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GOVERNMENT OF KARNATAKA

Design, Build, Operate & Transfer


Of
PROVIDING PURE DRINKING WATER SUPPLY TO HOSADURGA TOWN AND
346 HABITATIONS OF HOSADURGA TALUK IN CHITRADURGA DISTRICT
AND RAW WATER TO 113 HABITATIONS OF TARIKERE TALUK,
CHIKKAMAGALURU DISTRICT, KARNATAKA STATE, INDIA.

(PHASE –I)

VOLUME-II
TECHNICAL BID

THE EXECUTIVE ENGINEER,


RURAL DRINKING WATER & SANITATION DIVISION, CHITRADURGA.
VOLUME – II CONTENTS
1. CONCEPT NOTE :PROJECTED POPULATION AND WATER DEMAND (
ANNEXURE-1) FOR PROJECT VILLAGES / HABITATIONS PROJECT AREA
FOR DESIGN Etc

2. DESIGN CRITERIA

3. DATA SHEETS TO BE FILLED BY BIDDERS

PART - A : GENERAL SPECIFICATION

1.0 DESCRIPTION OF THE WORKS:


2.0 GENERAL REQUIREMENTS:
3.0 STANDARDS:
4.0 CONTRACT ADMINISTRATION
5.0 HEALTH, SAFETY AND WELFARE
6.0 PROGRAMME OF WORK:
7.0 INSPECTION AND TESTING OF PLANT DURING EXECUTION OF THE
WORKS
8.0 TESTING OF PLANTS
9.0 TRAININGS
10.0 SPECIAL TOOLS, SPARE PARTS, TOOLS AND TEST EQUIPMENTS
11.0 OPERATION AND MAINTENANCE PERIOD
12.0 TEST ON COMPLETION FOR OPERATION AND MAINTENANCE PERIOD OF
THE WORKS

PART - B : PARTICULAR SPECIFICATION


1.0 CAPACITY OF THE WORKS:
2.0 PUMPING STATIONS AND MECHANICAL WORKS:
3.0 WATER TREATMENT WORKS
4.0 PARTICULAR SPECIFICATIONS – ELECTRICAL WORKS
5.0 PARTICULAR SPECIFICATIONS – CIVIL WORKS
6.0 PARTICULAR SPECIFICATIONS – BUILDING SERVICES WORKS
7.0 PARTICULAR SPECIFICATIONS – INSTRUMENTATION WORKS

PART - C : PLANT MATERIALS AND WORKMANSHIP

PART - D ; PIPELINE WORKS STANDARD SPECIFICATIONS

PART - E : MECHANICAL STANDARD SPECIFICATIONS

PART - F : ELECTRICAL STANDARD SPECIFICATIONS

PART - G : CIVIL STANDARD SPECIFICATIONS


PART – H : INSTRUMENTATION SYSTEM STANDARD SPECIFICATIONS

PART – I : LIST OF APPROVED MAKES


CONCEPT NOTE

PROVIDING PURE DRINKING WATER SUPPLY TO HOSADURGA TOWN AND 346 HABITATIONS OF
HOSADURGA TALUK IN CHITRADURGA DISTRICT AND RAW WATER TO 113 HABITATIONS OF TARIKERE
TALUK, CHIKKAMAGALURU DISTRICT, KARNATAKA STATE, INDIA. Under DBOT

(Part of Special conditions of Contract)

1. OVERALL DBOT TENDER SCOPE

(i) Traditionally, the projects for water supply are tendered in terms of what is known as “Item Rate”
tender. In other words, the Detailed Scheme Report (DSR) and detailed design and technical
estimate of the work are drawn-up in advance by the agency calling the tender. The bidders, in
such a case, execute the already designed water supply scheme and bidding is basically on the
cost of execution of a known design and DSR.

(ii) In the present case the tender is for (i) Design (ii) Build (iii) Operate & (iv) Transfer. This
methodology of tender has been selected for the following reasons –
a. Providing Water Supply to Hosadurga Town and Other 346 Habitations of Hosadurga
Taluk Chitradurga District, & Enroute Uncovered Habitations Tarikere Taluk water supply
project is a “Greenfield” water-supply project. Therefore, there are viable multiple
alternatives in terms of design and technology (within the overall standards as laid down
by CPHEEO & Other relevent Guidelines/Standards).
b. Further, the size of the project is large and major part of rural area of Hosadurga Taluka,
Hosadurga town of Chitradurga District will get drinking water-supply over a geographical
area spread over about 1416.4 sqkm. This means the design options are multiple.
c. The Tamil Nadu Water Supply & Drainage Board (TWADB) has executed DBOT projects
on similar scale and experience has shown that the approach of DBOT can give more
optimal solutions in terms of design and cost and also reduce execution time of the large
water-supply projects.
d. KUIDFC has also used DBOT method to execute “Davangere Town Sewerage
Treatment Plant”.
e. In the same lines, Gadag district entire rural habitations covering water supply scheme
has been awarded and work implementation has started.
f. In this context the Cabinet approval has been accorded for implementation of this project
on DBOT based tender in Phases.

(iii) The (a) source of water, (b) population to be catered and their location (the water requirement at
destination villages/habitations) shall be made available to the DBOT bidders as input data (c)
as for as possible suitable Government land available for the components of the scheme be
selected and bidder should get permission from the concerned departments wherever it is
inevitable to locate any component in private lands, bidder has to make his own arrangements
to procure required land.

(iv) It is expected that bidders shall propose and prepare an optimal design to meet the drinking
water supply requirement and actually prepare a Scheme Report as accurate as possible which
will be the basis of contract. This Scheme Report shall be submitted as part of the Technical Bid
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and same shall be evaluated by a Committee of Technical Experts. A bid which proposes a
Scheme Report that is technically not sound, is perfunctory /superficial, and does not conform to
actual field facts/reality and CPHEEO Standards & Guidelines shall be rejected at the stage of
Technical Evaluation itself.

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GENERAL
District Profile

CHITRADURGA Located at a distance of 202 kms Northwest of Bangalore, in the heart of the Deccan
Plateau, Chitradurga is recognized as the land of valour and chivalry. The district headquarters town,
Chitradurga owes its name to “Chitrakaladurga,” or “Picturesque castle”. This is a massive fortress on
top of granite hills that rises dramatically from the ground. Archaeological remains found in the area,
trace its history to the 3nd millennium B.C.

A rock cut edict of Emperor Ashoka, near Bharamagiri reveals that Chitradurga was part of the Mauryan
Empire dating to the 3rd century B.C. After the fall of the Mauryans, this land was under the rule of royal
dynasties like the Rashtrakutas, Chalukyas and Hoysalas. But it really achieved eminence, as a
feudatory state of the Vijayanagar Empire, under the dynastic rule of the Nayakas or “Paleyars”, known
for their heroic exploits. The most eminent of the feudatory chieftains, was Madakari Nayaka, who after
the fall of the Vijayanagar Empire, declared his suzerainty and consolidated his power. This hill fortress
built by the Nayakas during the Vijayanagar era, became their stronghold later. In 1779, the fort was
captured by Haider Ali, who along with his son Tipu Sultan, was responsible for its expansion and
strengthening. After Tipu Sultan’s defeat by the British, the fort came under the rule of the Royal
Mysore family.

Chitradurga features bold rock hills and picturesque valleys, huge towering boulders in unimaginable
shapes. It is known as the "stone fortress" (Kallina Kote). The landscape looks much like a mischievous
giant's playground, with boulders thrown around, forming silhouettes against the sky. According to a
story in the Epic Mahabharatha, a man-eating gaint named Hidimbasura lived on the Chitradurga hill
and was a source of terror to everyone around. When the Pandavas came with their mother Kunti in the
course of their exile, Bhima had a duel with Hidimba. Hidimba was slain by Bhima and peace returned
to the area. Legend has it the boulders were part of the arsenal used during that duel. In fact, the
boulders on which major part of the city rests belong to the oldest rock formation in the country.

Timmana Nayaka a chieften under the Vijayanagar empire rose to the rank of governor of Chitradurga
as a reward for his excellence in military achievements, from the Vijayanagara ruler. This was the
beginning of the rule of the Nayakas of Chitradurga. His son Obana Nayaka is known by the name
Madakari Nayaka 1588 CE. Madakari Nayaka's son Kasturi Rangappa 1602 succeeded him and
consolidated the kingdom to rule peacefully. As he had no heirs to succeed him, his adopted son, the
apparent heir was enthroned but was killed in few months by the Dalavayis.

Chikkanna Nayaka1676 the brother of Madakari Nayaka II sat on the throne, and his brother succeeded
him with the title Madakari Nayaka III in 1686. The unwillingness of Dalawayis to accept Madakari
Nayaka III's rule gave an opportunity to one of their distant relatives, Bharamappa Nayaka to ascend
the throne in 1689. He is known as dthe greatest of the Nayaka rulers. Somehow, the subjects of
Chitradurga did not experience a good reign of the successive rulers as they ruled on the throne for
very brief periods. The Hiri Madakari Nayaka IV 1721, Kasturi Rangappa Nayaka II 1748, Madakari
Nayaka V 1758 ruled this area but there is not much to mention of their rule.

Taluk Profile

Hosadurga Taluk is in Chitradurga District around 200km from Bangalore. Agriculture is the main
activity of this region. According to Dr. D M Nanjundappa Committee Report, Hosadurga Taluk is
classified as Most Backward Taluk. The villages of the Taluka are having drinking water supply
schemes with bore wells as source.
Tarikere Taluka:
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Ground Water Scenario
The bore wells were drilled from a minimum depth of 64 mbgl to a maximum of 200.1mbgl. Depth of
weathered zone ranges from 6.0mbgl to 27.0 mbgl. Yield ranges from 0.64 to 5.5 lps. Transmissivity
ranges from 0.5m2/day to 75.88 m2/day. Storativity ranges from 0.07 to 0.21. Seasonal water- level
fluctuation varies from 2.65 m to 3.37m. In Hosadurga Taluk, except the western part which falls under
critical category, the rest of the taluk is safe. 22% of the taluk falls under over exploited category.
Because of over exploitation the yield from bore wells dwindles down during summer and the water
supply is affected and the villages face scarcity of drinking water.

The present coverage is about 0-25 is 252 habitations, 25-50 is 33 habitations, 50-75 is 17 habitations,
75-100 is 44 habitations. In some cases the bore well water is contaminated with Alkalinity, Nitrates,
Chloride, TDS, Fluoride, Iron and pH and other harmful chemicals. The Alkalinity contamination varies
from 604.00mg/l to 2026.00mg/l of 42 Samples, Nitrates contamination varies from 98.00mg/l to
138.00mg/l of 16, Chloride contamination varies from 1005.00mg/l to 1330.00mg/l of 9 Samples, TDS
contamination varies from 2166.00mg/l to 2400.00mg/l of 10 Samples, Fluoride contamination varies
from 1.51 mg/l to 4.40 mg/l of 54 Samples, Iron contamination varies from 0.50 mg/l to 5.00 mg/l of 16
Samples, pH contamination varies from 8.53 to 9.00 of 18 Samples out of 920 samples.

Because of water quality issue and coverage the Elected Representatives of the taluk have requested
the Government to provide potable and dependable water supply to the taluk. So it is necessary to
provide safe and dependable water supply scheme to the villages and Town. The source of supply has
to be dependable and water should be potable and free from harmful chemicals. This is possible if
surface water (River or Tank) is taken as source with Water Treatment Plant.

Rural Drinking Water and Sanitation Department of Govt. of Karnataka is the agency responsible for
planning and execution of water supply and sanitation projects in rural areas of Karnataka State.
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RDW&SD has formulated a project for supplying potable water to all the habitations in the project area
of Hosadurga Taluk from a sustainable surface source as a step towards solving the problem
permanently. RDW&SD has prepared a Preliminary Report for the above multi village drinking water
supply scheme for a general understanding and for broad guidelines.

The source of supply should be dependable and water should be potable and free from harmful
chemicals. This is possible if surface water (River or Tank) is taken as source with Water Treatment
Plant. Since demand of each village will be usually small we should go in for Multi Village Water Supply
Scheme with common source and Water Treatment Plant. Then clear water should be transmitted to
the service reservoirs/storage stand posts in the Habitations to be covered through Master Balancing
Reservoir or Tanks and network of gravity mains, looking in to the topography of the area. In some
cases where the village is located at higher elevation, intermediate sump with pumping arrangement
will have to be provided for supplying water to such village.

2. POPULATION PROJECTION AND WATER DEMAND ANALYSIS:

2.1. POPULATION PROJECTION:


Projected population for different project years for each of the census village was calculated by various
methods considering past population values for years 1991, 2001 and 2011. As the said project is a
mega project covering 346 Nos. of villages/habitations and Hosadurga Town, the design base year has
been considered as 2020 with 3 years planning, execution and commissioning period. The project
intermediate design year shall be 2035 and project ultimate design year shall be 2050. Based on past
growth trend, the projected population value considered for each village is lowest value obtained from
various projection methods. The total projected population of habitations in the project area for the
project implementation year of 2020 is 3.08 Lakhs, project intermediate year of 2035 is 3.82 Lakhs and
project ultimate year of 2050 is 4.8 Lakhs.

2.2. PROJECTED WATER DEMAND:


Water demand has been worked out for different project years considering per capita water supply rate
of 85 lpcd as per Govt. of Karnataka. As practiced in RDW&SD rural water supply projects, 20% losses
has been considered as transmission and distribution losses. Loss of water in WTP has been
minimized by recirculating the filter backwash water (i.e., 5%). The summary of projected water demand
as arrived for the project area is given in Table. As seen in said table, the total projected water demand
for villages in the project area for the project implementation year of 2020 is 35.11 MLD, project
intermediate year of 2035 is 44.36 MLD and project ultimate year of 2050 is 57.00 MLD.

