19.12.3 PREPARATION OF MORTAR FOR PLASTERING:

19.12.3.1 Materials:

Cement Mortar:

Cement mortar shall have the proportion of cement to sand as mentioned in the item or in the special provisions and shall comply with following:

Cement:

Cement shall conform to IS: 12269 - 1987 Ordinary Portland Cement shall be used. The weight of ordinary Portland cement shall be taken as 50 kg per bag. The
Contractor shall ensure that the cement is of sound and required quality before using it. Any cement, which has deteriorated, caked or which has been damaged
shall not be used. The Specifications covered under the section brickwork and concrete work shall be applicable in addition.

Water:

Water shall be clean, clear and free from injurious quantities of salt, traces of oil, acids, alkalis, organic matter and other deleterious materials. The sources of
water shall be approved by the Design-Build-Operations Engineer or his representative and the containers for conveyance; storage and handling shall be clean. If
necessary, standard cement tests shall be conducted using the water intended to be used, in comparison with those adding distilled water to check quality of
water.
Water shall meet the requirement of 4.3 of IS: 456 2000. Generally potable water is fit for mixing and curing.

Fine Aggregate:

All fine aggregate shall conform to IS: 383 1970.

Sand shall be clean, well graded, hard, strong, durable and of gritty particles free from injurious amounts of dust, clay, kankar nodules, soft or flaky particles,
shale, alkali, salts, organic matter, loam, mica or other deleterious substances and shall be approved by the Design-Build-Operations Engineer or his
representative. The maximum size of particles shall be limited to 5mm. If the fine aggregate contains more than 4 percent of clay, dust or silt, it shall be washed.

The fine aggregate for cement mortar for masonry and first cost of plaster should generally satisfy the following grading:

I.S. Sieve Percent by wt. Passing sieve

4.75mm 100

2.36mm 80-95

1.18mm 70-90

600microns 40-85

300microns 5-50

150microns 0-10

The fineness modules shall not exceed 3.00.

The fine aggregate for cement mortar for fine joints of ashlars masonry, pointing and second coat of plaster may have the following grading:

I.S. Sieve Percent by wt. Passing sieve


4.75mm 100

2.36mm 100

1.18mm 75-100

600microns 40-85

300microns 5-50

150microns 0-10

The fineness modulus shall not exceed 1.6.

IS: 2116 1980 shall generally apply for sand for plaster. The fine aggregate should be stacked carefully on a clean, hard surface so that it will not get mixed up
with deleterious foreign materials.

19.12.3.2 Proportion:

Cement and sand shall be mixed in specified proportions, sand being measured in measuring boxes. The proportions will be by volume. The mortar may be
hand mixed or machine mixed.

19.12.3.3 Preparation:

In hand mixed mortar, cement and sand in the specified proportions shall be thoroughly mixed dry on a clean impervious platform. Fresh and clean water as
specified above shall be added gradually and thoroughly mixed to form a stiff plastic mass of uniform colour so that each particle of sand shall be completely
covered with a film of wet cement.

The water cement ratio may be as under or as directed by the Design-Build-Operations Engineer or his representative.
Quantity of water per
Cement Sand Water Cement ratio 50 kg. of cement
(Litres)

1 1 0.25 12.5

1 1 0.28 14.0

1 2 0.30 15.0

1 2 0.35 17.5

1 3 0.40 20.0

1 4 0.53 26.5

1 5 0.60 30.0

1 6 0.70 35.0

1 8 0.90 45.0

Machine mixed mortar shall be prepared in an approved mixer. Water cement ratio shall be as per hand mixed mortar. The mortar so prepared shall be used
within 30 minutes of adding water. The mortar remaining unused after that period, mortar, which has partially hardened or is otherwise damaged shall not be re
tempered or remixed. It shall be destroyed or thrown away.

19.12.4 PREPARATION OF BACKGROUND FOR APPLICATION OF PLASTER:

Cleanliness:
All dirt, dust and other foreign matter on masonry and laitance on the concrete surfaces shall be removed by watering and brushing as required. If the
background contains soluble salts particularly sulphates, the application of plaster shall be done only after the efflorescence of the salts is complete and the
efflorescence is completely removed from the surface.

Joints in brickwork, stone masonry and hollow block, masonry shall be raked out to a depth of not less than 10mm as the work proceeds. Local projection in
brickwork and masonry beyond the general wall face shall be trimmed off where necessary.

Roughness:

Smooth surfaces of in-situ concrete walls and ceilings etc. shall be roughened by wire brushing, if it is not hard; and by hacking or bush hammering if it is hard,
to provide for proper adhesion. Projecting burrs of mortar because of gaps at joints in shuttering shall be removed. The surface shall be scrubbed clean with wire
brushes. In addition concrete surface shall be pock marked with a pointed tool at spacing of about 50mm, the pocks made to be not less than 3mm deep.

Suction Adjustments:

Adequate drying intervals shall be allowed between the erection of masonry and plastering to bring the surface suitable for suction adjustment. High rate of
suction makes the plaster weak, porous and friable. The wall shall not be soaked but only damped evenly before applying the plaster. If the surface becomes dry
in spots, such areas shall be moistened again to restore uniform suction. Excessive water leads to failure of bond between the plaster and the background.

Evenness:

Any local unevenness must be levelled and projections removed to avoid variance in the thickness of plaster.

Immobility:

Differential movements between the background and the plaster due to moisture change, temperature change, structural settlement, defection, etc. cause cracks.
The major part of such movements shall be allowed to set in before the plaster is applied.

19.12.5 PLASTERING:

Plastering Generally:
The type and mix of mortar for plastering, the number of coats to be applied, the surface finish of the plaster and the background to which the plaster is to be
applied shall be as indicated.

The mortar for dubbing out and rendering coat shall be of the same type and mix. Dubbing out may be executed as a separate coat or along with the rendering
coat.

Protection:

All existing work and fittings that are likely to be damaged in the application of plastering shall be protected. Care shall be taken to avoid, as far as possible, the
splashing of mortar on to the finished surfaces such as joinery, paint work and glazing; all such splashes shall be cleaned off immediately.

Screeds 150 x 150 mm shall be laid vertically and horizontally not more than 2m apart to serve as guides in bringing the work to an even surface.

Plastering shall be done from top to bottom and care shall be taken to avoid joints in continuous surface.

Maintenance of proper time intervals:

To avoid break down of adhesion between successive coats, drying shrinkage of first coat shall be allowed to be materially completed before a subsequent coat is
applied.

All corners, arises, angles, junctions shall be truly vertical or horizontal as the case may be and shall be carefully finished. Rounding or chamfering of corners,
arises and junctions shall be carried out with proper templates to the required size. Plastering of cornices, decorative features, etc. shall normally be completed
before the finishing coat is applied.

In suspending the work at the end of the day, the plaster shall be cut clean to the line both horizontally and vertically. When recommencing the plastering, the
edge of the old work shall be scraped clean and wetted with lime putty or cement slurry before plaster is applied to the adjacent area. Partially set and dried
mortar shall not be re tempered for use.

Cleaning of completion:
On completion, all work affected by plastering and pointing shall be left clean, special care shall be taken when removing any set mortar from glass and joinery,
etc. to avoid damaging their surface.

19.12.6 ONE COAT PLASTER WORK:

Mortar shall be firmly applied to the masonry walls and well pressed into the joints and forcing it into surface depressions to obtain a permanent bond. The
plaster shall be laid in a little more than the required thickness and levelled with a wooden float. On concrete walls, rendering shall be dashed on to roughened
surface to ensure adequate bond. The dashing of rendering coat shall be done using a strong whipping motion at right angles to the face of walls. The surface
shall be finished even and fair. Unless indicated to be finished even and smooth.

19.12.7 TWO COAT PLASTER WORK:

First Coat:

The first coat of the specified thickness shall be applied in a manner similar to one coat plasterwork. Before the first coat hardens, the surface of the cement and
cement lime plasters shall be scored to provide key for second coat. In case of lime plasters the surface shall be beaten with edges of wooden thapies and close
dents shall be made on the surface, to serve as a key to the subsequent coat. The rendering coat shall be kept damp for atleast two days, it shall be allowed to
become thoroughly dry.

Second Coat:

Before starting to apply second coat, the surface of the rendering coat shall be damped evenly. The second coat shall be completed to the specified thickness in
exactly the same manner as the one coat plaster work.

19.12.8 NEERU FINISH:

After applying and finishing the undercoats and before they set, the finishing coat of specially prepared lime putty about 1.5mm thick shall be applied. It shall be
well polished with a trowel.

19.12.9 SAND FACED PLASTER:


After the undercoat of cement and sand mortar 1:4 not less than 10mm thick, has been applied and finished, the final coat of cement and sand mortar 1:4 shall be
applied to a thickness not less than 5mm and brought to an even surface with a wooden float. The surface shall then be tapped gently with a wooden float lined
with cork to retain a coarse surface texture, care being taken that the tapping is even and uniform.

19.12.10 CURING:

Each coat shall be kept damp continuously for at least two days. Moistening shall commence as soon as the plaster has hardened sufficiently and is not
susceptible to injury. The water shall be applied preferably by using a fine fog spray. Soaking of wall shall be avoided and only as much water as can be readily
absorbed shall be used. Excessive evaporation on the sunny or wind ward sides of buildings in hot dry weather shall be prevented by hanging matting or gunny
bags on the outside of the plaster and keeping them wet.

After the completion of finishing coat, the plaster shall be kept wet for at least seven days and shall be protected during that period from extremes of temperature
and weather.

19.12.11 WATER PROOFING PLASTER:

Integral water proofing compound shall be mixed with cement in the proportion indicted by weight. Care shall be taken to ensure waterproofing material gets
well and integrally mixed with cement and does not run out separately when water is added.

19.13 - DUCTILE IRON PIPES

19.13.1 MATERIALS:

Ductile Iron:

Ductile iron is an iron / carbon / silicon alloy, in which the carbon exists in a pure form as spherical graphite due to addition of small amount of magnesium to
molten cast iron. The spherical shape of its graphite increases the mechanical properties such as tensile strength, toughness and ductility. The pipes
manufactured by ductile iron shall conform to IS: 8329 2000.

Cement:
The cement used for internal cement mortar lining shall be ordinary Portland cement and shall conform to IS: 12269 - 2013 with its latest amendments.

Aggregate:

The aggregate shall conform to IS: 383 with its latest amendments.

Water:

The water used in the preparation of cement mortar mix shall conform to the requirements of mixing water given in IS: 456.

Rubber Gaskets:

The Rubber Gaskets used for push-on joints shall conform to IS: 12820 2004. The quality of rubber required shall be as per IS: 5382. Rubber ring bundles
from every lot shall carry with them manufactures test certificate for the following mechanical properties.

a) Hardness

b) Tensile strength

c) Compression strength

d) Oil immersion test

e) Water absorption test

f) Stretch test and visual examination

The test procedures, the scale of sampling and the criteria for acceptance shall be as per IS: 5382 and IS: 3400.

The Design-Build-Operations Engineer or his representative shall at all reasonable times have free access to the place of manufacture for inspection and
examining the test conducted by manufacturer.

Rubber rings shall be clearly labeled in bundles to indicate the type of ring, the type of joint, the size of the pipe with which they are to be used, the
manufactures name and trademark, the month and year of manufacture.
Rubber gaskets should be stored in a cool, dark place protected from excessive exposure to heat, direct sunlight, ozone, oil and grease. The rubber gasket should,
whenever possible, be stored in a relaxed form free from tension, compression or any other deformation.

19.13.2 CLASSIFICATION:

Pipes have been classified as K7, K8, K9, K10, K12, K14 depending on service conditions and manufacturing process.

19.13.3 INSPECTION:

All works and materials under specification will be inspected during all phases of manufacture and testing and such inspection shall not relieve the Contractor of
his responsibility to furnish materials and performed work in accordance with this specification.

The Contractor shall notify the Design-Build-Operations Engineer or his representative, in advance of the production of materials and fabrication thereof, in
order that the Owner may arrange for mill and shop inspection.

The Design-Build-Operations Engineer or his representative may reject any or all materials or work that do not meet with any of the requirements of these
specifications. The Contractor shall rectify or replace such rejected material / performed work at his own cost to the satisfaction of the Design-Build-Operations
Engineer or his representative.

The Design-Build-Operations Engineer or his representative shall have free access to those parts of all plants or any other premises and sites that are concerned
with the furnishing of materials or the performance of work under this specification.

The Contractor shall furnish to the Design-Build-Operations Engineer or his representative responsible facilities and space without charge for inspection, testing
and obtaining of any information he desires in respect of the character of material used and the progress and manner of the work.

The Contractor shall furnish all the test results from an approved laboratory at any time during the progress of work to the satisfaction of the Design-Build-
Operations Engineer. The laboratory shall be approved by the Owner.

19.13.4 MANUFACTURE OF D.I. PIPES:


The metal used for the manufacture of pipes shall be such that the pipes are of ductile iron complying with the metallurgical properties specified in IS: 8329.
Therefore the manufacturer shall arrange good quality control system for selection of raw material. It shall be manufactured by any method at the discretion of
the manufacturer, provided that the requirements defined in IS: 8329 are complied with. It is also essential that either the Contractor / supplier or the
manufacturer should ensure that the manufacture of D.I. pipes and Specials should be fully covered by ISO 9000 certification.

The pipes shall be stripped with all precautions necessary to avoid warping or shrinkage defects. The pipes shall be free from surface or other defects. Pipes
showing small imperfections which result from the method of manufacture and which do not affect their serviceability, shall not be rejected on that account
alone. Minor defects arising out of manufacturing process may be rectified with the consent of the Design-Build-Operations Engineer.

Pipes centrifugally cast shall be heat treated in order to achieve the necessary mechanical properties and to relieve casting stresses in accordance with
IS: 13655-1993.

If the specified mechanical properties and Brinell hardness are not as per the standard, the pipe may be subject to reheat treatment.

In case of push-on flexible joints, the spigot ends shall be suitably chamfered for smooth entry of pipe in the socket fitted with the rubber gasket.

In case of flanged pipes, the flanges shall be at right angle to the axis of the pipe and machined on the face. The boltholes shall be drilled.

The bolthole circle shall be concentric with the bore and the two flanges of the pipe shall be correctly aligned.

19.13.5 SAMPLING:

Sampling criteria for various tests, unless specified in the standard, shall be as laid down in IS: 11606 - 1986.

The material acceptance tests shall be carried out on ductile pipes grouped in batches as follows. Each batch shall be made up of pipes cast successively as
under:

DN 80 to 250 200 pipes

DN 300 to 600 100 pipes


DN 700 to 1000 60 pipes

19.13.6 MECHANICAL TESTS:

Mechanical tests shall be carried out during manufacture. Test shall be conducted for every four hours of production. The results obtained shall be taken to
represent all the pipes of all sizes made during that period.

19.13.7 DUCTILE IRON FITTINGS:

The fittings shall conform to IS: 9523 2000. The manufacture of fittings is similar to the Ductile Iron pipes and the mechanical properties of these fittings also
similar to pipes.

19.13.8. TENSILE TEST:

Two test pieces obtained by cutting bars from spigot end of two pipes selected for testing when tested in accordance with the methods specified in IS: 9523
2000 shall satisfy the following requirements:

0.2% Percentage
Nominal Tensile Elongation after
Proof
Grade Diameter Strength fracture, Min on
Stress
(Dn) mm Min, MPa Gauge Length =
Min, MPa 5.65 So

1 80-1000 300 420 10

2 1100-2000 300 420 5

NOTE: The proof stress shall only be measured when specially agreed between the manufacturer and the purchaser.

19.13.9 BRINELL HARDNESS TEST:


For checking the Brinell hardness, the test shall be carried out on test bars cut from the fitting used for test conforming to IS: 1500 2005. The Brinell hardness
shall not exceed 230 HB on the external unmachined surface.

19.13.10 HYDROSTATIC TESTS:

For hydrostatic tests, all fittings shall be kept under pressure for 15 seconds; they may be struck moderately with a 700-g hammer. They shall withstand the
pressure test without showing any leakage, sweating or other defect of any kind. As far as possible, hydrostatic test shall be conducted before coating the fittings.

19.13.11 WORKS AND INSTALLATION TEST REQUIREMENTS:

All fittings shall withstand hydrostatic test pressure at works as specified in the following Table:

Table: Hydrostatic Test Pressure For Fittings for K9 Class

Nominal Diameter Hydrostatic Test Pressure For Fittings


(Dn) Mpa
(1) (as per IS 9523)

Upto 300 6.0

350 to 600 5.0

700 to 1000 4.0

1100 to 2000 2.5

19.13.12 CEMENT MORTAR LINING:

The process of lining for D.I. pipes is done at the factory itself and it shall conform to IS 11906 - 1986 and its latest amendments.

19.13.13 MORTAR:

The mortar of the lining shall be composed of cement, sand and water.
Additives may be used, provided that they do not prejudice the quality of the coating and that of the transported water and that the lining remains in accordance
with all the requirements of International Standard.

The mortar shall be thoroughly mixed and shall have consistency, which results in a dense and homogeneous lining.

The mortar shall contain by mass at least one part of cement to 3.5 parts of sand.

19.13.14 CONDITION OF THE INTERIOR SURFACE OF THE PIPE BEFORE APPLICATION OF THE LINING:

All foreign bodies, loose scale or any other material, which could be detrimental to good contact between the metal and the lining, shall be removed from the
surface to which the lining is to be applied. The inner surface of the pipe shall also be free of any metal projections likely to protrude beyond 50% the thickness
of the lining.

19.13.15 APPLICATION OF THE LINING:

The mortar of the lining is case centrifugally inside the pipe.

Apart from the inner surface of the joint, the parts of the pipe coming into contact with the transported water shall be entirely covered with mortar.

The mortar shall be free of any cavities or visible air bubbles and care shall be taken to ensure maximum density at all points. The consistency of the mortar, the
time required and the speed of centrifuging the pipe shall be controlled so that segregation of the sand in the lining is reduced to a minimum.

Once centrifuging is finished, the lining shall be cured at temperatures greater than 0oC. Any loss of water from the mortar by evaporation shall be sufficiently
slow that hardening is not impeded.

Repairs to damaged or defective areas are allowable. The damage mortar shall first be removed from these areas. Then the defective part shall be repaired by
using a trowel with fresh mortar so that a continuous lining having a constant thickness is again obtained.

For the repair operation, the mortar shall have a suitable consistency; if necessary, additives may be included to obtain good adhesion against the side of the
existing undamaged mortar.

19.13.16 THICKNESS OF THE LINING:


The normal thickness of cement mortar lining shall not be less than for various size of pipes as shown below:

Diameter Lining Thickness


DN (mm)
(mm)

80 250 3

300 900 5

over 900 6

Thickness of lining shall be checked frequently as the Design-Build-Operations Engineer may direct in order to maintain proper control on the lining operations.
Graduated needle or other approved appliance shall be used for measuring the thickness. The tolerance in the lining thickness shall be +3mm and no minus
tolerance is allowed.

19.13.17 SURFACE CONDITION OF THE HARDENED LINING:

The surface of the cement mortar lining shall be uniformly smooth. Only isolated grains of sand are allowed to appear on the surface of the lining.

The lining shall be free from corrugations or ridges that could reduce the thickness of the lining to less than the minimum value at one point, as specified in the
above table.

On contraction of the lining, the formation of cracks cannot be avoided. These cracks, together with other isolated cracks, which may result from manufacture or
may develop during transportation, are acceptable up to a width of 0.8mm.

The structure of the lining is related to the centrifuging process.


On the inner surface of the lining, a thin layer of the sand and cement is formed which may extend up to approximately one quarter of the total thickness of the
mortar.

The manufacturer shall take maximum care in keeping the internal surface of pipe even and uniformly smooth. The check of unevenness of pipe shall be done as
per IS 11906 - 1986.

19.14 - LAYING AND JOINTING OF D.I. PIPES

19.14.1 TRANSPORTATION:

The transportation of materials to work site and stacking shall be done in such a manner as to cause minimum inconvenience to the traffic and other construction
works. Pipes shall be protected during handling against impact, shocks and free fall to avoid cracks and damage. Pipes shall be loaded for transportation is in
such a way that they are secured and no movement can take place on the vehicle during transit. The same care shall be taken if pipes are transferred from one
vehicle to another, however short the journey may be. The cement mortar lining of pipes that are damaged during transportation is to be repaired by hand
application if possible; otherwise it has to be rejected. The decision for rejection shall be taken by the Design-Build-Operations Engineer or his representative.

19.14.2 UNLOADING OF PIPES:

Each pipe consignment shall be inventoried and inspected with care upon arrival even though the pipes have been inspected and loaded with care at the factory.
Overall examination shall be made during unloading to ensure that the pipes have reached destination in good condition. If there is any sign of rough treatment
on the coating, each pipe shall be inspected for damage.

While unloading, pipes shall not be thrown down from the truck to the hard roads. Cranes or Mechanical equipment shall be used for unloading the pipes from
the truck. If mechanical equipment is not available, care should be taken to unload the pipes on timber skids. Unloading them on timber skids without a
steadying rope and thus allowing the pipe to bump hard against one another should not be allowed. In order to avoid damage to the pipes specially to the spigot
end, pipe should not be dragged along concrete and similar pavements with hard surfaces.

The pipes shall be laid on timber battens and secured with wooden wedges. The pipes shall be stacked with each tier at right angles to the preceding tier.

19.14.3 LOWERING OF PIPES AND FITTINGS:


The pipes shall be lowered cautiously to prevent disturbances of the bed and sides of the trench.

Proper implements, tools and facilities satisfactory to the Authority shall be provided and used for the safe and convenient execution of the work. All pipes,
fittings, valves and hydrants shall be carefully lowered into the trench, piece by piece, by means of a derrick, ropes or other suitable tools or equipment, in such a
manner as to prevent damage to pipes materials and protective coatings and linings. Under no circumstances shall pipes materials be dropped or dumped into the
trench. Pipes over 300mm diameter shall be handled and lowered into trenches with the help of chain pulley blocks or preferably by cranes. Tripod supports
used for this purpose shall be regularly checked to prevent all risks of accidents.

19.14.4 CLEANING OF PIPES AND FITTINGS:

All lumps, blisters and excess coating material shall be removed from the socket and spigot end of each pipe. The outside of the spigot and the inside of the
socket shall be wire-brushed and wiped clean and dry and free from oil and grease before the pipe is laid.

19.14.5 LAYING:

Before lowering the pipe, the trench section shall be got approved from the Design-Build-Operations Engineer or his representative. Trenches are to be dug to
the specified level / grade. Sufficient cushion shall be provided for protection from surface traffic, future changes in the ground elevation. The width of the
trench shall be to the required specifications providing room for pipe laying operation, backfilling, compaction etc., Trenches should be shored and braced when
conditions so warrant.

The bottom of the trench shall form a continuous bed for the pipe. Where rock is encountered, trenches shall be dug deeper and then filled and compacted to
grade with suitable bedding material. The Contractor shall have to provide and maintain sight rails and boning rods wherever required till the completion of
work. The pipe shall be laid in reasonably dry condition and under no circumstances they shall rest on slushy bedding.

The pipes shall be lowered slowly into the trench by means of chain pulley block and tripod stand or with the help of ropes and suitable size of wooden bullies or
with the help of cranes. They shall be brought to the required level by giving packing with wooden sleeper pieces and ultimately with well-consolidated hard
muram if required. The chain pulley block and tripod stand must be approved from the Design-Build-Operations Engineer or his representative. Under no
circumstances pipe shall be allowed to be thrown in the trenches.
At the end of each day, the end of the pipe should be plugged to prevent entry of rodents, foreign substances, water etc.

19.14.6 SUPPORT OF PIPE FOR NALLAH CROSSING:

Venteak piles are proposed for portion of pipeline which crosses the nalla or slushy soils. Each pipe shall be supported on a pair of Venteak piles driven upto
3.50m or firm ground whichever is met earlier.

One pair of timber piles shall be driven about 150mm behind the shoulder of toe socket and another pair about 750mm in front of the spigot end of the pipe.

The size of timber section to be used for Venteak piles shall be:

100mm x 100mm for pipe sizes upto 300mm

150mm x 150mm for pipe sizes above 300mm

A cross piece of section same as that of pile shall be bolted to a pair of piles which have been driven to the required depth.

The level of the cross piece should be such that when the pipe rests on its top, its Invert level coincides with the proposed invert of the pipe.

The pipe shall be aligned for straightness and secured in position by wooden wedges nailed down to the wooden cross piece.

The spigot end of each pipe shall be thoroughly homed in to socket of preceding pipe and jointing made.

The pipe shall be further secured from moving upwards by timber crosspieces bolted to the supporting piles. The section of the crosspiece shall be same as that
of pile.

The socket ends of all pipes shall face up hill irrespective of the direction of water flow. Any deviation either in plan or elevation of less than 11 deg. angle
shall usually be effected by laying straight pipes round a flat curve, of such radius that rubber gasket shall not be disturbed in its place.

19.14.7 TESTING:

After laying and jointing, the pipeline must be pressure tested to ensure that the pipes and joints are sound enough to withstand the maximum pressure likely to
be developed under working conditions. The Contractor shall submit for the Design-Build-Operations Engineer or his representatives approval, details of his
proposed methods and programme for testing including details of test equipment and shall arrange for all tests to be witnessed by the Design-Build-Operations
Engineer or his representative. The Contractor shall provide all things necessary for carrying out testing and cleaning including water pumps, gauges, piped
connections, stop ends, and all other temporary works.

Pipelines shall be properly completed and supported before being put under test. No testing will be permitted until ten days after thrust blocks and other holding
down works have been completed. In addition to any tests of individual joints or other interim tests which may be specified elsewhere, the Contractor shall
submit, all parts of the pipelines to a final test. Notwithstanding the foregoing, the Contractor may at any stage of construction, carry out such other tests as he
considers desirable to check materials and workmanship on the pipeline but this shall not relieve the Contractor of his obligations to achieve successful tests
under the contract.

All water required for testing and cleaning the pipelines shall be potable water and shall be provided by the Contractor at his cost. The test can be carried out by
means of a hand pump or a pressure pump.

Pipelines shall be tested in lengths between valve pits or such lengths as the Design-Build-Operations Engineer or his representative may direct or permit.

Fittings required for temporarily closing the openings in pipelines to be tested shall be properly designed for this purpose and shall be adequately strutted to
withstand the pressure specified.

The completed pipeline may be tested in sections; the length of section should be decided by considering:

(a) the availability of suitable water;

(b) the number of joints to be inspected; and

(c) the difference in elevation between one part of the pipeline and another.

The maximum length that can be tested in one operation shall be restricted to 500m and minimum length shall be 50m.

Where joints are left uncovered until after testing, sufficient materials should be backfilled over the centre of each pipe to prevent movement under the test
pressure.
The Contractor shall make his own arrangements to procure necessary equipment, apparatus etc., required for testing and shall provide necessary labour for
filling with water the length of pipes to be tested, fixing all apparatus and for carrying on the testing operations until the length of pipe, specials and connections
are firmly passed by the Design-Build-Operations Engineer or his representative. If the testing apparatus and equipment are available with the Owner, they can
be hired by the Contractor at usual conditions and charges.

The length to be tested shall be provided with two blank flanges fastened on the usual manner by collar bands and bolts to the end pipes or if the length to be
tested shall have a sluice valve at each end, such blank flanges may be dispensed with.

The length of pipes to be tested shall first be filled in with water from a higher section of pipes already laid or with clean water obtained, as the Contractor may
arrange with the approval of the Design-Build-Operations Engineer or his representative.

Before the actual testing pressure is applied, any air which has logged in the length of pipe to be tested shall be got rid of, by screwing on at the highest part of
the length of pipes or temporary air valve, or by opening a temporary stop-cock or by other means as the Design-Build-Operations Engineer or his representative
may direct.

Each pipeline or section thereof, shall be filled with water and all air removed. The pressure in the pipelines shall be raised steadily until the site test pressure is
reached in the lowest part of the section. This pressure should be maintained, by pumping if necessary, for a period of not less than 1 hour. The pump should
then be disconnected and no further water permitted to enter the pipeline for a period of 1 hour. At the end of this period, the reduced pressure in the pipeline
should be measured, the original test pressure restored by pumping and the loss measured by drawing off water from the pipeline until the pressure has fallen to
match the reduced pressure previously noted. The loss shall not exceed 0.02 litre per mm diameter per Kilometer per 24 hours for each bar of head applied. If
the pipeline fails to pass the test, the faults shall be located and repaired and the pipeline retested until it passes the pressure test. All exposed pipe, fittings,
valves and joints shall be visually inspected during the tests.

If the length of pipeline under test is found to be satisfactory and no leaks or sweating are found at the pipe joints or at the joints of specials and connections, then
this length of pipeline will be passed by the Design-Build-Operations Engineer or his representative.

But should any pipe, joint, special or connection be found to sweat or leak, Contractor shall make good at his cost such defective joints and the length of pipe line
shall be retested until all pipes, joints specials and connections are found to be satisfactory.
After satisfactory test, the Contractor shall remove water from the pipeline and clean it after testing at his own cost, without flooding adjoining areas.

Duration of Hydraulic Test:

The test is for 1 hour only. The rate of allowable leakage is given on per day basis. The leakage observed within one hour shall be converted to per day basis
and compared with criteria given.

Maximum field test pressure for pipes with flexible joints:

Table 1 on page 11 of IS:12288 is not applicable in this case as our test pressures are well below the maximum field hydraulic test pressures given in the table.

Allowance of test pressure for lower elevations:

As regards allowance for lower points, there is marginal level difference in levels, between 2 points in the section to be chosen for testing and hence the
difference in pressure developed will be insignificant.

19.14.8 INTERCONNECTION WORK:

The interconnection work between the existing main (if any) and the proposed main to be laid under this contract shall proceed from the new main to the existing
main. Before actually proceeding with the interconnection work, the Contractor shall make ready necessary tools and plants required for the work at site, such as
pump sets, shoring materials etc. He shall also keep ready at site necessary pipes, jointing materials, specials and valves required for the work. The Contractor
shall keep necessary skilled workmen of sufficient strength at site and once the work commenced, the entire interconnection work shall proceed without
interruption by engaging labour for carrying out the work on a continuous basis both day and night till the work is completed. The work shall be executed as per
programme drawn up by the Design-Build-Operations Engineer or his representative and shall be completed within the time ordered by the Design-Build-
Operations Engineer or his representative, for each individual interconnection. The work shall be carried out under the direction of the Design-Build-Operations
Engineer or his representative from the beginning to end.

Laying of specials, valves (except straight pipes from the branch of the new main to the connecting point in the existing main) including conveying specials etc.
from the stores or site of stacking, excavating, timbering, pumping out water from the trenches, lowering, aligning, jointing specials and valves, cutting the
existing mains, dealing with water, inserting the necessary branches, jointing, testing, refilling etc. is included in the item of providing, laying and jointing DI /
MS pipes. Any ancillary work either of Temporary or Permanent nature required for interconnection and not covered by schedules shall be executed by the
Contractor at no extra cost.

19.14.9 FLANGED JOINTS:

Flanged joint should be made by painting the facing of the flange with white lead freely and bolting up evenly on all sides. A thin fibre of lead wool may be very
useful in making the joints water tight where facing of the pipes is not true.

When packing must be used, it should be of rubber insertion three ply and of approved thickness. The packing should be of the full diameter of the flange with
proper pipe hold and boltholes cut out evenly on both the inner and outer edges. Where the flange is not full faced, the packing may be of diameter of the
packing strip only, proper placing of the packing should be checked before another pipe is jointed on.

19.14.10 DISINFECTION OF MAINS:

Based on the Design-Build-Operations Engineer or his representatives decision this clause will be applicable for the present Contract.

Upon completion of a newly laid main or when repairs to existing pipes are made, the main shall be disinfected as directed by the Design-Build-Operations
Engineer or his representative.

The main shall be flushed prior to disinfection except when the tablet method is used. After initial flushing, the hypochlorite solution shall be applied to the
water main with mechanically or electrically powered chemical feed pump designed for feeding chlorine solutions. For small applications, the solution may be
fed with a hand pump.