Projected population Requirement of Water


Immedi Interme
Sl Ultimat Immediate Intermedia Ultimate
Particulars ate diate
No e stage stage te Stage stage
stage Stage
2020 2035 2050 Liters Liters Liters

1 HOSADURGA RURAL 270772 321899 383455 28769526 34201772 40742095

2 HOSADURGA URBAN 37619 60213 96377 6348206 10160944 16263619

Total 308391 382112 479832 35117732 44362716 57005714

3 TARIKERE RURAL 83464 91876 101145 8868050 9761825 10746656

Grand Total 391855 473988 580977 43985782 54124541 67752370

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3.0 SELECTION OF SURFACE SOURCE FOR THE PROJECT:
After experiencing short falls in ground water sources, other natural sources such as surface source
were investigated. River Vedavathi flows through the taluk to get bridged at Mari Kanive dam. The River
is one of the main source for drinking water for the town and villages of Hosadurga Taluk.

Vani Vilasa Sagar Dam located across Vedavathi river near Marikanive. The distance is around
40.0kms from source to Hosadurga Town. Using this as source other water supply schemes have been
taken up and the requirement for this scheme will not satisfy because of total allocation for this dam is
only 8.20 TMC. And River Vedavati is not sustainable or dependable since it is not perennial.

Bhadra Reservoir located nearby Lakkavalli village of Tarikere Taluk Chickamagular District across
Tungabhadra River. The distance is around 80.0kms from source to Hosadurga Town. From this source
water supply scheme can be taken up as it has more dead storage capacity and also the static head
and distance are relatively less.

Tungabhadra Reservoir located nearby Mallapur village of Hospet Taluk Bellary District across
Tungabhadra River. The distance is around 210.0kms from source to Hosadurga Town. Taking up
water supply scheme from this source works out to be uneconomical the source is distance from the
proposed area and the static head are high. Hence Bhadra Reservoir very is considered as source. A
Multi Village Water Supply Scheme with Bhadra Reservoir as source is proposed for covering 346
Habitations of Hosadurga Taluk, Chitradurga District and covering 113 Habitations of Tarikere Taluk.

It is found that tapping water from Bhadra Reservoir the water requirements of Hosadurga taluk
including all habitations and town are fulfilled. Also, the source is perennial and the static head is less
when compared with the other source.

The water allocation for this scheme required about 0.873 TMC to cater the needs of Hosadurga taluk
including all habitations and town and Enroute Uncovered Habitation Tarikere taluk. The Permission
from the Government sanctioned through Letter No: WRD58MMB2013 Dated 22 / 07 / 2014 of 1.00
TMC.

4.0 PROJECT PROPOSAL:


Under the proposed project, it is considered to draw required quantity of raw water from Bhadra
Reservoir and supply to project habitations after treatment. The project components includes intake
structure, raw water rising mains and raw water pumping stations, WTP, clear water bulk supply mains,
master balancing tanks or reservoirs (ZBTs/MBRs), gravity feeder mains up to all habitations in project
area These shall be designed for ultimate stage water demand i.e. 67.75 MLD. Treated water pumping
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station,intermediate pumping stations (IPSs), local lifting stations (LS), etc. The project villages are
grouped into to clusters with each cluster having 15-18 villages. All the project components shall be
designed for ultimate stage water demand of 57.00 MLD. The intake structure may be located at
Bhadra Reservoir water spread. The raw water to be conveyed to ridge GLSR were the Tarikere
requirement can be bifurcated, by pumping and to proposed WTP by gravity to be located within the
project area. Intermediate pumping station shall be provided to avoid very high head pumping. The
treated water from WTP shall be conveyed to ZBTs/MBRs at each cluster through a bulk water
transmission main network. The treated water stored at MBRs shall be conveyed to existing OHTs in
each habitation through a gravity feeder main network duly disinfecting with 0.5mg/lt of residual chlorine
available at village OHT feeding point. Whichever village is not having any OHT, a separate OHT of
50% of ultimate daily demand or 10000 lt capacity whichever is higher with 7.5 m stating at the highest
level in that village shall be constructed as part of this scheme. The design of the entire scheme as per
the design criteria given elsewhere.

Phase – I

The Phase – I Works includes


1) Head works consists of Intake well, Connecting main, inspection wells, unitized sump with pump
house to accommodate HT motors, HT Panel, Boards, Control panels, Battery bank, EOT
Cranes and gate arrangement for total ultimate stage demand.
2) Pumping machinery (2+1) Manifold Surge protection.
3) Express feeder with substation and 50% Capacity DG sets.
4) Raw water rising main to carry ultimate stage discharge and appropriate outlet points for
Tarikere taluk demand.
5) Construction of water treatment plant for 44.36 MLD making sufficient provision to make
extension for later stage requirement of total capacity 57.00 MLD with all inter connection,
automation, internal electrification, roads, drainage and Mechanical equipment with etc.,
Establishing of substation with express feeder for WTP and further pumping requirement with
50% capacity DG sets.
6) Clear water storage sump, pumping station, pumping machineries for further pumping to ZBT’s /
IPS’s and surge protection.
7) Clear water rising main to 92 Habitations, Hosadurga TMC and Phase – 2requirement to be
carried to hosadurga town.
8) Construction of Intermediate pumping station with sump for ultimate stage and pumping
machines for Hosadurga TMC separate line, ZBT’s – 2,4 and 5 Make necessary provision for
other ZBT’s i.e. Phase – II.
9) Express feeder and substations, along with 50% capacity, DG sets.
10) Clear water rising main to TMC, ZBT’s 2,4 and 5.
11) Construction of ZBT’s 1,2,3.4.
12) Laying of gravity main from ZBT’s 1,2,3,4. to Habitations OHT’s
13) Additional OHT’s for Habitations wherever requirement added.
14) Operation Maintains of the entire scheme for 5 years with SCADA, automation and Intergration
to Phase – II .

Phase – II

The Phase – II Works includes


1) Pumping machineries for further pumping to ZBT’s / IPS’s and surge protection.
2) Clear water rising main to balance 254 Habitations.
3) Construction of Intermediate pumping station with sump for ultimate stage and pumping
machines for necessary Habitations.
4) Clear water rising main to ZBT’s 6,7,8,9,10,11,12,13 and 14.
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5) Construction of ZBT’s 5,6,7,8,9,10,11,12,13 and 14.
6) Laying of gravity main from ZBT’s 5,6,7,8,9,10,11,12,13 and 14 to Habitations OHT’s
7) Additional OHT’s for Habitations wherever requirement added.
8) Operation Maintains of the entire scheme for 5 years with SCADA , automation and Intergration
to Phase – I .

5.0 OPERATION PHILOSOPHY FOR MANAGEMENT OF BULK WATER SUPPLY:


As the proposed surface water scheme is a mega project involving many project components including
intake, IPSs, LSs, ZBTs, pipelines etc. which are interlinked with each other, manual operation of the
scheme is difficult and requires huge manpower. In case of manual operation there are chances of
human error and system cannot be synchronized completely to prevent overflows, water losses, and
inequitable supply among habitations. Hence a comprehensive proven "Integrated Water Management
System" shall be provided for the scheme for automated operation. The system provided shall include
Integrated District Management System (IDMS), Water Management Districts (WMDs), Air
Management System (AMS) and Reservoir Management System (RMS) or SCADA system for effective
operation and maintenance of the scheme.

6.0 SECURING OF LAND:


The required extent of land for intake structure cum pumping station, WTP, clear water storage tank,
pumping station, BPT, intermediate sumps, pumping stations, MBRs / ZBTs etc. shall be located on
available Government land and if bidder proposes alternative, suitable land should be secured by
Contractor only at his own cost, and transfer to ownership of Deparment. The lands secured by the
Contractor from private sources shall be registered in the name of the respective gram panchayats only
before starting the work. The Contractor shall secure in-principle agreement from land owners to sell
the land. The value of lands shall not be higher than Guidance Value (fixed by GOK for 2014 - 2015)
plus 50%. Also it is the responsibility of Contractor to obtain right of way / right of use permission from
land owners and other Govt. agencies.

The tentative locations identified by RDW&SD, subject to final feasibility/ acceptance by bidder with the
flexibility to choose his own alternative sites with minimum land acquisition at his own cost.

Sl
Components Tentative Locations Identified by RWS&SD
No

1 Head works Water spread of Bhadra Reservoir


Along the road and byepass Tarikere town up to
2 Raw water rising main
ridge and to WTP
3 Water Treatment Plant Near Ahamadanagar
4 Clear Water Rising Main up to ZBT All Along existing Roads

5 Intermediate Pumping Stations One near Hosadurga Town

ZBT’s at higher altitudes comprising 15-39


6 Locations of ZBTs habitations depend on elevation to deliver water
by gravity
Clear Water Gravity Main from ZBTs to All Along existing Roads from respective ZBTs
7
Habitations OHTs to Habitations OHTs

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7.0 TECHNICAL COMMITTEE
The Review and Evaluation Committee (Technical Expert Committee) to review and evaluate the
technical proposal/PSR/Evaluation shall be formed with Chief Engineer RDW&S Dept and other expert
members of credibility and independent standing – including experts from Premier
Institutions/Organizations. The recommendations of this committee regarding the technical bid shall be
final and binding.

8.0 SITE VISIT BY BIDDERS


It is essential to visit all the probable/feasible site locations by bidder and to produce documentary
evidence having visited all the proposed locations.

9.0 PROPOSED SERVICE LEVEL


The present service level and the source has been mentioned in the population list and as per
Karnataka Government’s Cabinet decision, it is proposed to provide 85 lpcd water and 135 lpcd to
Urban area.

FURTHER THE FOLLOWING CONDITIONS WILL ALSO BECOME PART


OF THE AGREEMENT WHICH MAY PLEASE BE NOTED.

a) However, for the above package the firm has to provide 01 Nos of AC Car/ Jeep with
Drivers, Consumables, Insurance tax etc till Completion of the project. And handover
the vehicle to the designated officers of the Department after completion of the Project.

b) The firm has to provide standard PC, and its Consumables with Internet facility to the
designated officers of the Board for project purpose at no extra cost till defect liability
period.

Sr. Specification Description


1. Processor Intel Core-I7 with Intel HD 4 GB Graphics
2. Memory 8 GB DDR3
3. Storage 1TB with Latest SATA
4. Graphics Integrated Intel HD graphics
5. Display 22” TFT/LED Monitor
6. Operating System Windows 10

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ANNEXURE 1

PROJECTED POPULATION AND WATER DEMAND FOR PROJECT TOWN IN PROJECT AREA FOR DESIGN

Projected Requirement at Requirement at


Supply
Sl. population tapping point (2035) tapping point (2050)
Name of Village / Habitation Rate
No.
(LPCD)
2035 2050 Litres MLD Litres MLD

1 Hosdurga Town (TMC) 60,213 96,377 135 1,01,60,947 10.160 1,62,63,621 16.263

Total 60,213 96,377 1,01,60,947 10.160 1,62,63,621 16.263

PROJECTED POPULATION AND WATER DEMAND FOR PROJECT VILLAGES / HABITATIONS IN PROJECT AREA
FOR DESIGN OF HOSADURGA RURAL 346 HABITATIONS

Requirement at Requirement at
Projected
Supply tapping point tapping point
Sl. population
Name of Village / Habitation ZBT'S Rate (2035) (2050)
No.
(LPCD)
2035 2050 Litres MLD Litres MLD

Phase - I
1 ALADAHALLY 1 1461 1740 85 155231 0.155 184875 0.185

2 BHAGASHETTIHALLI 1 1476 1758 85 156825 0.157 186788 0.187

3 KADADANAKERE BOVIHATTI 1 138 165 85 14663 0.015 17531 0.018

4 KONDAJI 1 858 1022 85 91163 0.091 108588 0.109

5 KONDAJI L.HATTI 1 225 268 85 23906 0.024 28475 0.028

6 KONGAVALLI 1 2276 2711 85 241825 0.242 288044 0.288

7 KONGAVALLI KURUBARA HALLY 1 932 1110 85 99025 0.099 117938 0.118

8 KORATIKERE 1 981 1169 85 104231 0.104 124206 0.124

9 MALALI 1 1862 2218 85 197838 0.198 235663 0.236

10 ADRIKATTE 1 959 1142 85 101894 0.102 121338 0.121

11 AHMEDNAGARA 1 947 1128 85 100619 0.101 119850 0.12

12 KUMBRAGUDLU 1 98 117 85 10413 0.01 12431 0.012

13 DASANAHALLI 1 265 316 85 28156 0.028 33575 0.034

14 HURLIHALLI 1 216 258 85 22950 0.023 27413 0.027

15 MARABAGATTA 1 930 1108 85 98813 0.099 117725 0.118

16 NERAGUNDHA 1 2132 2539 85 226525 0.227 269769 0.27

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17 NERAGUNDHA GOLLARAHATTI 1 324 386 85 34425 0.034 41013 0.041

18 SANIHALLI 1 2770 3299 85 294313 0.294 350519 0.351

19 SHETTIHALLI 1 1779 2119 85 189019 0.189 225144 0.225

20 BAGUR 2 4228 5035 85 449225 0.449 534969 0.535

21 K.T. NAGARA 2 157 187 85 16681 0.017 19869 0.02

22 DODDARANGAIAHNAHATTY 2 280 334 85 29750 0.03 35488 0.035

23 IYLAPURA 2 680 810 85 72250 0.072 86063 0.086

24 KODIHALLI 2 1062 1265 85 112838 0.113 134406 0.134

25 PALYADAHALLY 2 349 416 85 37081 0.037 44200 0.044

26 ADVISANGINAHALLI 2 806 960 85 85638 0.086 102000 0.102

27 ARALIHALLI 2 1909 2274 85 202831 0.203 241613 0.242

28 BOKIKERE 2 1927 2295 85 204744 0.205 243844 0.244

29 K.K.HATTY 2 748 891 85 79475 0.079 94669 0.095

30 CHANNASAMUDRA 2 1656 1972 85 175950 0.176 209525 0.21

31 M.G.DIBBA 2 1420 1691 85 150875 0.151 179669 0.18

32 HONNEKERE 2 1475 1757 85 156719 0.157 186681 0.187

33 HONNEKERE G. HATTI 2 737 878 85 78306 0.078 93288 0.093

34 RANGAPURA 2 103 123 85 10944 0.011 13069 0.013

35 MACHANAHALLI 2 950 1132 85 100938 0.101 120275 0.12

36 BYADRAHALLI 2 431 514 85 45794 0.046 54613 0.055

37 CHIKKABYALADAKERE GATE 2 106 127 85 11263 0.011 13494 0.013

38 MUTHAGONADHI 2 423 504 85 44944 0.045 53550 0.054

39 KADADANAKERE 2 987 1176 85 104869 0.105 124950 0.125

40 G. LAMBANIHATTI 2 113 135 85 12006 0.012 14344 0.014

41 GAVIRANGAPURA BETTA 2 448 534 85 47600 0.048 56738 0.057

42 CHINNAPURA 2 631 752 85 67044 0.067 79900 0.08

43 SANKAIAHNAHATTY 2 185 221 85 19656 0.02 23481 0.023

44 LAKKENAHALLY 2 382 455 85 40588 0.041 48344 0.048

45 MADHURE 2 2813 3350 85 298881 0.299 355938 0.356

46 MANTENAHALLY 2 857 1021 85 91056 0.091 108481 0.108

47 NAGENAHALLY 2 2074 2470 85 220363 0.22 262438 0.262

48 SHIVANAKATTE 2 795 947 85 84469 0.084 100619 0.101

49 SIDDARAMANAGARA 2 160 191 85 17000 0.017 20294 0.02

50 YALAKAPPANAHATTY (S) 2 422 503 85 44838 0.045 53444 0.053

51 YALAKKAPPANAHATTY (NORTH) 2 460 548 85 48875 0.049 58225 0.058

52 ANIVALA 3 2173 2588 85 230881 0.231 274975 0.275

14
53 BALEKERE 3 1177 1402 85 125056 0.125 148963 0.149

54 HALEKUNDURU 3 578 689 85 61413 0.061 73206 0.073

55 HOSAKUNDUR 3 1038 1236 85 110288 0.11 131325 0.131

56 KUDUR G.HATTI 3 726 865 85 77138 0.077 91906 0.092

57 SRIRANGAPURA 3 1803 2147 85 191569 0.192 228119 0.228

58 BURUDEKATTE 3 1735 2066 85 184344 0.184 219513 0.22

59 BURUDUKATTE G.HATTY 3 385 459 85 40906 0.041 48769 0.049

60 RANGAIAHNOOR 3 308 367 85 32725 0.033 38994 0.039

61 CHIKKAMMANAHALLI 3 428 510 85 45475 0.045 54188 0.054

62 CHIKKAYAGATI 3 895 1066 85 95094 0.095 113263 0.113

63 NARINA FACTORY COLONY 3 183 218 85 19444 0.019 23163 0.023

64 JAMMAPURA 3 496 591 85 52700 0.053 62794 0.063

65 MALLAPPANAHALLY 3 3249 3869 85 345206 0.345 411081 0.411

66 ARASANAPALYA 3 87 104 85 9244 0.009 11050 0.011

67 KABBINAKERE 3 528 629 85 56100 0.056 66831 0.067

68 BEESANAHALLY 4 975 1161 85 103594 0.104 123356 0.123

69 BEESANAHALLY LAMBANI HATTY 4 483 576 85 51319 0.051 61200 0.061

70 DEVIGERE 4 2070 2465 85 219938 0.22 261906 0.262

71 GALIRANGAIAHNAHATTY 4 861 1026 85 91481 0.091 109013 0.109

72 GUTHIKATTE G.HATTY 4 661 788 85 70231 0.07 83725 0.084

73 GUTIKATTE 4 599 714 85 63644 0.064 75863 0.076

74 GUTIKATTE LAMBANIHATTY 4 699 833 85 74269 0.074 88506 0.089

75 JAYANAGAR FORM 4 142 170 85 15088 0.015 18063 0.018

76 JANTIKOLALU 4 1035 1233 85 109969 0.11 131006 0.131

77 KABBALA 4 959 1142 85 101894 0.102 121338 0.121

78 KALLAHALLI 4 328 391 85 34850 0.035 41544 0.042

79 KUMBARAKATTE 4 374 446 85 39738 0.04 47388 0.047

80 MAVINAKATTE 4 1198 1427 85 127288 0.127 151619 0.152

81 A.K.HATTY 4 810 965 85 86063 0.086 102531 0.103

82 SANNAKITTADAHALLY G. HATTY 4 2180 2596 85 231625 0.232 275825 0.276

83 HEBBALLY 4 1790 2132 85 190188 0.19 226525 0.227

84 LAMBANIHATTY 4 265 316 85 28156 0.028 33575 0.034

85 HERUR 4 1424 1696 85 151300 0.151 180200 0.18

86 HOSA KADIVANAKATTE 4 364 434 85 38675 0.039 46113 0.046

87 KADIVANAKATTE 4 182 217 85 19338 0.019 23056 0.023

88 KONDAPURA 4 1773 2112 85 188381 0.188 224400 0.224

15
89 KRISHNAPURA 4 457 545 85 48556 0.049 57906 0.058

90 NAGARAKATTE 4 1220 1453 85 129625 0.13 154381 0.154

91 THUMBINAKERE 4 466 555 85 49513 0.05 58969 0.059

92 KRISHNAPURA 4 321 383 85 34106 0.034 40694 0.041

Total 87828 104623 7820 9331737 9.332 11116208 11.12

Phase – II

Requirement at Requirement at
Projected Supply
Sl. tapping point tapping point
Name of Village / Habitation ZBT'S population Rate
No. (2035) (2050)
(LPCD)
2035 2050 Litres MLD Litres MLD