In the case of mains of large diameter, water from the existing distribution system or other approved source shall be made to flow at a constant measured rate into
the newly laid pipeline. The water shall receive a dose of chlorine also fed at a constant measured rate. The two rates shall be proportioned so that the
concentration in the water entering the pipeline is maintained at not less than 300 mg/l. The chlorine shall be applied continuously and for a sufficient period to
develop a solid column of Slug of chlorinated water that will, as it passes along the line, expose all interior surfaces to a concentration of at least 300 mg/l. for
atleast 3 hours. As the chlorinated water flows through tees and crosses, related valves and hydrants shall be operated so as to disinfect the appurtenances.
In the case of newly laid mains in which scrupulous cleanliness has been exercised, the tablet method can be adopted and in this method, the initial flushing is
dispensed with. The calcium hypo chlorate tablets, are placed in each section of pipe and also in hydrants, hydrants branches and other appurtenances. The
tablets shall be attached by an adhesive and must be at the top of the main. The main shall then be filled with water and the water shall remain in the pipe for
atleast 24 hours.

After the applicable retention period, the heavily chlorinated water shall be flushed from the main until the chlorine concentration in the water leaving the mains
is no higher than that generally prevailing in the system or less than 1 mg/l.

After final flushing and before the water main is placed in service, a sample or samples shall be collected from the end of the line and tested for bacteriological
quality and shall show the absence of coliform organisms. If the initial disinfection fails to produce satisfactory samples, disinfection shall be repeated until
satisfactory samples have been obtained. When the samples are satisfactory, the main may be placed in service.

The Contractor is expected to carry out the disinfection work as a part of laying the pipes and his rates for laying the pipes should include the disinfection and
other connected works till the main is placed in service unless otherwise specified in the schedule.

19.15 APPURTENANCES

A. SLUICE VALVES

19.15.1 GENERAL:

All valves shall be double-flanged valves and in the size range 50mm to 300mm conforming to IS: 14846 2000 or any other national standard equivalent or
higher than the Indian Standards mentioned. The materials used in construction, the design and all other relevant features shall be such that the valves are
entirely suitable for use of force mains. Valves shall be of suitable pressure rating which shall not be less than twice the normal operating pressure.

19.15.2 DESIGN:

The design of the valves will be such that erosion, cavitation, vibration and head loss (in the fully open position) shall be a minimum.

19.15.3 SLUICE VALVES:


Sluice valves shall generally conform to IS: 14846 - 2000. Valves should close with clockwise rotation of the hand wheel. The direction of closing should be
marked on the hand wheel. Valves shall be flanged (flat faced) and drilling shall conform to IS: 1537.

19.15.4 MATERIALS OF CONSTRUCTION:

Body - C.I. to IS: 210 Gr. FG 200

Wedge - C.I. to IS: 210 Gr. FG 200

Seat Rings - Bronze / SS 304

Channel lining - Gun Metal

Shoe - Gun Metal

Spindle - SS A1S1 431

Parameters:

Quantity - As per Bill of Quantities

Size - As per Bill of Quantities

Rating - 10 Bar (PN 1.0)

Shop Testing Witnessing:

Seat leakage test - 10 bar (1.0 M Pa)

Body Hydrostatic test - 15 bar (1.5 M Pa)

Back Seat Leakage test - 15 bar (1.5 M Pa)

19.15.5 VALVE BODIES:


a. Castings:

The structure of the castings shall be homogeneous and free from non-metallic inclusions and other injurious defects. All surface of casing which are not
machined shall be smooth and shall be carefully filed to remove all foundry irregularities.

b. Forgings:

All major stress bearing forgings shall be made to a standard specification, which shall be submitted if required to the Design-Build-Operations Engineer or his
representative for approval before work is commenced. Forgings shall be subjected to non-destructive tests to detect flaws if any. Forgings shall be heat treated
for the relief of residual stresses. The name of the maker and particulars of the heat treatment proposed for such forging shall be submitted to the Owner. The
Design-Build-Operations Engineer or his representative or his inspector may inspect such forgings at the place of manufacture with a representative of the
Contractor.

c. Workmanship:

Workmanship and general finish shall be of first class commercial quality and in accordance with best workshop practice.

All similar items of the valve and their component parts shall be completely interchangeable. Spare parts shall be manufactured from the same materials as the
originals and shall be accurate and to specified tolerances so that replacements made to manufacturers drawings may be readily installed.

All parts, which can be worn or damaged by dust, shall be totally enclosed in dust proof housings.

d. Protective coating:

Protective coating shall comply with IS: 14846 - 2000.

19.15.6 LUBRICATION:

All the points where lubrication is needed, the Contractor shall furnish full details of the method to be employed. The supply of the requisite lubricating
equipment and lubricants for commissioning and operating and maintaining the valves shall be furnished.

19.15.7 FLANGES:
Valves of sizes 80mm 300mm shall have flat flanges as per IS: 1538 Part IV Table I. The flange-to-flange distances shall be as per IS 14846.

19.15.8 JOINTING MATERIALS:

Each valve shall be supplied under this Contract, with all requisite joint rings, nuts, bolts and washers for making the joints on all the valves to be installed under
this Contract. Jointing material between the connecting flanges shall conform to the relevant IS code. Unless otherwise specified bolting used for jointing
exposed connections shall be of carbon steel, conforming to IS: 210 Grade 20 Grade B, with galvanized finish.

19.15.9 FACTORY TESTS:

All the valves shall be tested at the factory for smooth, trouble free operation and operating torque requirements by operating between fully open and fully closed
position three times.

The hydrostatic tests shall consists of

Closed End Tests where valve is held on both sides. Each valve is subjected to three hydraulic tests.

a. Wedge open and pressure applied for 5 minutes to the whole body of the valve pressure as required.

b. Second Test shall be applied to one face with pressure as required.

c. Third Test shall be similar to second, but pressure applied to the other side of the wedge with same pressure.

For valves having terminal position shall be subjected to open-end test.

Testing for valves from Foreign Manufacturers:

i) Sampling: Each valve is recommended to be tested.

ii) Testing and Inspection: For foreign manufacturer: The testing and inspection procedure in this case shall confirm with respective equivalent
code.

B. AIR VALVES
19.15.10 Constructional Features:

Double ball air valves shall be of the kinetic, double orifice type able to release air in small quantities under pressure and in large quantities during filling. They
have to allow for large inflow of air during emptying. The type and locations shall be fixed according to the detailed design and after approval by the Design-
Build-Operations Engineer or his representative. The valves shall have an integrated sluice valve. If required, they shall be installed on a flange welded on the
MS pipe / special. The possible air velocity (inflow and outflow) must be at least 20 m/s.

Materials of Construction & Pressure Rating:

Body CI to IS Gr. FG 200

Cowl CI to IS Gr. FG 200

Valve seat, nut Leaded tin bronze

Spindle SS. AISI 304

Orifice SS. AISI 304

Ball Seasoned teak wood, covered with neoprene rubber

Ball seat Anti-stick material such as nitrile rubber or equivalent

Pressure Suitable for 16 Kg / sq.cm, Working Pressure.

19.16 - FIXING OF VALVES

19.16.1 FIXING OF SLUICE VALVES:

19.16.1.1 General:
The specification lays down the requirement for lowering, laying and jointing Sluice valves.

19.16.1.2 Preparation:

The sluice valves and tailpieces shall be examined before laying for cracks and other flaws. Only undamaged sluice valves and tailpieces shall be used.

The sluice valve shall be operated and checked before laying. All grit and foreign material shall be removed from the inside before placing. All the four faces
shall be thoroughly cleaned and coated with a thin layer of mineral grease. The tightening of gland shall be checked with a pair of inside calipers. Clearance
between the top of stuffing box and the underside of the gland shall be uniform on all sides.

19.16.1.3 Jointing Materials:

The Contractor shall provide all the necessary jointing materials such as nuts, bolts, rubber packing, white zinc, jute, lead wool etc. at his cost. All tools and
plant required for installation of sluice valve shall be provided by the Contractor at his cost. All the jointing materials shall be got approved from the Design-
Build-Operations Engineer or his representative before use. The nuts and bolts shall conform to IS: 1364 and the rubber packing shall conform to IS: 638.

19.16.1.4 Installation:

The sluice valve shall be lowered into trench carefully, so that no part is damaged during lowering operation. If necessary tailpieces shall be fitted with sluice
valve first outside the trench and then lowered into the trench.

The rubber packing shall be three ply and of approved thickness. The packing shall be of full diameter of the flange, with necessary holes and the sluice valve
bore. It shall be even at both the inner and outer edge. The flange faces shall be thoroughly greased. If flanges are not free the Contractor shall use thin fibres of
lead.

After placing the packing, nuts and bolts shall be inserted and tightened to make the joint.

The valve shall be tightly closed being installed to prevent any foreign materials from getting in between the working parts of the valve.

Each flange bolt shall be tightened a little at a time taking care to tighten diametrically opposite bolts alternately.
The sluice valve shall be installed in such a way that spindle shall remain in truly vertical position. The other end of the tailpiece shall be fitted with pipes so that
continuous lines can work. Extra excavation necessary to facilitate the lowering and fixing of sluice valve shall not be paid for.

19.16.1.5 Testing:

After installation of sluice valve the same is tested to 1 times of its test pressure. The joints of sluice valve shall with stand the test pressure of pipeline.

Defects noticed during test and operation of sluice valve shall be rectified by the Contractor at his own cost, without any extra claim, to the entire satisfaction of
the Design-Build-Operations Engineer or his representative.

19.16.1.6 Mode of Measurement and Payment:

The measurement shall be taken per number of sluice valves of specified size and payment shall be on number basis for providing and fixing.

19.16.2 FIXING OF AIR VALVES:

19.16.2.1 General:

The specification placed down requirement for lowering laying and fixing Air Valves.

19.16.2.2 Preparation:

The air valves and the isolating valves shall be examined before laying for cracks and other flaws. Only undamaged air valve shall be used. The air valves shall
be opened and shaken for the air opening below the vulcanite balls on the bronze seats of the balls before fixing. All grid and foreign material shall be removed
from the inside before placing. The flanged face shall be thoroughly cleaned and coated with a thin layer of mineral grease. In case of screw down type, the
threads shall not be in damaged condition.

19.16.2.3 Jointing Materials:

The Contractor shall provide all the necessary jointing materials, such as nuts, bolts, rubber packing, white zinc jute, lead wool etc. at his cost. All tools and
plant required for installation of air valve shall be provided by the Contractor at his cost. All the jointing materials shall be got approved from Design-Build-
Operations Engineer or his representative before use. The nuts and bolts shall conform to IS: 1364 and the rubber packing shall conform to IS: 638.
19.16.2.4 Installation:

The air valves shall be fixed on a branched flange Tee on the main pipeline. The air valve and isolating sluice valve shall be housed in a chamber.

19.16.2.5 Testing:

The specification pertaining to sluice valve shall also apply to air valves.

19.16.2.6 Mode of measurement and payment:

The measurement shall be taken per number of air valves of specified size and payment shall be on number basis for providing and fixing.

19.16.3 FIXING OF FRC. M.H. FRAME AND COVER IN RCC SLAB:

19.16.3.1 General:

The specification includes all requirements of fixing Fibre Reinforced Concrete (FRC) M.H. frame and cover of specified size and weight in the RCC slab with
locking arrangement. For fixing the FRC. M.H. frame and cover of specified size and weight, the frame shall be fixed generally at the time of casting RCC slab
with proper anchoring.

After fixing the M.H. frame and cover locking arrangement shall be provided as per following unless specified in the wording of the item. The size of the M.S.
flat shall be 50mm x 10mm with M.S. bar U shape of 16mm dia. The U shape M.S. bars shall be properly embedded in the RCC roof slab and anchored. The
FRC. M.H. frame and cover and the locking arrangement after fixing shall be painted with anticorrosive black paint. The work shall be done to the entire
satisfaction of the Design-Build-Operations Engineer or his representative.

19.16.3.2 Mode of measurement and payment:

The item shall include:

a) All labour for fixing M.H. frame and cover

b) All material and labour of locking arrangement


c) Painting of the frame, cover and locking arrangement.

19.17 MISCELANEOUS

19.17.1 PRESSURE GAUGES

19.17.1.1 Material:

The brief specifications for pressure gauges is as follows:

The pressure gauges shall be of Bourdon type having a range between 0 to 9kg / sq.cm. The diaphragm material should be of 316 SS. Accuracy
of the pressure gauge shall be 1% with a dial diameter of 150mm. The case shall be of IP 65, die cast AI. The pressure gauge shall be directly mounted with
connection of 12.5mm ( inch) N.P.T.M.

19.17.1.2 Erection:

The pressure gauges shall be, mounted as near to the process as possible. Impulse tubing / piping length shall be minimum possible. The pressure gauges shall be
mounted in a vibration free location. They shall be readily accessible from grade, platform, fixed walkway or fixed ladder and shall be visible from where related
equipment is operated.

The pressure gauges shall have one isolating valve and one drain / vent valves for depressuring. The drain / vent valve shall be plugged. The valves used shall
be having 12.5mm ( inch) NPTF connections and the material shall be ASTM A 216 GR. WCB or ASTM A 105 unless otherwise specified. The trim shall be
AISI 410 unless otherwise specified. All connection shall be made using thread seals preferably PTFE tape. Right tools shall be used and any limits regarding
torque for tightening shall be strictly adhered to. Impulse piping shall be done using 12.5mm ( inch) OD seamless annealed SS tubing to ASTM A 269 GR.TP
136 L with minimum wall thickness of 1.65mm. Compression fittings shall be used. The impulse piping must be supported by an angle of channel and
strapped at every meter length. The angle / channel itself must be supported by welding it to some structure. The pressure gauge shall be covered with box.

B. ELECTRICAL WORKS

20.0 INTENT OF SPECIFICATION


20.1.1 This specification is intended to cover the supply and installation of entire electrical equipment, for 45 MLD capacity TTRO Plant and items &
accessories including consumable against lump sum price.

Scope of schedule of item as mentioned herein are suggestive but not conclusive. The Contractor shall furnish all, but not limited to equipment, materials and
accessories and service as required to fulfill the performance of proposed plant.

20.1.2 Design-Build-Operations Engineer or his representatives interpretation of the meaning of the specifications, drawings shall be final who shall
have the right to accept or reject any material or work which in his assessment is not complete to meet the intent of this specification and/or
applicable standards.

20.1.3 The equipment and accessories shall be complete in all respects and any device not included in this specification but essential for proper
operation of the plant shall be deemed to be with in the scope of this specification whether specifically mentioned or not. Installation rates shall be
for erection, painting, connection and testing.

20.2 SCOPE OF WORK

Supply, installation, testing & commissioning of all electrical equipment, control devices, fittings, cables/wires, conduits, hardware & consumable including
earth excavation/backfilling, structural works for MS fabricated cable trays/equipment support, all allied civil works excluding buildings & equipment civil
foundation, etc.

In outdoor areas cables shall be mostly laid directly buried underground with adequate mechanical protection wherever applicable. Whereas in indoor areas,
cables shall be laid in trenches/wall/ceiling/structures through suitable trays/cleats.

Supply of steel and cement required in the execution of the contract work shall be the responsibility of the Contractor.

Installation of the contract work including furnishing labour (skilled, unskilled) and supervisory personnel inclusive of the services of an experienced engineer,
having authorised & valid supervisory license is included in the scope of services.
All installations are to be carried out as per the statutory requirement of local Electrical Inspectorate/I.E. rules/applicable IS code/code of practices obtaining
statutory clearance from Electrical Inspectorate shall be in the scope of executing Contractor.

20.2.1 SCOPE & SCHEDULE OF ITEMS :

Note :-

Electrical items shall be provided as per IS Standards compatible for TTRO Plant requirements All items are for design / supply / installation /testing
/commissioning including supports/hangers/hardware/ accessories / consumable etc. or correct understanding of the work scope, schedule of items mentioned
herein:

Sl. Items Quantity

No.
i) 11KV structure with D/O type air break isolator/D/O 1set
fuses/LA etc. of adequate rating

ii) 11KV, 350 MVA, 3 Panel indoor switchgear board (i.e ) one
incomer & two outgoing, 18.73kA Short Circuit level 1 set
with VCB type Circuit Breakers., CT, PT, protective relays,
copper bus bar etc

iii) 11/0.433 KV Dyn11, 5000 KVA Indoor type power 1 set


transformers with Buchholz relay of suitable capacity for
full load of 45 MLD TTRO Plant with all accessories and fittings
etc complete as per IS: 2026
iv) Al.LT Bus duct, Phase segregated type 3 Sets
v) 11 KV 3 phase 18.73 KA PCC 2 Sets
vi) 415 V, 3 Ph, 4W, 43.1KA, (1sec) P.C.C. 4 sets
vii) 11 KV Power cum Motor Control Centres 4 Sets
viii) 415V Power cum Motor Control Centres :-
a)PMCC NO.1 1Set b)PMCC NO.2 1Set
c) PMCC NO 3 1 Set
ix) 415V Motor Control centres :-
a) MCC NO.1 1 Set
b)MCC NO.2 1 Set
c)MCC NO.3 1 Set
d)MCC NO.4 1 Set
e)MCC NO.5 1 Set
f) MCC No 6 1 Set
g)MCC No 7 1 Set
x) D.G. Power Dist. Board 1 Set
xi) Automatic P.F. improvement capacitor with
integral control panel 2 Sets
xii) 415V, 3PMCB type 3 sets
xiii) MCB type TPN, LDB, 6 Way per phase, 20A SP per way 5 Nos.
xiv) AMF type D.G. set 415V, with static excitation 1 Set
including AMF panel, Battery/Battery charger and other
aux. Equipment /accessories
xv) Motors and Pumps Lot
xvi) Local start/stop push button station (LM6)
a) w/o ammeter Lot
b) with ammeter Lot
xvii) Indoor and outdoor illumination system to achieve lux level as Lot
mentioned in F.4, 10.2/Welding S.O./small S.O.
xviii) Cable
a) 11/6.35KV XLPE, AL (armoured) Power cable Lot
b) 1.1KV PVC/A AL Power Cable Lot
c) 1.1KV PVC / A Cu control cable Lot
i) For ammeter in LCS 3x2.5 sq.mm Lot
ii) For start/stop PB in LCS 5x2.5 sq.mm Lot
d) 1.1KV PVC / A Cu 3 x 2.5 sq.mm lighting cable Lot
e) 1.1KV PVC unarmoured AL earthing cable Lot
xix)Complete earthing system as per specified size in design Lot
basis (F 3.3)
xx) Cable glands, sockets, steel, other erection hardware and
accessories etc Lot
xxi) Supply/fabrication/erection/painting of M.S. structural steel
as required for cable trays/supports/hangers/cleats etc. to
complete the entire electrical work Lot
20.3 GENERAL SPECIFICATION

20.3.1 EQUIPMENT SELECTION

The general basic, requirements for design and selection of equipment shall be :-

- Safety of Personnel and Equipment

- Adequate operational reliability

- Ease of Installation, Operations

- Interchangeability of Equipment and parts

- Robust and Economical Design

20.3.2 CODES & STANDARDS The performance of the entire system shall be in conformity with the following Codes and Standards of latest edition :-

- Indian Electricity acts/ Rules

- Relevant IS Code of Practices

- Publications of IEC

- Publications of TAC, in view of benefit in plant insurance premium.

- Guidelines laid down by Electrical Inspectorate, Tamilnadu

20.3.3 DESIGN BASIS

The basic design data to be considered shall be as follow :-


Design Temperature - 45 C Max

Design Temperature - 10C Min.

Relative Humidity - 100% at 20C

Incoming Supply Conditions :

Voltage and Variations - 11KV10%

Frequency and Fluctuations- 50 Hz3%

Combined variation - 10%

Fault Level at 11KV - 350 MVA Symmetrical (1 sec)

System Grounding - Effective

Soil Resistivity - 10 ohm Mtr(Uniform)

Number of Thunderstorm per year - 47

Atmosphere - Tropical and corrosive due to proximity of sea

Fault Level at 415V (Design) - 43.1KA Symmetrical (1 sec.)

Control circuit voltage -110V DC for 11KV Switchgear from build in power pack within the scope of SW.GR.240V AC for PMCCs/MCCS tapped from P &N
HV cabling - 3C XLPE 11KV (E)
LV cabling -Al conductor PVC/A, excepting motor upto & including 3.7KW by 3 x2.5 Cu Sq.mm PVC/A cables
Control cable - Multicore 2.5sqmm Cu conductor PVC/A
Cable C.T. to Ammeter circuits- - Do - with 2.5 sqmm cu
LDB to Lighting points 2.5 sq.mm 3C Cu conductor PVC/A cable
Earthing
Earth pit : G.I. pipe electrode as per IS:3043
Main Earth Grid : 75x8 mm G.I. strip.
Trafo./PCC.MCC/MLDB : 50x8 G.I strip.
LDB/Welding S.O. : 1x25 sq.mm PVC (AYY) cable
LCS/JB etc. : 1x6 sq.mm PVC (AYY) cable
20.3.4 TANGEDCO Power is expected to be transferred through TANGEDCO single circuit 11 kV two pole structure to the proposed new pole structure with
D.O type H.T isolators, fuses and lightning arrestors. Power is transmitted through H.T cables buried underground and terminated to the indoor 11 kV switch
gear board located in substation. The TANGEDCO will terminate 11kV, H.T supply only at two-pole structure. The contractor shall lay H.T feeder XLPE cable
from the RMG out door type structure to the H.T.Board inside the TTRO Plant area.
20.3.5 The 11kV Switchgear shall comprise of Vacuum Circuit Breaker and feed one transformer installed indoor and connected by busducts to the Main 415V
Power Control Centre. This P.C.C. shall in turn feed all down stream PMCC / MCC and MLDB etc. for feeding various loads.
20.3.6 All motors shall be suitable for outdoor installation with tropical insulation and protective category of IP-55 unless otherwise stated. All motors shall
be started and stopped by push buttons at Local Control Stations located near respective motors. Starters shall be housed in MCCs/ PMCCs with stop/O/L reset
PB. Motors > 37kW are to be provided with ammeter at respective LCS. All motors with capacity below 10 HP shall have Direct-On-Line starting provisions
unless otherwise specified and motor with higher capacity shall have fully automatic star/Delta starters or soft starters.
20.3.7 In out door areas cables shall be mostly buried directly underground with adequate mechanical protections wherever applicable. In indoor areas, cables
shall be laid in trenches through fabricated cable trays. Cable shall be so selected that voltage drop at consumer end does not exceed 3%. Cables having
aluminium conductor shall not be less than 6 sq.mm.
20.3.8 Earthing system shall be carried out by GI strips, wires, electrodes by GI pipes. All equipment shall have two separate and distinct earth points. Earth
resistance shall not exceed one ohm at any point. Equipment earthing except all machinery & SW. Boards shall be done with PVC unarmed AL cables.
20.3.9 Indoor lighting shall be carried out by compact fluorescent lamps(energy efficient T5lamps) and outdoor by Metal halide fitting. Outdoor lighting shall
be peripheral by flood lights (Metal Halide 400 W) on suitable towers and independent street lighting (Metal Halide 250 W) in roads inside plant. M.L.D.B.s
shall be suitably located in sub-station/ MCC room or Pump Houses.
20.3.10 Automatic power factor improvement panel with integral capacitor bank shall be included to maintain a power factor of 0.95 to 0.99.
20.3.11 Adequate numbers of small and welding power outlets to be provided at appropriate places.
20.3.12 3 No. 415 V AMF type D.G. set have been envisaged to feed all the critical loads to the process requirement & lighting loads and other loads against
failure of normal power supply from TANGEDCO. However, on revival of normal power supply, D.G. set shall be manually or automatically stopped & change
over to normal supply. Each DG set 750 kVA.
20.3.13.PREFERRED MAKE
Preferred makes for major items are indicated in the enclosed List of Recommended Vendor for Electrical Equipment. The contractor shall clearly indicate the
makes he proposes. Detailed catalogues and literature shall be made available for all items proposed and these shall be approved before use on the work.
20.3.14 DRAWINGS/ DOCUMENTS
20.3.14.1 Preliminary Drawings/ Documents
The Contractor should furnish the following documents and information along with the design submission to the Design-Build-Operations Engineer or his
representative for approval.
a) Schedule of quantities with brief specifications.
b) Filled-in data sheets.
c) Technical catalogues and information to elaborate the technical aspects of equipment offered.
d) List to deviation if any
20.3.14.2 Execution Drawings/ Documents
Following detailed design drawings / documents to be prepared in line with recommended specification / drawings and submitted to the Design-Build-Operations
Engineer or his representative in a timely manner to allow for review and approval.
List of drives/loads with Qty / Making / specification
a) Single line diagram and control diagram of complete electrical system.
b) Power and earthing, lightning layout.
c) Internal and external lighting layout.
d) MTO & Cable schedule.
e) Interconnection schedule.
f) GA drawing for all equipment including sectional drawing, wherever applicable.
g) Operation and maintenance manual for all vital equipment.
20.3.14.3 As built Drawings/ Documents
All above final documents and drawings incorporating modifications (if any) done during erection/commissioning, shall be furnished as below :
a) Complete set of CD.
b) Tracing in original
c) Five sets of prints.
20.4 TECHNICAL SPECIFICATION
20.4.1 11 kV AB ISOLATORS
The switch shall be break type suitable for outdoor installation on vertical/horizontal steel structure. The complete switch shall be mounted on a channel steel
base with fixing holes. All steel work and hardware shall be hot dip galvanized to resist corrosion. Galvanizing shall be 0.91 kg/m2.
Disconnectors and earthing switches, including their operating mechanism shall be designed such that they cannot come out of their open or closed positions by
gravity, wind pressure, vibrations, reasonable shocks or accidental touching of the connecting rods of their operating mechanism. Isolators shall be provided
with provision of locking in open and the closed positions. Suitable arcing contacts which will close first and open after the main contacts shall also be provided.
The switch shall be single throw-single break or single throw double break.
Contacts shall be turn and twist type with wiping action.
The insulators shall be of post type, high quality brown porcelain, highly glazed and shall be of appropriate voltage rating, suitable for atmospheric conditions
specified. Arching horns shall be provided to protect insulators against flashover during system over voltages. Grading rings may be provided to obtain uniform
voltage stress distribution, where required.
All poles of the switch shall be gang operated by a common operating mechanism such that all the poles close or open simultaneously.
The mechanism shall be positive type, which will prevent the switch being left in the intermediate position, and prevent slow closing.
Operating mechanism shall be operated from ground level and shall be complete with G.I. pipe, with equalising braid, operating handle, etc.
The operating mechanism shall be provided with two earthing terminals complete with hardware for connecting the earth conductors of specified size and type.
Operating handle shall also be provided with an equalising braid earth connection to prevent unequal potential between structure and rod during faults.
20.4.2 a LIGHTNING FACILITIES:
Minimum of 12 numbers of tower lights shall be provided with a height of 10m each towers consist of 6 nos. of 400 W Metal Halide flood Lights with necessary
earthing, lightning arrester, S.S. control panel etc.
Minimum of 60 nos. of street light shall be provided with 250W MH lamp fittings at a height of 6m, with necessary earthing and control panel etc.
20.4.2 b LIGHTNING ARRESTORS
The arrestors shall be suitable for outdoor installation under atmospheric conditions as specified elsewhere.
The arrestors shall be metal oxide gapless type comprising of a stack of
zinc oxide valve elements. The assembly shall be single phase, single pole type. The entire arrestors unit shall be housed in a high strength porcelain insulating
casing with metallic cover plate and terminal assemblies. The end castings shall be well sealed to protect the unit from moisture or breathing.
The zinc oxide discs shall be sintered discs of powdered zinc oxide to form polycrystalline ceramic to offer highly non-linear characteristic.
The stack of zinc oxide valve elements (discs) shall be spring loaded to assure good electrical contact between the discs & increase mechanical strength.
The stack of discs shall be perfectly secured inside the porcelain housing by silicone rubber wedges to offer better terminal dissipation & mechanical strength.
Galvanized fittings shall be gasket and cemented to the porcelain housing to provide a complete moisture-tight seal.
When the arrestor assembly consists of different units, grading rings shall be provided for uniform voltage distribution among individual units.
Grading Resistor of high stability Ceramic or equivalent shall be provided across each spark gap, to ensure uniform voltage distribution across spark gap and in
turn correct spark over.
20.4.3 11kV SWITCH BOARD
Despite specified climatic and other environmental conditions, in general, hostile tropical climate with high humidity and heavy rainfall, an atmosphere
conducive to fungus growth and corrosion prevails.
The Switch boards shall be of cubicle type, suitable for indoor installation, floor- mounting and free-standing. The design shall be totally enclosed, dust - tight,
damproof and verminproof offering degree of protection as per relevant IS.
Busbars shall be of uniform cross-section throughout the entire length of the switchboard and suitable for carrying rated current continuously and short circuit
current for specified duration without overheating.
The circuit breakers shall be of vacuum type with manual spring charge & closing mechanism with shunt trip devices.
The circuit breakers shall be of horizontal draw out construction, with or without vertical isolation. The circuit breaker including its operating mechanism shall
be mounted on a wheeled carriage moving on guides, designed to align correctly and allow easy movement on the circuit breaker. There shall be three discrete
positions viz. Service, Test and Isolated.
The operating mechanism shall be mechanically & electrically trip free and non-pumping. Anti pumping feature may be built-in and separate anti-pumping relay
may be provided.
Current transformers shall be cast epoxy resin type. The PTs shall be of shell type single phase construction with HRC fuses at both ends and plug-in connection
on primary side.
The PTs shall be capable of operating continuously at 110% of the rated voltage, without any damage, when star- star connection is required in non-effectively or
ungrounded system, the PTs shall be suitable for continuous operation with a persistent phase to ground fault.
Power pack of 110 V DC derived from PT backed up by condensers shall be capable of performing two successive operations.
Relays type & numbers shall be in accordance with the protective scheme specified.
Relays may be of electro-magnetic self-powered type. The protection Relay can be Non Numerical electro- mechanical relay.
All relays shall be provided with positive action hand/mechanical operation indicator. The indicators shall be visible from the front.
The switchboard shall be provided at the bottom throughout its entire length with a earth bus of electrolytic copper or aluminum of adequate size to carry the
fault current for the duration same as short time rating of the circuit breaker.
Earthling or moving carriage of drawout equipment shall be achieved by scraping earthing device. The earthing device shall maintain positive earth continuity
in all Service Test and Isolated positions.
One earthing trolley suitable for earthing of cables and common for all circuit breakers of the same type/rating shall be provided.
All wiring for control , protection, alarm, and indicating circuits on all equipment shall be carried out with at least 650V grade, PVC insulated, stranded , tinned
copper, 2.5 sq. mm. Conductors.
20.4.4 POWER TRANSFORMER
20.4.4.1 TRANSFORMERS
20.4.4.1.1 General
a) Transformers rated, which are designed to receive power at high voltage shall be of oil immersed type and shall not employ forced cooling of oil. Radiator
banks shall be of the detachable type. Transformer shall be suitable for outdoor duty and shall be installed inside closed room.
b) Transformers shall be complete with all fittings / accessories / devices etc. which are required for their satisfactory operation along with 150mm (6 inches)
wdg. temp indicator, 150mm (6 inches) oil temp indicator buchholz, trip alarm contacts for winding temp, oil temp. It shall have HV cable box. For Transformer
of 1,000 kVA and above, bus duct shall be used in LT side whereas for transformer below 1,000 kVA, cable box shall be provided in the LT side. Radiators shall
also be detachable type along with HT cable boxes and disconnecting chamber on HT side. Transformer shall be complete with all accessories like conservator,
breather, air vent, lifting hooks, bi-directional roller etc.
c) Transformers shall employ copper conductor windings.
d) Transformers in clause (b) above shall have a separate bushing brought out on the transformer tank for earthing of neutral. Transformers designed for HV
cable connections shall incorporate disconnecting chambers.
e) Transformers in clause (a) above shall have off load tap changing gears with auto / manual operating features. The tap changer range shall be 10% to + 5% in
steps of 2.5%. The voltage profile of the transformer shall confirm to the voltage profile of power distribution agency. Transformers in clause (b) above shall
have off load tap changers.
f) If the measured loss (load/ no load or both) of the transformers is found to exceed the guaranteed loss figure, (with due consideration for tolerance, if any,
indicated in the bid), the contractor shall be penalized on the basis of following for each kilowatt or part there of that exceeds the guaranteed loss. The bidder
shall propose very low loss transformer with high efficiency.
All transformers shall be capable of operating continuously and without adverse effects of overheating under all specified conditions of operation including
variation in system of 10% voltage and 3 % frequency or 10% combined voltage and frequency unless otherwise specified.
Transformer shall be designed to withstand without any injury the thermal and mechanical stress caused by the short circuit currents of magnitude and duration
specified.
Transformer shall be designed for frequent direct on-line starting of motors having an equivalent rating in kVA upto CMR of the transformer and shall be
capable of withstanding the forces arising from the starting currents of these motors.
Cores shall be built from cold rolled, low loss, grain oriented silicon steel laminations. The core laminations shall be insulated from each other by a suitable high
temperature resistant, oil-proof, adherent coating material. Core clamps and clamping bolts shall be heavily insulated from the core laminations.
Winding shall be three phase with minimum Class A insulation. High conductivity electrolytic quality copper shall be used for winding. Winding shall be
suitably braced to withstand the dynamic forces due to short circuit.
Insulating oil shall conform to IS-335. Comparatively small transformers if required (Upto 2000 kVA) shall be supplied Under Oil. For large transformers
with radiator banks, it may not be feasible to ship the transformer Under Oil, oil being supplied separately. Tested insulating oil required for filling or topping
up the transformers including radiator banks and conservator shall be supplied loose, in non-returnable drums. The quantity of oil shall be sufficient for filling
at site, with 10% extra quantity of oil supplied loose.
An off-circuit manually operated tap changer shall be provided on H.V. side constant kVA taps in steps of 2 shall be provided as per Data sheets.
Padlocking facility shall be provided on the tap changer.
H V side shall have cable box suitable to accommodate XLPE cable.
V terminals shall be brought out into the terminal chamber with throat connection suitable for connection to the bus duct.
Separate neutral terminal (other than that provided in the terminal chamber) of star connected winding of transformer shall be brought out with an outdoor type
bushing. The terminal shall be suitable for connection of two earth conductors.
Fittings and Accessories shall be as per IS - 2026 with Buchholz Relay, winding and oil temperature indicators with switches all terminal in Marshalling box.
The neutral earthing shall be properly made.
20.4.5 BUS-DUCT
Bus bars 3 ph, 4W, 425 V shall be electrolytic Aluminium and of phase segregated type.
The enclosure of the bus-duct shall be fabricated from structural steel and/or cold-rolled sheet of minimum 2 mm thickness.
The fabrication / assembly of bus-duct shall be so designed as to offer dust-proof and vermin proof enclosed with IP 68 degree of protection. Adequate access
shall be available for inspection/replacement/tightening of busbar supports/ fish plats/ fasteners.
Rain hood / canopy shall be provided for outdoor portion of the bus-duct. Rain hood/canopy shall be designed to offer complete protection from rain.
Non-deteriorating type gaskets shall be provided at all mating surfaces. The gaskets used for outdoor portion of the bus-duct shall not deteriorate due to
hostile climate conditions and direct exposure to sunlight.
Busbars shall be air insulated . The clearances between phase and neutral shall be as per BS 162.
Busbar supports shall be made of high quality insulating material such as DMC, SMC, araldite etc.
When the bus-duct passes through building wall from indoors to outdoors, a wall frame assembly with seal off bushings shall be provided to prevent
interchange of air between two sections. The seal off bushings shall be flanged type.
Flanged ends shall be provided to facilitate connection of bus-ducts both at the transformer and switchgear end.
Flexible connections shall be provided at the end terminations, both at transformer end and switchgear end and at intermediate places depending upon length
and configuration of the bus-duct. The connectors shall preferably be laminated to cater for linear expansion of busbars. The material of flexible shall be same
as busbars. If different material is used care shall be taken to prevent bimetallic corrosion.
A space heater circuit comprising of switch, fuses, thermostat and a heater suitable for 240 V single phase supply shall be provided in the bus-duct . The space
heater shall be located at a suitable location to maintain temperature of air 5 C above ambient throughout the length of the bus duct.
A drain plug shall be provided on the bus-duct at the lowest point to drain condensed water.
Maximum operating temperature at any point of the bus shall not exceed 85 C with the limiting ambient conditions specified. Eddy current heating shall be
taken into account while designing the enclosure.
20.4.6 PCC/PMCC/MCC/MLDB/LDB
PCC/PMCC/MCC/MLDB/LDB shall be floor mounting , free standing, totally enclosed and dust, damp and vermin proof, compartmentalized and powder
coated.
Enclosure shall have minimum degree of protection - IP 52.
All circuit breaker feeders shall be draw out type others fixed type.
All feeders to be housed in separate compartments. All compartments to be fully segregated from one another, as well as from busbar chamber, with sheet steel
barriers. This type of construction may be single front or double front as required. Each feeder compartment to have a separate door, Incoming shall have
busduct entry from top and outgoing feeder bottom through cable ally where outgoing CB feeders bottom exit from respective compartment itself.
SW. Boards, shall have main horizontal and riser busbars air insulated, housed in a separate compartment, segregated from all other compartments, with sheet
steel barriers. Busbars shall be of high conductivity electrolytic copper or aluminium, suitable for carrying the rated and short time current without
overheating . Busbars shall be adequately supported on insulators to withstand dynamic stresses due to short circuits. Busbar support design should ensure free
thermal expansion.
Busbars for risers shall be rated to carry 125% of the rated current of all feeders connected to the risers.
The circuit breakers shall be of air break and of horizontal draw out construction, with 3 poles and isolable bottled neutral link, manual spring charging spring
closing, thermomag/static & under voltage release with self powered restricted earth fault relay for incomes.
Isolators shall be heavy duty load break, of AC 23 category.
Isolators shall be rated for 120% of circuit full load current with minimum rating of 25 Amps.
All fuses shall be HRC, link type.
All power contactors shall be rated for 125% of feeder full load current. Minimum rating shall be not less than 16 Amps, duty category AC3 except for
auxiliary contactor which shall have 10 Amps 4NO +4NC.
All bimetal overload relays shall be of hand reset type with at least one NO and one NC contact with reset type push buttons, mounted on door such that it shall
be possible to reset the O/L relay with door closed.
The MCC shall be provided with a continuous earth bus having sufficient cross section to carry the specified fault current for specified duration without
exceeding the safe temperature throughout its entire length.
All control wiring except C T secondary wiring shall be carried out with minimum 1.5 sq. mm copper conductor. C T secondary wiring shall be carried out with
2.5 sq mm. Copper conductor.
Adequately rated anti-condensation space heaters shall be provided in each breaker panel and in cable to maintain inside temperature, 5C above outside ambient
temperature.
All L D B shall be sheet steel enclosed with ELCB (300mA) / MCB and with 20A S.P. 9 kA MCB O/G feeder.
20.4.7 INDUCTION MOTOR
Procurement of all motors (addition & replacement ) shall be included in mechanical part covered else where.
Motor body or frame shall be of close grained cast iron or of welded steel construction in case of large motors unless otherwise stated. The design of the body
shall ensure ruggedness and damping of vibration. The rotor along with the fan and half coupling or other drive device (if fitted) shall be statically and
dynamically balanced.
Fans provided for totally enclosed fan-cooled motors shall preferably be of the non-direction type, with protection against accidental contact. In case they are
uni-directional, direction of rotation shall be clearly indicated on the non-driving end of the motor.
Fans for motors used in hazardous areas (Zone 1 and 2) shall be manufactured from non-sparking material and if non-metallic shall be painted with an
electrically conducting paint, to prevent accumulation of static charge.
Motors shall be of weatherproof construction (IP 68). (non-flame proof).
All motors shall have ball and/or roller bearings or bearings of the sleeve type . Vertical motors shall have special thrust bearings.
Terminal boxes for power cables shall be located on right hand side when viewed from the driving end or on top. The terminal boxes shall be rotatable in steps
of 90% without disturbing the motor winding connections to the terminal block.
Unless otherwise specified, motors shall be designed for direct-on-line starting.
All motors shall be suitable for starting under specified load conditions with 85% of the rated voltage at the terminals.
Minimum locked rotor thermal withstand time at rated voltage shall be 10 seconds under cold condition and 8 seconds under hot condition.
Unless otherwise agreed, the starting time of the motor shall be less than the hot thermal withstand time of the motor.
All motors shall be capable of atleast two starts in quick succession after the motor windings have attained their maximum permissible temperature.
Starting torque of squirrel cage induction motors started on full voltage shall generally not be less than 200% of the full load torque. Cases, where higher
starting torque is required will be indicated in Data sheets. Pull out torque (breakdown) of motors shall not be less than 200% of the full load torque.
L.V. motors shall have class B insulation unless Data sheet specify another class of insulation.
Winding of motors shall be treated or impregnated with suitable varnishes to render them non-hygroscopic and resistant to dirt and oil. Windings shall also be
treated to make them resistant to acidic/ alkaline vapours when the atmosphere is specified as corrosive.
All rotors shall be free from excessive inherent axial thrust. End play of motor shall be kept to a minimum, unless Data sheet specify the end-float required.
Anti-condensation heaters shall be provided for motors of 37 kW and above. Heaters shall normally be suitable for 250 volts. Single phase, A. C. supply,
designed for continuous operation unless otherwise specified in Data Sheet. Heaters shall be metal encased with a low surface temperature. In addition, a
removable, threaded, plug shall be provided to remove condensed moisture.
20.4.8 CABLES
All power and control cables for use on medium/high voltage shall be heavy duty type, aluminum / copper conductor. P V C/ X L P E insulated inner sheathed,
armored and overall P V C sheathed as described below.
P V C INSULATED CABLES (MEDIUM VOLTAGE)
The conductors of nominal area less than 25 sq. mm shall be circular and above that it may be circular or sector shaped.
The inner sheath shall be of vulcanized rubber proofed or plastic tap and shall not be harder than P V C used for insulation. This shall conform to requirement of
type ST- 1 of IS 5831 (latest revision).
Armouring shall be applied over inner sheath, where specified and shall be of galvanized steel strip as per IS 3975. The armour shall be applied as closely as
possible with left hand direction of lay. For cables having diameter over the inner sheath less than 13 mm, the armour shall be of galvanized
round steel wires or galvanized steel strips. The dimension and resistance of armour shall be as per IS 1554 Part I. (latest revision).
The outer sheath of the cable shall be applied by extrusion and shall be of black colour P V C compound conforming to requirements of type ST - 1 compound
of IS 5831(latest revision). The thickness of outer P V C sheath and its tolerance shall be as per IS 1554 (Part -I) (latest revision). To protect the cable against
rodent and termite attack, suitable chemicals may be added into the P V C compound of the outer sheath.
XLPE INSULATED CABLES (HIGH VOLTAGE)
The conductors shall be made from 3 core, sector aluminium wires. These shall be standard and compacted circular in shape upto 35 sq. mm size cables.
The conductors of 3 1/2 core cables having their nominal cross section 50 sq. mm and above shall be either circular or sector shaped. The conductor and its
construction shall conform to IS 8130 and IS 7098 (Part-I).
Insulation
The insulation shall be chemically cross-linked polyethylene conforming to the physical, electrical and ageing properties as required by IS 7098 (Part-I) (latest
revision). Only natural colour compounds shall be used for insulation of cables. It shall be free from voids and shall withstand all mechanical as well as thermal
stresses under steady state and transient operating conditions.
Conductor screening shall be non- metallic and shall consist of either semi-conducting tape or extruded semi-conducting compound.
Insulating screening shall be in two parts, first non-metallic semi-conducting part and second metallic part. Non-metallic part shall be applied directly over
insulation of each core and shall consist of tapped or extruded semi-conducting compound. On top of this, metallic screening of non-magnetic tap or braid or
concentric serving of wire shall be adopted.
In cables having three cores, the individual core shall be laid up with suitable non-hygroscopic fillers and then applied with common covering of PVC or
thermoplastic material by extrusion or tapping such that circulating of cable is maintained. The sheath shall conform to requirements of type ST-3 compound of
IS 5931. The thickness of sheath shall be as per IS 7098 (Part II) (latest revision).
The Armouring and outer sheath of XLPE cables shall be generally in line with Clauses as described above. However size and tolerance for XLPE cable shall be
as per IS 7098 (Part II) (latest revision), except for outer sheath to be of typeST-2 as per IS 5831(latest revision).
20.4.9 AUTOMATIC P.F CORRECTION PANEL & CAPACITOR BANKS
Each capacitor bank and its automatic control panel shall be coupled to each other to form one composite unit. The unit shall be free standing, floor mounting,
with a 3 mm thick base channel with foundation bolt holes.
The housing of the capacitor banks shall be of open construction with free ventilation for capacitor units. The connections from the capacitor units to the control
panel shall be carried in totally enclosed, dust-proof, vermin-proof bus-ways or wire-ways.
The control panel shall be fully compartmentalized and extensible for future expansion. Busbars and feeder circuits shall be segregated.
The automatic control panel shall comprise of the following :-
Main Isolating Switch, PTN,500 V rating to suit Aluminium Busbars, rating to suit Link type HRC Fuses and Fuse Bases for Power Circuit.
Main Contactors for Control circuit
Bimetallic Thermal Overload Relays for each power circuit.
Auxiliary contactors for control circuit.
Power Factor Relay for sensing and correcting the power factor of the system with number of steps.
Auto-manual change-over switch
ON and OFF push buttons for manual control of each capacitor unit.
ON indicating lights with incandescent lamps complete with ballast resistors for each capacitor unit.
Indicating lights as above but for Manual and Auto operation indication.
Control fuses, HRC link type with fuse fittings.
Any other components, required for satisfactory and safe operation.
Capacitor Banks shall comprise identical delta connected three phase units.
Capacitor Banks shall be either non-flammable, non-toxic All poly propylene type with extended foil design, capacitor shall be compact in size and hermetically
sealed. In built fuses & surge suppressor shall be provided for protection of each capacitor element.
Capacitor Bank to be provided with a busbar chamber on the top dust/ damp protected, verminproof in construction, fabricated from 2mm thick sheet steel.
Continuous neoprene gaskets to be provided at all mating surfaces. Bus-bars to be aluminium, supported on porcelain insulators.
Connection of individual units to bus-bars to be made through link type HRC fuses of specified ratings. Individual unit to be provided with internal silvered
fuses and discharge resistors connected across terminals.
The capacitor bank to be complete with fixing channel suitable for floor mounting.
20.4.10 INTERNAL AND EXTERNAL ILLUMINATION
20.4.10.1General
The illumination system shall consist of lighting towers, lighting poles, main panel distribution boards, complete with FSU, ELCB, MCB , Cables , JB, terminal
blocks, glands, conduits and accessories and supporting and anchoring materials, lighting fixtures with fluorescence tubes, sodium vapor lamps, wires etc. All
materials, fittings and appliances used in electrical installation shall conform to be relevant IS specifications and shall be anticorrosive painted/ FRP enclosures.
20.4.10.2 Illumination Level The following minimum levels of illumination shall be provided in the respective areas :
All internal and external areas shall be provided with lighting. The illumination levels to be achieved shall be as follows:

AREA LUX

Office and labs 300 Lux

Switchgear Room 200 Lux

Control Room 300 Lux

Pump House 200 Lux

DG set room 200 Lux


Chemical and general store 150 Lux

Chemical Plant room 200 Lux

Other indoor areas 100 Lux

Outdoor plant from and 50 Lux

Building entrance 100 Lux

Indoor Plant Area 200 Lux

Outdoor Plant Area 50 Lux

Transformer Area 100 Lux

Roads 10 Lux

20.4.11. A. DIESEL GENERATOR SET (AMF TYPE)


Suitable 0.8 P.F., 415 Volts, 3 phase, 4 wires, 50 HZ, 1500 rpm DG with all accessories and cooling system ( 1 number ) shall be provided to meet peak load.
Neutral shall be solidly earthed. The D.G. set should be enclosed in suitable Sound Proof Acoustic Enclosures. The set shall start automatically on partial or
complete mains failure or fall in voltage beyond set limit (adjustable) through automatic control system cum sensor and has capacity to meet the peak power
demand of plant.
DIESEL ENGINE:
Diesel engine shall be water cooled, turbocharged after cool developing. The engine shall be complete with following accessories:
Radiator with blower fan
Corrosion inhibitor coolant
Paper element filters fuel, lube oil and bye pass
Flywheel housing and flywheel to suit double bearing alternator
Engine barring mechanism
Spider type flexible coupling
Dry type air cleaners with pre cleaners and vacuum indicators
Residential silencers
Stainless steel exhaust flexible bellows
Motor driven priming pump
Electric starters
Battery charging alternator
Solid state potentiometer
Electronic control panel (displaying the following ) with PCC 2100
o Battery Voltage
o Coolant Water Temperature
o Lubricating Oil Pressure
o Engine Speed
o Engine Hours
Safety Control : High Water Temperature (HWT)
: Low Lube Oil Pressure (LLOP)
: Over Speed (OS)
ALTERNATOR:
415V, 3 phase, 4 wires, 50Hz, 1500 rpm, separately excited (PMG) self regulated, with brush less excitation, band of voltage regulation 0.5% of rated voltage,
from no load to full load. Insulation class H. The alternator generally conforms to BS: 5000 / IS: 4722.
BASE FRAME:
Sturdy, fabricated, welded construction, channel iron base frame for mounting the above engine and alternator.
FUEL TANK:
990 Liters capacity fuel tank with mounting brackets, complete with level indicator, fuel inlet and outlet, air vent, drain plug, inlet arrangement for direct filling
and set of 5 ft. long fuel hoses.
BATTERY:
Set of 4 nos. 12V, 27 plates, dry and uncharged batteries with leads and terminals with automatic charger.
CONTROL PANEL:
Free standing, floor mounting panel, with hinged doors, un drilled bottom gland plate
and accommodating the following:
Air circuit breaker, Manually operated, L&T / Equivalent make, 1600A, with under voltage release, over load relay with short circuit protection.
Combined digital meter for A/V/F CADEL/ Equivalent make
Combined digital meter for k W / k VA / PF CADEL/ Equivalent make
Electronic counter display type k W H meter L&T/ Equivalent make
Analog hour meter to display hours of run
Over current cum earth fault relay
Current transformers
Indicating lamps for SUPPLY ON & LOAD ON
Instrument fuses
AV, PADS:
One set of anti vibration mounting pads
20.14.11.B. SUBMERSIBLE PUMPS
The Contractor shall provide manufacturer's published pump curves, system curves and the necessary hydraulic calculations to justify the sizes of any pumps
selected.
The Contractor shall provide the following shop drawings:
impeller diameter
maximum impeller diameter
minimum impeller diameter
velocity of liquid in pump suction at duty point
velocity of liquid in pump delivery at duty point
velocity of liquid in the pump casing or impeller eye at duty point
net positive suction head (dry well submersibles only)
the materials of construction shall be specified in detail and itemised against a sectional drawing of the pump proposed.
After approval of the pump types the Contractor shall submit the test data as required under factory inspection and testing. The Contractor shall submit
Operation and Maintenance Manuals and Instructions which shall include all the documentation provided as above and as required in the Specification.
PUMP REQUIRMENTS
Pumps and drives shall be rated for continuous duty and shall be capable of pumping the flow range specified in the Specification without surging, cavitation, or
excessive vibration to the limits specified. All pumps and drives shall be from approved manufacturers.
The pumps shall meet maximum allowable shut-off head.
The pumps shall not overload the motors for any point on the maximum pump speed performance characteristic curve and the pump operating range, within the
limits of stable pump operation, as recommended by the manufacturer, to prevent surging, cavitation and vibration.
To ensure vibration-free operation, all rotative components of each pumping unit shall be statically and dynamically balanced to IS:11723 Part 1 - 1992 and the
following
requirements shall be met:
The mass of the unit and its distribution shall be such that resonance at normal operating speeds is within acceptable limits.
In any case, the amplitude of vibration as measured - at any point on the pumping unit shall not exceed the below limits
At any operating speed, the ratio of rotational speed to the - critical speed of a unit, or components thereof, shall be less than 0.8 or more than
1.3.

Vibration levels shall not exceed the levels as per relevant IS.
The completed units, when assembled and operating, shall be free of cavitation, vibration, noise, and oil or water leaks over the range of operation.
All units shall be so constructed that dismantling and repairing can be accomplished without difficulty.
The Contractor shall be responsible for proper operation of the complete pumping system, which includes the pump, motor, variable speed drive unit (if
designated), and associated controls furnished with the pump.
The Contractor shall ensure that the controls and starting equipment are suitable for use with the pump motor, taking into account all requirements including
starting currents and number of starts per hour.
For the performance curve of the selected pump impeller, the head shall continuously rise as flow decreases throughout the entire curve from run out to shutoff
head.
The Contractor shall ensure that drive motors, variable speed drive systems (if specified) and pumps shall be supplied and tested together by the pump
manufacturer, who shall supply full certification for the proper function of the entire pumping system.
If variable speed drive systems are specified, motor and drive system shall be fully compatible, and shall be of sufficient power and torque, and be capable of
sufficient heat transfer for starting, accelerating and continuously operating over the entire range of head/capacity conditions, from minimum to maximum pump
operating speed, as designated. The motor shall be de-rated to take into consideration the reduced cooling effect when running at the lowest speed with the
variable speed drive.
DESIGN CONDITIONS
Pumps shall be single stage mono-block type with nonclog design. It should pump all kinds of liquid encountered in the TTRO Plant.
Profile gasket should be provided in pump casing so as to avoid metal to metal contact between pump and the specially designed duckfoot bend/ flanged elbow,
automatic coupling to ensure leak proof joint with delivery pipe . The profile of pump side flange shall be matched with pump claw so as to automatically lock by
virtue of its own weight or an automatic coupling device for easy installation and easy removal.
Pumps shall be designed and constructed to satisfactorily operate and perform within the designated design conditions and the requirements specified herein.
They shall be designed for a life of 100,000 hours with service intervals at 20,000 hours.
Castings, fabrications, machined parts and drives shall conform to the industry standards for strength and durability and shall be rated for continuous duty over
the entire operating range.
Bearings shall be of the anti-friction type designed for load and life in accordance with relevant IS according to the type of bearing used. The maximum operating
speed shall not exceed 1450 / 960 rpm and shall be supplied as per requirement.
Pumps shall be of non-clog design and shall be supplied along with special duckfoot bend / flanged elbow, lifting chain, guide wire / guide pipe.
Suitable RCC slab / ISMB (with necessary anti-corrosive painting) to be erected over suction well to fix guide wire / guide pipe holding bracket.
The pump, motor and associated electrical equipment shall be rated for a minimum 10 starts per hour, unless otherwise specified.
The Contractor shall ensure that the pump manufacturer provides certification which
guarantees the following:
flow rate
total head
power input
efficiency

MATERIALS
Pumps shall be manufactured of the following materials as a minimum:
volute casings shall be cast iron, as per IS 210 Gr Fg 200 with 2 to 3 % Nickel. The internal surfaces shall be free of rough spots. The casing
shall have center line discharge.
impellers shall be stainless steel (CF8M ) .
Pump shaft shall be of stainless steel (SS- 410) . The shaft shall be of one piece construction.
motor casings shall be cast iron,
shafts shall be stainless steel,
fasteners shall be stainless steel,

The lifting system shall be manufactured of the following materials:

the guide rail system shall be CI.


lifting chains shall be MS-GLVD.

FABRICATION
General. Pumps shall be fabricated in accordance with the following requirements:
Pumps shall be capable of handling all kinds of liquid encountered in the TTRO Plant.
in the case of submersible installations no portion of the pump shall bear directly on the floor of the wet well.
pumps shall utilise a guide system to permit easy removal and reinstallation without dewatering the pump sump discharge connections shall be
made automatically with a simple downward motion without rotation when the pump is lowered into operating position. The pump shall be
capable of being removed without disconnecting any fasteners
an appropriate length of chain shall be connected to the motor eyebolts to permit raising and lowering of the pump.
Impellers shall be fabricated according to the rated motor size as follows: non-clog type statically and dynamically balanced, keyed to the shaft
provided with pump-out vanes to prevent material from getting behind the impeller and into mechanical seal area
impellers shall not be trimmed unless approved by the Design Builds - Operations Engineer or his representative. Provision for adjustment of
clearance between impeller and casing for restoring the pump efficiency, without dismantling the pump will be an added advantage.
single/multi vane or vortex type, with a cutter impeller in the case of small flows.

Discharge Connection and Guide Rails shall be fabricated as follows:


Sliding guide bracket and discharge connections shall be provided which, when bolted to the floor of the sump and to the discharge line, will receive the pump
discharge connecting flange without need of adjustment, fasteners, clamp, or similar devices.
The guide rails shall not support any portion of the weight of the pump.
The pump discharge connections shall incorporate a sealing face and connection yoke to allow for automatic coupling to the fixed discharge connection pipe
work.
Pump Shafts shall be fabricated as follows:
pump shafts shall be of such diameter that they will not deflect more than 0.05 mm measured at the mechanical seal, whilst operating at full
driver output.
the shaft shall be turned, round and polished
the shaft shall be key-seated for securing the impeller.

Shaft Seals shall be fabricated as follows :


the drive motor and pump/motor bearings shall be sealed along the shaft with tandem mechanical seals operating in an oil filled chamber. The
seals shall require neither routine maintenance nor adjustment, but shall be capable of being easily inspected and replaced.
two back to back mechanical seals shall seal the motor off from the pump.
the upper seal shall be oil lubricated with a carbon rotating component and fixed tungsten carbide component.
the lower seal shall have both parts in tungsten carbide.
a detector shall indicate when moisture is leaking past the first seal.

Bearings shall be fabricated as follows :

bearings shall be capable of taking the static weight of the rotating parts and any thrust generated by the operation of the pump
the upper bearing(s) shall be of the grease lubricated sealed for life type; the lower bearing(s) shall be lubricated by the internal oil supply
the bottom bearing(s) shall be of the angular contact ball bearing type in combinations with roller bearing(s)
if required in the project specification, remote indication shall be provided for bearing high temperature-, using a thermistor at the lower bearing,
to provide a signal at 950 C.

Motors shall be fabricated as follows :

Motors shall be 415 V, phase, 50 Hz, rated at 10 % above the maximum power requirement
Motors shall be squirrel cage, induction, air filled, totally sealed to IP 68,suitable for the maximum immersion depth to be encountered, rated for
zone 2 use with group 1 gases, to BS 5345
Motor insulation shall be Class F, limited to a Class B temperature rise
Motor temperature shall be monitored using a thermistor, in each phase of the winding, set to stop the motor when the monitored absolute
temperature reaches 1300 C
A watertight cable junction box sealed from the motor shall be provided for the motor power and control cables shall be EPR insulated, Niplas
sheathed flexible 450/750 volts grade, oil and grease resistant, with tinned annealed copper conductors in accordance with BS 6007. The cable
shall be brought directly out of the submersible motor without joints, and shall be of sufficient length, minimum 20 m to be terminated in an IP67
junction box outside adjacent to the wet well. They shall be sized in accordance with the electricity utility regulations and BS 7671. The cable
must be leak tight in respect of liquids and firmly attached to the terminal box. They should be laid in a suitable PVC encasing pipe from control.
Motors shall be capable of start up and operation in the event of a completely flooded wet well. Motors shall be selected to meet the maximum
power required for the selected impeller at all operating conditions
Motor cooling shall either be by means of the pumped medium or by oil. The use of external cooling water is not acceptable
motors shall be de rated for dry well and/or variable speed operation
all parts of the pump and motor shall be 100% holiday free fusion bonded epoxy coated to a minimum thickness of 300 microns.

CONTROL PANEL
The control panel shall be made of 12 SWG (2.6mm) sheet steel for the front side and 14 SWG (2.0mm) sheet steel for bottom and other sides with powder
coating for long life. It should have suitable starter. The control panel consists of multi section unit containing one pump and one incomer/control. The sections
are interfaced, via, cable way/marshalling section. All wires and links are of electric grade copper conductor. The control of the pumps viz., Mercury/magnet
activated/ any other float switch with auto for duty pump.
Power circuit is operating at 3 phase ,415 Volts, 50 Hz supply and for control circuit it is single phase 230 V, 50 Hz supply.
Type of starter shall be as under :
upto 10 HP DOL
From 12 Hp to 40 HP - Star - Delta.
50 HP and above Auto Transformer Starter / Soft Starter.
The following protections should be provided in the panel: short circuit protection, over load protection, over temperature protection for motors, single phasing
preventer, reverse rotation protection, dry run failure protections to be made. Suitable range ammeter, voltmeter, selector switch, auto-manual switch, pump
running lamp, pump fault lamp, fault reset push button, phase indicating lamps, indication of high level in the well, hours run counter should also be provided.
The control panel wiring circuit should be furnished in triplicate.
The pump should be controlled by the magnetic/mercury float switches while the pumps run in auto. The floats with switches should be available in the wet wells
and the connections from float should be made to the individual control panel through the cable duct. Necessary control sensor wiring should be made to convert
the signals of mercury/magnet float switches while the level is high/low so that the pump starts/stops on auto mode.
The necessary push button stations with control wiring should be made on the wells for each pumpset each stations as per standard rules.
The control panel, pumpset and accessories for pumps should be manufactured by same manufacturer. The pump and motor shall be accordance with the relevant
standards.
AUTOMATIC CONTROL
The automatic level control shall be arranged such that when level rises in the well the pumps starts successively at the different pre-determined levels. When the
level drops the pumpsets stop in the same order as that in which they have started. The different start and stop levels for several pumps/single pump have to be
chosen according to the liquid and as desired by the Design Build - Operations Engineer or his representative. Magnetic/mercury float switches have to be used
for this purpose.
Labels. Each pump shall have a stainless steel label permanently fixed to the pump and an identical label fixed to the pump starter compartment.
FACTORY INSPECTION AND TESTING
The Contractor shall secure from the pump manufacturer certification that the following inspections and tests have been conducted on each pump at the factory,
and submit to the Design Build - Operations Engineer or his representative prior to shipment:
the pump casing has been tested hydrostatically to 1.5 times the maximum closed valve pressure
impeller, motor rating and electrical connections checked for compliance with the Specifications
motor and cable insulation tested for moisture content or insulation defects
prior to submergence, the pump has been run dry to establish correct rotation and mechanical integrity
the pump has been run for 30 minutes submerged under a minimum of 2 m water after the operational test and the insulation tests above and after
the performance test below

Each pump shall be tested at the factory for performance according to BS 5316 Part 1, including:
flow
inlet pressure
outlet pressure
motor power
torque
efficiency

The Contractor shall secure from the pump manufacturer the following certification and submit to the Design Build - Operations Engineer or his representative
prior to shipment:
certified copies of the pump characteristic curves and reports generated by the tests described above
foundry composition certificates for all major castings (pump case, impeller, motor housing) showing exact material composition and tests
conducted to ensure compliance with the pump manufacturer's material specifications.