93 KORACHARAHATTY 5 1474 1756 85 156613 0.157 186575 0.187

94 HULLUKATTE L.HATTY 5 99 118 85 10519 0.011 12538 0.013

95 HULUKATTE 5 634 755 85 67363 0.067 80219 0.08

96 POOJARIHATTY 5 182 217 85 19338 0.019 23056 0.023

97 MASANIHALLY 5 647 771 85 68744 0.069 81919 0.082

98 MASANIHALLY GOLLARAHATTY 5 290 346 85 30813 0.031 36763 0.037

99 MASANIHALLY LAMBANIHATTY 5 229 273 85 24331 0.024 29006 0.029

100 RANGEHATTI 5 30 36 85 3188 0.003 3825 0.004

101 AKKITHIMMAIAHNAHATTI 5 715 852 85 75969 0.076 90525 0.091

102 BOCHANAHALLI 5 528 629 85 56100 0.056 66831 0.067

103 D. BOVIHATTI 5 667 795 85 70869 0.071 84469 0.084

104 DEVAPURA 5 3162 3765 85 335963 0.336 400031 0.4

105 NAGATHIHALLI 5 485 578 85 51531 0.052 61413 0.061

106 GALABENAHALLI 5 182 217 85 19338 0.019 23056 0.023

107 HONNENAHALLI 5 3325 3960 85 353281 0.353 420750 0.421

108 KODIHALLI 5 1171 1395 85 124419 0.124 148219 0.148

109 NARSIPURA 5 593 707 85 63006 0.063 75119 0.075

110 BANASIHALLI 5 1593 1897 85 169256 0.169 201556 0.202

111 S. ROPPA 5 351 418 85 37294 0.037 44413 0.044

112 D. MALLAPURA 5 1222 1456 85 129838 0.13 154700 0.155

113 DODDGHATTA 5 2182 2599 85 231838 0.232 276144 0.276

114 H.ROPPA 5 281 335 85 29856 0.03 35594 0.036

115 DUGGAVARA 5 1368 1629 85 145350 0.145 173081 0.173

116 N. BOVIHATTI 5 818 974 85 86913 0.087 103488 0.103

117 BOVIHATTI 5 767 914 85 81494 0.081 97113 0.097

16
118 GULIHATTI 5 1654 1970 85 175738 0.176 209313 0.209

119 THANIGEKALLU 5 1602 1908 85 170213 0.17 202725 0.203

120 NAGATHIHALLY 5 1870 2227 85 198688 0.199 236619 0.237

121 OBALAPURA THANDA 5 93 111 85 9881 0.01 11794 0.012

122 OBLAPURA 5 1992 2372 85 211650 0.212 252025 0.252

123 SOPPINAGUDLU 5 180 215 85 19125 0.019 22844 0.023

124 BENAKANAHALLI 5 864 1029 85 91800 0.092 109331 0.109

125 DEVARAHATTI 5 529 630 85 56206 0.056 66938 0.067

126 JANKAL 5 3627 4319 85 385369 0.385 458894 0.459

127 KAMSAGARA 5 220 262 85 23375 0.023 27838 0.028

128 KANTAPURA 5 1076 1282 85 114325 0.114 136213 0.136

129 MUDLABOVIHATTI 5 864 1029 85 91800 0.092 109331 0.109

130 VEERVANAGATHIHALLI 5 547 652 85 58119 0.058 69275 0.069

131 RANGAVVANAHALLY 5 921 1097 85 97856 0.098 116556 0.117

132 MAHALAKSHMIPURA 6 191 228 85 20294 0.02 24225 0.024

133 GORAVINAKAL 6 3117 3712 85 331181 0.331 394400 0.394

134 CHITHAIAHNAHATTI 6 786 936 85 83513 0.084 99450 0.099

135 HUNAVINADU 6 1852 2206 85 196775 0.197 234388 0.234

136 HUNAVINADU JANATHA COLONY 6 197 235 85 20931 0.021 24969 0.025

137 GOLLARAHATTY 6 794 946 85 84363 0.084 100513 0.101

138 JODISRIRANGAPURA 6 403 480 85 42819 0.043 51000 0.051


VADDARAHATTY & LAMBANI
139 6 673 802 85 71506 0.072 85213 0.085
HATTY
140 KACHAVARA 6 412 491 85 43775 0.044 52169 0.052

141 KAPPAGERE 6 2310 2751 85 245438 0.245 292294 0.292

142 SIDDHAPPANAHATTI 6 586 698 85 62263 0.062 74163 0.074

143 HUNASEKATTE 6 780 929 85 82875 0.083 98706 0.099

144 SODARANAL 6 616 734 85 65450 0.065 77988 0.078

145 ATTIGHATTA 6 1423 1695 85 151194 0.151 180094 0.18

146 BILICHITHAIHNAHATTI 6 485 578 85 51531 0.052 61413 0.061

147 GORAVI GONDANAHALLY 6 1103 1314 85 117194 0.117 139613 0.14

148 JOGAMMANA HALLI 6 674 803 85 71613 0.072 85319 0.085

149 KANNAGUNDHI GOLLRAHATTI 6 504 601 85 53550 0.054 63856 0.064

150 KELLODU 6 2577 3069 85 273806 0.274 326081 0.326

151 KURUBRAHALLI 6 496 591 85 52700 0.053 62794 0.063

152 KYADUGERE 6 806 960 85 85638 0.086 102000 0.102

153 LINGADAHALLI 6 563 671 85 59819 0.06 71294 0.071


17
154 ATHIMAGGE 7 1045 1245 85 111031 0.111 132281 0.132

155 ATHIMAGGE BHOVIHATTI 7 786 936 85 83513 0.084 99450 0.099

156 MUDDAIHATTY 7 239 285 85 25394 0.025 30281 0.03

157 M. MALLAPURA 7 631 752 85 67044 0.067 79900 0.08

158 BANTANAGAVI A.K. HATTY 7 403 480 85 42819 0.043 51000 0.051

159 BANTANAGAVIHATTY 7 557 664 85 59181 0.059 70550 0.071

160 DODDATHIMMAINAHATTY 7 195 233 85 20719 0.021 24756 0.025

161 GADIYAPPANA HATTY 7 273 326 85 29006 0.029 34638 0.035

162 KAREKALHATTY 7 116 139 85 12325 0.012 14769 0.015

163 MALIGEHATTY 7 599 714 85 63644 0.064 75863 0.076

164 RAMAJJANAHALLY 7 673 802 85 71506 0.072 85213 0.085

165 B. AK.HATTI 7 136 162 85 14450 0.014 17213 0.017

166 B. HALEYUR 7 214 255 85 22738 0.023 27094 0.027

167 B.GOLLARAHATTI 7 358 427 85 38038 0.038 45369 0.045

168 S.SIDDARAHATTI 7 482 574 85 51213 0.051 60988 0.061

169 DODDKITTADAHALLY 7 1544 1839 85 164050 0.164 195394 0.195

170 NAKIKERE 7 2053 2445 85 218131 0.218 259781 0.26

171 SANNAKITTADAHALLY 7 376 448 85 39950 0.04 47600 0.048

172 BEVINAHALLI 7 726 865 85 77138 0.077 91906 0.092

173 IYYANAHALLI 7 551 657 85 58544 0.059 69806 0.07

174 ANCHIBARIHATTI 7 838 998 85 89038 0.089 106038 0.106

175 LAKKI HALLI 7 4100 4882 85 435625 0.436 518713 0.519

176 MADHIHALLI 7 759 904 85 80644 0.081 96050 0.096

177 DASAJJANAHATTY 7 199 237 85 21144 0.021 25181 0.025

178 KERIKODIHATTI 7 467 557 85 49619 0.05 59181 0.059

179 KODIHALLIHATTY 7 1433 1707 85 152256 0.152 181369 0.181

180 NAGAINATTY 7 848 1010 85 90100 0.09 107313 0.107

181 SERANAKATTE 7 369 440 85 39206 0.039 46750 0.047

182 THIMMAIAHNAHATTI 7 735 876 85 78094 0.078 93075 0.093

183 KENKERE 7 1720 2049 85 182750 0.183 217706 0.218

184 MADADAKERE 7 3616 4306 85 384200 0.384 457513 0.458

185 BOVIHATTY 7 546 651 85 58013 0.058 69169 0.069

186 B.V.NAGAR 7 831 990 85 88294 0.088 105188 0.105

187 A. GOLLRAHATTI 8 390 465 85 41438 0.041 49406 0.049

188 A. LAMBANIHATTI 8 476 567 85 50575 0.051 60244 0.06

189 ALAGHATTA 8 2044 2434 85 217175 0.217 258613 0.259

18
190 BALLALASAMUDRA 8 1902 2265 85 202088 0.202 240656 0.241

191 HANDANAKERE 8 18 22 85 1913 0.002 2338 0.002

192 KALKERE 8 1911 2276 85 203044 0.203 241825 0.242

193 ULAVINAGONDHI 8 119 142 85 12644 0.013 15088 0.015

194 GANDHINAGAR 8 402 479 85 42713 0.043 50894 0.051

195 SIRAGIPURA 8 29 35 85 3081 0.003 3719 0.004

196 KATIHATTI 8 636 758 85 67575 0.068 80538 0.081

197 D.B.KERE GATE 8 73 87 85 7756 0.008 9244 0.009

198 MANJULAGARDEN 8 27 33 85 2869 0.003 3506 0.004

199 HALEYUR 8 268 320 85 28475 0.028 34000 0.034

200 BOMMENAHALLY 8 1267 1509 85 134619 0.135 160331 0.16

201 HOSAHATTY 8 429 511 85 45581 0.046 54294 0.054

202 KABBLA 8 2495 2971 85 265094 0.265 315669 0.316

203 MALLENAHALLY (JODI) 8 765 911 85 81281 0.081 96794 0.097

204 MATHURU 8 1723 2052 85 183069 0.183 218025 0.218

205 THONACHANA HALLY 8 832 991 85 88400 0.088 105294 0.105


THONACHANA HALLY
206 8 323 385 85 34319 0.034 40906 0.041
BOVIHATTY
207 THUMBINKERE 8 520 620 85 55250 0.055 65875 0.066

208 THUMBINKERE BOVIHATTI 8 231 276 85 24544 0.025 29325 0.029

209 GOLLARAHALLY 8 1447 1723 85 153744 0.154 183069 0.183

210 HAGALAKERE 8 2070 2465 85 219938 0.22 261906 0.262

211 HOTHRAGONDAHALLI 8 659 785 85 70019 0.07 83406 0.083

212 KAREHALLI 8 3381 4026 85 359231 0.359 427763 0.428

213 MENASINODU 8 997 1188 85 105931 0.106 126225 0.126

214 MENASINODU GOLLARAHATTI 8 425 507 85 45156 0.045 53869 0.054

215 MENASINODU BOVIHATTI 8 147 176 85 15619 0.016 18700 0.019

216 BELAGUR 9 8982 10695 85 954338 0.954 1136344 1.136

217 HARIYANAHALLI 9 933 1111 85 99131 0.099 118044 0.118

218 HARIYANAHALLI LAMBANI HATTI 9 179 214 85 19019 0.019 22738 0.023

219 SINGENAHALLI BOVIHATTI 9 785 935 85 83406 0.083 99344 0.099

220 SINGINAHALLI 9 307 366 85 32619 0.033 38888 0.039

221 PEELAPURA 9 1028 1225 85 109225 0.109 130156 0.13

222 THOTADAMANE 9 972 1158 85 103275 0.103 123038 0.123

223 DYAVAJJANA PALYA 9 609 726 85 64706 0.065 77138 0.077

224 GARAGA 9 2351 2800 85 249794 0.25 297500 0.298

225 HANUMANAHATTI 9 289 345 85 30706 0.031 36656 0.037


19
226 KEREHASAHALLY 9 886 1055 85 94138 0.094 112094 0.112

227 KODIHALLY 9 1267 1509 85 134619 0.135 160331 0.16

228 KODIHALLY KOPPALU 9 233 278 85 24756 0.025 29538 0.03

229 AVALIPALYA 9 319 380 85 33894 0.034 40375 0.04

230 HOSAKERE 9 736 877 85 78200 0.078 93181 0.093

231 THANDGA 9 1923 2290 85 204319 0.204 243313 0.243

232 THANDGA LAMBANIHATTY 9 710 846 85 75438 0.075 89888 0.09

233 YADAGHATTA 9 433 516 85 46006 0.046 54825 0.055

234 YADAGHATTA BOVIHATTI 9 476 567 85 50575 0.051 60244 0.06

235 YADAGHATTA B.HATTY 9 72 86 85 7650 0.008 9138 0.009

236 BOMMANAPALYA 10 168 201 85 17850 0.018 21356 0.021

237 GAVIRANGAPURA 10 700 834 85 74375 0.074 88613 0.089

238 KURUBARAHALLI 10 1373 1635 85 145881 0.146 173719 0.174

239 RAMADASAPURA 10 48 58 85 5100 0.005 6163 0.006

240 MALLIHALLY 10 741 883 85 78731 0.079 93819 0.094

241 MYALARAPURA 10 481 573 85 51106 0.051 60881 0.061

242 SOMENAHALLI 10 1056 1258 85 112200 0.112 133663 0.134

243 SUDUGADANA PALYA 10 312 372 85 33150 0.033 39525 0.04

244 SUJIKAL 10 1268 1510 85 134725 0.135 160438 0.16

245 HARAGONDANAHALLY 10 753 897 85 80006 0.08 95306 0.095

246 HARAGONDANAHALLY A.K.C 10 222 265 85 23588 0.024 28156 0.028

247 SYEDSABPALYA 10 704 839 85 74800 0.075 89144 0.089

248 NAGARAGERE 10 950 1132 85 100938 0.101 120275 0.12

249 S.HYDERSAB PALYA 10 467 557 85 49619 0.05 59181 0.059

250 GARIMBILU 10 679 809 85 72144 0.072 85956 0.086

251 S.NERLAKERE 10 2063 2457 85 219194 0.219 261056 0.261

252 KALANAYAKANAHATTY 10 338 403 85 35913 0.036 42819 0.043

253 MARABAGATTA INDRANAGAR 10 281 335 85 29856 0.03 35594 0.036

254 GULIHALLY 10 844 1005 85 89675 0.09 106781 0.107

255 BANYANAIKANAHATTY 11 254 303 85 26988 0.027 32194 0.032

256 BUKKASAGARA 11 1294 1541 85 137488 0.137 163731 0.164

257 KEREMUNDLAHATTY 11 252 301 85 26775 0.027 31981 0.032

258 CHIKKATEKALAVATTY 11 1481 1764 85 157356 0.157 187425 0.187

259 RAMDAS NAIKA THANDA 11 427 509 85 45369 0.045 54081 0.054

260 DODDATEKALAVATTY 11 3493 4160 85 371131 0.371 442000 0.442

261 KAVALARAMANE 11 318 379 85 33788 0.034 40269 0.04

20
262 (S) BOVIHATTY 11 301 359 85 31981 0.032 38144 0.038

263 SIRIGONDANAHALLY 11 990 1179 85 105188 0.105 125269 0.125

264 BACHAWARA 11 523 623 85 55569 0.056 66194 0.066

265 H.BOVIHATTY 11 261 311 85 27731 0.028 33044 0.033

266 HARLAHALLY 11 1676 1996 85 178075 0.178 212075 0.212

267 HOSUR 11 204 243 85 21675 0.022 25819 0.026

268 KAINADU 11 1195 1423 85 126969 0.127 151194 0.151

269 SOMASANDRA 11 725 864 85 77031 0.077 91800 0.092

270 AJJIKAMSAGRA 11 1141 1359 85 121231 0.121 144394 0.144

271 GANJIGERE 11 216 258 85 22950 0.023 27413 0.027

272 GANJIGERE KORACHARAHATTI 11 294 351 85 31238 0.031 37294 0.037

273 SANNA THIPPENAHALLI 11 77 92 85 8181 0.008 9775 0.01

274 THIPPENAHALLI 11 489 583 85 51956 0.052 61944 0.062

275 LAMBANIHATTY 11 419 499 85 44519 0.045 53019 0.053

276 AREHALLI 11 2733 3255 85 290381 0.29 345844 0.346

277 BANDEGOWDANAPALYA 11 586 698 85 62263 0.062 74163 0.074

278 DODDAIAHNAPALYA 11 933 1111 85 99131 0.099 118044 0.118

279 MATHODU 11 4523 5386 85 480569 0.481 572263 0.572

280 ARENAHALLY 11 829 988 85 88081 0.088 104975 0.105

281 CHIKKAHULLEHALENAHALLY 11 669 797 85 71081 0.071 84681 0.085

282 NAYIGERE 11 539 642 85 57269 0.057 68213 0.068

283 G.N.KERE 12 3402 4051 85 361463 0.361 430419 0.43

284 GIRIYAPURA 12 905 1078 85 96156 0.096 114538 0.115

285 EARAJANAHATTY 12 220 262 85 23375 0.023 27838 0.028

286 HALETHIMMAPPANAHATTI 12 700 834 85 74375 0.074 88613 0.089

287 HOSATHIMMAPPANAHATTI 12 435 518 85 46219 0.046 55038 0.055

288 THIGALARAHATTY 12 59 71 85 6269 0.006 7544 0.008

289 DALVAYIKATTE 12 816 972 85 86700 0.087 103275 0.103

290 GIRIMALLAIAHNAPALYA 12 385 459 85 40906 0.041 48769 0.049

291 HEGGERE 12 2606 3103 85 276888 0.277 329694 0.33

292 KADAVAGERE 12 1444 1720 85 153425 0.153 182750 0.183

293 VENGALAPURA 12 1603 1909 85 170319 0.17 202831 0.203

294 BAJJAPPANAHATTI 12 328 391 85 34850 0.035 41544 0.042

295 B. LA. HATTI 12 141 168 85 14981 0.015 17850 0.018

296 SADARAHALLY 12 650 774 85 69063 0.069 82238 0.082

297 KACHAPURA 12 684 815 85 72675 0.073 86594 0.087

21
298 BARAMANPALYA 12 178 212 85 18913 0.019 22525 0.023

299 SRIRAMPURA 12 7346 8747 85 780513 0.781 929369 0.929

300 CHIKKABYALADAKERE 13 2807 3343 85 298244 0.298 355194 0.355

301 SHIVANAGARA 13 268 320 85 28475 0.028 34000 0.034

302 AMMANAHATTI 13 690 822 85 73313 0.073 87338 0.087

303 DODDABYALADAKERE 13 1073 1278 85 114006 0.114 135788 0.136

304 KANCHINAGARA 13 179 214 85 19019 0.019 22738 0.023

305 JAYASUVARNAPURA 13 431 514 85 45794 0.046 54613 0.055

306 D.COLONY 13 318 379 85 33788 0.034 40269 0.04

307 KASAPPANAHALLY 13 1253 1492 85 133131 0.133 158525 0.159

308 LASHMIDEVARAHALLY 13 1083 1290 85 115069 0.115 137063 0.137

309 BALENAHALLY 13 465 554 85 49406 0.049 58863 0.059

310 DODDAKARPURADA KATTE 13 728 867 85 77350 0.077 92119 0.092

311 KAGGALAKATTE 13 305 364 85 32406 0.032 38675 0.039

312 KAGGALAKATTE BOVI HATTI 13 302 360 85 32088 0.032 38250 0.038

313 MUDIYAPPANAHATTI 13 732 872 85 77775 0.078 92650 0.093

314 KANBENHALLY 13 622 741 85 66088 0.066 78731 0.079

315 PUJARI THANDA 13 62 74 85 6588 0.007 7863 0.008

316 AJJAYANAHATTY 13 295 352 85 31344 0.031 37400 0.037

317 HOSAGOLLARAHATTY 13 738 879 85 78413 0.078 93394 0.093

318 KANCHIPURA 13 4267 5081 85 453369 0.453 539856 0.54

319 VARADARAJA NAGARA 13 168 201 85 17850 0.018 21356 0.021

320 KITTADAL 13 2056 2449 85 218450 0.218 260206 0.26

321 KELAGAHATTI LAMBANI HATTY 13 195 233 85 20719 0.021 24756 0.025

322 MEGALAHATTI L.HATTI 13 237 283 85 25181 0.025 30069 0.03

323 NAGANAYAKANAKATTI 13 677 807 85 71931 0.072 85744 0.086

324 KARALAMOVINAHALLI 13 154 184 85 16363 0.016 19550 0.02

325 KANNAGUNDHI BOVIHATTI 13 211 252 85 22419 0.022 26775 0.027

326 MATTINAHOLE 13 816 972 85 86700 0.087 103275 0.103

327 GOLLARAHATTI 13 153 183 85 16256 0.016 19444 0.019

328 K.E.B. COLONY 13 90 108 85 9563 0.01 11475 0.011

329 AGASRAHALLY 14 795 947 85 84469 0.084 100619 0.101

330 ITTEGEHALLY 14 535 638 85 56844 0.057 67788 0.068

331 HINDEDEVARAHATTI 14 407 485 85 43244 0.043 51531 0.052

332 HUNASEKATTI 14 467 557 85 49619 0.05 59181 0.059

333 KRISHNAPURA 14 199 237 85 21144 0.021 25181 0.025

22
334 SIDDHAPURA 14 229 273 85 24331 0.024 29006 0.029

335 THARIKERE(JODI) 14 680 810 85 72250 0.072 86063 0.086

336 NAYAKARAHATTI 14 912 1086 85 96900 0.097 115388 0.115

337 YELLABOVIHATTI 14 1152 1372 85 122400 0.122 145775 0.146

338 SEVANAGARA 14 1298 1546 85 137913 0.138 164263 0.164

339 MALAPPANAHALLY 14 438 522 85 46538 0.047 55463 0.055

340 ERANNANAPALYA 14 730 870 85 77563 0.078 92438 0.092

341 MENGASANDRA 14 1442 1717 85 153213 0.153 182431 0.182

342 CHIKKATHIMMAIAHNAPALYA 14 281 335 85 29856 0.03 35594 0.036

343 KAPPANAKANAHALLY 14 1107 1319 85 117619 0.118 140144 0.14

344 SHANTHAPPANAPALYA 14 159 191 85 16894 0.017 20188 0.02

345 HOSUR BOVIHATTY 14 382 455 85 40588 0.041 48344 0.048

346 SIDDAGONDANAHALLY 14 995 1185 85 105719 0.106 125906 0.126

Total 234071 278832 24870076 24.87 29625832 29.63

PROJECTED POPULATION AND RAW WATER DEMAND FOR ENROUTE UNCOVERED HABITATIONS OF
TARIKERE TALUK

Requirement at
Projected Requirement at
Supply tapping point
Sl. population tapping point (2035)
Name of Village / Habitation Rate (2050)
No.
(LPCD)
2035 2050 Litres MLD Litres MLD