SITE INSPECTION AND TESTING


The equipment delivered to the Site shall be examined by the Contractor to determine that it is in good condition and in conformance with the approved working
drawings and certifications. All equipment shall be installed in strict conformance with the Specification and the manufacturer's instructions.
The Contractor shall provide the services of the pump manufacturer's representative to supervise the installation, commissioning and start-up of the pumping
equipment.
The commissioning tests shall be performance and reliability trials, mainly for the purpose of satisfying the Design Build - Operations Engineer or his
representative that the pumpsets have been correctly assembled and installed and that their performance matches that obtained during the manufacturers works
tests. In the event of an unwarranted change in the pump performance characteristics or power consumption, all necessary steps shall be taken as soon as possible
to establish the cause and remove the fault. Similar action shall be taken for an undue increase in bearing or gland temperature, increased gland leakage rates,
unsatisfactory vibration levels or any other fault or defect in the operation of the pumpset.
The site reliability trials shall include the following:
A record of bearing and coupling clearance and alignments shall be tabulated to show the "as-built" condition of each pump
A record of all overload, timing relay and oil pressure relays shall be tabulated to show the "as-built" condition of each motor starter
All cables shall be megger tested to confirm the integrity of the insulation. A tabulated record of results shall be made.
The control panel shall be statically tested with motors disconnected to confirm the correct sequence of operation
Each pump shall be operated individually over the range from closed valve to maximum emergency top water level, on a recirculation basis,
using fresh water, and for a minimum of four hours continuously. During this test the following parameters will be recorded: -

- motor phase currents

- pump output

- ambient and test water temperatures

- motor/pump casing temperature (dry well submersible only)

- power consumed

- power factor

- vibration (dry well submersible only)

The commissioning trials shall extend until each pump unit has run 'continuously' for at least 3 days under all operating conditions. The term 'continuously' shall
include running at various speeds or on a start/stop basis as determined by the control system.
The Contractor's supervisory staff and the pump manufacturers representative shall be present during the period of the tests and trials. The Contractor shall be
responsible for any failure of the whole equipment or any part thereof, whether such failure shall be determined by the methods detailed herein or otherwise. If
the Contractor interrupts the pump test or trial, or through negligence on the part of the Contractors staff, it shall be completely repeated for the pumpset
concerned.
MOTORS
All motors shall be suitable for operation on a 415v, 50 Hz, 3 phase, AC supply.
Motors shall be capable of giving rated output without reduction in the expected life span when operated continuously under the following supply conditions.
i Variation of supply voltage from the rated motor voltage : + / - 10%

ii Variation of supply frequency from the rated frequency : + / - 5%

iii Combined voltage and frequency Variations : + / - 10%


All motors shall be capable of starting 6 times per hour. Starting current of motor shall not exceed 200% of the rated full load current for star - Delta starting and
600% of rated full load current for DOL Starting and also be limited below the maximum limit specified by the electricity supplying authority under any
circumstances.
Motor shall be capable of starting and accelerating the load with the applicable method of starting without exceeding the acceptable winding temperatures, when
the supply voltage is in the range of 10% above of the rated motor voltage.
Motor shall be designed to withstand 120% of the rated speed for two minutes without any mechanical damage in either direction or rotation.
The insulation class of motor winding shall conform to class - F and the maximum temperature rise shall not exceed 950C, when measured by winding resistance
method and 850C, when measured by thermometer method for an ambient temperature of 450C.
Motor shall be offered for routine and type tests in accordance with IS: 4029 and IS: 325 at the manufacturers works. Test certificates shall be endorsed to the
effect that they are properly balanced and free from vibration. In addition, a test shall be required to establish the maximum transient starting current.
Pump motors shall be of the squirrel cage submersible type, protected to IP. 58 and rated at 10 per cent above the calculated maximum power required on site.
The motor shaft shall be of large diameter, lightly stressed to ensure rigidity, with impeller and bearing location shoulders and a keyway for location of the
impeller.
The motor windings shall be protected with a waterproof material and shall incorporate a thermistor in each phase to safeguard against high winding
temperatures.
The thermistor shall be connected into the control circuit of the starter and arranged for hand reset only.
The motor shall incorporate a cut-out device to detect the presence of any liquid in the motor enclosure.
The motor frame shall incorporate lifting points and shall be fitted with a galvanised lifting chain, reaching to, and secured at the access point.
The terminal connections for the power and protective circuits shall be housed in a completely sealed and waterproof junction box, complete with all external
corrosion resistant cable glands.
The pump units shall be provided with power and protection circuit cables of sufficient length to reach from the motor junction box to the local isolator, located
at the access level.
The power cable shall be 600/1000V grade flexible stranded copper wire, insulated and overall sheathed with under-water grade compound flexible insulation.
The cable shall be rated to take the full motor current under the prevailing liquid and ambient temperature conditions.
CHARACTERISTIC CURVES
Characteristic and system curves for the pumps shall be supplied to a reasonably large scale which shall show the capacity of the pumps under single and multi
pump operation at the duty point.
When tested through their complete range of workable heads at the maker's works, all the pumps shall give results which conform to the curves submitted with
the Tender.
Curves showing pump efficiency and kW loading shall also be included.
PERFORMANCE TEST
Each pump shall be tested at the manufacturers premises for the full operating range of the pump. Pump performance shall be within the tolerance limits
specified in the relevant standards. The contractor shall furnish the guaranteed values of discharge and efficiency for the total head at duty point for each pump.
20.15 ELECTRICAL INSTALLATION
This specification covers the technical requirements for equipment, materials, and installation methods, testing and commissioning of electrical system.
The Contractor shall possess a valid E A grades license for the Tamilnadu state in which site is located and shall ensure its validity during the duration of the
contract. The Contractor shall furnish authenticated copies of certificates to the Design Build - Operations Engineer or his representative for himself and his
workmen before commencement of work.
The Contractor shall employ adequate skilled and unskilled labour to complete all work according to programme of work. Skilled workers shall possess the
minimum qualifications stipulated by statutory or competent authorities.
The Contractor shall employ adequate numbers of supervisor to control the labour force and to carry out the work as per schedule. Supervisory staff shall also
possess the minimum qualifications stipulated by statutory and competent authorities.
Various types, of equipment shall be installed in accordance with drawings and / or manufacturers instructions and good engineering practice. Particular attention
shall be paid to lubrication of moving parts & bearings, alignment tightness of all connections (mechanical and electrical) and wiring.
The transformers shall be moved to its location and shall be correctly positioned on its base.
All parts of the transformers, which are supplied loose, such as conservator, radiator banks, buchholz relays, dial thermometers, bushings, etc. shall be fitted onto
the transformers.
Transformer oil if supplied in drums shall be filled into the transformer after duly testing/filtering, upto the correct level required. The transformer may have to
be dried out and oil filtered.
The Contractor shall place the switchgear correctly on the base or foundation prepared for the same. If the switchgear consists of a switchboard with number of
panels bolted together, he will place all sections of the switchboard correctly, align them and bolt the sections together to form one continuous switchboard. The
switchgear shall then be secured to the foundation by means of nuts and bolts or foundation bolts grouted in the base. The Contractor shall also make inter-
section bus / wiring connections.
In case of wall/structure mounted equipment, boards, the Contractor shall fabricate and install the structural steel frame work suitable for mounting the various
equipment, boards. The Contractor may have to prepare drawing showing the proposed general arrangement, of the structural frame which shall be to the
approval of the Design Build Operations Engineer or his representative. The fabrication and installation of the framework shall be recommended only after
the approval of drawing. Various items of the equipment, board shall be mounted in accordance with the approved drawings.
Cable routes and mode of installation shall generally be as shown in the construction drawings.
Identification tags indicating cable designation, shall be affixed to each cable at ends and at an interval not exceeding 15 meters or at the location where cables
change direction or elevation.
H.V. XLPE /PVC armoured cables shall be terminated or jointed by means of cold setting epoxy based cast resin jointing system or heat shrinkable or push on
type cold setting kit.
All cable glands should be of nickel plated or brass, double compression type. All AI/Cu cables should be terminated through crimping type Al/Cu lugs
respectively.
All electrical equipment viz. transformers, switchgear, motor control centres, motors, control stations, switches, lighting, fittings and other electrical apparatus
shall be connected to the main earth loop by means of two separate and distinct external earth conductors. The material, type and size of the earth conductors will
be as shown in the drawings or as specified.
Electrical installation in hazardous areas if applicable as defined in I.S. 5571 shall be carried out with utmost care and special precautions shall be taken to
ensure operational safety.
All personnel, especially supervisory staff, working on such installations shall be fully conversant with the applicable National Standards and Code of Practice
and shall have previous experience of such work.
The Contractor shall take all reasonable safety precautions during construction and testing of the works. Particular attention shall be paid to the following :
a) To prevent any conductor or apparatus becoming accidentally or inadvertently charged.
b) Prior to the electrical installation (or part thereof) being connected to the main supply the Contractor shall ensure that uncommissioned or incomplete
circuits cannot be inadvertently energized and completed circuit cannot be used without the Design Build - Operations Engineer or his representatives
Consent.

c) No night work is carried out without work-permit issued by the Design Build - Operations Engineer or his representative in FLP zones (if stipulated by
process application)

The tests specified below shall be carried out on the electrical equipment and installation before commissioning the same. The tests shall be performed by or
under the direct supervision of a competent person, qualified to carry out the tests. All tests shall be carried out in the presence of the Authorised Representative
of the Owner, unless this stipulation is waived in writing.
20.16 PAINTING
All surfaces of equipment/structural steel shall be sand blasted, degreased and pickled in acid as required to provide a smooth & clean surface, free of rust / scale
/ grease.
After cleaning, the surface shall be given one coat of high quality red-oxide or yellow chromate and baking in the oven (for equipment only).
All surfaces shall be then finished with 2 (two) coats of finished syn. chemical paint of shade 631 of IS :5 (latest revision) or with a paint shade of purchasers
choice.
20.17 DETAILS OF TESTS
I POWER & DISTRIBUTION TRANSFORMERS
i) Check HV & LV cable terminations, ground connections, fittings and accessories, oil level and oil leaks at various joints. Check breather, thermometers &
buchholz relay for proper functioning and operation. Check junction boxes, marshalling box, etc. for correct wiring.
ii) Oil Test Crackle test and dielectric test as per Clause 7.11 of IS 10028(latest revision). The oil shall withstand at least 40KV with a gap of 4 mm.
iii) Insulation Resistance Test This may be carried out on new transformer without drying out the transformer, provided the transformer has not been idle or
stored for a long period. Otherwise, this test shall be carried out during drying out of transformers. Insulation resistance test shall be carried out between
primary & secondary to ground as well as between primary and secondary. Windings not under test shall be grounded during the test.
A megger rated 1000 volts or higher shall be used for the test.
iv) Polarity & Phasing Out Test Check external connection of the transformer in accordance with diagram of connections and phase sequence (anti-
clockwise).
II HV & MV SWITCHGEAR
i) Check proper mechanical operation of circuit breakers including alignment of trolleys in case of draw out type circuits breakers, smooth operation of
all mechanical parts, lubrication, mechanical interlocks etc.
ii) Check contact alignment and wipe, proper sequence of closing and opening of main and arcing contacts.
iii) Check electrical relays, instruments & Controls for correct wiring.
iv) Insulation test on busbars phase to phase to ground. This test will be carried out with circuit breakers in service position, but contacts remaining open.
v) Insulation test on relays & control wiring including current and potential transformers and wiring of CT & PT secondaries.
vi) Insulation test circuit breakers in withdrawn position phase to phase to ground with contacts closed.
vii) Adjust correct settings of relays and/or direct acting trips as specified.
viii) Operation Test Energise only control circuits and carryout closing and tripping operations (where AC supply derived from main supply is used for
operation, the switch gear bus may be energised). Check operations of electrical interlocks. Check tripping of circuit breakers by manual operations of
protective relays contacts. Check operations of mechanical closing and tripping devices. Check lockout conditions for closing of circuit breakers by simulating
the required conditions. Check control, indications, sequence interlocks and alarms.
ix) Polarity and connections of instrument transformers Check for correctness of CT & PT connections provided. Check electrical continuity of secondary
with ELV tester.
x) Check operation of instruments, meters, relays and tripping of circuit breakers by primary / secondary injections as specified.
xi) Check continuity of power circuits and earth continuity of all non current metallic parts with a low voltage (6 volts or less) continuity tester.
III. MOTOR CONTROL CENTRES, SWITCHGEARS
i) Check equipment, internal wiring, smooth mechanical operation, interlocks, etc.
ii) Check continuity of power circuits and earth continuity of all non current metallic parts with a low voltage continuity tester.
iii) Insulation test for power & control between phases , between phases and neutral and between phase/neutral and ground.
iv) Check operation by energising control circuits (without energising power circuits) for correct functioning. Simulate external controls and interlocks for the
same. Note chatter or humming of Contactor and rectify, if necessary.
v) Polarity and connections of instrument transformers check for correctness of CT & PT connections provided. Check electrical continuity of secondary
circuits with ELV tester.
IV MOTORS & ROTATING EQUIPMENT
i) Check equipment for free movement of rotor, and pay, lubrication, and for any
ii) Insulation test of motors between winding and ground. Use 500 volts megger for M.V. motors and 1000 volts megger for HV motors
iii) Check electrical continuity with ELV tester.
iv) No load running of motor noting down no load current and voltages in all three phases.
V CABLES
i) Insulation Test between each phase and neutral and between each phase/neutral and ground.
ii) D.C. High Voltage Test on HV cable in accordance with the relevant Indian Standards and Code of Practice. This test shall be carried out on cables
installed in final positions, and all joints and terminations have been made. The cables, however, may not be connected to the equipment, so that the equipment
may not be subjected to the test voltage.
iii) In case of lighting wiring, insulation test shall be carried out on lighting feeders with branch circuits open. Branch circuits shall be tested separately with
lamp holders, plug receptacles and lighting fittings in position, but without lamps. In case of lighting circuits with lamp ballasts and glow starters insulation
resistance may be measured between phase and ground only.
iv) In case of directly buried cables, insulation resistance of cables shall be measured before and after the back-filling.
v) Test all receptacles for correct phase sequence.
VI EARTHING SYSTEM
i) Measure earth resistance of each electrode separately. If a number of earth electrodes are interconnected with one another, combined earth resistance
shall also be measured. The earth resistance of each electrode and/or a group of electrodes shall not exceed the values specified.
ii) Carry out line earth loop impedance test. The loop comprises the line conductor from the point of fault, back to the supply transformer, the path through
transformer winding, the earthed neutral point of the transformer and path from that point to the point of fault through the earthing system.
iii) Continuity test for earth continuity conductors with ELV Tester.
iv) Copper plates to be used for all earthing circuits.
20.18 STATUTORY APPROVAL
The Contractor shall be totally responsible for obtaining statutory approval from the electrical inspector or any other statutory authority for the entire installation
carried out by him unless otherwise specified and agreed. Necessary test reports shall be submitted by him to electrical inspector. This will be an integral part of
the contract and shall not be paid for separately. The contractor shall liaison with the TANGEDCO for getting power supply and necessary fees if any shall be
paid by the Owner. Necessary license, if required for any disinfection arrangements from the Department of Explosives shall be taken by the Contractor.
20.19 ACCEPTANCE OF INSTALLATION
On completion of the work the Design Build - Operations Engineer or his representative, together with the Contractor, will carry out an Inspection of the
Installation. The Design Build - Operations Engineer or his representative will issue a completed copy of the Owners Acceptance of Electrical Installation to
the Contractor as confirmation that the work has been accepted, subject to any matters noted on the form being attended to.

20.20 LIST OF RECOMMENDED VENDORS FOR ELECTRICAL EQUIPMENTS


1.TransformerCrompton/GEC/Voltamp/Kirloskar/Indotec/TamiNaduElectricals/Equivalent
2) 11 kV Switchgear GEC/Siemens/Crompton/System controls/L& T/ABB/Equivalent
3) 415V, PCC/PMCC/MC/MLDB/LDB L & T/Siemens/GEC/ABB/Kirloskar/ HAVELL/INDOASIAN//Equivalent/CPRI Approved with components
specified
4.Cable Torrent/Asian/Universal/Fort Gloster/Omega/RPG/KEI/Ravin/Ralison/Equivalent
5.Air Circuit Breaker L&T/GEC/Siemens/Schneider/Equivalent
6.Motor Siemens/NGEF/ABB/Kirloskar/Crompton/Equivalent
7.HRC Fuses Siemens/ EE/L & T/Equivalent
8.Contactor L & T/Siemens/Telemech/ Kirloskar (Lovato)/Schneider/Equivalent
9.Relays GEC/ABB/Easun Reyrolle/Tele communication/L & T/Equivalent
10.Bi-metal Relays Siemens/L & T/Kirloskar (Lovato)/Schneider/Equivalent
11.Meters GEC/Automatic Electric/SIMCO/Equivalent
12.Earth Leakage Circuit Breaker Indo-Asian/GEC/S & S/L & T/Equivalent
13.Miniature Circuit Breaker MDS/Indo Asian/Indo Kopp/Havell/Siemens/ Telemechanique/Equivalent
14.Luminaries Philips/Crompton/GE/Bajaj/Equivalent
15.Power Capacitor Crompton/Universal/Asian/NGEF/Siemens/Equivalent
16. D.G. Set (With AMF Panel)
i) Engine Cummins /Warsila / DISEL (I) LTD./CATER PILLAR/Equivalent
ii) Alternator NGEF/JOTI/KEC/Greaves Cotton/ Stamford / Leroysomer/Equivalent
iii) AMF Panel Reputed CPRI Approved Vendor
17.Pump set: Kirloskar/Jyoti/KSB/ABS/Grundfos/M&PI/Kishor/Equivalent.
18.Dewatering Sump pump:Kirloskar /KSB /ABS /Grundfos /Kishor /Equivalent.
19.Submersible pumpsets : Kishore / Grundfos / ABS / KSB / Aqua/Equivalent
20.21 PRICE BREAKDOWN
20.21.1 Whenever requested by the Design Build - Operations Engineer or his representative the Contractor shall furnish detailed price breakdown for supply
and installation of each of the items of electrical works including for each type/size of applicable cable/ light fitting/ Earth pit / Earth stations.
20.21.2 This breakdown prices are required for the purpose of justification for progress payment and also for working out addition and deletion, if any, in the
scope of work at a later date.
21. INSTRUMENTATION WORKS
21.1 General
The scope covers, besides verification of broad specifications for instrument items enclosed the following activities
a) Detailed engineering of all instrument items shall be under Contractors scope.
b) Supply of total instrumentation systems including all erection hardwares to suit process requirements perfectly.
c) To maintain Contractor's own quality assurance plan [Contractor(Vendor)'s quality plan i.e. VQP] for all instrument items.
d) Testing, calibration and checking of all instrument items including all erection hardwares before installation.
e) Erection of all instrument items such as, but not limited to, panels, cable ladders, cable tray, cables, supports, etc, as per good engineering practice.
f) Testing calibration and checking of all instruments, instrument - loops and interlocks after erection.
g) Commissioning of all instrument items during commissioning of plants.
h) To supply optionally consumable recommended spares for instruments for O&M period.
i) Providing Telemetry and SCADA Monitoring system to the proposed 45 MLD TTRO Plant. The scope of work under this contract includes: a)
Instrumentation And Telemetry System b) Remote Telemetry Unit (RTU) c) Supervisory Control And Data Acquisition System (SCADA) d) Computer System
For Telemetry Units and e) Wide Area Network.
j) The scope of the work involves Supply, delivery, erection, testing and commissioning of control systems and field instruments for Data access, such as flow
meters, pressure and level transmitters and indicators, online analyzers for measuring Ph, TOC, Residual Chlorine, Turbidity, conductivity, silica, ORP, dissolved
oxygen analyzers etc and all equipment should be hardwired with the Remote Telemetry Units(RTUs) housed in the treatment plant. The minimum field
instruments / Instrumentation system required to be erected under the Project are listed elsewhere in this Bid document.
k) Sensing & Collection of process parameters such as flow rate, pressure in pipelines, dissolved oxygen content, pH etc., along with valves and motor on/ off
status and other electrical parameters from the various process units shall be monitored and logged at preset intervals using Remote Telemetry Units(RTU). They
should function as a Programmable Logic Controller(PLC), Data logger and supports multi-communication modems like GSM dialup, SMS, and Industrial
Ethernet Broadband. The software should have the capability of automatic selection of communication like GSM dialup and so that the units installed at various
stations will transfer Data and in time of crisis it will also intimate the problems through SMS. In addition to the Online parameters, other parameters to be
analyzed manually if any in the laboratory should be incorporated in the SCADA system along with the auto generated results .
l) Officials of the Owner at Kodungaiyur STP should be provided with Personal Computers along with other peripherals. A Wide Area Network should be
established through dedicated Ethernet lines for the proposed TTROP in the local loop. Connecting to the existing V-SAT Telemetry network available in
CMWSSBs Head office at Chindadripet, Chennai 600002 along with all the required necessary hardware and software support will fall within the scope of this
contract.
m) The contractor has to maintain the entire Telemetry system during the O&M period.
21.2 The Contractor shall generate plant - wise documents and drawings such as but not limited to the following as per good engineering practice for Design
Build Operate Engineer or his representatives approval.
a) Preparation of plant - wise piping and instrument diagrams using latest ISA (Instrument Society of America) Symbols.
b) Instrument Schedule (List)
c) Design data sheets for all panel - mounted & Field instruments in ISA format (latest).
d) Design Data sheets for instrument control panel.
e) Design Data sheets for Instrument Junction Boxes for power supply & signal cables.
f) Design Data sheets for power and signal cables.
g) Design Data sheets for Double Compression Type Nickel - plated Brass Cable glands.
h) Design Data sheets for Cable trays and Ladder trays, where applicable.
i) Control system description and operating principles.
j) Control panel layout including internal layouts and wiring details.
k) Junction Box wiring diagrams.
l) Interlock and safety system function descriptions where applicable.
m) Alarm & trip schedule including cause and effect diagrams, where applicable
n) Instrument process hook - up diagrams with bill of quantities.
o) Plant-wise Instruments and Junction Boxes location plans.
p) Plant-wise power supply Distribution Diagram.
q) Plant-wise cable routing diagram from field instruments of Junction Box to control room.
Note : It is envisaged that power cables and instrument signal cables will run separately and cables in the field (where buildings and sheds are not available) shall
be buried underground and thereafter shall run through trenches /walls / columns inside the buildings.
r) Plant -wise instrument cable schedule.
s) Calibration and Test Certificates of Instruments.
t) Contractor quality plan.
u) Spare parts list (item-wise).
v) Plant-wise cable routing layout in details near the entry of the control room.
w) Types and sizes of process connections of field instruments in general.
21.3 Contractor shall also comply with the SPECIFICATIONS OF INSTRUMENTATION which is followed herewith. In case of any contradiction Contractor
shall get the same clarified from the Design Build Operate Engineer or his representative before placing the order for supply of these items.
21.4 MINIMUM FIELD INSTRUMENTS / INSTRUMENTATION SYSTEM REQUIRED
The following is the minimum requirement of Instruments for the various process units

Item no 1 Inlet pipe

a Supply, Delivery, erection, testing and commissioning of electromagnetic flow


meter for measuring influent to the TTRO Plant including cables earthing etc
complete. 1 Set

Item no 2 Pre Chlorination contact Tank / Rapid sand filter feed sump

A Supply, Delivery, erection, testing and commissioning of Universal multi


controller display unit so as to display influent to the TTRO Plants TSS, pH,
Conductivity, BOD/COD, TOC, Silica including accessories, cable etc.complete
1 Set

B Supply, Delivery, erection, testing and commissioning of Turbidity/ suspended


solids sensor with self cleansing mechanism so as to measure online influent to the
TTRO Plants TSS ,including accessories, cable etc.complete 1 Set

C Supply, Delivery, erection, testing and commissioning of Differential pH sensor so


as to measure online influent to the TTRO Plants pH, including accessories, cable
etc.complete 1 Set

D Supply, Delivery, erection, testing and commissioning of conductivity sensor so as


to measure online influent to the TTRO Plants conductivity, including
accessories, cable etc.complete 1 Set

E Supply, Delivery, erection, testing and commissioning of indicative BOD/COD


using TOC method sensor so as to measure online influent to the TTRO Plants
BOD/COD , TOC including accessories, cable etc.complete 1 Set

Item no 3 Rapid Gravity Filters

A Supply, Delivery, erection, testing and commissioning of differential pressure


transmitter complete with level sensor, Electronic unit with 4-20mA output and
along with mounting frame and structure for mounting the level measuring
assembly for Filter back wash 1

Item no 4 Ultrafiltration feed sump

a) Supply and delivery of level transmitters and other Instrumentation works


including cables and earthing etc complete 1 Set

Item no 5 Ultra filtration units

a) Supply, Delivery, erection, testing and commissioning of differential pressure


transmitter complete in each skid inlet and outlet, Electronic unit with 4-20mA
output and along with mounting frame and structure for mounting the level
measuring assembly for ultra Filtration with allied accessories. 1 Set

b) Supply, Delivery, erection, testing and commissioning of Differential pH sensor so


as to measure online back wash line down streams pH, including accessories,
cable etc.complete 1 Set

c) Supply, Delivery, erection, testing and commissioning of PSV in inlet to ultra


filtration including accessories, cable etc.complete 1 Set

d) Supply, Delivery, erection, testing and commissioning of flow element with


transmitter, indicator, integrator/totalizer and recorder at the out let of each UF skid
including accessories, cable etc.complete 1 Set

e) Supply, Delivery, erection, testing and commissioning of timer for back washing,
fast flush for complete automatic(PLC based) for entire operation of ultrafiltration,
with alarm at end of cycle to be provided including accessories, cable etc.complete
1 Set

Item no 6 UF Permeate Tank

a) Supply, Delivery, erection, testing and commissioning of Instrumentation control


panel for including for all displays for flow measuring devices, and level switches,
level indicators, level transmitters(high and low) level transmitter for interlocking
purpose to auto start/trip UF backwash pumps The level transmitters shall have
level indication in both local as well as in control room etc complete. 1 Set

b) Supply, Delivery, erection, testing and commissioning of flow transmitter in local


and control room in addition to totalizing facility in the line taken from UF
permeate tank to be provided including accessories, cable etc.complete 1 Set

c) Supply, Delivery, erection, testing and commissioning of Residual chlorine


analyser in the line taken from UF permeate tank to be provided including
accessories, cable etc.complete 1 Set
Item no 7 Cartridge Filters

a) Supply, Delivery, erection, testing and commissioning of differential pressure


transmitter in each cartridge filter module including accessories, cable etc.complete
1 Set

Item no 8 Reverse osmosis skids

A Supply, Delivery, erection, testing and commissioning of flow indicators, pressure


indicators on feed , permeate and reject lines in each stream including accessories,
cable etc.complete 1 Set

B Supply, Delivery, erection, testing and commissioning of differential pressure


transmitter in each RO skids module including accessories, cable etc.complete 1
Set

C Supply, Delivery, erection, testing and commissioning of conductivity and multi


channel Silica analyzer at outlet including accessories, cable etc.complete 1 Set

D Supply, Delivery, erection, testing and commissioning of conductivity, silica ORP


and pH analyzer in common inlet header including accessories, cable etc.complete
1 Set

E Supply, Delivery, erection, testing and commissioning of conductivity, silica


analyzer in common outlet header of RO skids including accessories, cable
etc.complete 1 Set

F Supply, Delivery, erection, testing and commissioning of flow element with


transmitter, indicator, integrator/totalizer recorder at the outlet of each RO skids
including accessories, cable etc.complete 1 Set
Item no 9 Chemical dosing Tanks and pumps

A Supply, Delivery, erection, testing and commissioning of level transmitters ( Both


level transmitters to have level indication in local as well as in control room)for
auto tripping of the dosing pump and agitators at low level of each tank including
accessories, cable etc.complete 1 Set

B Supply, Delivery, erection, testing and commissioning of flow indicators in each


discharge line of dosing pumps, including accessories, cable etc.complete 1 Set

Item no 10 Air Blower Room

a) Supply, Delivery, erection, testing and commissioning of pressure gauges


Temperature detector with all accessories complete 1 Set

b) Supply, Delivery, erection, testing and commissioning of air flow meter with all
accessories complete 1 Set

Item no 11 Product water pumping main for conveying product water

a) Supply, Delivery, erection, testing and commissioning of electromagnetic flow meter


for 800mm dia conveying pipe lines including all accessories complete 1 Set

b) Supply, Delivery, erection, testing and commissioning of pressure gauges with all
accessories complete 1 Set

Item no 12 Administrative Office / Laboratory / SCADA Building

CONTROL SYSTEM
A Supply, Delivery, erection, testing and commissioning of PLC/RTU - 32 Bit CPU with
64MB memory, Digital Inputs card, Digital Output card, Analog input 4/20 mA card,
Ethernet, RS232, RS485, 6" In-built color touch screen display, Power supply with
battery and closed cubical - control Desk with power supply, internal Wiring & required
accessories for TTRO Plant 1 Set

B Supply, Delivery, erection, testing and commissioning of PLC/RTU - 32 Bit CPU with
128KB memory, Digital Inputs card, Digital Output card, Analog input 4/20 mA card,
Ethernet, 6" MMI - color, Power supply and closed cubical for control desk with power
supply, internal Wiring & required accessories 1 Set

SCADA SYSTEM

A Supply, Delivery, erection, testing and commissioning of SCADA Application server -


Intel i7 -860, 2.8 Ghz , 8MB cache, with original INTEL Motherboard, 8 GB DDR3-
1066 RAM, 20 inch LCD Monitor, 500x2 GB SATA Hard disk, Floppy Drive, DVD
writer, Multimedia Keyboard, Optical mouse, 10/100/1000 MBPS Ethernet Card,
Windows XP professional (Licensed version), Anti- Virus software3yrs warranty 1
Set

B Supply, Delivery, erection, testing and commissioning of Personal Computer Intel i3 ,


with original INTEL Motherboard, 2 GB DDR3 RAM, 20 inch LCD Monitor, 500 GB
SATA Hard disk, DVD writer, Multimedia Keyboard, Optical mouse, Speakers,
10/100/100 MBPS Ethernet Card, Windows XP professional (Licensed version), Anti-
Virus software and standard computer furniture 3 Sets

C Supply, Delivery, erection, testing and commissioning of Printer - Color Laser Jet, A4
size 1 Set
D Supply, Delivery and installation of SCADA software (Licensed version) 1 Set

E Supply, Delivery, erection, testing and commissioning of On-line UPS unit of capacity
2KVA with maintenance free batteries to have a battery back up of 1 Hours. The UPS
input shall be 230 V, 50 Hz, 1-Phase and output shall be 230 V AC, 50 Hz. 2 Sets

F Supply, Delivery, erection, testing and commissioning of necessary


telemetry/communication equipment for MPLS connectivity with service provider 1
Set

G Supply Delivery and installation of Office XP (Professional) software 4 Sets

Item no 13 Ozone Building


The outlet ozone gas of each ozone-generating module shall be measured by a
A
common ozone analyzer (common for all ozone generating modules), of digital
display model in gm / Nm3 (range 0 to 400) having accuracy of 0.1 gm/Nm3 based on
UV adsorption technique. 1 Set
CABLING WORKS

A Supply, Delivery, erection, testing and commissioning of Signal, control and power
cables and connecting the field instruments to the PLC control panel 1 Set