1 Sevalal Nagar 160 176 85 17000 0.017 18700 0.019


2 Siddlipura 774 852 85 82238 0.082 90525 0.091
3 Gopala 2613 2876 85 277631 0.278 305575 0.306
4 Gundenahalli 458 504 85 48663 0.049 53550 0.054
5 Arsikere 511 562 85 54294 0.054 59713 0.060
6 Kesarakoppa 668 735 85 70975 0.071 78094 0.078
7 Sompura 205 226 85 21781 0.022 24013 0.024
8 Lakkavalli 6080 6692 85 646000 0.646 711025 0.711
9 Upparabeeranahalli 969 1067 85 102956 0.103 113369 0.113
10 Mudugodu 4222 4648 85 448588 0.449 493850 0.494
11 Shanthipura 567 624 85 60244 0.06 66300 0.066

12 Sale Borna Halli 863 950 85 91694 0.092 100938 0.101

13 Vaddaradibba 428 471 85 45475 0.045 50044 0.050

14 Hirigapura 217 239 85 23056 0.023 25394 0.025

15 Mandaravalli 351 386 85 37294 0.037 41013 0.041

16 Doddakundur 873 961 85 92756 0.093 102106 0.102


23
17 Hunasanahalli 880 969 85 93500 0.094 102956 0.103

18 Haruvanahalli 770 847 85 81813 0.082 89994 0.090

19 Gurupura 413 454 85 43881 0.044 48238 0.048

20 Kundurkaval 140 154 85 14875 0.015 16363 0.016

21 Guddadabeeranahalli 455 501 85 48344 0.048 53231 0.053

22 Malalichannenahalli 4367 4807 85 463994 0.464 510744 0.511

23 H.Rangapura 864 951 85 91800 0.092 101044 0.101

24 Hurulihalli 323 356 85 34319 0.034 37825 0.038

25 Gulladahatti 122 135 85 12963 0.013 14344 0.014

26 Jodikodihalli 624 687 85 66300 0.066 72994 0.073

27 Hirekathur 210 231 85 22313 0.022 24544 0.025

28 Seethapura 80 89 85 8500 0.009 9456 0.009

29 Kerehosahalli 899 990 85 95519 0.096 105188 0.105

30 Ramapura 85 94 85 9031 0.009 9988 0.010

31 Chikkathur 182 200 85 19338 0.019 21250 0.021

32 Seethapura (Kaval) 633 697 85 67256 0.067 74056 0.074

33 Sidakanahalli 80 89 85 8500 0.009 9456 0.009

34 Yalugere 826 909 85 87763 0.088 96581 0.097

35 Attiganalu 361 398 85 38356 0.038 42288 0.042

36 Byrapura 588 647 85 62475 0.062 68744 0.069

37 Nagarajapura 732 806 85 77775 0.078 85638 0.086

38 Siddaramapura 1502 1653 85 159588 0.16 175631 0.176

39 Ramenahalli 789 869 85 83831 0.084 92331 0.092

40 Lakkenahalli 157 173 85 16681 0.017 18381 0.018

41 Ittige 1271 1399 85 135044 0.135 148644 0.149

42 Mallenahalli 568 625 85 60350 0.06 66406 0.066

43 Mirlenahalli 304 335 85 32300 0.032 35594 0.036

44 Mudenahallikaval 8 9 85 850 9E-04 956 0.001

45 Mudugundi 248 273 85 26350 0.026 29006 0.029

46 Soppinahalli 171 189 85 18169 0.018 20081 0.020

47 Bommenahalli 188 207 85 19975 0.02 21994 0.022

48 Santedibbadakaval 2 3 85 213 2E-04 319 0.000

49 Samatala 926 1019 85 98388 0.098 108269 0.108

50 Savemardikaval 331 365 85 35169 0.035 38781 0.039

51 Shanubhoganahalli 640 705 85 68000 0.068 74906 0.075

52 Vaderahalli 400 440 85 42500 0.043 46750 0.047

24
53 Doddabokikere 696 766 85 73950 0.074 81388 0.081

54 Rajanahalli 281 309 85 29856 0.03 32831 0.033

55 K.Chattanahalli 1039 1144 85 110394 0.11 121550 0.122

56 Jannapura 6 6 85 638 6E-04 638 0.001

57 Bokikere 747 823 85 79369 0.079 87444 0.087

58 Kotebasavanahalli 14 15 85 1488 0.001 1594 0.002

59 Mundre 1809 1991 85 192206 0.192 211544 0.212

60 Pundanahalli 316 348 85 33575 0.034 36975 0.037

61 Nagabovanahalli 497 547 85 52806 0.053 58119 0.058

62 Bhaktana Katte 1750 1927 85 185938 0.186 204744 0.205

63 Siragalipura 409 451 85 43456 0.043 47919 0.048

64 Koppadahalli 584 643 85 62050 0.062 68319 0.068

65 Gijikatte 408 449 85 43350 0.043 47706 0.048

66 Thygadakatte 1259 1386 85 133769 0.134 147263 0.147

67 Banoor 977 1076 85 103806 0.104 114325 0.114

68 Abbinaholalu 375 413 85 39844 0.04 43881 0.044

69 Giriyapura 492 542 85 52275 0.052 57588 0.058

70 Basavapura 865 952 85 91906 0.092 101150 0.101

71 Thyarajjanahalli 192 212 85 20400 0.02 22525 0.023

72 Beernahalli 708 779 85 75225 0.075 82769 0.083

73 Hanne 637 701 85 67681 0.068 74481 0.074

74 Gejjegondanahalli 974 1072 85 103488 0.103 113900 0.114

75 Hebbur 1229 1353 85 130581 0.131 143756 0.144

76 Asunde 23 26 85 2444 0.002 2763 0.003

77 Mylanahalli 104 114 85 11050 0.011 12113 0.012

78 Katiganere 1240 1364 85 131750 0.132 144925 0.145

79 Gowrapura 1680 1850 85 178500 0.179 196563 0.197

80 Thippagondanahalli 511 562 85 54294 0.054 59713 0.060

81 Rangapura 180 198 85 19125 0.019 21038 0.021

82 Paravatharayanakere Kaval 42 46 85 4463 0.004 4888 0.005

83 Sollapur 1603 1765 85 170319 0.17 187531 0.188

84 Tamatadahalli 216 237 85 22950 0.023 25181 0.025

85 Sriramapura 596 656 85 63325 0.063 69700 0.070

86 Southanahalli 393 433 85 41756 0.042 46006 0.046

87 Malenahalli 757 833 85 80431 0.08 88506 0.089

88 Mallenahalli 512 563 85 54400 0.054 59819 0.060

25
89 Gondedahalli 396 436 85 42075 0.042 46325 0.046

90 Baggavalli 2055 2262 85 218344 0.218 240338 0.240

91 Baggavalli Kaval 8 9 85 850 9E-04 956 0.001

92 Veerapura 1081 1190 85 114856 0.115 126438 0.126

93 Kurubarahalli 216 237 85 22950 0.023 25181 0.025

94 Nagavangala 1660 1828 85 176375 0.176 194225 0.194

95 Somenahalli 120 132 85 12750 0.013 14025 0.014

96 Channapura 1681 1851 85 178606 0.179 196669 0.197

97 Chinnapura 459 506 85 48769 0.049 53763 0.054

98 Kenchenahalli 93 103 85 9881 0.01 10944 0.011

99 Sunnadahalli 1109 1221 85 117831 0.118 129731 0.130

100 Nandi 1236 1361 85 131325 0.131 144606 0.145

101 Gulladamane 1196 1317 85 127075 0.127 139931 0.140

102 Ranganathapura 463 510 85 49194 0.049 54188 0.054

103 Nandi Battlu 1798 1979 85 191038 0.191 210269 0.210

104 Lingadahalli (Kaval) 220 243 85 23375 0.023 25819 0.026

105 Sahyadripura 177 195 85 18806 0.019 20719 0.021

106 Lingadahalli 6825 7513 85 725156 0.725 798256 0.798

107 Shankaraghatta 54 59 85 5738 0.006 6269 0.006

108 Manchethevaru 751 827 85 79794 0.08 87869 0.088

109 Tanigebylu 1818 2001 85 193163 0.193 212606 0.213

110 Thigada 829 913 85 88081 0.088 97006 0.097

111 Kallahalu 3 4 85 319 3E-04 425 0.000

112 Marekallahalli 5 5 85 531 5E-04 531 0.001

113 Kamanadurga 2404 2647 85 255425 0.255 281244 0.281

Total 91876 101145 9761833 9.76 10746668 10.75

26
SYSTEM DESIGN CRITERIA FOR PROVIDING WATER SUPPLY TO HOSADURGA TOWN AND OTHER 346
HABITATIONS OF HOSADURGA TALUK CHITRADURGA DISTRICT, & ENROUTE UNCOVERED
HABITATIONS TARIKERE TALUK.

The system design criteria to be followed for the proposed water supply scheme for supplying treated
water to villages in Hosadurga Taluk shall be as given below;

S. Description Design Criteria


No
1. Project beneficiaries 346 Villages in Hosadurga Taluk and Hosadurga Town of
Chitradurga district and 113 Habitations of Tarikere taluk in
Chikkamagalur District.
2. Project design year  Base Year : 2020
 Intermediate Year : 2035
 Ultimate Year : 2050
3. Projected population  Base Year : 391855
(346Habitations) as mentioned  Intermediate year - 473988
above  Ultimate year – 580977
4. Projected water demand (346 Raw Water
Habitations)  Base Year : 2020-43.98 MLD
 Intermediate year – 2035-54.12 MLD
 Ultimate year – 2050-67.75 MLD
Clear Water (village entry)
 Base Year : 2020-41.39 MLD
 Intermediate year – 2035-50.94MLD
 Ultimate year – 2050-63.76 MLD
(water requirement for each village is enclosed)
5. Source of surface water Bhadra Reservoir.
6. Bhadra Reservoir levels  Full Reservoir Level-657.75M (2158 ft)
 Dead Storage Level-631.54 M (2072 ft)
7. Raw water with drawl point in  Lowest water levels as per last 30 year’s data whichever is
water spread of Bhadra lower at suitable location.
Reservior  Raw water drawl arrangement shall be such that water can be
drawn up to Minimum level.
 Invert level of lowest inlet grating in intake well shall be keptat
a level to draw water from lowest water level.
8. Raw water drawl arrangement The raw water to Jack well shall be through piped intake with
from river connecting RCC pipe or intake channel below lowest water level /
and it shall be provided with a silt trap before entry into intake

27
S. Description Design Criteria
No
structure toprevent silt entry and is to be designed for twice the
design flow with entrance velocity of Max 1.50 m/sec.
9. Design guidelines for piped  Piped Intake Well and Connecting Pipes or Intake Channel
intake well and Connecting with forebay and unitise sump:
pipes with inspection chamber  Material of connecting pipe: RCC NP4 class with pipe and
control arrangement for flow.
 Hours of raw water drawl per day : 22 hours
 Design flow for inlet to pipe inlet : 2.0 times ultimate design
flow
 Design entrance velocity in inlet gratings: Max. 8 m / min
 Design velocity in each connecting pipe : 1.50 m / sec
 Access opening : Min. 750 x 750 heavy duty CI manhole with
cover
 Access ladder: MS caged ladder with epoxy coating both
inside and outside.
 Cleaning chambers : RCC inspection chambers / cleaning
chambers shall be provided for connecting pipes at spacing’s
not greater than 50 m.
10 Intake structure and pumping  Type of structure : Lower suction chamber, Pump delivery
.
station at Cauvery River bank chamber and motor floor chamber with electrical room in RCC
Bhadra Reservoir framed construction
 Design flow for intake structure : Ultimate design flow
 Hours of raw water pumping per day : 22 hours
 Sump model analysis to be carried out before finalizes the
detail design.
 Type of raw water pumps: Vertical Turbine (VT) pumps with
hollow shaft and external oil lubricated. The life span of
pumping machinery shall be designed as per norms of
CPHEEO Manual
 Design flow for pumps : Intermediate design flow
 Number of pumps: Min. 3 Nos. (2 working + 1 standby) or any
number with minimum 50% standby
 Pump setting level: 1.0m above the invert level of jack well.
 Invert level of connecting pipes at intake structure : same as
invert level of lowest grating / piped inlet
 Invert level of intake structure : Min. 2.00 m below invert level

28
S. Description Design Criteria
No
connecting pipes
 CI sluice vavles to be provided for the lowest inlet of piped
intake well if intake well and connecting pipes are proposed
 Foundation level : As per design based on geotechnical
investigation
 Floor level of pump delivery chamber : Min. 1.50 m above HFL
 Height of pump delivery chamber : Min. 2.50 m clear up to
soffit of roof beams
 Height of motor floor : Min. 6.00 m or adequate height clear up
to EOT crane hook
 Height of electrical panel room / control room : Min. 5.00 m
clear up to soffit of roof beams
 Piping and fittings : DI / MS with epoxy coating
 Capacity of EOT crane : Min. 5.0 Ton or 1.50 times heaviest
equipment to be lifted whichever is higher
 DG capacity: One pump working (Minimum 50% pumping
capacity) + other loads. DG with acoustic enclosure as per
CPCB norms
 Surge protection system : As per surge analysis with all the
accessories with best latest technology viz. Air vessel /
Bladder vessel / Surge Tank etc.,
 Access opening : Adequate size opening
 Access ladder : MS caged ladder with epoxy coating with
intermediate RCC landings
 Exhaust fans : To meet Min. 10 air changes
 Min. 3.75 m wide asphalted approach road to be provided
excluding shoulders from nearest existing road
 Associated rooms / facilities : electrical panel room, LT room,
battery / UPS room, SCADA / control room, operator rest
room, water filtration unit for domestic use, toilets with waste
disposal facility, compound wall etc.
 Floor area of rooms : As per equipment / machinery layout as
per IEE rules and approved by Client
11 Raw water rising main  Pipe material : MS of design thickness with internal food grade
.
epoxy lining of required thickness with two coats of primer and
external guniting confirming to IS: 3589