21.5 SPECIFICATIONS OF INSTRUMENTATION


21.5.1 SCOPE
21.5.1.1 Contractor shall be fully responsible for design, materials selection, and selection of the proper instruments for their system to be offered.
21.5.1.2 All equipment and their supplied items shall be of proven quality with respect to design, materials and working environments of site. No prototype
instrument or instruments of experimental nature shall be offered or supplied.
21.5.1.3 Contractor shall take care of instrument cables, cast aluminium Junction Boxes, Nickel-plated Brass cables glands, pipes and pipe - fittings and all other
hardwares , as may be necessary for supply, erection & commissioning to entire satisfaction of the Design Build Operate Engineer or his representative.
21.5.1.4 Contractor shall prepare and submit piping & instrument Diagrams for the system in his scope of supply, showing all the instruments and inter
lock/trip requirement. Each instrument shall be given individual tag numbers from blocks of numbers to be allotted by the purchaser. Symbols shall be as per
ISA S5. 1.
21.5.1.5 Contractor shall clearly define the operational philosophy, suggested by him, which should be in line with requirements specified in the job
specification. Contractor shall also clearly specify the provision of control panels requirement for their package in the offer.
21.5.2 DESIGN PHILOSOPHY
21.5.2.1 Instrumentation shall be complete in every respect and liberal to the extent of providing data or all operation variables sufficient for the safe,
efficient, easy operation, easy fault diagnosis, start - up and shut down of the plant.
21.5.2.2 The design and installation of instruments shall be generally in accordance with ISA/API recommended practices and other applicable IS standards.
21.5.2.3 All instruments and equipment shall be suitable for use in a hot , humid & tropical industrial climate in which inflammable gases may be present.
21.5.2.4 Location of process connection shall be either from the side or from the top of the process equipment and pipes but not from the bottom. The location of
lower side connection shall be high enough to prevent plugging due to dirt or other suspended solid.
21.5.2.5 The design of control panel shall incorporate provision for expansion by providing spare capacity. Each panel shall be designed to accommodate 10%
minimum additional equipment including 10% spare cable entry points and 20% spare terminals.
21.5.2.6 Instrument power circuits shall be individually protected from fault with the help of fuses. Power supply to the individual instrument shall be
disconnectable with the help of switch and protected with the help of fuse.
21.5.2.7 Power supply for all panel - mounted and field instruments shall be 240 VAC 10% 50 1.5 HZ except field installed transmitters which shall have
24VDC loop- powering from corresponding receiver instruments in control panel.
21.5.2.8 All indicating Lamps on control panel for status indications of all drives should be "clustered LED" where power supply shall be 240VAC 10%. Also
the lamps for windows of annunciator shall be bright "clustered LED". Use of filament lamps shall be avoided.
21.5.2.9 Ranges for instruments shall be selected, in general, such that in normal process operation the indication on the indicator or chart is between 40% to 60%
of span.
21.5.2.10 Adequate alarms shall give audible and visual warning of malfunction in the plant. For all drives :"stop:" alarm is to be provided in the
annunciator and also lamp (red) indication to indicate "drive running".
21.5.2.11 For all lamps "Test" facility shall be provided in the panel.
21.5.2.12 Orifice calculation shall be done preferable as per ISO 5167 standard. Alternatively the same should be done as per BS - 1042 part -1 (latest
issue).
21.5.2.13 All transmitter shall be provided with local output meter with LCD display. This display shall preferably be plug - in type.
21.5.2.14 The Contractor shall ensure that packing of instrument and accessories is adequate to prevent them from such contingencies as rough handling,
weather condensation , dew, vermin, shock and vibration.
21.5.2.15 Contractor shall be responsible for distribution of Instrument power supply. The Contractor shall specify the total estimated power consumption
under normal and peak local condition along with the offer.
21.5.2.16 In control panel and all Junction Boxes shall have at least 20% spare terminals.
21.5.2.17 All multicore Signal cables shall have at least 20% spare cores.
21.5.3.0 GENERAL SPECIFICATION OF INSTRUMENTS
Instrument concept.
21.5.3.1 All instruments shall be electronic type, Transmitters shall be "smart" type and conventional electronic type where "smart" version is not available.
All accessories shall be compatible to the relay based Automation system and shall be confirm IS standards.
21.5.3.2 Electronic panel mounted instruments shall generally operate on 240 VAC. Field -mounted transmitter shall work on 2 -wire 24 VDC to be
available from corresponding receiver instrument. Transmission output signals shall be 4-20 mA. External load shall be at least 600 ohms.
21.5.3.3. All electronic instruments shall be immune to Radio Frequency interference.
21.5.3.4. Space between consecutive cable tray supports shall not be more than 1500 mm. All cables from JB to panel shall run on 3 mm thick G.I Cable Tray
and should be neatly arranged and clamped - Trays shall be supported by 50 x 50 x 6 Angle iron.
21.5.3.5. All cores of cables in JB and control panel shall be provided with interlock ferrules at both ends for correct and easy identification. Similarly all cores
of cables running between field instrument to JB shall be properly ferruled.
21.5.4 INSTRUMENTATION AND TELEMETRY SYSTEM
Description of work
21.5.4.1 Supply, Deliver, install and commission instrumentation and controls hereinafter specified to perform the intended function. Work shall include all
necessary materials, equipment, labour and services.
21.5.4.2 In order to ensure the inter changeability of parts, the maintenance of quality, the ease of communications between the various subsystems and the
establishment of minimum standards of quality, manufacturers standard offerings, shall be of the same product family of a single manufacturer. In order to issue
this compatibility between all equipment, it shall be the responsibility of the Contractor to enforce this requirement with the equipment suppliers.
21.5.4.3 Equipment shall be fabricated, assembled, installed and placed in proper operating condition in full conformity with these specifications, engineering
data, instructions and recommendations of the equipment manufacturer as approved by the Owner.
21.5.4.4 The contractor shall engage a single system supplier, who shall provide all of the services, equipment and appurtenances required to achieve a fully
integrated and operational instrumentation and control system. To facilitate the Owners future operation and maintenance, products shall be of the same major
instrumentation manufacturer.
Quality Assurance
21.5.4.5 The system supplier shall be required to demonstrate to the Design Build Operate Engineer (after award of Contract) of sufficient experience in the
design, manufacture and commissioning of instrumentation and control systems of comparable size, type (WTP/STP/TTROP/Desalination Plant) and SCADA
system (involving Pressure, Flow, Level and Energy parameters) to the proposed project. The system supplier shall have in-house engineering, programming,
fabrication, and testing capability to expedite the project in its entirety. The supplier shall have a permanent, local Chennai support office with experience on
similar projects and capable of maintaining or upgrading the SCADA system and other instrumentation systems.
21.5.4.6 The proposed SCADA system shall be open system architecture utilizing standard operating and communication systems. The System Supplier shall
provide documentation of successful and field performance of the proposed system, including hardware and software, for application of similar type, size, and
complexity. The Supplier shall demonstrate that such system has been successfully employed in water supply or sewerage system applications. Unproven or
proprietary systems shall not be acceptable. The Design Build Operate Engineers decision shall be final and binding on both the parties.
21.5.4.7 The system supplier shall employ full time personnel for detail engineering, scheduling installations, testing, start-up service for calibration and
commissioning and warranty compliance for the period specified.
21.5.4.8 The following evidence shall be submitted by the successful Bidder to the Design Build Operate Engineer before finalization of the Supplier.
A. Experience of the Supplier in performing projects similar to this one.
B. Information on the proposed SCADA system hardware and software system to allow the Design Build Operate Engineer to determine if the proposed
system is both state-of-the-art as well as proven at other, similar installations.
Should the Design Build Operate Engineer review this information and determine the submitted information is not sufficient to determine the capabilities of
the supplier, the successful Bidder shall submit additional information as requested. Should the Design Build Operate Engineer determine the proposed single
system supplier for the instrumentation system does not meet the experience requirements listed above, an alternate supplier shall be proposed and new
experience information submitted. The Design Build Operate Engineers decision in selecting the Supplier shall be final and binding on both the parties.
Shipping Precautions
21.5.4.9 Special instructions for proper field handling, storage and installation required by manufacturer for proper protection, shall be securely attached to each
piece of equipment prior to packaging and shipment. None of the equipment shall be shipped to the site until the sites are environmentally suitable.
Identification
21.5.4.10 Each component shall be tagged to identify its location and function in the system. Identification shall be prominently displayed on the outside of the
package.
Test Equipment
21.5.4.11 Test equipment shall be provided, together with items such as instruction manuals, carrying / storage cases, unit battery charger where applicable,
special tools, calibration fixtures, cord extenders, patch cords and test leads, which are not specified but are necessary for checking field operation of equipment
supplied under this Contract.
Source Quality Control
21.5.4.12 The manufacturers of the equipment and fabricators of RTU cabinet supplied under this Contract shall allow the Design Build Operate Engineer or
his representative (if required) to inspect and witness the testing of the equipment at the site of fabrication. Equipment shall include the cabinets, special control
systems, flow measuring devices, pressure measuring devices, level measuring devices, transmitters and other pertinent systems and / or devices. A minimum of
ten working days notification shall be provided to the Design Build Operate Engineer or his representative prior to testing. Shipments shall be made after the
consent of the Design Build Operate Engineer or his representative.
21.5.4.13 INSTRUMENTATION EQUIPMENT
21.5.4.13.1 Field Instruments
The instruments to be supplied for measuring flow, level and pressure shall be of robust design, inherently free of faults and requiring as little maintenance and
adjustments as possible for effective operation.
Instruments, supports etc. are all to be of materials resistant to or protected from the temperature and humidity to be encountered in the atmosphere present in the
tropical climate.
Instruments are to be of a type which will maintain reasonable accuracy without adjustment. All necessary transmitters / converters, indicators, cabling, etc. for
the instrumentation system shall be provided as required by the manufacturer.
Electronic equipment shall be of the solid-state type and of the manufacturers latest design. The equipment shall use one of the following standards DC ( direct
current) signals, unless otherwise specified (1) 0 to 5 volts, (2) 4 to 20 mill amperes.
Instruments shall be provided with mounting hardware and floor stands, wall brackets, or instrument racks.
All work shall be in strict accordance with codes and local rulings.
Transmitters shall be provided with either integral indicators or conduit mounted indicators in metric process units, accurate to one percent unless otherwise
stated.
Electronic equipment utilizing printed circuitry shall be suitably coated to prevent contamination by dust, moisture and fungus. The field mounted equipment and
system components shall be designed for installation in dusty, humid and highly corrosive service conditions.
Equipment shall be heavy-duty type, designed for continuous industrial service. Equipment shall be of the latest equipment models which are currently in
production. All equipment shall be of modular construction and shall capable of field expansion. All identical components shall be by the same manufacturer.
The master control room equipment will be installed in air-conditioned areas; however, the equipment shall nevertheless be designed to operate satisfactorily up
to 50degree C ambient temperature and 90 percent humidity assuming air conditioning may not be available.
Field cabinets and enclosures shall be IP55 gasket with multi-point latching doors.
21.5.4.13.2 Accuracy and Range of Measurement
The process instrument system supplied here under shall have the following ranges and / or accuracy depending on type and application:

Instrument Type Accuracy


Pressure Gauge 100 kN./m2 or over 0.5%

Pressure Gauge Under 100 kN./ m2 --------

Unless otherwise specified, the accuracy of the primary plus the secondary instruments shall be within + - of the scale deflection. If the accuracy of the
equipment is not within this specified range at low flows the supplier shall state the accuracy he can guarantee and the same shall be approved by the Design
Build Operate Engineer or his representative. Where the accuracy of the equipment is not within 2% of the full scale deflection calibration curves shall be
provided in graphical form together with the test certificates.
21.5.4.13.3 Electrical Requirements
Equipment shall be designed to operate on 230 volt, 50 Hertz alternating current power source except where specifically noted. All regulators and power supplies
required for compliance with the above shall be provided between power supply and interconnected instrument loop. Where equipment requires voltage
regulation, constant voltage transformers shall be supplied.
Analogue transmitter and controller outputs shall be 4-20 milliamps into a load of 0-750 ohms, unless specifically noted otherwise.
All switches shall have double-pole double-throw contacts rated at a minimum of 600 VA, unless specifically noted otherwise.
Equipment shall be designed and constructed so that in the event of a power interruption, the equipment shall resume normal operation without manual resetting
when power is restored.
21.5.4.13.4 Energy Monitoring System
The Energy Monitors shall be communicating type and capable of indicating the following parameters such as
Current per-phase.
Neutral current.
Voltage, phase-to-phase & phase-to-neutral.
Real Power (kW), per phase & three-phase total
Reactive Power (kVAR), per phase & three phase total
Apparent Power (kVA), three phase total
Power Factor (true), three-phase total
Frequency readings
Real Energy (kWh)
Reactive Energy (kVARh)
Real Power Demand (kWd) or Reactive Power Demand (kVArd) or Apparent Power Demand (kVAd) readings, three phase total, present and max value
Operating time
Pump on/off status and pump operating hours
Winding and bearing temperatures of motors (necessary cables, leads and other necessary components to be provided from the motors as required to connect to
the RTU and will form part of the contract).
21.5.4.13.5 FLOW MEASURING SYSTEM
Flow measuring system shall consist of flow sensor/ transducers, flow computer and flow transmitter.
Flow transducers shall be rugged in construction and shall be suitable for continuous operation. Flow transducers shall have waterproof construction and shall be
suitable for installation in underground/ above ground pipeline. To avoid the effects of disturbances in the velocity profile, a straight and uninterrupted run,
upstream as well as downstream from the location of the flow sensor shall be provided in accordance with the requirements of the flow meter manufacturer. The
flow transmitter shall be suitable for field or panel mounting and shall accept an input from the flow sensor. It shall process the input signal and provide 4-20 mA
dc output proportional to flow rate. The flow range shall be adjustable.
A zero span adjustment facility shall be provided for flow transmitter and indicator. Flow measurement shall not be affected by physical properties of liquid
encountered viz., temperature, pressure, viscosity, density etc., within given limits. Contractor shall provide compensating electronic circuits if required. The
overall accuracy of flow measuring systems shall be at least 1.0% of the measured value unless otherwise stated.
Flow metering as specified will be either open channel type or full bore electromagnetic type as applicable.
21.5.4.13.5.1. Electromagnetic Flow meter
Full Bore Electro Magnetic Flow meters For Closed Pipe Measurements (Flanged Type)
Full bore bi-directional electromagnetic flow meters shall be designed, manufactured and calibrated to international standards. They should also have actual flow
rate & Totalizer (Forward / Reverse) for effective water management purposes. The accuracy will be +/- 0.5% of reading. Any deviations with the reasons must
be stated at the time of getting the approval of the Design Build Operate Engineer.
The supplier shall have full ISO 9000 series accreditation and fully traceable calibration methods to either of the two primary standard means of testing. These
are mass (ISO 4185) or volume (ISO 6817). The suppliers shall also have a testing facility in India or abroad so that methodology and procedures can be
verified. Each meter shall be wet calibrated with 3 point calibration at sufficient flow rates to verify performance in accordance with the specification. The
testing facility shall be duly accredited in accordance with ISO 17025 standards.
The sensors shall be as per ISO standard lengths (ISO 13359), so that interchangeability can be carried out. The sensor shall also have built in grounding and
empty pipe detection electrodes for efficient operation purposes. Ground probes, rings, flanges or straps will be strictly not acceptable. The liner material shall be
either certified Hard Rubber (HR) / Polyurethane (PU) only. The sensor & transmitter should be capable of working in tropical environment. The meter body
shall be available in flanged or with custom connectors as specified in the data sheets. The wafer design will be strictly not acceptable.
The sensors will be rated IP68 for direct burial or submersible operation. The transmitter will be rated IP 67 / IP 68 in line with local operating conditions.
Installations shall be made with cables and /or conduits that guarantee the integrity of the system under all operational conditions.
The transmitter/converter shall be wall-mounted type with a two-line backlit display for the indication of Actual flow rate, Totalizer (Forward / Reverse). A glass
window within the protection enclosure will be provided for local reading purposes. The material of the enclosure shall be sufficient to guarantee full operational
life.
The transmitter will be capable of being fully programmed with push button / using HART communicator or other protocols as required to suit the RTUs. It
shall have a set-up menu so that all relevant parameters may be user-set from the self-prompting driven menu. The repeatability shall be 0.1% of reading or
better, minimum +/-0.5mm/s.
The transmitter shall have Digital output. The current output shall be galvanically isolated. It shall be fitted with switched mode power supply capability 85-
260V and 45-65Hz to cope with power transients without damage.
The pulsed DC type flow sensors shall normally be installed remotely from the transmitters and are to be subject to harsh environmental conditions. Design for
direct burial is therefore mandatory. At some locations, underground chambers may be used and in such cases the operation under fully submerged conditions
may occur. Thus, in either case a full IP68 design is necessary. The sensor shall therefore be made from SS 316 materials with flanges of up to PN10 rating
from carbon steel, suitably treated for the application. The sensor coil housing shall be powder coated cast aluminium with NEMA 4X rating (IP 67 / 68) or
painted carbon steel. The paint should be of durable anti-corrosion grade. The tube liner shall be suitable for potable water /sewage/treated Product water usage,
therefore certified hard rubber or polyurethane is specified.
It shall be possible to separate the sensor and transmitters up to 150 meters without the need for signal boosters or amplifiers. It is assumed that the water
conductivity will be at least 150s/cm.
The successful bidder shall provide full data on each flow meter required, including optimizing and sizing programs calculation sheet. The proposed flow meter
model no. by the manufacturer should be available on their official website with complete technical catalogue / operating manual for flow meter (sensor /
transmitter).
Field verification tools and equipment shall be supplied to ensure continued successful operation of the sensor and transmitter. Thus, manufacturer shall supply
the necessary tool for inline validation of calibration for the flow meter.
The Totalizer value shall be protected by EEPROM during power outage, and utilizes an overflow counter.
The flow meter supplier shall provide 3-point calibration report as carried out based on relevant standards, before dispatch of the flow meters. Calibration facility
should be accredited to ISO 17025.
If pipe tapers are required on either sides of the sensor then the flow sensor manufacturers recommendation, in consultation & agreement with the Design
Build - Operate Engineer or his representative, shall be followed as to the geometry and positions of the tapers. The flange adapters confirming to relevant
standards & necessary reducer / expander assemblies as may be required for flow meter fixing shall be provided based on manufacturers recommendation
suitable for water mains. The electrometric gaskets (SBR) shall be used for these fittings must comply with BS 2494 W and should be Type W.
Jute or other fibrous materials shall not be used for sealing of screw joints. Only PTFE tape may be used. EPD Electrodes / Grounding electrode should be
included.
If there is any problem with ovality of pipes after the pipes are cut, the contractor as per the relevant standards shall jack up the pipes and the jointing work shall
be carried out.
The sensor / transmitter cables shall be capable of withstanding the climatic condition as applicable at site and should be weatherproof. The cable shall be
installed in a suitable PVC duct to minimize the risk of damage during excavations for other works. All the cable shall be laid at a minimum depth of 0.5 m
below the ground. Maximum length between the sensor and the transmitter shall not be more than that recommended by the meter manufacturer.
The transmitter shall operate so as to avoid loss of data in the event of temporary loss of electrical power supply and Bidder shall price the option of provision of
maintenance free battery back up facility (8 hours duration) to cater for temporary loss of such power supply. The Bidder must allow for normal variations in
mains electrical
power parameters to be expected at site. The following to be ensured by the bidder:
a) Quick set up via web browser
b) Communication via Internet.
c) Integrated web server, values available to any web browser.
d) Data offered in HTML and XML format.
e) OPC capability
f) Continuous communication.
g) Communication capabilities with Digital protocol, HART devices
as also analog 4-20 mA
h) Communication via modem, Ethernet or GSM/GPRS
i) Synchronised time stamping of all measured values.

21.5.4.13.5.2. Open Channel Flow Meter


If Open channel is provided anywhere in the TTRO Plant, then the following specifications shall apply.
Open channel flow measuring system shall consist of level transducer, flow computer and flow transmitter. The level of the fluid in the flume shall be measured
by the ultrasonic level transducer. The level measured shall be used along with the physical characteristics of the flume to compute the flow rate.
The level transducer shall be suitable for flange or bracket mounting as required and shall be environmentally protected as per IP65. It shall have ambient
temperature compensation and adjustable datum setting facilities.
The design and application of ultrasonic level meter shall take into account the channel construction, the material size, shape, environment, process fluid or
material, the presence of foam granules, size etc.
The installation shall avoid any degradation of performance from spurious reflections, absorption, sound velocity variations, sensor detection area, temperature
fluctuation, specific gravity changes and condensation. For application where spurious reflections are unavoidable the control unit shall be provided with
facilities for spurious reflection rejection.
The structure required for supporting the level sensor, platform, railings etc. shall be in the Contractors scope.
The Online flow meter should employ an ultrasonic principle to measure flow. It should provide isolated 4-20mA/0-10VDC output based on flow rate. It should
have inbuilt LCD display and housed in an IP65 enclosure. Maximum error in measurement should be within +/-0.2% m at head change of 3m at 22degC and 40-
70%RH. The probe unit should be in-corrosive and unaffected by H2S laden atmosphere.
Specification:
Operational:
Display: Graphic dot matrix LCD, minimum 128 x 64 pixels with LED backlighting; minimum 10 mm main character height; minimum 2 mm auxiliary
information character height; menu screens shall contain up to six text lines.
Environmental:
Ambient Conditions:
Operation: upto 50C ; 0 to 95% relative humidity, non-condensing ( suitable for Chennai climate)
Storage: upto 50C; 0 to 95% relative humidity, non-condensing ( suitable for Chennai climate).
Relays (four): Types/Outputs: Electromechanical relays; SPDT (Form C) contacts; U.L. rated 5A 115/230 VAC, 5A @ 30 VDC resistive.
Operational Mode: Each of the 4 relays shall be possible to set so as to be driven by the measured flow, depth or volume (resettable)
Sensor Function Modes:
Alarm: Settings shall be possible for low alarm point., low alarm point deadband, high alarm point., high alarm point deadband, off delay, and on delay.
Control: Settings shall be possible for high/low phasing, setpoint, deadband, off delay, and on delay.
Penstock: Settings shall be possible for high/low phasing, off delay, and on delay.
Flow Pulse: Relay shall provide a fixed 0.5/ required second contact closure pulse output each time a user-set volume is reached.
Status: Not configurable; relay shall activate only when a diagnostic WARNING condition like i) line power interruption, ii)sensor or analyzer failure, and other
abnormal operating conditions arises.
Indicators: Relay annunciators (Each of the 4 relays) indicate respective relay on/off status.
Temperature Compensation: It shall be Automatic upto the expected maximum temperature of Chennai.
Sensor-to-Analyzer Distance: It shall be provided in accordance with the requirements of the flow meter manufacturer.
Calibration Methods: It shall be provided in accordance with the requirements of the flow meter manufacturer.
Communication:
RS-232: It shall enable configuration and retrieval of measured data for one analyzer using IBM-compatible PC and GLI optional software tool kit.
It shall have Memory Backup (non-volatile)
All user settings shall be retained indefinitely in memory (EEPROM)
Analyzer Performance (Electrical, Analog Outputs):
Accuracy: Minimum 0.5% of span.
Sensitivity: Minimum 0.1% of span
Repeatability: Minimum 0.1% of span
Response Time: Not more than 180 seconds to 90% of value upon step change.
Mechanical: Enclosure: It shall have NEMA 4X; polycarbonate face panel, epoxy-coated high-quality cast aluminum door and case with four 13 mm conduit
holes, nylon mounting bracket, and stainless steel hardware or any other superior enclosures.
Mounting Configurations: It shall have suitable horizontal and vertical mounting. 21.5.4.13.6 LEVEL MEASURING SYSTEM
21.5.4.13.6.1. Ultrasonic Level Meters
Ultrasonic level measuring devices applied for liquid level measurement shall comprise a transducer, control unit and remote indicator.
The transducer shall be suitable for flange or bracket mounting as required and shall be environmentally protected to IP 65.
The design and application of ultrasonic level meters shall take into account the vessel or channel construction, the material, size, shape, environment, process
fluid or material, the presence of foam granules, size etc.
The installation shall avoid any degradation of performance from spurious reflections, absorption, sound velocity variations, sensor detection area, temperature
fluctuations, specific gravity changes and condensation. For applications where spurious reflections are unavoidable the control unit shall be provided with
facilities for spurious reflection rejection.
If turbulence exists, shielding, stilling tubes or other measures shall be provided to avoid effects on the measurement.
Ultrasonic level type measurement devices shall be used to monitor all tanks. They should be housed in an IP68 enclosure with an integrated display unit. It
should have a 4-20mA/0-10VDC output based on level and a resolution of atleast 1mm. Measuring range should be atleast 0.3 to 8m. The unit should be CE /UL
certified.
21.5.4.13.6.2. Conductivity Level Switches:
The electrodes used for conductivity level switches shall be stainless steel. Single electrode systems (one electrode per holder) shall be used (except where their
use is impractical) with insulated electrodes such that only the tip of each electrode is exposed to the liquid at the operating level.
Relay or control units operating with level electrodes shall have adjustable sensitivity. Electrodes for use in fluids of low or variable conductivity shall be fitted
with conductivity discs.
Where relay or control units are not mounted in control panel, they shall be provided with surface mounting enclosures with a degree of protection to IP-54 for
indoor locations or IP 65 for outdoor location.
21.5.4.13.6.3. Ultrasonic Differential Level Measuring System:
If Differential level measurement is required anywhere in the TTRO Plant, then the following specifications shall apply.
The ultrasonic type differential level measuring system shall consist of ultrasonic type level sensors on upstream and downstream of the Process unit, differential
level computer / transmitter and indicator.
The flow computer / transmitter shall be microprocessor based and shall have facility for programming (i.e. adjustment of set points).
The ultrasonic transducer shall be suitable for flange or bracket mounting as required and shall be environmentally protected as per IP-65. It shall have ambient
temperature compensation and adjustable datum setting facilities.
21.5.4.13.7 DIRECT DIGITAL CONTROLLERS (DDC)
21.5.4.13.7.1 Design and Construction Requirements:
Standalone DDC panels shall be microprocessor-based, multi-tasking, multi-user, real-time digital control processors. Each standalone DDC panel shall consist
of modular hardware with plug-in enclosed processors, communication controllers, power supplies, and input/output modules with connectivity to the Network
Controller through a RS485 or Ethernet communication bus.
The DDCs should be application specific and should be located as near as possible to the controlled equipment reducing cabling runs. The DDCs should be able
to control the equipment connected to it on a standalone mode so that in case of failure of the first tier network the DDCs will be able to perform the minimum
control functions assigned to it. The DDCs should have an inbuilt display on its facia with keypad to access all the information being monitored by the DDC.
21.5.4.13.7.2 Programming:
All the DDCs should be equipped with electrically erasable PROMs and the control software for the DDC can be downloaded through the central operator
workstation. It should additionally provide a serial port for downloading and reconfiguring of software through a laptop locally. The control logic for the DDCs
should be programmed through a user-friendly graphic programming language with control algorithms like PID loops, ladder logic, sequencers etc inbuilt into
the software.
21.5.4.13.7.3. Input/Output point types:
Each DDC panel shall support the following types of point inputs and outputs: Analog inputs shall monitor the following analog signals:
4-20 mA Sensors,
0-10 VDC Sensors,
1000ohm RTDs
Binary inputs shall monitor dry contact closures. Input shall provide filtering to eliminate false signals resulting from input bouncing.
Counter inputs shall monitor dry contact pulses with an input resolution of one HZ minimum. Analog outputs shall provide the following control outputs:
4.20 mA Sink or Source
0-10 VDC
Binary outputs shall provide SPDT output contacts rated for 2 amps at 24 VAC and they shall not activate main contactors of starter thus avoiding burdening of
relays. 21.5.4.13.8 Universal Multi Controller
21.5.4.13.8.1 DESCRIPTION
Modular System: The Multi-parameter Universal Controller shall be a fully modular system consisting of a Display Module and one or more Probe Modules.
Display ModuleThe Display Module should be a full-featured controller with a large color touch-screen display. The intuitive, easy to use interface shall be
used for any number of parameters. One Display Module controls either a single Probe Module or a number of Probe Modules connected by a digital network.
The Display Module should be fully portable and should be able to be disconnected and moved anywhere within the network.
Probe ModuleEach Probe Module should provide power to the system and should be able to accept up to 4 or more digital sensors. Probe Modules should
have facility to be networked together to accommodate many more sensors attached to the same network.
Digital Reliability and Integration: Digital signals between the controller and attached sensors assure data integrity and immunity from signal interference.
Digital outputs from the controller shall make it easy to integrate the controller into an existing network. Built in advanced communication features shall include:
Ethernet port (standard)It shall be possible to attach a computer directly to the controller to operate the system from the computer, download data logs and
upload software updates.
GSM wireless modem use it for fully remote operation of the controller, including transfer of data and software updates.
21.5.4.13.8.2 ENGINEERING SPECIFICTIONS
The controller shall consist of a portable display module connected to one or more probe modules.
The portable display module shall have a color graphical touch-screen display.
Connections between the sensors and the controller shall be plug and play.
The controller shall have the option for MODBUS or PROFIBUS DP communication.
The interface unit shall allow operators to control sensor and interface functions with menu-driven software.
The controller shall have up to four potential free relays, four analog outputs and four analog inputs per probe module (all expandable via the controllers internal
network).
The controller shall have an Ethernet service port for direct connection to a personal computer for transfer of data and software updates.
The controller shall be housed in an IP65 enclosure.
The AC power supply shall be housed in the interface unit and automatically accept input in the range of 100 to 230 V AC, 50/60 Hz. An internal 24 V DC
power supply shall be available as an option.
The controller shall be proven one against defects in material and workmanship.
21.5.4.13.8.3 TECHNICAL SPECIFICATION
Ambient Conditions :
Operation: upto 50C ; 0 to 95% relative humidity, non-condensing ( suitable for Chennai climate)
Storage: upto 50C; 0 to 95% relative humidity, non-condensing ( suitable for Chennai climate)
Power Requirements : Capable of working 100 to 230 V AC, 50/60 Hz, and a option to work in 24 V DC (if required)
Display: 1/4 VGA graphical backlit TFT color touch screen with minimum Resolution of 320 x 240 pixels
Relays : Up to four SPDT, user-configurable contacts rated 100 to 230 Vac, 5 Amp resistive maximum, per probe module. Additional relays made available via
digital network connection.
Outputs: Up to 12 analog 0/4-20 mA, maximum impedance 500 Ohms per probe module. Additional analog outputs are available via digital network
connection. Digital communications via MODBUS (RS-485) or PROFIBUS DP should be made available.
Inputs :Up to 12 analog 0-20 mA, maximum impedance 500 Ohms per probe module. Additional inputs made available via digital network connection.
Control :PID, high/low phasing, setpoint, deadband, overfeed timer, off delay, and on delay.
Alarms: Low alarm point, low alarm point deadband, high alarm point, high alarm point deadband, off delay, and on delay.
Communication:
MODBUS (RS-485): Advanced communications/networking with PLC or SCADA system directly from analyzer.
PROFIBUS DP, GSM cellular module.
Ethernet service port (standard)
Memory Backup: All user settings are retained indefinitely in memory (non-volatile) (EEPROM)
Mounting Configurations: Surface, panel, and SS pipe (horizontal and vertical)
Enclosure: IP65; ABS (display module) and metal (probe module) enclosure with corrosion-resistant finish
21.5.4.13.9 Turbidity and suspended solids sensors
21.5.4.13.9.1 DESCRIPTION
It shall use a dual-beam infrared / scattered light photometer to measure turbidity. An LED light source shall transmit a beam of infrared light into the sample
stream at an angle of 45 to the sensor face. A pair of photoreceptors in the sensor face shall detect the scattered light at 90 to the transmitted beam. A
backscatter photoreceptor shall be used to accurately measure suspended solids. It shall be positioned at 140 to the transmitted beam and shall detect light
scattered in high-solids sample streams.
21.5.4.13.9.2 ENGINEERING SPECIFICATIONS
The suspended solids and/or turbidity sensor shall consist of a digital sensor designed to connect to a universal controller.
The suspended solids and/or turbidity sensor shall use dual infrared light beam technique design utilizing an LED light source in the sensor to transmit an
infrared/scattered dual beam into the sample stream at an angle of 45 degrees to the sensor face.
A photoreceptor located in the sensor face shall detect scattered light (turbidity) at 90 degrees to the transmitted beam.
A backscatter photoreceptor positioned at 140 degrees to the transmitted beam, shall detect light scattered for suspended solids readings.
The sensor shall analyze the dual-beam data and provides a color independent measurement.
The sensor shall have a self-cleaning device to prevent erroneous values and maintenance problems caused by biological activity, scum build-up, and gas
bubbles.
The self-cleaning device shall ensure that measurements are accurate, continuous, and completely color independent.
The sensor shall have an operating range of 0.001 to 50 g/L and/or 0.001 to 4000 NTU suspended solids and turbidity.
The sensor shall be capable of immersion in a tank or insertion into a pipe.
The materials of construction shall be PVC or polished stainless steel, depending on the sensor selection.
The sensor shall have an operating temperature of up to 40C.
The initial response time shall be 1 second and user-adjustable up to 300 seconds.
The accuracy shall be less than 1% of reading or 0.01 NTU, whichever is greater for turbidity and less than 5% of reading for suspended solids.
21.5.4.13.9.3 SPECIFICATIONS :
Parameter : Turbidity, Suspended Solids
Measuring Range : Turbidity: 0.001 to 4000 NTU
Suspended Solids : 0.001 to 50 g/L
Units of Measure :
Turbidity: User selectableNTU, FNU, or TE/F
Suspended Solids: User selectableg/L, mg/L, ppm, or % solids
Accuracy: Defined according to ISO/WD 13530.
Turbidity Less than 1% of reading or 0.001 NTU, whichever is greater Suspended Solids: Less than 5% of reading
Repeatability: Defined according to ISO/WD 13530.
Turbidity : Less than 1% of reading
Suspended Solids : Less than 3% of reading
Detection Limit:
Turbidity : 0.001 NTU
Suspended Solids : 1 mg/L
Response Time : Initial response in 1 second
Signal Average Time: User selectable ranging from 1 to 300 seconds
Calibration
Turbidity: Formazin or StablCal Standard
Suspended Solids: Based on gravimetric TSS analysis with a correction factor procedure
Mounting: Fixed to the rim of the tank
Flow Velocity : 3 m/s maximum
Operating Temperature : Up to 40C
Sample Temperature : Up to 40C
Sample Pressure : 6 bar maximum
Sensor Construction
Wiper : Silicon
Sensor body : Stainless steel or PVC
Cable Length : Required cable length shall be provided
21.5.4.13.10 Differential pH sensors
21.5.4.13.10.1 Description
It shall have three electrodes so that Process and reference electrodes measure the Ph differentially with respect to a third ground electrode so as to have very
good measurement accuracy, reduced reference junction potential, elimination of sensor ground loops, greater reliability, resulting in less downtime and
maintenance.
Built-in Encapsulated Preamp It shall have encapsulated construction so as to protect the sensors built-in preamp from moisture and humidity, ensuring
reliable sensor operation. The preamp in the pHD analog sensor shall produce a strong signal, enabling the sensor to be located well away from the analyzer.
Durable Body Materials Both the digital and analog pH and ORP differential sensors shall have a durable body for chemical compatibility with the expected
process solutions of the proposed TTRO Plant. A sensor with a stainless steel body shall be provided for immersion applications.
21.5.4.13.10.2 Engineering specifications :
Stainless Steel pH Sensor
The pH or ORP sensor shall be of differential electrode technique design using two measuring electrodes to compare the process value to a stable internal
reference standard buffer solution. The standard electrode shall have non-flowing and fouling-resistant characteristics.
The sensor shall be capable of chain mounting for immersion applications, and shall be constructed of SS316.
The built-in electronics of the sensor shall be completely encapsulated for protection from moisture and humidity.
The sensor shall have a built-in preamplifier to enable the signal to be transmitted up to 100 m with standard cabling and up to 1000 m with a termination box.
The sensor signal shall have an integral temperature sensor to automatically compensate measured values for changes in process temperature.
The sensor shall include a titanium ground electrode (standard) to eliminate ground loop currents in the measuring electrodes.
The sensor shall be of proven one.
The Probe / Sensor should be of detachable type and able to work with the digital controllers.
SPECIFICATION OF pH SENSOR
Measuring Range : 2 to 12 pH
Sensitivity : 0.01 pH
Stability : 0.03 pH per 24 hours, non-cumulative
Operating Temp : Digital Sensor / Analog Sensor with Digital Gateway / Immersion Sensor: 0 to 50C
Flow Rate : 3 m per second, maximum
Sensor Pressure/Temperature Limits : 6.9 bar / 70C
Built-in Temp Element : NTC 300 ohm thermistor for automatic temperature compensation and analyzer temperature readout
Transmission Distance: shall be restricted to 100 m, maximum and 1000 m, maximum when used with a termination box
Sensor Cable (integral): 4 conductor cable with one shield and polyurethane jacket; rated to 105C of required
Wetted Materials : Suitable for TTROP operations
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21.5.4.13.11 Conductivity sensors It shall be high performance sensors using high quality, rugged materials for demanding applications of the STP/TTROP
environment. Each sensor shall have RTD temperature element built into its tip for exceptionally fast response to changes in temperature with 0.1C accuracy.
The sensors shall measure the required conductivity expected in a TTROP.
TECHNICAL SPECIFICATIONS
MEASURING RANGES
Conductivity 01000 S/cm
Resistivity 0.001-20 Mohm
Temperature Measurement Range: upto 50C
Accuracy:2% of reading above 200 S/cm
Sensitivity:0.5% of reading
Response Time:90% of reading within 30 seconds of step change
Repeatability:0.5% of reading
Flow Rate:03 m/s, maximum, fully immersed
Transmission Distance: shall be restricted to 100 m maximum and 1000 m maximum when used with a termination box
Sensor Cable: Digital: PUR (polyethylene) 5-conductor, shielded, rated to 150C Analog: Without junction box:- 6 wire cable (4 conductors and two isolated
shield wires) With Junction Box head: (if required) 6-position terminal strip supplied in integrally-mounted junction box of SS 316.
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21.5.4.13.12 Not used
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21.5.4.13.13 Indicative BOD / COD & TOC: Continuous absorbance / Transmittance measurements shall be used to protect plant treatment processes from
high organic loads.
Specifications:

Measuring Technique UV absorption measurement (2-beam technique), reagent-free

Measuring Path From 1 mm to 50 mm pathlengths (as per requirement)

Measuring Range 0.01-3000 m-1

Compensation 550 nm

Measuring Interval (= > 1 min


min)

Cable length As per requirement restricted to a maximum of 120 m

Control function PID, time control, 2-point controller (as per requirement)

Probe pressure limit Maximum 0.5 bar

Ambient sample Up to +40 C


temperature

Sample pH 4.5 to 9 pH

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21.5.4.13.14 Not Used
------------------------------------------------------------------------------------------------------
21.5.4.13.15 Not Used
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21.5.4.13.16 Residual Chlorine Analyser.
21.5.4.13.16.1 Residual Chlorine Probe
A. The residual chlorine analyzer system shall consists of an in - mounting probe assembly and an indicating transmitter. The system shall measure and indicate
combined residual chlorine concentration of the process liquid and transmit a linear 4 20mA DC signal propositional to the residual. The sensor assembly shall
be of the immersion type and residual measurement shall be made amperometrically. It shall be composed of corrosion resistant materials and contain a field
replaceable membrane held in place with a threaded retainer ring.
B. Electrode materials shall be suitable for the measurement and immersed in an electrolyte solution to measure the type of residual specified. A thermistor
mounted in the sensor shall provide wide range automatic temperature compensation from 0 to 55 degree C. The probe shall be insensitive to varying hydraulic
heads to a maximum of 3 meters and pH variations encountered during normal process operation. A corrosive and weather resistant hypalon covered cable
supplied with the probe shall be used for connecting to the transmitter. Under normal conditions, the probe shall not require servicing more frequently than every
other month and shall operate within specifications at process fluid velocities from 0 meters up. Probes or analysers requiring sample pumps or chemical addition
to the process are not acceptable.
C. The system shall be supplied with a mounting bracket/ support post assembly. The assembly shall include a locking lever for holding the probe in the raised or
service position, in the fully submerged position or at any position in between the extremes.
21.5.4.13.16.2 Residual Chlorine Transmitter
The residual chlorine transmitter shall be of all solid state electronic construction with integrated circuitry mounted on two pinned circuit boards. It shall
measure the residual chlorine concentration over any of size ranges which are field selectable. The measured value of the residual concentration shall be
displayed on a meter mounted on the transmitter case with a direct reading linear scale of 0 10 mg/l. The instrument case shall be IP68 or NEMA 4, VALOX
and polycarbonate enclosure field mounted on the handrail mounting bracket with the probe assembly. Ambient temperature range shall be 10 50 degree C.
Input Output isolation shall be incorporated in the circuitry and the transmitter output shall be 4 20mA DC into 0 600 ohms. Power supply shall be 230 V
AC 15%. 50 Hz (likely to go down up to 47.5 Hz). The system shall be supplied with membranes and premixed electrolyte for one year operation.
21.5.4.13.17 CONTROL PANELS
Access doors or panels shall have continuous stainless steel hinges and approved latching or fastening means to allow access. Fabrication shall be of 2mm thick,
steel, suitably braced internally for structural rigidity and strength. The enclosure when fabricated of steel shall be finished with two rust- resistant phosphate
prime coats and two air dry silicone alkyd finish coats of enamel which shall be applied by either hot air spray or conventional cold spray methods. The final
finish shall be smooth, free of runs, and uniform in tone and thickness. Control panel enclosures shall be rated IP55.
All wiring shall be numbered in accordance with the numbering system used on the wiring/ connection diagrams. Wiring and connection diagrams shall conform
to ISA S5.4 Instrument loop diagrams and shall be submitted as part of the shop drawings for approval of the Design Build Operate Engineer or his
representative.
All wiring shall terminate in a master terminal board, rigid type and numbered. The master terminal board shall have a minimum of 25 percent spares. Terminal
blocks shall be barrier type with the appropriate voltage rating (600 Volts minimum). They shall be the raised channel mounted type for DIN rail mounting
(marshalling).
Wire and tube markers shall be the sleeve type with heat impressed letters and numbers. DIN rail mounted terminal strips shall be provided for the purpose of
connecting all control and signal wiring. Direct interlock wiring between equipment will not be allowed. Only one side of a terminal block row shall be used for
terminal wiring. The field wiring side of the terminal shall not be within 150 mm of the side panel or adjacent terminal.
Nameplates shall be provided and mounted on each RTU enclosure. The nameplates shall be approximately 25mm x 75mm constructed of black and white
laminated, phenolic material having engraved letters approximately 6 mm high, extending through the black face into the white layer. Nameplates shall be
attached to panels by self tapping Type 316 stainless steel screws.
All components shall be mounted in a manner that will permit servicing, adjustment, testing and removal without disconnecting, moving or removing any other
component. Components shall be mounted on plates on the inside of the panels in such a manner that allows for removal of the components without removal of
the plate. Components shall not be mounted directly to the enclosure. Mounting shall be rigid and stable unless shock mounting is required otherwise by the
manufacturer to protect equipment from vibration.
Components mounting shall be oriented in accordance with industries standard practices. All internal components shall be identified with suitable plastic or metal
engraved tags attached with drive pins adjustment to (not on) each component identifying the component in accordance with the drawing specifications and
suppliers data.
21.5.4.13.18 Not Used
21.5.4.13.19 SURGE PROTECTION DEVICES
Surge protection devices (SPDs) shall be suitable for with standing the surge arising out of high energy static discharge / lighting strikes and protect the
instrument to which it is connected against damage. SPDs shall provide protection through the use of quick acting semi conductors like Tranzorb, zener diodes,
varistors and an automatic disconnect and reset circuit. SPDs shall be passive and shall require negligible power for operation. During the occurrence of a surge it
shall clamp on the allowable voltage and pass the excess voltage to the ground. The SPD shall be self resetting to minimize the down time of the measurement
loop.
SPDs shall be provided to protect devices transmitting and receiving analogue and digital signals derived from field devices located outdoors. The surge
protection device shall be rated for surge rating of 10kA.
21.5.4.13.20 CABINETS FOR FIELD INSTRUMENTS
Wall mounted cabinets shall be provided for enclosing transducer unit and associated accessories which are mounted outside the main control panel. The cabinet
shall be of die-cast aluminum, field provided not less than IP-55 protection unless otherwise stated and shall be lockable. The cabinet shall have facilities for
earthing. A steel plate shall be provided inside the cabinet for mounting instrument and accessories.
21.5.4.13.21 ALARM SYSTEM
Alarms shall be initiated by the opening or closing of volt-free contacts which shall remain unchanged throughout the periods in which the alarm conditions exit.
Alarm Circuits shall be cable of conversion from open-healthy to open-alarm or vice versa by a simple modification after installation requiring no additional
parts or special equipment.
Each alarm shall initiate the operation of both visual and audible devices. Audible devices in the same room or area shall have distinguishable sounds and
adjustable sound levels.
21.5.4.13.22 Matrix Type alarm Annunciators
The alarm annunciator shall be microprocessor based, modular, split type unit with alarm windows mounted on the front door and electronic modules inside the
panel.
The weather protection class for alarm annunciator shall be IP-54 of IS 13947, Part-I. Each alarm shall initiate a visible and audible indication of the specified
condition. Unless otherwise specified, alarm indicators shall be grouped together in annunciator units each having at least 20% spare ways. Alarm indicator
lamps (Cluster LED type) and shall have transparent screens engraved with legends approved by the Design Build Operations Engineer. The legend area of each
indication shall not exceed 40mm high and 75mm wide.
When any alarm condition occurs, a condition device common to an alarm annunciator system shall sound and the appropriate indicator shall flash on an off. The
flashing rate shall not be less than 2 Hz and shall not exceed 5 Hz. On pressing an accept pushbutton, the audible device shall be silenced and the flashing light
shall become steady. The alarm indicator shall remain illuminated until the alarm condition ceases and a reset pushbutton has been operated.
The operation or acceptance of one alarm shall not inhibit the operation of the audible device or the flashing of the appropriate alarm indicator if a further alarm
condition occurs. At unmanned locations alarms operated on two or more annunciators shall require acceptance at each annuciator.
Alarms shall be accepted automatically and the appropriate audible device silenced after an adjustable period of 1 to 5 minutes. An integral test pushbutton
shall be provided to illuminate each lamp in the appropriate group and to operate the audible device but shall not cause a spurious alarm condition on any other
annunciator. Alarm circuitry shall be arranged so that spurious or transient alarm states persisting for less than 0.5 seconds do not initiate any action. Alarm
annunciator / indicator legends or labels shall be arranged with three lines of text as follows:
Top line Location
Middle Line Parameter
Bottom Line Status
e.g. reservoir 1
level high & level low
21.5.4.13.23 UNINTERRUPTIBLE POWER SUPPLY (UPS)
All the DDCs and control instrumentation should be powered through centralized UPS. Bidder shall provide true ON Line 3 Phase UPS system with rated
working load plus 100% standby with parallel redundant in a room. The UPS system shall be provided with necessary by pass arrangement. Each UPS shall have
minimum one hour battery back up. The batteries shall be of maintenance free type. All DC or AC voltage required for instrumentation system shall be derived
within the control panels by providing a regulated DC power supply units or transformers. Generators of small capacity sufficient to feed UPS, shall be supplied
and installed along with control gear, changeover scheme, exhaust and earthing.
The UPS shall be floor mounted, self contained and metal clad and shall be suitable for operating on a non linear load. It shall be front door accessible.The UPS
system shall be true ON-Line. The ON LINE UPS shall be incorporating a six-pulse rectifier and pulse width modulation inverter technology with 100%
microprocessor control with built in static and manual bypass switch.
The UPS shall incorporate a DC under voltage trip circuit to electrically trip the UPS in order to protect the battery.
The noise level of the unit shall not exceed 60dB (A) at 1m from the UPS cabinet.
The output of the inverter shall be a sine wave having less than 5% THD for linear loads and less than 4% to 50% non linear load. It shall be suitable for load
power factor 0.8 lag.
The unit shall have dynamic response such that a 100% step load causes an output voltage transient of less than 4% with a recovery time of less than 4 ms. For
three phase output units the output voltage shall not very by more than 1% for an unbalance for 10%. The load crest factor shall not be less than 3:1. The
efficiency at full load and 0.8 power factor shall be greater than 88%. Indicators to indicate UPS status UPS alarm conditions
The UPS shall provide a volt free contact output to indicate:
Warning. i.e low battery capacity
Fault Static bypass in use.
The UPS shall have an overload capacity of 150% for 30 seconds and shall be protected in the event of a short circuit of the output.
The batteries shall be housed, either within the UPS enclosure or within a separate matching battery cubicle suitable for location adjacent to the UPS. The
batteries shall be maintenance free lead acid type sealed for life.
Terminals shall be shrouded to prevent accidental contact. The battery enclosure shall be corrosion resistant and ventilated to prevent the build up of gases.
Warning notices shall be provided for wall mounting to warn of the presence of charge gases. The battery supply of the UPS shall be via a fused load break
switch dis-connecter circuit breaker. The battery recharge time to 90% of full charge shall be approximately ten times the discharge time at full load. The UPS
battery shall have a back up of 30 minutes at full load and supported with inverter of suitable capacity.
21.5.4.13.24 AIR CONDITIONING / AIR HANDLING / COOLING AND VENTILATION / EXHAUST :
The bidder shall design and provide AC / Air cooling / Ventilation and exhaust system as per the norms, regulations, statutory and process design requirement.
The control room shall be provided with air conditioning of required capacity. All plant rooms shall be provided with push pull ventilation with air intake
through a fan filter unit and exhaust with propeller fans. The design of supply air capacity should be based on 20 air changes per hour or heat load with inside
temperature limited to a maximum of 5deg C above ambient temperature. The equipment shall comprise of air intake louver, panel type filter, centrifugal air
supply fan, GI ducting, Grills, propeller fans and their gravity louvers.
21.5.4.13.25 Instrumentation Cables
All conduit and cable entering control panels shall be gland sealed to prevent the intrusion of gas and moisture.
All signal cables for carrying 4-20 Ma , 0-5 V, low level transducer outputs, etc shall be copper PVC insulated twisted pairs, individually screened with tinned
copper drain wire, overall screened, steel wire armoured and overall PVC sheath. The twisted pairs shall be constructed with 24-30 twists per metre.
The rated working voltage shall be 100 V rms and the maximum working voltage shall be 600 V rms. The continuous current rating shall be at least 5.
Insulation between conductors and earth shall not be less than 10 Mega Ohms at 500 Volts.
Screening shall provide a minimum of 95% coverage of Copper braid or Mylar backed Aluminium foil. Individual shields in multi core cables shall be insulated
from each other and from the overall shield and armoring.
Multi stranded cables of a minimum conductor size 24/0.2 mm plain copper shall be used.
Strict segregation shall be followed with not more than one type of signal run in any multi core cable. The different types of signals shall be segregated from
each other and shall be contained in separate cables.
21.5.4.13.26 Instrumentation Circuit Routes
Signal cables shall not be run in the same conduits or duct as power cables.
Installation in rigid steel conduit or steel trunking` is preferred.
Signal cables which are not completely enclosed in a steel raceway shall be separated by at least 1000mm from LV power cables, and at least 3000mm from HV
cables. Wherever signal and power cables cross they shall do so at right angles.
All cables running from the field instruments to the RTU panel shall be a single, Continuous length, without joints, except at marshalling boxes. The boxes shall
have terminal blocks with 20 percent spares in addition to terminals for all wires including spare wires. Special care shall be exercised to carry earthing lines
through marshalling boxes and control panels.
21.5.4.13.27. Instrumentation Earthing
The Earthing arrangements shall, unless otherwise specified, comprise:
1) Earth electrodes top provide adequate conductive capacity for the works system.
2) 200mm x 200mm inspection pits to allow ready access to the electrodes connection.
3) An earth continuity conductor of adequate capacity between each control panel earth bar and the earth electrodes.
4) A bolted removable tinned copper link mounted in a suitably located link base.
The earth electrodes shall be in the form of copper rods suitably grouped and connected. All metal works, other than current carrying parts of the instrumentation
system, shall be properly bonded to earth.
21.5.4.13.28 Installation
Instrumentation and necessary equipment shall be installed in accordance with the manufacturers instructions. The locations of equipment shall be determined in
the field.
All piping to and from field instrumentation shall be provided with necessary unions, test tees, couplings, adaptors and shut-off valves.
Brackets and hangers required for mounting of equipment shall be provided. They shall not interfere with any other equipment.
The screen on each process instrumentation cable shall be continuous from source to destination and be earthed as directed by the manufacturer of the
instrumentation equipment but in no case shall more than one earth point be employed from each screen.
21.5.4.13.29 Tests
Test plan shall be submitted to the Design Build Operations Engineer for approval as part of the project plan. Furnish the services of the servicemen, all special
tools, calibration equipment and labour to perform the tests. Certified copies of the tests shall be furnished in duplicate to the Owner.
Following installation, check-out and final adjustment of all the instruments, a performance check shall be made on each. Meters shall be tested at 0 percent, 25
percent, 50 percent, 75 percent and 100 percent of scale, as required. All status and alarm switches as well as all monitoring and control functions shall also be
checked. Each device installed must be signed off by the Design Build Operations Engineer as acceptable. Testing shall be done from the signal source to the
final element or device including all field wiring.
If, during running of the tests, one or more points appear to be out by more than the specified amount, adjustments or alterations shall be made as necessary to
bring equipment up to specification performance. Following such adjustment, the tests shall be repeated for all specified points to ensure compliance.
21.5.5. REMOTE TELEMETRY UNIT (RTU):
21.5.5.1 Remote Telemetry Units
GENERAL:
The Remote Telemetry Units(RTUs) will be installed in the proposed Kodungaiyur 45 TTRO Plant as mentioned.
The RTU device must support state-of-the-art TELEMETRY and CONTROLLER features. It must use latest technology and be available with 32 bits
processors.
The RTU/PLC should have an integrated MMI facility (Color Graphical User Display with minimum 150 mm size).
RTU should be capable of the following
Complete automation of the various pumping station operations.
Accurate recording of all events
Effective alarm management for the personnel concerned
Complete remote surveillance.

RTU shall collect field analogue and digital data (every minute or a status change which ever is sooner) and store in the data logger memory.
All data shall be encoded with date and time as well as a unique message identifier.
In case of emergency, such a tripping of motors, power failure condition etc., The RTU should immediately send information of alarm status with time stampings
to the Design Build Operations Engineer concerned / Plant personnel through GSM SMS text messaging.
The digital and analog data will be gathered by the respective RTUs (functioning as data loggers) to which they are connected. All stations with RTUs will be
configured in industrial Ethernet LAN (Local Area Network) so that the collected data is accessible at all stations. Onboard Ethernet RTU communication should
be minimum 4 ports. One communication port should be on the 32bit CPU itself. All modems should have RS232 and RS485 communication for configuration.
TECHNICAL SPECIFICATION FOR RTU UNIT
21.5.5.2 General Specifications
The RTU system must be fully modular and have local I/O as well as remote I/O possibilities.
The system must be made out of :
A CPU card
Communication cards
Inputs/Outputs Cards
Ruggedised backplane racks to insert the cards

Each CPU must be able to handle up to 4096 I/O locally or in a network configuration. CPU must support both Ethernet and RS485 for networking.
The RTU must both support state-of-the-art TELEMETRY and CONTROLLER features. It must use latest technology and be available with 32 bits processors.
The system must fulfill:
Total modularity
High noise immunity and compliance with the most demanding norms
High computing power
High communication speed
Easy programming tools
High memory capacity
User-friendliness
High security
Remote upgrades
The system must be totally modular and based on a Rack concept of different sizes, where IO and communication cards are inserted.
21.5.5.3Communications cards:
The system must at least have the following communication capabilities :
Ethernet 10/100 Base-T

ISDN Modem

GSM-GPRS Modem

RS485/RS232 card

21.5.5.4 Inputs/outputs cards:


The following cards must be available:
Digital Inputs with isolation 1/1 or by group

Digital Outputs with isolation 1/1 or by group

Relay Outputs

Analog Inputs high resolution of 14 bits minimum

Analog Outputs 12 bits minimum

Combo cards: combined Inputs/Outputs: digital and analog

Power Supply cards (85-260VAC)

21.5.5.5 Built-in battery charger


The RTU must have a built-in battery charger for loading an external lead battery. In case of main power failure, the system must be able to switch on the battery
without any stop of the normal functioning of the system (including automation) program. An alarm status must be available in case of main power failure.
21.5.5.6 Master Clock:
Time synchronization of all the RTUs should be satellite synchronized (Synchronization should be automatic) for uniform timed data logging and for
synchronizing in data logging appropriate hardware to be provided along with the RTUs and also the global positioning of the station.
RTU enclosure must be rugged, not in plastic and preferably made out of high-density aluminium profiles or similar. Hardware architecture must follow the
strictest norms related to:
Electro-magnetic noise immunity
Vibrations immunity
High and low temperatures stability

Cards inserted onto the rack must be tightened with auto-blocking locking screws to avoid secure long-term fittings. The system must be vibration-proof (tests to
be provided).
21.5.5.7 Backplane racks
They should be able to receive 5,10, 15 or 20 cards. The racks must be fixed on standard DIN rails or on 19 racks.
21.5.5.8 The cards
Each card must have its own "identity card", which contains generic information (type of card, average consumption, ...) and specific information (serial number,
results of tests passed during production, calibration values, production date, repair(s) made, ...). On site, any inversion of cards must immediately be detected
and start-up of the application is automatically blocked. Automatic test of the correct functioning of the card must be made at regular time intervals by the
processor card. Cards must be hot removable while power on without damaging the card (hot-swappable).
Terminal blocks must be placed in front in order to provide a better access (test, maintenance, etc.) for cabling. Various statuses LED must be available.
Minimum specifications for all cards
Working conditions: -20 to +65C
Storage conditions: -25C to +80C
Humidity: 0 to 95% non-condensed
Protection of I/O according to IEC-61131 norm

Test reports of working in high and low temperature environments must be provided.
MTBF of the system must be above 400 hours.
21.5.5.9Functionality
The system must be able to use various modems simultaneously, and independently from the automation program. The system must be able to use internal as
well as external modems.
It must be possible to reprogram any external device connected to the system by using the RTU.
The CPU must have a processor that can run in a real multi-tasking environment and must have sufficient memory in order to store:
Automation programs made in Ladder-Diagram (minimum 64 Kbytes of program) and/or in BASIC.
Dedicated specific C custom drivers (C, assembler, etc ...).
Communication protocol drivers able to communicate with COM ports : Ethernet, RS232, RS485 or any type of modems.
HTML pages for the visualization and command of the outstation from a remote Internet Browser.

Several protocols must be possible, including at least MODBUS slave and master (RTU and ASCII), TCP/IP, ModBus-TCP, DNP3.0 and IEC-870-5 (-101+-
103+-104).
It must also be possible to interface any type of device by writing a specific communication driver.
For maintenance purposes, a non-specialist should be able to attend the exchange of a faulty card, simply by changing the card.
The unit must be equipped with an internal battery charger. In case of main power breakdown, the unit must automatically go in safe mode through the external
back-up battery without stopping the automation program.
The system must be able to send alarm messages to any SMS Systems including the possibility to send alphanumeric messages on GSM using the SMS
technology (short message service).
Remote commands and acknowledgment of alarms in the system must be possible using DTMF codes sent by a telephone, or by SMS using a mobile phone.
SMS remote control commands must support passwording in order to avoid unauthorized access.
The system should have an automatic detection of main power supply power breakdown and the information can be usable in the automation program.
The system has a detection of the status of the external back-up battery.
The RTU must support IP-forwarding.
The RTU must support SOE (Sequence Of Event) and RBE (Report By Exception).
21.5.5.10 Embedded Internet
System must integrate Internet technology on, at least, three levels:
Embedded WEB Server
Email support
FTP (push/get) support

It must be possible to use standard Internet Explorer from Windows to view dynamic pages directly within the system, including the possibility to view all alarms
(and acknowledge them), and also to display the archives of the outstation through trend graphs. If any add-ons or plug-ins are needed within the PC platform,
those will have to be free of charge.
Automatically at fixed hours, or on an alarm condition, the system must be able to send e-mails including statistical reports. Several users can then receive from
the remote site pre-worked information. Historical data and alarms can be sent as attached file for consulting and analyzing data Off-line.
FTP feature (File Transfer protocol) must also be supported by the system.
21.5.5.11 Programming tools
Application programs should be sent to the unit locally or remotely by modem. Firmware update: a new Operating System should also be able to upload locally
or remotely by any modem, avoiding a change of EPROM in the outstation.
Programming software must be full 32 bits and able to run under Windows 95/98/2000/XP and NT 4.0 (or up) versions. The programming tool must be
developed in object programming language and must be IEC 61131-3 compatible.
It has to permit:
- To program the automation in Ladder Diagram and in BASIC

- To insert program lines

- To delete program lines

- To define Functions and Function Blocks saved in libraries


- To import Functions and Function Blocks from an external libraries

- To move entire or part of program lines

- To detect automatically faulty programming lines

- To visualize in real time the entire program remotely, step-by-step

- To display and print a cross-reference report

The programming tool must have the necessary WEB editor to create the on-line views
to be displayed in a simple browser like Internet Explorer. A utility to create statistical
reports by email and FTP must be supplied.

21.5.5.12 Specifications For 32 BIT CPU of RTU

General

Processor : 32 bits, CPU

Clock Real Time Clock : Backed-up

Display : 150mm MMI

Memory

SD RAM : 16 Mb

Flash EPROM : 16 Mb
RAM : 1 Mb

Memory Extension : 2 Gb via MMC Card(Multimedia Card)

Battery

Voltage : 3V

Use : Backup of Clock and RAM (data logging)

Lifetime : CPU under voltage: 10 years

Number of simultaneous

communication port : No Limitation

RS 232

Connector : 9 pin Sub-D (male)

Cabling : DTE model (same as PC)

4 Wires: TxD, RxD, RTS, CTS

Protocol : ModBus-RTU Slave

LED : RxD: ON when receiving


TxD ON when transmitting

RS 485

Connector : Screw connector (3 x 5.08mm)

Cabling : 2 Wires + GND

Protocol : ModBus-RTU Master and Slave

LED : RxD: ON when receiving

TxD: ON when transmitting

Isolation : No isolation between signal and Power Supply

Ethernet

ETHERNET PORT : 2 PORTS

Model : 100 BASE-TX (4 wires)


Connector : RJ-45

Cabling :To a switch with straight pinned CAT5 cable

To a PC: with a Crossover CAT5 cable

Speed : 10/100 Mbits

Protocols : ModBus/TCP Master and Slave, SMTP,

FTP, HTTP, Ping

Onboard Ethernet RTU communication should be minimum 4 ports. One


communication port should be on the 32bit CPU itself. All modems should
have RS232 and RS485 communication for configuration.

USB Support

USB Port : 1 PORT IN BUILT IN CPU 32 BIT

Input/Output
Synchronization I/O : Multipoint connection between CPU

For synchronize actions on several

CPU in the same cabinet

Synchronization Input : To receive Synchronization Output

from other CPU

Protection:

Over voltage: max. 33 V

Inversion: max. 29 V

Synchronization Output : To connect to Synchronization Input of

other CPU

Temperature
Working : Standard: 15C to 50 C

Power Supply

Voltage : 6 .. 30 VDC

The RTU power supply shall accept AC or DC input and provide all necessary power to support the RTU operation. The power supply outputs shall be fully
isolated from the input power source and include both monitoring and control of the various outputs to allow advanced power management functionality. The
power supply shall be able to run from its standby battery for a minimum of 1 hour.

21.5.5.13 Specifications For Power Supplies-230VAC

Input

Voltage input AC : 85..260 Vac (47..50 hz)

Output

Battery charger: Mode : Constant current / limited voltage

Voltage : Max: 13.8 V

Current : Typical: 90 mA

Output connection: BAT : Battery (+ 12V)


UPS : Backup power supply to another rack :

Output current BUS (3.3V) : 3A

Output Power : Max: 15W

21.5.5.14 Analog Input Modules

The Analog input modules must allow connection of at least 8 Analog inputs to a multi-channel Analog to Digital Converter (ADC) with a minimum of 14 bits
resolution, overall accuracy of at least 0.1% of full scale.

The Analog input modules shall use a removable connector block that has screw terminals for both the I/O wiring and cable screen. The connector block should
use at least two screws for securing the connector to the module assembly and feature a terminal cover that includes provision for writing of tag names and
provides cable connection details.

Specification for 8 Analog Inputs

General

Quantity : 1 group of 8 analog inputs

Signals : Choice between 10..+10V or 20..+20mA

Resolution : 14 bits
Mode : Bipolar

Precision

Current : 5 A

Voltage : 2.5 mV

Temperature : 1 C

Time of Measurement

Current : 1 msec

Voltage : 1 msec

Digital Input

Validity Input associated to : Returns 0 when signal <2.4mA and

each analog input 4..20mA >21.6mA Returns 1 when the signal is


valid

Isolation

1 group isolated : Isolation by group of 7 inputs

Level of Isolation : 1500 Vrms


between group

between inputs and ground

between inputs and earth

21.5.5.15 Digital input modules

The digital input modules must allow connection of at least 16 inputs, with configurable frequency / pulse and sequence of events (SOE) recording.

21.5.15.1 Specification for 16 x DIGITAL INPUTS:

General

Quantity : 16 channels. Each can be cabled as Input or Output

Replacement : Hot insertable / removable.

Test Automatic test of the access of the card by the CPU

Voltage at input

Typical : 24 VDC

Max for a LOW level : 5 VDC

Min for a HIGH level : 11 VDC


Max : 60 VDC

Sampling

Min Period LOW-HIGH : 20 msec 20msec

Frequency (software) : At each cycle of BASIC / Ladder

Isolation

2 groups isolated : Isolation by group of 8 inputs

Isolation from the Ground : Isolation from the CPU ground and the earth

Level of isolation : 1500 Vrms

between group

between Inputs and ground

between Inputs and earth

Protection

Test : Automatic test of the access of the card by the CPU

RC Filter : 1592 Hz
Voltage inversion : Up to 55 VDC

Current

Max at the input : 2.0 mA at 30 VDC

3.5 mA at 60 VDC

21.5.5.16 Digital output modules

21.5.16.1 Specifications for 16 x DIGITAL OUTPUTS:

General

Quantity : 16 channels Output

Replacement : Hot insertable / removable.

Test Automatic test of the access of the card by the CPU

Voltage /Current

Working voltage on V : 6 to 60 VDC

Current per output : Max: 200 mA


Voltage per output : Max: 60 VDC

Short-Circuit current : Min: 0.2A, Typical:0.9A, Max: 1.2A

Impedance : Typical: 1ohm, Max: 10ohms

Consumption : 80mA

LED

Individual : LED corresponding to the activation of each output By

software, with possibility to disable the LED to save energy

Isolation

2 groups isolated : Isolation by group of 8 inputs

From the Ground : Isolation from the CPU ground and the earth

Level of isolation : 1500 Vrms

between group

between Outputs and ground

between Outputs and earth


Protection

Test : Automatic test of the access of the card by the CPU

Over Load : Max: 60 VDC

Reverse Voltage : Max: 55VDC

Short-Circuit +Over Load : Thermal Protection with automatic recover

21.5.17 Specification for GSM / GPRS Modem

General

Replacement : Hot insertable/removable.

Test : Automatic test of the access of the card by the CPU

21.5.18 Modem GSM / GPRS

Frequencies : TRI-BAND: EGSM900 / DCS1800 / PCS1900

MHz

Emitting power : CLASS 4 (2W) pour EGSM900


21.5.19 RS 232 RS485

Mode : RS232 or RS485 (no simultaneous use of both mode)

Isolation : No isolation. End is linked to earth by internal connection

RS232 : Signals: RxD, TxD, CTS, RTS, DTR, DSR,

DCD, RI. connector 9 pin sub-d (male)

RS485 : 2 wires (A+ and B-) for multi-points connection

Screw connector: female with a step of 5.08mm

LEDs RxD : to Indicate reception of data (common to 2 ports)

TxD : to Indicate transmission of data

Temperature

Storage : 10 to 70C

Working (ambient) : Standard: 10C to 50C

Hygrometry : 15 to 95% without condensation


21.5.20 Specifications for Ethernet 4 Ports

General

Card Replacement : Hot insertable / removable:

Security : Automatic test of the card by the CPU

Ethernet

Switch : 4 x Ethernet

Connectors : 4 x RJ-45

Cables : To a HUB: with a straight cable CAT5

To a computer: with a cross cable CAT5

Speed : 10 / 100Mbits

Protocols : ModBus/TCP Master and slave, SMTP, FTP,

HTTP, Ping

Temperature

Storage : 10 to 70C
Working Condition : Standard: 10C to 50C

Humidity : 15 to 95% without condensation

21.5.21 Specifications for GPS - TIMING

General

Replacement
Hot insertable/removable.

Test Automatic test of the access of the card by the CPU

GPS Receiver

General L1 (1575 MHz), C/A code, 12 channels, continuous tracking receiver

Precision: position 3 m CEP (SA off)

clock 500 ns (SA On)

Acquisition: Cold start


< 60 sec
Warm start
< 3 sec

Antenna connector Active antenna: SMA compatible

Power delivered by the card : 3 to 3.6 VCC


LEDs Tick Second: 1 Hz

Lock: validity of the GPS signal received. Minimum 4 satellites

Ant. Status: active antenna connected

RxD, TxD: communication on serial port (RS232 or RS485)

Synchronization

Internal Generates an internal clock signal every 1 ms (precision 200 s)

Output Open collector, to synchronize to other RTU

Frequency : 1 sec. Precision : 200 s.

To CPU-32 Synchronization from the BUS

Tick of the CPU-32 : 1 ms (used for time stamping)

Global precision : 1 ms

RS232 RS485

Mode RS232 or RS485 (no simultaneous use of both modes)

Isolation No isolation. End is linked to earth by internal connection

RS232 Signals: RxD, TxD, CTS, RTS, DTR, DSR, DCD, RI

Connector: 9 pin Sub-D (male)


Temperature
Storage
10C to 70C

Working (ambient)
Standard: 10C to 50C

Ruggedized: 10C to 70C

Hygrometry 15 to 95 % without condensation

Mounting On The Rack Bus

Dimension Not To Exceed The Rack Size Limit

21.6 SUPERVISORY CONTROL AND DATA ACQUISITION (SCADA) SYSTEM

21.6.1 Description of work

SCADA package will be used to deliver an effective plant monitoring and control system. This system will be fast, efficient, and completely scalable with the
flexibility to choose own system design.

SCADA package with sufficient tags for development and customisation will be installed in the computers, located in the Plant

SCADA will be used for acquiring data from the field devices through Remote Telemetry Units (RTU).

21.6.2 SCADA Package for RTUs

SCADA software shall be Installed in application servers at the plant and should be capable of controlling and monitoring the various instruments.
SCADA should acquire data from RTU and displays in SCADA screen. In addition to the display action, the logs of each station should be transferred using data
export to data base processing software (Oracle, ODBC, EXCEL,etc.,). It should support the power of internet by using powerful tools to transfer and export
historical data to the majority of database applications

21.6.3 Description of System

SCADA specified herein shall be designed, installed, tested and customized as follows:

To collect, store and accurately analyse, reliable operating information for present and future uses
To perform Real-time process control.
To assist plant operating personnel by noting and announcing off-normal operating conditions and equipment failures
To perform calculations based on sensor (automatic) / manual operator data inputs
To accumulate and store equipment running times
Store and retrieve all operation information
Compile and prepare daily, weekly and monthly reports
To provide information required on the graphic displays.
Provide central or local control using clear, concise, resizable graphics pages screens.
Graphical control buttons to pages, to perform single or multiple tasks.
Animations to display the operating status and performance of the various process units.
Display text messages and graphics to show the status of a process or the state of an alarm.
Specify keyboard commands that operate universally or just for individual pages.
Monitor, control, log, and display all alarms.
Provide historical and real-time trending in graphical format.
Monitor performance and efficiency as it happens by using trend and data logging facilities.
21.6.4 Security levels

To restrict access to a particular system element (command, object, report, alarm, etc.),. SCADA should provide privileges to the users who will use it. User
Privileges for Owner to be defined for three user privileges. They are as follows:

1. Operator Level (Privilege 3)


2. Engineer Level (Privilege 2)
3. Manager Level (Privilege 1)

The RTU shall have two types of security, one for the programming and configuration interface and the other for the RTU ports.

21.6.4.1 Programming and Configuration Interface - User Security

The programming and configuration interface shall support at least six levels of user access that can be configured by a system administrator. These should
include as a minimum,

0) Unlimited Access Allows unlimited access, can read and write all RTU
parameters including configuration parameters. RTU
parameters include :- Local Registers, Network Registers,
System Registers, Hardware (I/O) Registers, Event Logs,
and Logic Program/s.

1) Read All, Write All Allows reading and writing of all RTU parameters, except
(except config.) for System Registers and Ladder Logic. Thus
reconfiguring an RTU is not possible from this access
level.
2) Read All, Limited Allows reading all RTU parameters. Writing is
Write Access
limited to some Local Registers. No other
parameters can be written at this access level.

3) Read-Only Access Allows reading all RTU parameters. No parameters can


be written at this access level.

4) Limited Read Access This access level allows reading some Local Registers.
only No parameters can be written.

5) No Access No RTU parameters can be read or written. This access


level is useful only for RTU port configuration.

Whenever the interface program is started, the user should be prompted to enter a username and password. This is checked against the User Database, to verify
the password, and to provide the authorized access level. Alternatively, the user can select 'View-Only' mode.

RTU Security

Each RTU Communication Port shall have a configurable access level. The default access level can be any of the 6 levels (0-5) specified above to control read
and write access to that port.

Thus, if a RTU port has default access level 4, then only some of the local data registers can be read via that port.

Thus, by configuring all RTU ports in a network with access levels 1-5 (not access level 0), the network is then completely secure against unauthorized re-
configuration, and can only be reconfigured by an authorized user, after unlocking the RTU common port.

21.6.5 User Interface


The operator shall be capable of to access displays via a printing device and/ or soft key menus with a choice of function keys, cursor, control keys, or any key on
the keyboard. Supported pointing devices shall include a mouse, touch screen, light pen or trackball.

The system shall support operator access to multiple displays at one time, including split screens where the operator may view more than one process area at a
time. In addition, the system shall support unlimited use of pop-up displays for additional help or diagnostic information.

Access to all displays and to all command functions shall be based on the operators security level to protect against unauthorized use. The security level shall be
established during the operator sign-on procedure.

Visibility and operation of command buttons, symbols etc shall be controllable based up on the operators security level. The operator shall be able to have
access to context sensitive help at any time during operation of the system.

The operator shall be able to access multiple data sources/ items with a single tag name.

21.6.6 Command / Control Functions.

An operator shall be able to control a discrete point using an action command button. This control includes momentary on, momentary off, toggle on-off, set, and
reset.

The operator shall be able to use command buttons to adjust set points up and down on a percentage or absolute basis. Each request for increase or decrease shall
be evaluated against valid operating limits before allowing the adjustment.

Control of individual set points shall be enabled based upon a users security level and password.

21.6.7 Display Capability.

The system shall allow the user to view animated graphics for process templates including valves, meters, etc. This includes:

1) Colour change of the object..


2) Blinking of the object based upon any alarm in the system or upon a designated group of alarms.
3) The system shall support animation; of objects via resizing, moving, and / or rotating objects based upon a change in a process variable.
4) Objects shall be animated upon any user defined criteria made up of other Tag names in the system. This includes the use of expressions containing
all mathematical functions and the status of analogue and discrete valves in the system.

The system shall support the capability for the operator to view scanned images from desk top or hand held scanners. It shall be possible to animate these images
to show a colour change based on the status of process operations including alarm or normal state.

The system shall support internally as well as third party pre-animated graphical objects developed using a tool kit.

21.6.8 Text Description

System shall support use of true-type scaleable fonts that may be scaled according to the desired size of the text. The fonts shall be loaded by the operating
system.

Text shall be able to blink based upon any user definable condition occurring in the system such as an alarm on a particular set point, alarm on any value in a
process group, or based on the actual value of a process variable. System shall display process value based upon the security level of the user. Text shall be able
to make visible or invisible based upon an alarm condition in the process or any other state change in the system.

21.6.9 Alarm Display Capability

System shall support displaying of alarms on any display as a user defined sizeable object, which may be placed by itself or along with other objects in a
window. It shall be possible to scroll forward or backward through the alarm displays by depressing command buttons. Current alarms shall be available as an
Alarm summary object and a chronological summary of Alarms shall be available as an Alarm History object.

The operator shall be able to select the alarms displaced by an object, alarms by group and/or priority by using command buttons. Up to 999 priority levels shall
be supported. The operator shall also be able to view and acknowledge alarms from any screen. The system shall support an unlimited number of alarm displays.
Alarms shall be colour coded according to the state and priority of the alarm including an acknowledged alarm, unacknowledged alarm, and an alarm that has
returned to normal but is not yet acknowledged. The user shall be able to choose from 32 different colours for display of each of these alarm states. The alarm
display object may also support event display with the colour used for events also being one of the 32 different colours.

The alarm display shall support the display of the following alarm parameters which are user selectable in the configuration mode:
Date
Time
Type of Alarm
Value of variable in alarm
Operator Name
Alarm Priority
Alarm Group name
Alarm limit
Alarm Description
Comment

It shall be possible to configure the system such that the operator is notified of an alarm no matter what display he or she is currently viewing. Notification shall
include the option of a pop-up alarm display window, a flashing process symbol such as a flow meter, an alarm text message that is available on each display, or
a dedicated alarm display window on the screen.

The user shall be able to display alarms on an individual or a group basis, with support for 16 groups each having up to 16 sub-groups. The alarm hierarchy shall
be capable of being nested up to 8 levels deep.

It shall be possible to inform the operator of an alarm condition via on audible tone, a pop-up display, or any combination of animation types on the screen.
Alarm acknowledgement may be performed on all alarms, alarms in a single group, and alarms in a collection of groups in defined in alarm group hierarchy or on
a point by point basis.

Alarm File Capability

Alarms shall be logged to a file for future viewing or review of alarm history data. The user shall have the capability to review the file for cause and event
analysis.
The alarms that are logged shall be configurable from a choice of the parameters listed in the previous sections.

Alarm Printing Capability

Alarms shall be printed to a printer using either a serial or parallel interface. The format of the alarm printout shall be configurable and made up of any of the
parameters listed in the previous sections.

Events

Events shall be logged for review by the operator, engineering or management personnel. The system shall log each new operator log-on and whenever an
operator changes a set point or turns any device on or off. Each time the event log records an event, it will record the operator logged in and the type of action
taken ( set point change, state change, etc ) along with a date and time stamp.

System Protection

The following describes the minimum required system protection capabilities

1) Foreground Program Switching

It shall be possible to configure the run-time system so as to prevent the operator from obtaining direct access to foreground program switching by disabling
certain keys in the system. In this way, only the foreground program switching which is built into the end application shall be accessible to the process operator.

2) File Menu Access

It shall be possible to configure the run-time system so as to prevent the operator from obtaining direct access to the File Menu or any other direct ability to open
and close files outside of the desired built-in capabilities of the final operator interface application.

3) System Level Interface

It shall be possible to provide password protection on a moveable mask that can cover the entire system level graphical user interface including the operating
system title bars, menu bars, etc such that only authorised personnel would have access to this level of control. This protection is necessary to prevent lesser
skilled personnel from causing damage to the operator interface application, from accidentally erasing files or records, or from accessing other software not
directly concerned with the desired plant monitoring and supervisory control application.

It shall be possible to also disable the Microsoft Windows key sequences <CTRL> <ESC> AND <ALT> <TAB> to prevent unauthorised access to applications
outside of the operator interface application environment. It shall also be possible to disable the <CTRL> <ALT> <DELETE> reset function of the PC.

4) Operator Log-On

It shall be possible to assign each operator a log-on password which defines a unique access level, thereby limiting access to various command functions based
on the operators access level.

Based on the operators unique password, it shall be possible to log each operators actions for later review.

It shall be possible to define an inactivity time span between operator actions on the system, requiring the operator to log on again with his password. This
capability is useful in preventing unauthorised access to the operator interface system while an operator is away from his station performing other duties.

Graphic Displays

The system shall include vendor supplied and user-defined graphic display generation through use of an interactive display generator software tool kit. As a
minimum, the following shall be provided:

1) The graphic displays shall be developed from the schematics and shall depict the entire process and auxiliary systems, to the degree of detail
determined by the Design Build Operate Engineer. As a minimum, the graphic displays shall include all analogue and digital points. The actual
number of displays shall be as required to accomplish the requirements. There shall be an early meeting consisting of Design Build Operate
Engineer, and the supplier to define what the actual graphic displays shall be, as well as the report formats and contents. All control and monitoring
shall be from graphic displays via poke points. The graphic displays shall also include the control system architecture and appropriate status and
alarms, including UPS alarms. The Contractor shall develop these graphic displays from the information provided by the Owner.
2) One graphic display will also be generated for the overall works site plan for the facilities.
3) A graphic display will be generated showing the entire control system architecture. All system monitoring and alarms shall be available at this
graphic display.
4) Acknowledge alarms directly from the display for either individual points, or all points in alarm.

Additionally, other index displays shall be provided which shall be either the list type or of the working type.

A historical log summary shall be available to allow the user to print all events and/or alarms, which occurred during the past several days starting at a user
specified date and time. Selection of the historical alarms and/ or events shall be based on message type (all events, general alarms, critical alarms), area or tag
for a specific time period. The printed report shall include the date and time of the condition, point tag name, description, area, digital state or analogue value,
status condition, and if an alarm, the limit value exceeded in engineering units. The historical log summary shall be ordered chronologically according to the date
and time of each transition to facilitate comparison with the system log.

All operator interaction, including supervisory control, shall be performed through the combined use of touch screen, mouse or keyboard via Windows type
displays. As a minimum, the following operator indicated functions shall be provided:

Log on/ Sign Off: Prevent unauthorized access to the system. When signed Off no functions are available from that CRT. Log on will require a password.
Provide capability to limit functions able to be performed based upon the sign on account and password.

Alarm Summary: Generate a dynamic colour display of all current alarms in the system in chronological order.

Acknowledge: Allows acknowledgement of all alarms in the system

Print: Copies the currently displayed screen

Area: Displays status information for points in a particular area

Cancel: Terminates a previously specified supervisory control command

Help: Presents additional helpful information about the current function or command.
Where there is no live data, the data will be entered into the system manually. All the information shown on the graphic displays mentioned herein shall be
incorporated into the reports.

Digital Trending

The digital trend printout shall consist of digital trending, in a vertical format, historical average of values from the database or current 5-minute averages. Each
point assigned shall be identified at the top of the respective column, by an abbreviated version of the point name, which is readily recognizable. There shall be
up to six points assigned for a particular digital trend with any variable in the database assignable. The trend period will also be assigned, including starting time,
frequency and finishing time. The trend period shall be confined to the specified data storage capabilities of the system.

Graphical Time-line Trends shall plot selected points. (vertical axis) against time (Horizontal axis). Data shall be displayed with pixel resolution and the graph
shall scroll smoothly without replotting all the data each time. Horizontal and Vertical background scale reference information shall also be provided.

The horizontal axis labeling shall be based on the time level of the data selected. The user shall be able to specify the start time for any historical trend and, once
data is displayed, shall be able to move forward and backward in time to view more or less recent data. For current data, display refresh rate shall be specified.

The vertical axis based on the range of the point being plotted. However, range over which the data is plotted shall be expandable, thus providing fine resolution
of the data. The alarm limits for each point shall be retrieved from the database and shown on the axis.

The user shall have the ability to place and move a pointer on the time line so that the actual numerical value of the variable at any point on the line is displayed
by moving the pointer along the time line.

Real-Time Trending

Real-Time trend displays shall support up to 4 trend pens and unlimited trend windows per display. Real-time trend displays shall able to continue to up date
regardless of whether the operator is currently viewing the trend window. Real-Time trend displays shall support the use of expressions of tag names including
add, multiply, divide, etc to permit proper scaling of variables.

Historical Trending
Historical trend display should allow the user to zoom in and out in time from 1 second up to 6 weeks in one display. It shall be possible to activate the zoom-in
and zoom-out features using action scripted command buttons available to the operator. The operator shall have the capability to pan backward and forward in
time to view historical logged data. The operator shall have the capability to print out historically trended information in the form of a printed record for
documentation process.

The operator should have the capability of disturbing a one trend display with eight different data sources across a network enterprise.

Historically collected data shall be available to be exported to a spreadsheet format for analysis, additional reports, etc.

Daily Operation Summary Report

The daily operation report shall summarise operation from midnight through the last complete hour of operation, printing hourly averages, and current daily
averages, maximum and minimum totals where applicable.

Values for which there are no data available shall be left blank or identified with a special character. Thus, only values, which are actually zero, shall be printed
as such.

The daily operation summary report shall be available for printing on demand, as often as preferred, until midnight of the following day.

Monthly Operation Summary Report

The Monthly operation report shall summarise operation for the previous calendar month. The report shall be generated on demand from the Operators console,
usually after all results for the previous month have been entered. The information printed will consist of daily averages or totals and manually entered data.

The report format shall be similar to the Daily Operation Summary Report and shall consist of the month and the year, plant name, report name, page number,
group headings, sub-headings, point identifications, engineering units, and a table of daily averages or totals for points included on the page. Monthly minimum,
average, maximum and totals where applicable shall also be printed for each column of points printed. Periods of no data, bad data, manually entered data or
edited data shall be clearly indicated on the report with text or symbols.

Annual Operation Summary Report


The Annual Operation Summary Report shall summarise operation from the previous calendar year. The report shall consist of monthly averages or totals for
important variables and manual inputs, stored on-line on the disc.

The format of the report shall be identical with the Monthly Operation Summary report with the exception of the month being deleted from the heading, replaced
by the year and the date column replaced by calendar months.

Specific System Application

This submittal shall cover the specific control schemes as well as the details of the alarms, trends, daily, weekly, monthly and yearly reports and process graphic
displays, that the system supplier should be developed in consultation with the Design Build Operate Engineer.

Submit detailed loop connection diagrams, for each monitoring and control loop. Each diagram shall be drawn on a single A3 size sheet for submittal purposes.
The format shall be based on the Instrument Society of America, Standard for Instrument Loop Diagrams, 1885.4. The loop diagram shall show all components
of the loop, both analogue and digital including electrical relays, switches, signal converters and any other devices necessary for the proper operation of the loop.
Each loop diagram shall show all wiring and piping details, identify all field termination and grounding points within cabinets and panels and identify connection
points on all devices. All components of the loop shall be shown on the diagram including equipment provided under these sections. It is the responsibility of the
Instrument/System supplier to co-ordinate with the Bidder / Engineer to ensure that all devices are properly interfaced.

21.7 COMPUTER SYSTEM FOR TELEMETRY UNITS

21.7.1 General

Supply, Deliver, install and commission computer systems and peripherals hereinafter specified to perform the intended function. Work shall include all
necessary materials, equipment, labour and services.

Database Server with SCADA software for monitoring the overall parameters of the plant, report generation and other allied works. Personal Computers as
specified will be provided to offices of various officials at the Plant and at Head office of Owner for monitoring the overall parameters of the plant.

21.7.2 System Hardware


The submittals shall provide complete documentation of the hardware proposed including:

A complete instrument and control system block diagram(s) showing in schematic form, the interconnections between major hardware components such as ;
control centres, panels, consoles, computer and peripheral devices, telemetry cabinets, local digit processor and like equipment. The block diagram shall reflect
any man / machine interface locations. All components shall be clearly identified with appropriate cross reference to the locations of each.

The diagram shall reference all interconnecting cabling requirements for digital components of the system including any data communication links. Data sheet
for each hardware components listing all model numbers, optional, auxiliary and ancillary devices that are being provided.

The data sheets shall be provided with an index and proper identification and cross referencing. They shall include but not be limited to the following
information:-

Plant Equipment Number and ISA tag number.


Product (item) name used herein and on the Drawings.
Manufacturers complete model number.
Location of the device.
Input Output characteristics.
Range, size and graduations including the LOW and HIGH limits for protection of equipment or site requirements.
Physical size with dimensions, enclosure IP classification and mounting details.
Materials of construction of all components.
Instrument or control devices sizing calculations where applicable.
Valve actuator data and wiring diagram where applicable.

Equipment specification sheets should fully describe the device, the intended function, how it operates and its physical environment and performance
characteristics. Each data sheet shall have appropriate cross reference to loop or equipment identification tags. As a minimum the specification sheets shall
include the following:
1. Dimensions, rigid clearances
2. Mounting or installation details
3. Connection
4. Electrical power or air requirements
5. Materials of construction
6. Environmental characteristics
7. Performance characteristics

The System Hardware submittal shall also contain all planning information, site preparation instructions, grounding and bonding procedures, cabling diagrams,
plug identifications, safety precautions or guards and equipment layouts.

21.7.3 System Software

The contractor shall supply a fully debugged operating system. The software required shall consist of those programs necessary for the system to efficiently
perform the functions specified herein, plus enable convenient and efficient preparation of new programs. The system shall be capable of operating in a
foreground/background mode. The contractor shall assume complete responsibility for the successful operation of all software and application programs provided
as part of the system. All programs can be completely debugged and operable prior to delivery of the system. The Owner shall not be required to expend any
programming effort in order to achieve a fully operational system.

The overall operating software package shall be modular, primarily comprised of an integrated group of proven, standard software modules. Individual standard
modules shall be designed such that adoption to this systems specific needs shall be accomplished through entry of definitive data in stored parameter tables.
The system software shall be of standard product. No programming shall be required beyond configuration and minor customization. The system software shall
be designed to provide a disturbed database.

All of the programs are to be generalized in nature such that the Owner may later add new functions. The scheduling and initiation of future application programs
and the servicing of their input and output requirements, including construction of new printing formats and other system interfaces, shall be accomplished
without recompiling of application software.
Specifications for the system are given as a guide, however manufacturers standard offerings that can accomplish all of the specified functions will be
considered. The system shall be capable of accepting process control operational directives in a conversational mode. Data validation shall be performed on
operator inputs and reject illegal entries.

System parameters such as data, time, set points, alarm limits, loop tuning constants, etc., shall be entered or modified via the operators terminal. Any input,
which modifies the system, shall be logged on the logging printer with data and previous value.

Software Licensing - The computer system supplier shall include all necessary licensing for operation of all software on all computer systems provided. The
supplier shall also update all software packages with the latest versions and patches until the expiration of the warranty and/ or maintenance period for this
project. The software shall include development key for the owner.

21.7.4 Operating System

The Operating System software shall be the latest version of Microsoft Windows operating system to provide system resource allocation and management in a
Real-Time, multi user environment.

The Operating System shall provide an orderly shutdown on loss of power or low voltage and automatically restart the system, including processor and
peripherals, upon restoration of power without operator intervention. The power failure protection shall protect against loss of program and/or work in progress at
the time of occurrence.

Software for PC shall be Office XP standard and Antivirus

21.7.5 Operator Station Software

The supervisory system shall consist of an open interface software (OIS) system that includes support of process supervisory control, data acquisition ,alarming,
historical data, collection and trending and management report generation .It shall be based on the concept of a fourth generation based graphics and object based
development. The OIS shall have an open architecture that allows the system to run in a multi tasking environment with support for on-line, dynamic data
exchange with other applications such as expert systems, spread sheets and database programs.
This on-line dynamic data exchange shall be possible with applications running on the local node as well as with other nodes running on a network including
distributed alarming, distributed SPC and distributed historical trending. The system shall have the built-in flexibility to permit easy configuration of the system
in accordance with the specific objectives of the end user as well as quick and easy modification of the end application by the user in the field.

The operator shall access displays via a printing device and/ or soft key menus with a choice of function keys, cursor, control keys, or any key on the keyboard.
Supported pointing devices shall include a mouse.

The system shall support operator access to multiple displays at one time, including split screens where the operator may view more than one process area at a
time. In addition, the system shall support unlimited use of pop-up displays for additional help or diagnostic information.

Access to all displays and to all command functions shall be based on the operators security level to protect against unauthorised use. The security level shall be
established during the operator sign-on procedure.

Visibility and operation of command buttons, symbols etc shall be controllable based up on the operators security level.

The operator shall be able to have access to context sensitive help at any time during operation of the system.

The operator shall be able to access multiple data sources/ items with a single tag name.

21.7.6 Command / Control Functions

An operator shall be able to control a discrete point using an action command button. This control includes momentary on, momentary off, toggle on-off, set, and
reset.

The operator shall be able to use command buttons to adjust set points up and down on a percentage or absolute basis. Each request for increase or decrease shall
be evaluated against valid operating limits before allowing the adjustment.

Control of individual set points shall be enabled based upon a users security level and password.

21.7.7 Display Capability

The system shall allow the user to view animated graphics for process templates including valves, meters, etc
21.7.8 Desktop Specifications

Architecture

Bus type/architecture PCI/PCI Express

Slots x bays total (available) 4(4) x 4(1)

Orientations allowed Vertical

Colour Business black

Form Factor Tower

Processor

Processor Manufacturer Intel

Processor Type Intel Core i-7 and Intel Core i-5 processor

Memory

Memory (RAM) std. / max.[8] 2 GB and 4GB

RAM slots total 2

RAM speed supported 1333 MHz

Memory Type DDR3

Hard Disk Drives

Hard disk size[4] 500 GB

Hard disk type Serial SATA


Graphics Subsystem

Type 2D/3D

Graphics Chipset Intel Graphics Chipset

Video RAM type DVMT

Max resolution (with max video RAM) 2048x1536 16777216 colours

Max colours (with max video RAM) 16777216

Graphics bus interface PCI Express

Monitor 20 LCD Flat screen

MM Keyboard & Optical Mouse

Optical Devices

Optical Drive Type


DVD writer
Audio

Speakers 2

Boot sequence control, Boot without keyboard or mouse,


Configuration password, Diskette I/O control, Diskette boot inhibit,
Hard file I/O control, Parallel port I/O control, Power on password,
Security features Security slot (for attachment of optional cable lock),

Expansion options
Plug and play support Yes

8 USB 2.0 (2 front, 6 back), External Display (VGA), External


Planar Expansion Port Microphone / Line in (back), Headphone/Line out, Keyboard Optical
Type Mouse

Parallel Port Type 1 Parallel

Serial Port Type 1 Serial

Expansion Bus PCI/PCI Express

21.7.9 A4 Monochrome LaserJet Printer specifications

Printing system

Print technology In-line laser printing technology with 8 MB memory

Print quality (colour, Up to 1200 x 600 dpi


best quality)

Print speed (black, Up to 17 ppm


normal quality, A4)

First page out (black, < 14 sec


A4)

Processor type Fujitsu FRV555 VLIW


Processor speed 150 MHz

Standard paper trays 1

Standard media sizes A4, A5, B5 (JIS), executive (JIS), envelopes (DL, C5, B5)

Paper handling 100-sheet multipurpose tray 1,

Memory / print languages / typefaces

Standard memory 8 MB

Hard disk capacity None

Connectivity

Standard connectivity Hi-Speed USB 2.0 (compatible with USB 2.0 specifications)
Hi-Speed USB 2.0 (compatible with USB 2.0 specifications), Fast
Ethernet embedded print server

Compatible network Microsoft Windows -7 ,XP Professional, Red Hat Linux 6.x and
operating systems later

Network interface Basic-featured Fast Ethernet Embedded Print Server


Optional Fast Ethernet embedded print server
Other technical information

Power requirements Input voltage 100 to 127 VAC (+/- 10%), 50/60 Hz (+/- 2 Hz); input
voltage 220 to 240 VAC (+/- 10%), 50/60 Hz (+/- 2 Hz)

21.8.0 TELEMETRY NETWORK

Telemetry Network system will be setup using V-SAT MPLS based technology. The work involves setting up and maintaining the SCADA and Telemetry
network system for the O&M period including all expenses such as installation etc., for transmission of data using V-SAT communication technology and liaison
works with the service providers for payment of rental fee and payment of rental fee for the network.

1. To avoid traffic/complication in the network, it is suggested to use V-SAT MPLS based technology so that there will have adequate bandwidth to
transmit data. The network will be connected to the existing Owners Head office server.
2. Appropriate equipment for V-SAT Telemetry Network will be supplied and installed and commissioned in the proposed TTRO Plant
3. Appropriate equipment to transfer data from the various process units to the control centre of the TTRO Plant and for integration with the RTU at the
TTRO Plant and existing servers at Owners Head office.
4. The RTU shall be interfaced through V-SAT and connected to Head office
SYSTEM CONFIGURTION:

The system configuration for Telemetry Network is as following:

The Head office will be connected to the service provider MPLS network with 512 Kbps dedicated bandwidth using V-SAT.
The various Instruments at the proposed TTRO plant will be hard wired and networked.
The digital and analog data will be gathered by the respective RTUs (functioning as data loggers) to which they are connected. All stations with
RTUs will be configured in industrial Ethernet LAN (Local Area Network) so that the collected data is accessible at all location inside the Plant
. Onboard Ethernet RTU communication should be minimum 4ports. One communication port should be on the 32bit CPU itself. All modems
should have RS232 and RS485 communication for configuration.

21.9 Tests and Acceptance

The SCADA system supplier shall perform Factory Acceptance Tests, On site Operability Tests and System Acceptance Tests.

A formal system test shall be performed by the supplier and witnessed by the Owners representative ( if required ) at the system suppliers factory, prior to
shipment. The purpose of the test shall be to verify the functional ability, performance and stability of the hardware and software. The system must operate
continuously for 3 days without failure before the test shall be judged successful. Successful completion of this test shall be the basis for approval of the system
to be shipped to the site.

Implicit in the scheduling of the factory test is the assumption that the supplier has determined through his own tests and quality assurance programs that the
equipment is ready (determined through his own tests and quality assurance programs that the equipment is ready) for shipment. Suppliers internal test
procedures for hardware shall be equal to or exceed the requirements set forth in ANSI Standard RP 55.1, Recommended Practice Hardware Testing of Digital
Process Computer, in so far as they apply.

Where hardware items are of standard manufacturer, and in current production, the manufacturer shall certify that applicable tests have been performed, and met,
in accordance with said standard, and be prepared to supply copies of data to Design Build Operate Engineer or his representative upon request. All assemblage
of devices together with operating programs shall be tested together as provided herein. The various tests performed during the witnessed factory test shall be
designed to demonstrate that hardware and software shall fulfill all the requirements of the specifications. The test conditions shall resemble, as closely as
possible, the actual installed conditions. All additional hardware or software that may be required to successfully verify system operation shall be supplied at no
cost to the Owner.

21.9.1 Some of the tests to be performed shall include but not be limited to the following.
1. Building and loading the system Data Base.
2. Demonstrate operability of the interfaces (hardware and software)
3. Demonstrate operability of the Data communication network.
4. Demonstrate all system software functions specified.
5. Verify the displays and interactive capabilities.
6. Simulate operating conditions to verify the performance of the monitoring and control functions.
7. Generate reports using test data.

During the test, the Owners representative shall have unrestricted access to the system and all faults identified during this period shall be corrected and retested
prior to completion of factory test. All test data and procedures followed during testing shall be logged and certified copies of logs shall be provided.