29
S. Description Design Criteria
No
 Hours of working per day : 22 hours
 Design flow : Ultimate design flow
 Hazen William's constant "C" to be considered with aging Max.
120
 Minor losses : Min 10% of friction loss
 Design velocity in pipeline : Max 1.50 m / sec (based on the
principle of techno-economic feasibility and financial viability
with due consideration to number of factors/parameters)
 Pipe bedding: CNS layer as per soil analysis
12 Water treatment plant  General
.
 Treatment Units: Cascade Aerator, Parshall Flume, Flash
Mixer, Clariflocculator, Rapid Sand Filter, Disinfection, Sludge
Thickener, Sludge Drying Beds, Filter backwash recovery tank
etc.
 Associated Buildings / Rooms: Chemical building, air blower
room, office, electrical panel room, control room, laboratory,
disinfection room, toilet, twin block staff quarters, waste
disposal facility etc.
 Type of construction : RCC
 Hours of operation per day : 22 hours
 Raw water quality : To be assessed by bidder during floods
and in lean periods.
 The design of WTP shall meet requirements as given in
CPHEEO manual on Water Supply and Treatment with latest
edition
 Coagulant : PAC / Aluminiumsulphate / any suitable
 Sludge treatment : Sludge thickening, drying and disposal
 Filter appurtenances: Rate setters, Filter rate controllers, filter
flow gauges, loss of head indicators, wash water controllers
and indicators, float chambers, under-drainage system,
calibrated notch for flow measurement etc.
 Piping and Fittings: DI as per design with epoxy inner lining.
 Wash water tank capacity : Two filter washing + one day
storage for daily service water requirement
 Wash water recovery: Sedimentation of filter back wash water
to be provided for returning supernatant to inlet of WTP after

30
S. Description Design Criteria
No
pre-chlorination. The sludge shall be thickened, dried and
disposed.
 Chemical storage area: Sufficient to store minimum one month
chemical requirementas per manual.
 Disinfection
 Disinfection system shall be as per CPHEEO / WHO
guidelines through latest proven technologyat clear water
Balancing reservoir / and at village OHTs / GLSRs just before
water is supplied to first consumer.
 Other facilities
 Min. 3.75 m wide asphalted plant roads excluding shoulders to
be provided connecting all the treatment units / buildings
 Min. 3.75 m wide asphalted approach road to be provided
excluding shoulders from nearest existing road
 Minimum floor area of rooms :
 Admin and SCADA building: In two floor min.100 sqm each
Office Room - Min. 25 m2
Laboratory - Min. 20 m2
Twin block staff quarters - Each block Min. 60 m2 with central
staircase for accessing the roof
Compound wall
Other rooms - As per equipment / machinery layout approved
by Client
 Treated water quality
"Acceptable" limits as listed in Table - 2.2 and Table - 2.3 of
CPHEEO Manual on Water Supply and Treatment. or IS-
10500 2012
13 Contact Tank / Clear Water  Contact Tank / Treated Water Storage Tank
.
Storage Tank and Clear Water  Design flow: Ultimate design flow
Pumping Station at WTP  Type of structure : RCC covered tank
premises and at intermediate  Hours of flow per day : 22 hours
pumping stations  Capacity : To store Min. one hours flow (or decide by Mass
Balancing analysis)
 Number of compartments: 2 Nos.
 Level : Shall provide positive suction for pumps
 Clear Water sump at Pumping Station

31
S. Description Design Criteria
No
 Type of structure : RCC framed construction
 Design flow for pumping station : Ultimate design flow
 Hours of clear water pumping per day : 22 hours
 Type of clear water pumps: Centrifugal pumps. The life span of
pumping machinery shall be designed as per norms of
CPHEEO Manual
 Design flow for pumps : Intermediate design flow
 Number of pumps: Min. 3 Nos. (2 working + 1 standby) or any
number with minimum 50% standby
 Height of pump floor : Min. 5.00 m clear up to EOT crane hook
 Height of electrical panel room / control room : Min. 4.00 m
clear up to soffit of roof beams
 Piping and fittings : DI / MS with epoxy coating
 Capacity of EOT crane : Min. 5.0 Ton or 1.50 times heaviest
equipment to be lifted whichever is higher
 DG capacity: One pump working (Minimum 50% pumping
capacity) + other loads. DG with acoustic enclosure as per
CPCB norms
 Exhaust fans : To meet Min. 10 air changes
 Surge protection system : As per surge analysis with all the
accessories with best latest technology viz. Air vessel /
Bladder vessel / Surge Tank etc.,
 Associated rooms / facilities: electrical panel room, LT room,
battery / UPS room, SCADA / control room, compound wall
etc.
 Floor area of rooms : As per equipment / machinery layout
approved by Client
14 Clear water rising mains /  Pipe material : Ductile Iron (DI) K9 Class confirming to IS:
.
Gravity mains / Bulk 8329 for diameters up to 450 mm with internal factory CM
transmission mains up to Clear lining and MS of design thickness with internal food
Water Sumps / Master gradeepoxy of design thickness and external guniting
Balancing Reservoirs / Tanks confirming to IS: 3589 for diameters above 500 mm
(MBRs / ZBTs)  Hours of working per day : 22 hours
 Design flow : Ultimate design flow
 Hazen William's constant "C" to be considered with aging Max.
120

32
S. Description Design Criteria
No
 Minor losses : Min 10% of friction loss
 Design velocity in pipeline : Max 1.50 m / sec (based on
theprinciple of techno-economic feasibility and financial
viability with due consideration to number of
factors/parameters)
 Pipe bedding: CNS layer as per soil analysis
15 Break Pressure Tanks (BPTs) if  Design flow: Ultimate design flow
.
proposed as per design  Type of structure : RCC tank
 Hours of pumped flow per day : 22 hours
 Capacity : To store Min. two hour flow (or Based on Mass
Balancing of inflow and outflow analysis)
 Compound wall
16 Intermediate Pumping Sumps  Intermediate Sumps (If Required)
.
and Lifting Stations  Design flow: ultimate design flow
 Type of structure : RCC covered tank
 Hours of flow per day : 22 hours
 Capacity : To store Min. one hour flow (or decide by Mass
Balancing analysis)
 Number of compartments : One or Two depending on capacity
 Level : Shall provide positive suction for pumps
 Intermediate Pumping Station (If Required)
 Type of structure : RCC framed construction
 Design flow for pumping station : Ultimate design flow
 Hours of pumping per day : 22 hours
 Type of booster pumps: Centrifugal pumps. The life span of
pumping machinery shall be designed as per norms of
CPHEEO Manual
 Design flow for pumps : Intermediate design flow
 Number of pumps: Min. 3 Nos. (2 working + 1 standby) or any
number with minimum 50% standby
 Number of pumps for small lift stations less than 50 HP: Min. 2
Nos. (1 working + 1 standby)
 Height of pump floor : Min. 5.00 m clear up to EOT crane hook
 Height of electrical panel room / control room : Min. 4.00 m
clear up to soffit of roof beams
 Piping and fittings : DI / MS with epoxy coating

33
S. Description Design Criteria
No
 Capacity of EOT crane : Min. 2.0 times heaviest equipment to
be lifted
 Lifting arrangement for small lift stations : Min. 2.0 Ton or 1.50
times heaviest equipment to be lifted capacity whichever is
higher chain pulley block
 DG capacity: One pump working (Minimum 50% pumping
capacity) + other loads. DG with acoustic enclosure as per
CPCB norms
 Exhaust fans : To meet Min. 10 air changes
 Surge protection system : As per surge analysis with all the
accessories with best latest technology viz. Air vessel /
Bladder vessel / Surge Tank etc.,
 Associated rooms / facilities: electrical panel room, LT room,
battery / UPS room, SCADA / control room, compound wall
etc.
 Floor area of rooms : As per equipment / machinery layout
approved by Client
17 Master Balancing Reservoirs  Design flow: Ultimate design flow
.
(MBRs) /Tanks / Zonal  Type of structure : RCC ELSR / GLSR as per hydraulic design
Balancing Reservoirs/Tanks and ground level
serving cluster of villages  Hours of pumped inflow per day : 22 hours
 Hours of gravity outflow per day : 22 hours
 Capacity : To store Min. two hours inflow(or decide by Mass
Balancing analysis)
 Outlet RL of reservoir : As per hydraulic design to feed OHTs
in villages / habitations in respective cluster by gravity for
residual head of 7m at nodes.
 Approach road and compound wall shall be provided for MBRs
/ ZBTs /ZBTs
 Staff rest room with toilet and waste disposal facility shall be
provided at MBRs / ZBTs/ZBTs
 Disinfection to be provided to have 0.5mg/lt residual chlorineat
village OHT entry.
18 Clear water gravity feeder mains  Pipe material: Up to 250 mm HDPE pipe /DI and pipe size
.
from MBRs / ZBRs / ZBTs to above 250mm shall beDuctile Iron (DI) K7 Class or K9 as
OHTs in each village / habitation perpressure requirement.

34
S. Description Design Criteria
No
 Hours of working per day : 22 hours
 Design flow : Ultimate design flow
 Hazen William's constant "C" to be considered with aging Max.
120
 Minor losses : Min 10% of friction loss
 Design velocity in pipeline : Max 1.50 m / sec (based on
theprinciple of techno-economic feasibility and financial
viability with due consideration to number of
factors/parameters)
 Pipe bedding: CNS layer as per soil analysis
 Bulk water meters for rate of recorders and Flow meters shall
be provided at all the village / habitation OHTs to measure
water supplied to each village / habitation for water audit and
to control flow into reservoir.
 The flow meters shall be connected to operation management
system.
19 Supply point at each village /  Treated water shall be fed to existing / proposed OHTs /GLSR
.
habitation in each village / habitation through gravity feeder mains as
bulk supply.
 Further Distribution is not in the scope of his contract.
 If existing OHT is not available in any of the projectvillage, one
new OHT of capacity to meet 50% daily ultimateyear demand
or 10000 lt capacity whichever is higher with7.5m or
appropriate staging shall be constructed and connected
 The design minimum residual head above full supply level of
existing / proposed OHTs in each village / habitation shall be
3.00 m.
20 Electrical works at head works, The design criteria for electrical works shall be as given below;
.
WTP, treated water pumping
station, IPS etc.
 Power Supply The power shall be derived from the Electricity Board supply via the
provision of dedicated 33 kV feeders for Jack well, WTP, IPSs and
11kV for lifting stations
 Electricity Board supply (a) Voltage : 33 kV / 11 kV as above
system (b) Frequency : 50Hz
(c) Voltage tolerance : plus or minus 10%
(d) Frequency tolerance : plus or minus 5%
35
S. Description Design Criteria
No
(e) Neutral earthing : Direct
(f) Three phase maximum fault level: Based on actual tapping
conditions
 Design Standards Electrical design shall be based on the standard practice with
relevance to IEE / NBC / ISS standards
 Transformer Sizing The transformer sizing shall be to supply on a continuous basis for
the total maximum working load at the site concerned including
internal and external lighting plus an additional allowance of 20% of
total load requirement as contingency.
Redundant Transformer shall be provided for each pumping station
Efficiency and power factor of LV shall be considered for sizing.
 Drive Motors Drive motors shall be TEFC all-weather proof.
Up to 5 HP the drive controls shall be with DOL starters, from 7.5
HP to 25 HP shall be through star / delta starters and further
beyond 25 HP rated motors shall be with soft starters. The PLC
and its software shall interface controls flawlessly the drives to the
intended program with the process technology and stream route
sequence and other requirements during the complete process.
 Power Factor Correction For maintaining the energy efficiency, the power system shall be
assisted by static capacitor banks in each load centre with auto
controls so that the power factor is always maintained above 0.95
P.F and optimum energy efficiency is achieved. The capacitor
banks shall be located on the LT side of the electrical distribution
system
 Lightning Protection System Lightning protection shall be provided for the buildings and tall
structures as per IS: 2309
 Earthing System Double earthing system shall be adopted for providing better
equipment safety using GI strips for more than 7.5 HP drives and
8G GI wire for lesser rated drives. The earth stations proposed shall
be of conventional type with 50 mm GI pipe as per IS 3043-1987.
Copper Plate type Earthing shall be provided for Transformer
Neutral earthing.
21 Operation and maintenance of The system shall include Integrated District Management System
.
entire water supply scheme (IDMS), Water Management Districts (WMDs), Air Management
through "Integrated Water System (AMS), Reservoir Management System (RMS) etc. to
Management System" operate the entire water supply system from source up to service
OHTs in each village / habitation through SCADA, automation etc.

36
(This technical bid sheet shall be evaluated by “Expert Technical Committee” and in each module the bidder must
score the minimum prescribed marks and overall 70% marks must be scored to technically qualify)

DATA SHEET TO BE FILLED BY BIDDERS AS PART OF TECHNICAL BID

In order to prove that the technical proposal of the bidder with respect to the Goods offered shall
be of acceptable quality and standard, the bidders shall furnish in the technical bid the details about the
Goods he is going to offer as to number of years they have been in production and similar capacity have
been sold, as indicated in the table below. This shall form part of technical bid and evaluated as part of
the technical bid.

The bidder/his representative shall visit the project locations and photograph at least 25 geo-
stamped and time-stamped photographs as a proof of the visit to the project location. These 25-
Geo&Time Stamped photographs shall be included as part of the data-sheets/technical bid
submission.

ITEM -1:(50 marks & must score minimum 40 marks to technically qualify)
Manufacturer's Experience
Manufacturer's Actual Details
Criteria
Name
Minimum No. & Minimum
of years other No. of years
Item Goods preceding the details preceding Minimum
Minimum
due date of of the the due date average
average units
tender the Propo of tender the units sold
sold per year
goods offered sed goods per year
are in Manuf offered are
production acture in production
r
Pumps, Electrical &
1
Mechanical equipment's :
1.1 Pumps :
Vertical Turbine
10 5 Units
Above 250HP
Centrifugal Pump
10 10 Units
Above 200HP
Submersible Pump
5 10 Units
Above 10HP
1.2 Electrical Transformer :
Above 750 KVA 5 Two
Valves :
2 From minimum size of 50mm
to maximum size of 600mm
50-200 5 100 Units
250-400 5 75 Units
450-600 5 40 Units
Enders Hanser
Electromagnetic / Ultrasonic
/ Siemens /
Flow Meter, Electronic and
ABB / Krohne–
3 ICA Equipment / Bulk water 5
Marshall or
meter max 800cum/hr and
equivalent to
below up to 1cum/hr
ISI
800-500 5 5 Units
450-200 5 10 Units
150-50 5 25 Units
37
50-1 5 100 Units
4 Pipes :
MS Pipes: 610-219mm 5 30 KM Length
DI K-9 Pipes:300-150mm 5 30 KM Length
HDPE Pipes:450-50mm 5 50 KM Length

ITEM – 2:-HEAD WORKS AND INTAKE STRUCTURE


(100 marks & must score minimum 60 marks to technically qualify)
Sl. Details to be filled by Bidder
Description
No. (attach PSR sheets to explain)
a) Intake Well
1 Design capacity (MLD)
2 Location of intake well with distance from Jack
well (m)
3 Invert level of lowest inlet pipe in intake well
(m) with respect to LWL (Availability of water
at intake location has to be substantiated with
last 30 years data from department.
4 Diameter of intake well (m)
5 Depth of intake well (m)
6 Design flow for inlet pipe of piped intake /
connecting pipes with 22 hours operation (m3 /
hour)
7 Diameter of connecting pipes (mm)
8 Pipe material and class of pipe for connecting
pipes
9 Invert level of connecting pipes at intake well
(m)
10 Top level of intake well (m)
11 Bed level of intake well (m)
12 Entrance velocity in inlet rose piece (m / min)
13 Flow velocity in connecting pipes / intake
channel at design flow (m / sec)
14 Number and sizes of intermediate inspection
chambers / cleaning chambers (Nos. / m)
15 Whether valves, manholes, ladders etc.
Considered as per specifications?
b) Jack well Structure
1 Volume of sump below low water level (cum)
2 Location of Jack well structure
3 Size of lower suction chamber (m x m)
4 Invert level of connecting pipes at intake
structure (m)
5 Bed level of Jack well structure (m)
6 Floor level of pump delivery chamber (m)
7 Depth of lower suction chamber (m)
8 Design flow for intake structure with 20 hours
operation (m3 / hour)
9 Size of middle pump delivery chamber (m x
m)
38
10 Clear height of middle pump delivery chamber
(m)
11 Size of top motor floor (m x m)
12 Clear height of motor floor (m)
13 Size of electrical panel room (m x m x m)
14 Size of control room (m x m x m)
15 Number of raw water pumps W + S (Nos.)
16 Type of pumps
17 Pump setting level (m)
18 Discharge capacity of each pump with 20
hours operation (m3 / hour)
19 Design head for each raw water pump (m)
20 Efficiency of pump (%)
21 Pump BKW and motor capacity (KW / HP)
22 Material for piping and fittings
23 Number and size of valves
a) Non return valves (Nos. / mm)
b) Actuator operated butterfly valves (Nos. /
mm)
c) Automatic air valves (Nos. / mm)
d) Expansion joint / bellow (Nos. / mm)
e) Pump control valve
24 Capacity of EOT crane (Ton)
25 Source and distance of electricity supply with
KV
26 Transformer capacity (KVA)
27 DG capacity (KVA)
28 Details of surge protection system
29 Size of below rooms:
- LT room (m x m x m)
- Battery / UPS room (m x m x m)
- SCADA / control room (m x m x m)
- Operator rest room (m x m x m)
- Water filtration unit (m x m x m)
- Toilets (m x m x m)
30 Details of flow meter
31 Whether manhole, ladder, exhaust fans etc.
considered as per specifications?

32 Whether approach road considered as per


specifications?

ITEM – 3:RAW WATER PUMPING MAIN UP TO WTP:


(50 marks & must score minimum 30 marks to technically qualify)
Sl. Details to be filled by Bidder
Description
No. (attach PSR sheets to explain)
1 Design capacity (MLD)
2 Design flow with 22 hours of operation (m3 /
hour)
3 Length of pipeline (m)
39
4 Diameter of pipeline OD / ID and thickness
(mm)
5 Velocity of flow at design capacity (m / sec)
6 Pipe material and class of pipe
7 Whether air valves, scour valves, line valves
etc. with Tamper proof enclosure system with
vandalized alert system considered as per
specifications?
8 Whether pipe bridges, pipe support structures,
ducts, and concrete encasing, trenchless at
SH, NH, railway crossings etc. considered as
per requirement?

ITEM – 4:WATER TREATMENT PLANT:


(100 marks & must score minimum 60 marks to technically qualify)
Sl. Details to be filled by Bidder
Description
No. (attach PSR sheets to explain)
1 Location
2 Design capacity (MLD)
3 Design flow with 22 hours of operation (m3 /
hour)
4 Treatment units proposed
5 Cascade aerator
Diameter of central shaft (mm)
Number of steps (Nos.)
Height of each step (m)
Diameter of bottom step (m)
Size of raw water channel (m x m)
Size of parshal flume (m x m x m)
Bypass with control gate / valve provided
connecting to filter feed channel
6 Flash mixing tank
Size of tank and free board (m x m x m)
Detention time (secs)
Capacity of turbine mixer (HP)
Coagulant considered
7 Clariflocculator
Number of units (Nos.)
Diameter of each tank (m)
Depth of tank and free board (m)
Diameter of flocculation zone of each tank (m)
Slope of bottom floor (%)
Detention time (hours)
Number and capacity of flocculation paddles
(HP)
Scraper bridge drive capacity (HP)
Material and diameter of sludge withdrawal
pipe
Number of sludge pumps W + S (Nos.)
Capacity of each sludge pump (HP)
40
Bypass with control gate / valve provided
connecting to treated water channel, Pre
chlorination arrangement.
8 Rapid sand filters
Number of filter beds (Nos.)
Size of each filter bed (m x m)
Depth of filter bed and free board (m)
Rate of filtration (m3 / m2/hr)
Depth of sand bed (m)
Depth of supporting gravel media (m)
Standing depth of water over filter bed (m)
Type of under drainage system
Number and capacity of air blowers
Material for piping and fittings

Whether rate setters, filter rate controllers,


filter flow gauges, loss of head indicators,
wash water controllers and indicators, float
chambers, under drainage system, calibrated
notch etc. considered as per specifications?
Whether sedimentation of filter back wash
water and return of supernatant to inlet
considered as per specifications?

9 Sludge thickener and sludge pumps Number


of units (Nos.)
Diameter of each tank (m)
Depth of tank and free board (m)
Detention time (hours)
Scraper bridge drive capacity (HP)
Material and diameter of sludge withdrawal
pipe
Number of sludge pumps W + S (Nos.)
Capacity of each sludge pump (HP)
10 Sludge drying beds
Number of beds (Nos.)
Size of each bed (m x m x m)
11 Size of rooms / buildings considered:
- Chemical building (two story) (m x m x m)
- Air blower room (m x m x m)
- Office room (m x m x m)
- Electrical panel room (m x m x m)
- Control room (m x m x m)
- Laboratory (m x m x m)
- Disinfection room (m x m x m)
- Toilet (m x m x m)
- Twin block staff quarters (m x m x m) and
numbers provided
12 Backwash tank:
Capacity of tank (m3)
Staging height (m)
41
13 Details of disinfection facility meeting
CPHEEO / WHO guidelines
14 Filter Back wash water recirculation tank size
15 Provision of plant road connecting units and
approach road considered as per
specifications?

ITEM – 5: CONTACT TANK / CLEAR WATER STORAGE RESERVOIR AND PUMPING STATION:
(50 marks & must score minimum 30 marks to technically qualify)
Sl. Details to be filled by Bidder
Description
No. (attach PSR sheets to explain)
a) Contact Tank / Clear Water Storage Reservoir
1 Design capacity (MLD)
2 Design flow with 22 hours operation (m3/ hour)
3 Number of compartments (Nos.)
4 Capacity of each compartment (m3)
5 Size of each compartment and FB (m x m x
m)

b) Treated Water Pumping Station


1 Design capacity (MLD)
2 Size of pump room (m x m)
3 Clear height of pump room (m)
4 Size of electrical panel room (m x m x m)
5 Number of clear water pumps W + S (Nos.)
6 Type of pumps
7 Discharge capacity of each pump with 20
hours operation (m3 / hour)
8 Design head for each clear water pump (m)
9 Efficiency of pump (%)
10 Pump BKW and motor capacity (KW / HP)
11 Material for piping and fittings
12 Number and size of valves
a) Actuator operated butterfly valves on
suction (Nos. / mm)
b) Non return valves (Nos. / mm)
c) Actuator operated butterfly valves on
delivery (Nos. /mm)
d) Automatic air valves (Nos. / mm)
e) Expansion joint / bellow (Nos. / mm)
f) Pump control valves
13 Capacity of EOT crane (Ton)
14 Source and distance of electricity supply with
KV
15 Transformer capacity (KVA)
16 DG capacity (KVA)

42
17 Details of surge protection system
18 Size of below rooms:
- LT room (m x m x m)
- Battery / UPS room (m x m x m)
- SCADA / control room (m x m x m)
19 Details of flow meter and bulk meter
20 Details of exhaust fans
21 Details of Yard Lighting
22 Drainage System in WTP

ITEM – 6:
CLEAR WATER BULK TRANSMISSION MAINS UP TO ZBTs:
(50 marks & must score minimum 30 marks to technically qualify)
Sl. Details to be filled by Bidder
Description
No. (attach PSR sheets to explain)
1 Diameter wise length of pipeline
................ mm ................m
................ mm ................m
................ mm ................m
................ mm ................m
................ mm ................m
2 Number of hours of flow considered (hours)
3 Velocity range at design capacity (m / sec)
4 Pipe material and class of pipe
Whether air valves, scour valves, line valves etc.
with Tamper proof enclosure system with
5
vandalized alert system considered as per
specifications?
Provision pipe bridges, pipe support structures,
6 ducts, and concrete encasing, trenchless at SH,
NH, railway crossings etc.

ITEM – 7:
INTERMEDIATE PUMPING STATIONS:
(50 marks & must score minimum 30 marks to technically qualify)
Sl. Details to be filled by Bidder
Description
No. (attach PSR sheets to explain)
a) Intermediate Sumps
1 Location
2 Design capacity (MLD)
3 Design flow with 22 hours operation (m3 / hour)
4 Number of compartments (Nos.)
5 Capacity of each compartment (m3)
6 Size of each compartment and FB (m x m x m)
b) Intermediate Pumping Station
1 Design capacity (MLD)
2 Size of pump room (m x m)
3 Clear height of pump room (m)
4 Size of electrical panel room (m x m x m)
5 Number of pumps W + S (Nos.)
43
6 Type of pumps
Discharge capacity of each pump with 20
7
hours operation (m3 / hour)
8 Design head for each pump (m)
9 Efficiency of pump (%)
10 Pump BKW and motor capacity (KW / HP)
11 Material for piping and fittings
12 Number and size of valves
a) Actuator operated butterfly valves on suction
(Nos. /mm)
b) Non return valves (Nos. / mm)
c) Actuator operated butterfly valves on delivery
(Nos. /mm)
d) Automatic air valves (Nos. / mm)
e) Expansion joint / bellow (Nos. / mm)
f) Pump Control Valve
Capacity of EOT crane / Chain pulley block
13
(Ton)
14 Source and distance of electricity supply with KV
15 Transformer capacity (KVA)
16 DG capacity (KVA)
17 Details of surge protection system
18 Size of rooms:
- LT room (m x m x m)
- Battery / UPS room (m x m x m)
- SCADA / control room (m x m x m)
19 Details of flow meter and bulk meter
20 Details of exhaust fans
21 Approach road considered.

ITEM – 8:MASTER BALANCING RESERVOIRS / TANKS:


(20 marks & must score minimum 12 marks to technically qualify)
Details to be filled by Bidder
Sl.
Description (attach PSR sheets to explain)
No.
ZBT-1 ZBT-2 ZBT-3 ZBT-… ZBT-N
1 Location
2 Design capacity (MLD)
3 Design flow with 22 hours operation (m3 / hour)
4 Type of tank : ELSR / GLSR
5 Capacity of tank (m3)
6 Size / Dia. of tank and FB (m x m x m)
7 Details of flow meter and bulk meter
8 Approach road considered.
9 Provision of Staff rest room considered.

ITEM – 9:CLEAR WATER FEEDER MAINS UP TO OHTs IN EACH VILLAGE / HABITATION:


44
(50 marks & must score minimum 30 marks to technically qualify)
Sl. Details to be filled by Bidder
Description
No. (attach PSR sheets to explain)
1 Diameter wise length of pipeline
................ mm ................m
................ mm ................m
................ mm ................m
................ mm ................m
................ mm ................m
2 Number of hours of flow considered (hours)
3 Velocity range at design capacity (m / sec)
4 Pipe material and class of pipe
5 Whether air valves, scour valves, line valves
etc. with Tamper proof enclosure system with
vandalized alert system considered as
perspecifications?
6 Provision of pipe bridges, pipe support
structures, ducts, and concrete encasing,
trenchless at SH, NH, railway crossings etc.
7 Provision of rate of flow meters are provided
at all the village / habitation OHTs and
connected to operation management system
with bulk water meters.

ITEM – 10: Locations with land availability details


(50 marks & must score minimum 30 marks to technically qualify with minimum land acquisition)
To qualify, bidder has to design the scheme utilizing the identified Governments lands and minimum
land acquisitions. If bidder proposes large land acquisition is liable to be rejected.