The supplier shall notify the Design Build Operate Engineer or his representative a minimum of 10 days in advance of his proposed starting date of the witnessed
factory test. At the time of notification, the system supplier shall submit a detailed test procedure for approval of the Design Build Operate Engineer or his
representative.

After the equipment has been delivered and installed at the site, a system operability test shall be performed to verify the integrity of the system. Some or all of
the tests performed during factory testing shall be repeated. The system must operate without failure for a period of 100 hours before this test will be considered
successful.

Before this test is started, the supplier shall satisfy himself that the system is operating correctly with live plant data Any malfunction during the test shall be
analyzed and corrections made by the system supplier. The Design Build Operate Engineer or his representative will determine whether any such malfunctions
are sufficiently serious to warrant a report of this test.

After completion of the operability tests, the system supplier shall be responsible for operation of the entire system for a period of 15 consecutive days, under
conditions of full system operation, without a single non field repairable mal functions. During this test, plant operating and supplier personnel shall be present
as required. The supplier is expected to provide personnel for this test who have an intimate knowledge of the hardware and software of the system. While this
test is proceeding, the Owner shall have full use of the system. Any malfunction, during this 15 consecutive day test period, which cannot be corrected within 24
hours of occurrence by the Suppliers personnel, or more than two similar failures of any duration, will be considered as a non-field repairable malfunction:
specified herein. In the event of rejection of any part or function, the contractor shall perform repairs or replacement immediately. The entire work should be
maintained for the complete O&M period.

21.10 Training Programme for SCADA system

The cost of training programmes shall be included in the contract, to be conducted with designated Owners personnel, covering programme, operation and
maintenance of the system as specifically set forth hereinafter. The training and instruction, insofar as practicable, shall be directly related to the system being
supplied here under. The training programs shall include a factory training program consisting of schooling and hands-on experience at an established user
oriented systems course: and a field training program consisting of hands-on instruction utilizing the Owners system.

The factory-training program to be held at the system suppliers factory shall run for a period of one week for five persons. The program shall cover fundamental
computer hardware and software overview, hardware operation and maintenance and system software and programming.

In addition to the above training, the supplier shall train up to ten assigned personnel in the operation of the RTUs for a period of 15 days. This training may
correspond with the 15 days system acceptance test.

Furnish a system suppliers representative for a field-training program to be run at the project site and consist of up to one weeks instruction for ten of the
Owners personnel. The program shall cover instrumentation debugging, troubleshooting, calibration and maintenance procedures, and system operation. This
training program will be held at a time chosen by the Owner and will be exclusive of any instruction give at the time system start up.

21.11 Final System Documentation

Prior to final acceptance of the system, operating and maintenance manuals covering instruction and maintenance on each type of equipment shall be furnished as
noted herein.

The instructions shall be bound in three-ring binders with drawings reduced or folded for inclusion and shall provide at least the following as a minimum
A comprehensive index
A complete As constructed set of approved shop drawings
A complete list of the equipment supplied, including serial numbers, ranges and pertinent data
Full specifications on each item
System schematic drawings As constructed, illustrating all components, piping and electrical connections of all systems.
Detailed service, maintenance and operation instructions for each item supplied.
Special maintenance requirements particular to this system shall be clearly defined, along with special calibration and test procedures.
The operating instructions shall also incorporate a functional description of the entire system, with references to the systems schematic drawings
and instruction.
Complete parts lists with stock numbers and name, address and telephone number of the local supplier.

The suppliers final documentation shall be new documentation written specifically for this project, but may include standard and modified standard
documentation. Modifications to existing hardware or software manuals shall be made on the respective pages or inserted adjacent to the modified pages. All
standard documentation furnished shall have all portions that apply clearly indicated. All portions that do not apply shall be lined out.

The manuals shall contain all illustrations, detailed drawings, wiring diagrams and instructions necessary for installing, operating and maintaining the equipment.
The illustrated parts shall be numbered for identification. All information contained therein shall apply specifically to the equipment furnished and shall only
include instructions that are applicable. All such illustrations shall be incorporated within the printing of the page to form a durable and permanent reference
book.

If the supplier transmits any documentation or other technical information which he/she considers proprietary, such information shall be designated.
Documentation or technical information which is designated as being proprietary will be used only for the design, construction, operation or maintenance of the
system and to the extent permitted by law, will not be published or otherwise disclosed.

The requirements for the suppliers final documentation are as follows:


As built documentation shall include all previous submittals, as described in this specification, updated to reflect the as-built system. Any errors in or
modifications to the system resulting from the Factory and/or Field Acceptance Test shall be incorporated in this documentation.

The Hardware Maintenance Documentation shall describe the detailed preventive and corrective procedures required to keep the system in good operating
condition. Within the complete Hardware Maintenance Documentation, all hardware maintenance manuals shall make reference to appropriate diagnostics,
where applicable, and all necessary timing diagrams shall be included. A maintenance manual or a set of manuals shall be furnished for all derived hardware,
including peripherals. The Hardware Maintenance Documentation shall include, as a minimum, the following instructions:

Operating Information The information shall include a detailed description of how the equipment operates and a block diagram illustrating each major
assembly in the equipment.

Preventive Maintenance Instructions These instructions shall include all applicable visual examinations, hardware testing and diagnostic routines and the
adjustments necessary for periodic preventive maintenance of the system.

Corrective Maintenance Instructions These instructions shall include guides for locating mal functions down to the card replacement level. These guides
shall include adequate details for quickly and efficiently locating the cause of an equipment malfunction and shall state the probable source(s) of trouble, the
symptoms, probable cause and instructions for remedying the malfunction.

Parts Information This information shall include the identification of each replaceable or field-reparable module. All parts shall be identified on a list in a
drawing; the identification shall be of a level of detail sufficient for procuring any repairable or replaceable part. Cross-references between system suppliers part
number and manufacturers part numbers shall be provided.

The Software Maintenance Documentation shall provide a detailed description of the entire software system. This documentation shall be sufficient for software
maintenance and modification of the entire software system. The following items shall be included with the software maintenance documentation.

1) Computer Manufacturers User Manuals All computer manufacturers manuals applicable to the system being provided.
2) System Suppliers User Manuals All applicable software manuals developed by the system supplier for the application software shall be
provided.
Application/ Custom Software Manuals These manuals shall include all software maintenance information not included in the computer manufacturers
and system suppliers standard manuals. Each custom program developed specifically for the system shall include the following information as a
minimum:

Table of Contents

Overview of the program.

3) Narrative describing exactly how the program works. All calculations, references to process I/O points and operator inputs should be mentioned.
4) A flowchart shall be provided to clarify the narrative description.
5) A list of variables used by the program including the function of each. A cross reference to the Software Functional design documentation shall
be provided where appropriate.

Software Listings

Two sets of well-annotated program listings of all software provided shall be furnished for all software items. These shall include, but not be limited to, the
following:

1. All listings associated with the system generation and software configuration of the specific system (i.e. system parameterization tables,
build maps, disk maps, etc.)
2. Listing of all data bases configured for and associated with the system
3. Listing of all custom or modified software developed specifically for the system

These listings shall reflect any changes made after the factory acceptance test.
Machine Readable Documentation The supplier shall provide one set of the following as built documentation in machine readable format: CD pack(s) of the
entire as-built software system in object format which shall contain information but cannot be edited, ready to mount and execute on the system

The machine readable documentation shall be 100% compatible with the software listings previously defined. As with the software listings, any changes made
during or after factory acceptance shall be reflected in the media.

Retrofit Documentation The Owner recognizes the fact that not all possible problems related to Real-Time events, software interlocks, flags, active tasks and
hardware utilisation can be discovered during the Acceptance tests. Therefore, the supplier shall investigate, diagnose, repair, update and distribute all pertaining
documentation of the deficiencies which become evident during the O&M period. All such documentation shall be submitted to the Design Build Operate
Engineer within 30 days of solving the problem.

Provide Operators Manuals for the system operators. These manuals shall be separately bound and shall contain all information necessary for the operator to
operate the system. The manuals shall be written in non-technical terms and shall be organised for quick access to each detailed description of the operators
procedure. Manuals shall contain, but not be limited to, the following information:

1) A simple overview of the entire system indicating the function and purpose of each piece of equipment.
2) A detailed description of the operation of Process Operator Console including all appropriate CRT displays.
3) Complete step-by-step procedures for starting up and shutting down the entire system
4) Complete step-by-step procedures for starting up or shutting down an individual component.
5) A complete description for operating all computer system equipment (i.e. CPU, CD drive etc)
6) Procedure for changing paper etc.,
7) A complete description of the operation of the control function. All operator input to these functions shall be described.
8) A listing of all data base point names with their respective point description.
9) A complete glossary of terms.
Schedule 10 [Deleted]
Project MOU between the Central Government, State Government and the ULB

TO Design, Build and Operate (DBO) of 45 MLD Capacity Tertiary Treatment Reverse Osmosis (TTRO) Plant at Kodungaiyur including Supply and
laying DI Transmission mains for conveyance of Product water to various industries in Manali area, Chennai, Tamil Nadu, India
Schedule 11[Deleted]

Performance Incentive Compensation

TO Design, Build and Operate (DBO) of 45 MLD Capacity Tertiary Treatment Reverse Osmosis (TTRO) Plant at Kodungaiyur including Supply and
laying DI Transmission mains for conveyance of Product water to various industries in Manali area, Chennai, Tamil Nadu, India
ANNEXURE
CV of the proposed Adjudicator

V SIVAKUMARAN, Chief Engineer (Retired), Chennai Metropolitan


Water Supply and Sewerage Board (CMWSSB), Chennai.
CURRICULUM VITAE
Name : V.Sivakumaran
Date of Birth : November 8, 1949
Nationality : Indian
Place of Living : Chennai, Tamil Nadu, India
Education
(A) i) Degree : Bachelor of Engineering (B E)
ii) Specialization : Mechanical Engineering
iii) Year of Passing : April 1972
iv) University : Madras University
(B) i) Degree : Master of Engineering (M E )
ii) Specialization : Environmental Engineering
iii) Year of Passing : April 1990
iv) University : Anna University, Chennai
Membership of
Professional Societies
: Life Fellow Institution of Engineers (India)
: Life Fellow Indian Water Works Association
: Life Fellow Indian Institution of Technical Arbitrators Association
Key Qualifications:
Retired as Chief Engineer, Chennai Metropolitan Water Supply and Sewerage Board (CMWSSB), Chennai, in November 2007, on superannuation. Has 35 years
of experience in Government Service, 5 years in Tamil Nadu Public Works Department involving Irrigation works, Building works and Ground Water
Investigation works, then 30 years in Chennai Metropolitan Water Supply and Sewerage Board involving Planning, Estimation, Contract Procurement, Execution
and Operation & Maintenance of Water Supply and Sewerage Projects for Chennai Metropolitan City.
Team Leader for the implementation of New Veeranam Water Supply Project during 2001-to 2004. The project was successfully implemented in record time to
supply 180 MLD of drinking water to Chennai City and the surrounding Urban areas. Involved in the execution and commissioning of 530 MLD Water
Treatment Plant at Chembarambakkam near Chennai during 2004 to 2007.
Associated in UNDP sponsored Hydrological and Artificial Recharge studies including implementation of the findings by developing a new well fields for the
extraction of 55MLD ground water to augment city/ Industrial water supply and preparation of OECF, JAPAN, funded Sewerage renovation project for the reuse
of sewage to Industries and improvements to water supply system. Involved in World Bank funded Water supply and Sewerage projects.
Also experienced in Source Monitoring, Operation & Maintenance of Water Supply and Sewerage system in Chennai City that includes Water Treatment Plants,
Water Distribution Stations, Water Distribution system, Ground Water extraction, Sewage Collection System, Sewage Pumping Stations and Sewage Treatment
Plants, serving a Population of about 6 Million (60 lakh) in 174 square kilometer area.
Has experience in construction management, progress monitoring, budgeting, approval of construction drawings, site inspection, quality control, conducting
review & coordination meetings and periodical reports etc. In the Operation Maintenance works, experienced in human resource management, material
management, Training, O&M Budget, quality control and revenue collection, Public contacts & complaint redress.
From December 2007 to May 2013 retained as Senior Consultant by the Tamilnadu Water Investment Co Ltd (TWIC Ltd ) for water supply and sewerage
projects.
Has Experience in Adjudication & Arbitration. (For Madurai & Erode Corporations and CMWSSB)
DETAILS OF PROJECTS:
Location: Tamilnadu Water Investment Company Limited (TWIC Ltd), Chennai.
Project Name:
1. Associated in Design, Drawing and finalization of the Detailed Project Report and Tender Documents for 200 MLD Water Supply Augmentation Project
for Salem Municipal Corporation. In this project the components of works are: Raw water drawl & pumping, Water Treatment Plant, Clear Water
Pumping, Conveying Main and Distribution System.
2. Preparation of Project Report for 24/7 Water Supply and Water Audit for Nanded Waghala Municipal Corporation, Maharashtra State.
3. Evaluation of Tenders (Technical and Financial Bids) for 125 MLD and 45.7MLD Sewage Treatment Plants for Madurai Municipal Corporation under
JNNURM Funding.
4. Evaluation of Tender Documents for Water Supply Project in Coimbatore Municipal Corporation under JNNURM Funding.
5. Preparation of Detailed Project Report including Bid Documents for Dedicated Water Supply Scheme to Erode City Municipal Corporation.
6. Associated in Proof checking of the major water supply projects prepared by TWAD Board for Vellore, Melur, Attur-Narasingapuram.
Location: Chennai Metropolitan Water Supply and Sewerage Board (CMWSSB), Chennai.
1. PROJECT NAME:
Chennai Water Supply Augmentation Project (New Veeranam Project) to Augment 180 MLD
of drinking water to Chennai City.
Location:
Tamil Nadu- From the source at Veeranam lake in Cuddalore district to Chennai City at a distance of 230 kilometer.
Year: September 2001 to October 2004.
Position Held: Chief Engineer.
Exact Duties:
Team Leader of the Project. Reviewed the Detailed Project Report prepared by a Consultant in the year 1996 for World Bank funding, modified and finalized the
Report to the requirements of the year 2001-2002. The Project Works were divided in to 5 packages, Rate Analysis done, specifications drawn and the Detailed
Estimates finalized at the price level of the year 2001-2002 for the total cost of Rs.720 crore, funded with Government share 30%, and the balance by loan from
financial institutions like LIC & Nationalized Banks and own funds of CMWSS BOARD. Tender documents were finalized for the works to be executed under 5
packages, tenders invited, evaluated and approval obtained from the competent authority. In addition to the selection of Contractors for the execution of works, a
Consultant firm was selected, through tender, for Project Management. The project works were completed in record time within the contract period of 18
months. The execution of Project works were commenced in February 2003 and completed and Commissioned in May/ June 2004. After trial operation, the
system is in continues operation from October 2004, at full designed capacity of supplying 180 Mld. of treated water to Chennai City. The entire execution works
were supervised, coordinated with various agencies and necessary approvals given. Major components of this project are:
a) CIVIL WORKS.
RCC structures for the Raw water drawl from the lake and pumping station to pump Raw water to Water Treatment Plant. (190 Mld ). Rehabilitation of
treatment Plant units for 180 Mld capacity. Break Pressure Tank (OHT) in RCC of 3ML capacity. Treated water pumping station for 180Mld capacity. Surge
Tanks. Water Distribution Station for 180Mld capacity. Under Ground clear water Storage Tanks in RCC of 9ML capacity each, two numbers. Valve
chambers, flow meter chambers, thrust blocks and all other associated civil works.

b) ELECTRICAL, MECHANICAL AND INSTRUMENTATION WORKS.


Raw Water Pumping Station 190Mld capacity. Transformer and allied units for 2500 KVA and 33/3.3 KV electrical supply. Horizontal split casing
centrifugal pump sets vertical mounted with extended shaft each with duty 1979 lpm at 41.5m head operated with 320 KW motors at 3.3KV electrical
supply. 4 Pumps for operation and 2 Pumps as standby units. DG set of 1000KVA capacity.

Treated Water Pumping Station 180Mld capacity. Transformer and allied units for 3500 KVA and 11/3.3 KV electrical supply. Horizontal split casing
centrifugal pump sets vertical mounted with extended shaft each with duty 1875 lpm at 67.5m head operated with 490 KW motors at 3.3KV electrical
supply. 4 Pumps for operation and 2 Pumps as standby units. DG set of 1500KVA capacity.

Water Distribution Station 180Mld capacity. Transformer and allied units for 1000 KVA and 11KV/415 volts electrical supply. Vertical Turbine pump sets
each with duty 1875 lpm at 25m head operated with 180 KW motors at 415Volts electrical supply. 4 Pumps for operation and 2 Pumps as standby units. DG
set of 1000KVA capacity.

c) WATER TREATMENT OF CAPACITY 180MLD:


All electrical, Mechanical, Piping and instrumentation works.
d) MANUFACTURING SUPPLYING AND LAYING OF MILD STEEL PIPES with internal cement mortar lining and glass fiber reinforced coal
tar enamel coating for external surface. For Raw water pumping main 1775mm dia MS pipes for 20 KM length. For Treated water pumping main 1750mm
dia MS pipes for 8KM length. For Treated water conveyance from BPT to WDS by gravity, 1875mm dia MS pipes for 180 KM length and 1500 mm dia
MS pipes for 20KM length.

e) CATHODIC PROTECTION units for the MS pipes.

f) TELEMETRY SYSTEM for the operation of the entire units.


2. PROJECT NAME:
Construction of New Water Treatment Plant of 530MLD capacity and treated water conveying pipe line partly funded under French Government assistance.
Location: Chembarambakkam, Chennai.
Year: 2004 to 2007
Position Held: Chief Engineer.
Exact Duties:
Supervision and Monitoring of the Construction of Water Treatment Plant for 530MLD treatment capacity which includes approvals, quality control, authorizing
modifications &changes as per the site requirements, coordination works etc. The main components of the works are: Raw water drawl arrangement, receiving
sump, pumping station in RCC and conveying main in MS Pipe 1500mmdia in two rows for 3KM length each for 564 MLD capacity. Electrical Mechanical
works, pump sets of 675hp, 5875m3 /hr each,4 working 2 standby. Cascade Aerators. Pre and post chlorination units. Pulsator Clarifier. Aquaqzur V Filters.
Chlorine contact tanks for the treated water capacity of 530MLD including electrical, mechanical and instrumentation works. Treated water under ground tank.
Treated water pumping station with pump sets of 700hp, 5521m3/hr each, 4 working, 2 standby. Treated water conveying main of 2000mm dia MS pipe 15KM,
1900mm dia MS pipe5.5KM. Trial operation of the plant and pipe line was commenced on 8th April 2007 and the entire plant was inaugurated on 19th July
2007. This plant is in successful operation.
3. PROJECT NAME:
Improvement works to sewage treatment plants.
Location: Chennai City.
Year: 1992-2004.
Exact Duties:
CMWSS BOARD has implemented Water Supply and Sewerage improvement works as proposed in the Master Plan with the financial assistance of World
Bank, other financial institutions and with Own fund in stages. Associated in these works at the level of Assistant Engineer to Chief Engineer and gained
experience in various activities of planning & design, development of Well Fields for ground water extraction, construction monitoring, leak detection &
rectification works and NRW studies in addition to Operation maintenance of the System.
Associated in preparation of OECF, JAPAN, funded Sewerage renovation project estimate to Rs 700 million for the reuse of sewage to Industries and
improvements to water supply system.
Responsible for major improvement works in Grit removal system, conversion of the less efficient/defunct Trickling Filter process units into Activated Sludge
Process units in 80MLD capacity sewage treatment plant, by introducing Floating Aerators with slight modifications in the civil structures and achieved the
desired quality of treated sewage which was supplied to Manali Industries for further treatment and used for industrial purpose. This enabled industries to meet
their water requirements in severe water shortage period during 1993.
4. PROJECT NAME:
UNDP sponsored Hydrological and Artificial Recharge Studies and Development of New Well Fields for the extraction of additional Ground Water to augment
Chennai water supply source.
Location: Chennai- Araniar Kozathaliar Basin.
Year: 1982 to 1987
Exact Duties:
Responsible for drilling exploratory bore wells, test bore wells, conducting pumping test, assess the ground water aquifer characteristics. Drilling and
construction of production bore wells. Erection and commissioning of turbine pump sets in the bore wells. The works were completed in 1987 when Chennai city
was facing severe water shortage. The project yielded 55MLD of ground water at that time to meet the Chennai city water requirements.
5.OPERATION AND MAINTENANCE EXPERIENCE:
Experienced in Operation and Maintenance of water supply and sewerage system in Chennai Metropolitan City serving a population of about 6 million (60
lakh). Responsible for operation & maintenance of 4 water treatment plants (capacities: 270MLD, 300MLD,180MLD, 530MLD), 180 sewage pumping stations,
2850km length water supply pipe lines, 2650km length of sewer system, Quality Control, men& materials management revenue collection, consumer complaint
redress etc.
6. OTHER TRAINING:
1985. Three months training in Advanced Drilling Techniques and Water well design and construction in USA under UNDP sponsored program.
1995: Visited USA, TOKYO, Singapore to acquire knowledge on the Reverse Osmosis Process for treatment of waste water & sea water and also other treatment
techniques.
1998: Attended 6 weeks management training course in one of the leading Western Australian University at Perth, Australia.
2006: Attended the International Water Congress, organized by the International Water Works Association at Beijing, China.
7. EMPLOYMENT RECORD.
a) From December 2007 to May 2013
Employer Tamil Nadu Water Investment Company Ltd, Chennai.
Position Held Senior Consultant for Water Supply and Sewerage Projects.
b) From September 2004 to November 2007.
Employer Chennai Metropolitan Water Supply & Sewerage Board.
Position Held Chief Engineer (Operation & (Maintenance )
c) From September 2001 to September 2004.
Employer Chennai Metropolitan Water Supply & Sewerage Board.
Position Held Chief Engineer (Water Supply Augmentation Projects)
d) From March 1999 to September 2001.
Employer Chennai Metropolitan Water Supply & Sewerage Board.
Position Held Superintending Engineer (Operation & Maintenance )
e) From August 1993 to March 1999
Employer Chennai Metropolitan Water Supply & Sewerage Board.
Position Held Executive Engineer.
f) From August 1980 to August 1993
Employer Chennai Metropolitan Water Supply & Sewerage Board.
Position Held Assistant Executive Engineer.
g) From August 1978 to August 1980
Employer Chennai Metropolitan Water Supply & Sewerage Board.
Position Held Assistant Engineer.
h) From January 1973 to August 1978
Employer Public Works Department (Tamil Nadu)
Position Held Assistant Engineer.
8. LANGUAGES:
Speaking Reading Writing
English Good Good Good
Tamil Good Good Good
Hindi Can speak and understand the conversation.
9. CONTACT DETAILS:
e-mail : sivakumaran49@yahoo.com
Mobile: 09444993459
Residence Phone: 044 2451 3459
10. ADDRESS FOR COMMUNICATION:
3/370A, 9th Street,
Venkateshwara Nagar, Kottivakkam,
Chennai 600041, Tamil Nadu, India.
CERTIFICATION
I, the undersigned, certify that to the best of my knowledge and belief, these data correctly describes me, my qualifications and my experience.

Signature:

Full name: V.Sivakumaran Date: November 6, 2014


SOIL INVESTIGATION REPORT
CONSULTANTS
GEO MINES ENGINEERS
GEOTECHNICAL ENGINEERING DIVISION,
I-FLOOR, # 3/82, VALLALAR STREET,
MOGAPPAIR WEST,
CHENNAI-600037
Ph. No. 98413 16631
Hello: 044- 3297 2963
Email : geomines@rediffmail.com
CLIENT
CMWSSB, CHENNAI

PROJECT PROPOSED CONSTRUCTION OF 45 MLD CAPACITY


TTRO PLANT AT KODUNGAIYUR, CHENNAI

TITLE GEOTECHNICAL INVESTIGATION REPORT


25-11-2014
GME/CMWSSB/925/2014-15

DATE REPORT NUMBER


REV. PREP.
BY
CONTENTS
SEC. PAGE
REPORT COVER PAGE I
CONTENTS I

CHAPTER-1 INTRODUCTION
1.0 Preamble 1
1.1 Scope of Work 1
1.2 Structure of the Report 1

CHAPTER-2 INVESTIGATION METHODOLOGY & TEST RESULTS


2.0 Field Testing 2
2.1 Preamble 2
2.2 Equipment Used and Method of Drilling 2
2.2.1 Equipment Used 2
2.2.2 Method of Drilling 2
2.3 In-situ Strength Tests 2
2.3.1 Standard Penetration Tests 2
2.4 Collection of Samples 2
2.4.1 Disturbed Soil Samples 2
2.4.2 Ground Water 3
2.5 Summary of Field Work 3
2.6 Laboratory Testing 3
2.6.1 Coarse Grained Soil Samples 3
2.6.1.1 Grain Size Analysis Tests 3
2.6.2 Fine Grained Soil Samples 3
2.6.2.1 Index Property & Free Swell Tests 3
2.6.3 Chemical Analysis Tests 3
2.6.3.1 Water Samples 3
FIGURE 2.0 Site Plan representing the locations of Field investigation points 4
2.1 Soil Profile at BH-01 Location 5
2.2 Soil Profile at BH-02 Location 6
2.3 Soil Profile at BH-03 Location 7
2.4 Soil Profile at BH-04 Location 8

TABLES 2.1 Laboratory Test Results on the Soil Samples collected from BH-01 9
2.2 Laboratory Test Results on the Soil Samples collected from BH-02 10
2.3 Laboratory Test Results on the Soil Samples collected from BH-03 11
2.4 Laboratory Test Results on the Soil Samples collected from BH-04 12
2.5 Chemical Analysis Test Results on the Water Samples collected from 13
borehole Locations

CHAPTE SUB-SURFACE STRATIFICATION


R-3
3.0 Preamble 14
3.1 Sub surface Stratification 14
3.1.1 Soil Profile at BH-01 Location 14
3.1.2 Soil Profile at BH-02 Location 15
3.1.3 Soil Profile at BH-03 Location 15

3.1.4 Soil Profile at BH-04 Location 16


CHAPTE FOUNDATION SYSTEM 17-18
R-4

CHAPTE
RECOMMENDATIONS 19
R-5

ANNEXU DESIGN OF DEEP FOUNDATION SYSTEM 20-21


RE
CHAPTER-1

INTRODUCTION

1.0 Preamble
CMWSSB, Chennai proposed to construct a 45MLD Capacity TTRO Plant at Kodungaiyur, Chennai.
For the purpose of designing the foundations, the responsibility of carrying out suitable soil investigation has been entrusted to M/s. Geo Mines
ENGINEERS, Chennai.
This report contains the field and laboratory test results along with Design computations and recommendations for suitable foundation systems.

1.1 Scope of Work


Sinking Four Standard Soil investigation bore holes of 150mm diameter up to depth of 8.00m below existing ground level as directed by the engineer-in-
charge.
Conducting Standard Penetration Test (SPT) at regular depth intervals.
Collection of Split Spoon Samples or Disturbed Soil Samples
Collection of water samples from each bore hole.
Conducting relevant laboratory test results.

1.2 Structure of the Report


Contents
Introduction
Investigation Methodology & Test Results
Figures & Tables
Sub-Surface Stratification
Foundation Systems
Recommendations
Annexure (Design Computations)

CHAPTER-2

INVESTIGATION METHODOLOGY & TEST RESULTS

2.0 Field Testing:


2.1 Preamble:

Four standard soil investigation boreholes were put. The equipment used and the methodology adopted to carry out the fieldwork is described below.

2.2 Equipment Used and Method of Drilling:


2.2.1 Equipment Used
The equipment used for performing the drilling operations is a Manual Rotary Drill Rig with direct mud circulation technique. The drill mud used was
made out of Sodium Bentonite.

2.2.2 Methodology of drilling

In the soil strata, the drilling operations have been carried out using special drill bits with direct mud circulation.

2.3 In-Situ Strength Tests:


2.3.1 Standard Penetration Test:
Standard penetration tests were conducted at the borehole locations, in accordance with IS: 2131. The tests were conducted at every change of strata up
to the depth of termination of the borehole as directed by the engineer-in-charge.

2.4. Collection of Samples:


2.4.1 Disturbed Soil Samples
The SPT-samples collected were used as disturbed soil samples. These samples were used for visual and physical identification and for conducting
laboratory classification tests as per I.S.1498-1970.

2.4.2 Ground Water


For conducting suitable chemical tests, the ground water sample was collected from the respective boreholes.

2.5 Summary of Field Work


The locations of the boreholes are shown in site plan given in Fig.2.0. The soil profiles obtained at each location is shown in Figs. 2.1 to 2.4.

2.6 Laboratory Testing:


2.6.1 Coarse Grained Samples:

2.6.1.1 Grain size Analysis Tests:

On the coarse grained samples, grain size distribution tests were conducted as per I.S.2720 (Part 4)-1985, to know the gradation characteristics and to
classify them. These results are presented in Tables 2.1 to 2.4.

2.6.2 Fine Grained Samples:

2.6.2.1 Index Property Free Swell Tests:

Atterberg Limits were carried out on fine grained soil samples to evaluate the limits of different consistency states. Generally Liquid limits, Plastic limits
and Shrinkage Limits tests were conducted as per I.S.2720 (Part-5)-1985 and I.S.2720 (Part 6)-1972. On such type of soil strata encountered at the
investigation locations, such tests were conducted and the test results are presented in Tables 2.1 to 2.4.

2.6.3 Chemical Analysis Tests:


2.6.3.1 Water Samples:
On representative water samples, chemical analysis tests were conducted to estimate pH, Chlorides and Sulphates. These results are presented in
Table-2.5.
N

BH-02 BH-04
BH-03

BH-01

Fig. 2.0: Site Plan Representing the locations of Field Investigation Points
Project : Proposed Construction of 45MLD Capacity TTRO Plant at Kodungaiyur, Chennai
Location: BH-01
Started On : 24/11/2014; Ended On : 24/11/2014;G.W.T: 2.50m below existing ground level

Density/Consistency
R.L of Layer (m)

SPT - Details

Type of Sample
0

Relative
G.W.T. (m)

Soil Profile

Depth of SPT
below E.G.L

15-30 cm

30-45 cm

N-Value
0-15 cm
Engineering Description

(m)
of Soil

0.50 Filled Up Soil - DS

Greyish Loose 1.50 2 3 4 7 Loose SS

Silty Clayey Fine Sand


2.50
Greyish 3.00 2 2 2 4 V.Loose SS

Very Loose

4.00 Silty Clayey Fine Sand

4.50 3 3 3 6 Loose SS

Greyish

Loose 6.00 2 3 3 6 Loose SS

Silty Clayey Fine Sand


8.00 8.00 2 3 3 6 Loose SS
Bore Hole Terminated at a depth of 8.00m below the existing ground level
Fig. 2.1 Soil Profile at BH-01 Location
Project : Proposed Construction of 45MLD Capacity TTRO Plant at Kodungaiyur, Chennai
Location: BH-02
Started On : 24/11/2014;Ended On : 24/11/2014;G.W.T: 2.00m below existing ground level
SPT - Details

Density/Consistency
R.L of Layer (m)

Type of Sample
0

Relative
G.W.T. (m)

Soil Profile

Depth of SPT
below E.G.L

15-30 cm

30-45 cm

N-Value
0-15 cm
Engineering Description of

(m)
Soil

1.50 1 0 0 0 V.Loose SS
G.W.T Greyish

Very Loose

Silty Clayey Fine Sand 3.00 1 0 0 0 V.Loose SS

4.00

4.50 4 4 5 9 Loose SS

Greyish

Loose 6.00 4 5 5 10 Loose SS

Silty Clayey Fine Sand


8.00 8.00 4 5 5 10 Loose SS
Bore Hole Terminated at a depth of 8.00m below the existing ground level
Fig. 2.2 Soil Profile at BH-02 Location
Project : Proposed Construction of 45MLD Capacity TTRO Plant at Kodungaiyur, Chennai
Location: BH-03
Started On : 24/11/2014;Ended On : 24/11/2014;G.W.T: 2.50m below existing ground level
SPT - Details

Density/Consistency
R.L of Layer (m)

Type of Sample
Relative
G.W.T. (m)

Soil Profile

Depth of SPT
below E.G.L

15-30 cm

30-45 cm

N-Value
0-15 cm
Engineering Description of

(m)
Soil

Greyish
Loose 1.50 2 3