Sl Tentative Locations Identified by Location proposed and confirmed


Components
No RWS&SD by Bidder
Water spread of Bhadra
1 Head works
Reservoir
Along the road and byepass
2 Raw water rising main Tarikere town up to ridge and
to WTP
3 Water Treatment Plant Near Ahamadanagar
4 Clear Water Rising Main up to ZBT All Along existing Roads
One near Hosadurga Town
Intermediate Pumping Stations
5
and Lifting Stations

ZBT’s at higher altitudes


comprising 15-18 habitations
6 Locations of ZBTs
depend on elevation to deliver
water by gravity
All Along existing Roads from
Clear Water Gravity Main from
7 respective ZBTs to Habitations
ZBTs to Habitations OHTs
OHTs

4.0 LIST OF MANUFACTURERS FOR DIFFERENT MATERIALS FOR REFERENCE.


45
( It is the responsibility of the contractor to select a proven vendor for trouble free
operation of the scheme)

1. M.S. PIPES

1. M/s. Steel Authority of India Ltd., No.8, VISL Building, J.C. Road, Bangalore – 560002.
2. M/s. Welspun, Trade World, `B' Wing, 9th Floor, Kamala Mills Compound, Senapati Bapat
Marg, Lower Parel, Mumbai- 400013
3. M/s. PSL Holdings, 22, Vaijavoor Village, Malai Vaiyavoor P.O., Mahuranthakam Taluk,
Kancheepuram Dist- 603308.
4. M/s Tata Steel Limited, Tata Steel tubes Division, PO Burmamines, Jamshedpur-831 007,
Jharkhand.\
5. M/s Asean pipes Ahamedabad.

2. D.I Pipes

1. M/s. Electrosteel Casting Ltd., 30, B.T. Road, Kharda, P.O. Sukhchar, Dist. 24,
Paraganas(N)- 700 115 – WestBengal
2. M/s.Jindal Saw Ltd., Samaghogha Village, Mundra Taluk, Dist. Kutch, Gujarat-392415
3. M/s.Lanco Industries Ltd., Rachagunneri-517 641 Sri Kalahasti, Chittor,A.P.
4. Tata Metallics DI PipesLtd.
5. M/s Electrotherm India ltd-Plot no 206-207,Shop no-1, Kunal-II, sector-21 Nerul ( E) Navi
Mumbai-400706 (Maharashtra)

3. H.D.P.E. PIPES

1. M/s. Jain Irrigation Systems Ltd., Jain Plastic Park, P.O. Box: 72, N.H. No. 6, Bambhori,
Jalagaon- 425 001
2. M/s. Duraline India Pvt. Ltd., Plot No. L-24, 25, Phase II A, Verna Electronic City, Verna,
Salcete, Goa- 403722
3. M/s. Pioneer Polyfab, Plot No. 12, Site IV, Industrial Area, Sahibabad Dist.,Ghaziabad.
4. M/s. Pennwalt Agro Plastics Ltd., Plot No. 272/A, Savli GIDC Village, Manjusar- 391 775.
Gujarat.
5. M/s. Reliance Industries, Surath, Hazira Manufacturing Fa Village, Botha Taluq, Surath,
Gujarat.
6. M/s Rishi Polymach Pvt. Ltd., 16-A belagola indutrial area metagalli,K.R. Road, Mysore– 570
017
7. M/s.Supreme Industries Ltd., 612, Raheja Chambers, Nariman Point, Mumbai- 400021.
8. M/s Time technoplast Ltd -C-Wing, 2nd Floor, Opp - HDFC Bank, Off. Saki Naka, Chandivali
Road, Andheri - (E)- Mumbai –400072

4. STONEWARE PIPES FOR WASTE DISPOSAL FACILITY

1. M/s.The Mysore Stoneware pipe & Potteries Ltd., Soladevanahalli Chickbanavar P.O.,
Bangalore-90

5. S & S RCC PIPES

1. M/s Indian Hume pipe Co. Ltd., Venkatala Village, Yelahanka Pos,Bangalore – 560064
2. M/s Aradhya Concrete Products, No. 301, Hebbal Industrial Area, Mysore-570016

46
6. G.I. PIPES FOR PLUMBING WORKS

1. M/s. Tata Iron & Steel Co. Ltd., No.45, Jubilee Building, II Floor `A' Wing, Museum Road,
Bangalore- 560001
2. M/s Surya Roshni Limited, Prakash Nagar, Delhi-Rohtak Road, Bahadurgarh-124
507, Haryana
3. M/s Jindal Pipes Ltd- Plot no 30, Institutional sector-44 Gurgoan-122002-Haryana
4. M/s Jindal Industries ltd -Delhi Road, Model Town,Hisar

7. CI D/F PIPES

1. M/s. NECO Castings Ltd., 65/2, Nildoh/Digdoh, MIDC Industrial area, Nagpur- 440016
2. M/s. Upadhaya Valves Mfg, Pvt Ltd., NH-6, VIII, Jangalpur, Andul Mogri Road,Howrah
3. M/s Electrosteel Casting Ltd., 30, B.T. Road, Kharda, P.O. Sukhchar, Dist. 24,
Paraganas(N)- 700 115 – WestBengal

8. DI SPECIALS

1. M/s. Kiswok Industries Pvt. Ltd, Bipranna Para, Via-Begri, Domjur, Howrah-711411
2. M/s. Electrosteel Casting Ltd., 30, B.T. Road, Kharda, P.O. Sukhchar, Dist. 24,
Paraganas(N)- 700 115 – WestBengal
3. M/s. Kejriwal Castings, P-200, Benaras Road, Netajigarh, Howrah – 711108
4. M/s Jindal Saw Ltd-Jindal Centre, 12 Bhikaiji Cama Place-New Delhi110066

9. CI SPECIALS

1. M/s. Kejriwal Castings, P-200, Benaras Road, Netajigarh, Howrah – 711108


2. M/s. Upadhaya Valves Mfg, Pvt Ltd., NH-6, VIII, Jangalpur, Andul Mogri Road,Howrah

10. SFRC MANHOLE FRAMES AND COVERS

1. M/s. Indo Precast Industries, C-5, IDA, Uppal, Hyderabad- 500039


2. M/s. Tanvi Cement Products, No. 128, Lakkenahalli, Bhadrapura Road, Solar Hobli, Magadi
Taluk, Bangalore RuralDist.
3. M/s Southern Concrete Industries, Plot No.22, C, KIADB Industrial Area, Doddaballapur,
Bangalore Rural District.
4. M/s S.S.V. Precast Industries, 4/8, B, IDA Nacharam, Hyderabad – 500076.
5. S.S. Polytech Concrete Products,No.32/4, Bukkasagara Village, Jigani Hobli, Anekal Taluk,
Bangalore
6. M/s Rajvaibhav Enterprises (P) Ltd., No.18, KIADB Industrial Area, Hoskote, Bangalore
Urban Dist.
7. M/s Swamy Concrete Products Pvt Ltd.,Plot No. 35, KIADB, Hirehally Industrial Area,
Hirehalli,Tumkur – 572168
8. M/s Mahesh Precast Industries, D-5-6, Industrial Estate, M.S.K. Mill Road, Gulbarga-585102
9. M/s Juneja Metal WorksVillage Variana, P.O. Nagra, Kapurthala Road,Jalandhar – 13.(DI
Manhole Cover)
11. AIR VALVES
1. M/s.VAG Valves(India)Pvt.Ltd.,FlatA,1sty Floor,Krupa Ashirwad Complex,Hyderbasti,
R.P. Road, Secunderabad- 500 003
2. M/s.ARI,Isreal.
3. M/s.Bermad,IsrealM/s. Kirloskar Brothers Ltd., Gate No. 252/253, Village Kondhapuri, Shirur Dist.Pune
47
4. M/s. Fouress Engg. (I) Ltd., Plot No. 324, Wagale Industrial Estate, Road No. 21, Thane (W)-
400608

12. SLUICE VALVES

1. M/s.VAG Valves (India)Pvt.Ltd.,FlatA,1st Floor,Krupa Ashirwad Complex,Hyderbasti,


R.P. Road, Secunderabad- 500 003(DI)
2. M/s. Kirloskar Brothers Ltd., Gat No.252/253, Village Kondhapuri, Shirur, Dist- Pune M/s.
Mayur Valve Co., W-95 (A), M.I.D.C. Satpur, Nashik- 422007
3. M/s. Indian Valve International, 84B, Bhupendra Bose Avenue, Kolkata- 700004
4. M/s. Kejriwal Castings, P-200, Benaras Road, Netajigarh, Howrah – 711108
5. M/s. Durga Engineering Co., 22/2, Deshpran Susmal Road, Howrah- 711101

13. BUTTERFLY VALVES

1. M/s.VAG Valves(India)Pvt.Ltd.,FlatA,1st Floor,Krupa Ashirwad Complex,Hyderbasti,


R.P. Road, Secunderabad- 500 003
2. M/s. Audco India Ltd.,B8,MMDA Indstl. Area, Maraimalainagar, Tamil Nadu- 603209
3. M/s. Kirloskar Brothers Ltd., Gate No.252/253, Village Kondhapuri, Shirur District-Pune
4. M/s. Tyco Valves & Controls India, Sy. No.150, Halol-Kalol, Godhra Road, P.O. Maghasar,
Dist. Panchamahal,Gujarat
5. M/s. Fouress Engineering, Plot 2, Phase 2, Peenya Industrial Area, Bangalore-560058

14. GATE VALVES


1. M/s. AV Valves, No. 160, Industrial Estate, Nunhai, Agra- 282006
2. M/s. Kirloskar Brothers, Udyog Bhavan, Tilak Road, Pune- 411002
3. M/s. Audco India Ltd., Marai Malai Nagar, B-8, Industrial Area,Chennai

15. NON RETURN VALVES/CHECK VALVES

1. M/s.VAGValves(India)Pvt.Ltd.,FlatA,1st Floor,Krupa Ashirwad Complex,Hyderbasti,


R.P. Road, Secunderabad- 500 003
2. M/s. Indian Valve International, 84B, Bhupendra Bose Avenue, Kolkata- 700004
3. M/s. Durga Engineering Co., 22/2, Deshpran Susmal Road, Howrah- 711101

16. DUAL PLATE CHECK VALVES

1. M/s.VAGValves(India)Pvt.Ltd.,FlatA,1st Floor,Krupa Ashirwad Complex,Hyderbasti,


R.P. Road, Secunderabad- 500 003
2. M/s. Upadhaya Valves, P 280, Binaras Road,Kolkata

17. PRESSURE RELIEF VALVES

1. M/s. Indian Valves Pvt Ltd., H.O.- 53, Industrial Estate, Satpur, Nashik- 422 007
18. SLUICE GATES

1. M/s Indian Valves Pvt Ltd., H.O.- 53, Industrial Estate, Satpur, Nashik- 422007
2. M/s.JashEngg.Ltd.,31,Sector`C‟,IndustrialArea,SanwerRoad,Indore-452015

48
19. FOOT VALVES

1. M/s Shree Balaji Industries, Shibtala, Kalital, Baltikuri, Howrah- 711402


2. M/s Calsens Pvt Ltd., 6/1A, British India Street, Kolkata– 700069

20. CEMENT

1. M/s.Vasavadatta, Cement, Prop.Kesoram Industries Ltd., Post Sedam- 585 222, Gulbarga,
Karnataka
2. M/s.Penna Cement Industries Ltd., Talaricheruvu Village, Tadpatri Mandal, Ananthapur Dist.
A.P.
3. M/s.Madras Cement, Flat No.100-100/1, M-Floor, Eden Park, No.20, Vittal Mallya Road,
Bangalore- 560001
4. Birla Cement
5. Ultratech
6. ACC
7. Zuari Cement
8. Ambuja Cement, Elegant Business Park, MIDC Cross Road „B‟ Off Andheri-Kurla Road,
Andheri (E) Mumbai400059
9. Chettinad Cement, House of chettinad “Rani Seethai Hall” 5th Floor # 603, Anna Salai,
Chennai 600006 PNo. 044 –28292727
10. Ramco Cement , The Ramco Cements Limited (Formerly Madras Cements Ltd), Auras
Corporate Centre, 98-A Dr.Radhakrishnan Salai Mylapore, Chennai - 600 004, PNo.044
- 28478666
11. Coromandal Cement, Coromandel Towers, 93, Santhome High Road,Karpagam Avenue,
R.A.Puram,Chennai600028.

21. WATER METER/FLOW METER/ Electromagnetic / Mechanical WaterMeter

1. M/s. Krohne Marshell, A34/35, MIDC Estate, H block, Pimpri, Pune- 411018
2. M/s Endress Hauser Flowtec (India) Pvt. Ltd., M-174/175 MIDC Waluj, Aurangabad–
431 436.
3. M/s. Siemens, 130, Pandurang Budhkar marg, worli, Mumbai400018
4. M/s. Krohne Marshell, A34/35, MIDC Estate, H block, Pimpri, Pune- 411018.
5. M/s Endress Hauser Flowtec (India) Pvt. Ltd., M-174/175 MIDC Waluj, Aurangabad– 431
436.
6. M/s ABB, Prestige Palladium Bayan, Greams Ln, Thousand Lights West, Thousand
Lights, Chennai, Tamil Nadu600006.
7. M/s Yokogawa, 115, Mahatama Gandhi road, 2nd floor, Kothari, buildings,
Nugambakkam, Chennai, Tamilnadu, India,600034.

22. BLEACHING POWDER &PAC


1. M/s. Sree Rayalaseema Hi-Strength Hypo Ltd., (Bleaching powder) Gondiparla, Kurnool- 518
004
2. M/s. Sriram Vinyl and Chemicals Industries, (PAC powder) Kota Nagar, Kota- 324004
3. M/s. Grasim Industries Ltd., (Bleaching & PAC powder) Chemical Division, Birlagram, Nagda
(M.P)- 456331
4. M/s Gujarat Alkalies & Chemical Ltd., (PAC Powder), P.O. Petro Chemicals- 391 346,
Vadodara.
5. M/s Kanoria Chemicals & Industries Ltd., (Bleaching Powder), Renukot, Sonebhadra, Uttar
Pradesh
49
23. RUBBER RINGS & RUBBER GASKETS

1. M/s.Durable Polymer Products Pvt Ltd., Boai, 2nd Lane, P.O.Jugberia, Kolkata- 700110
2. M/s. Prabhat Elastomers Pvt. Ltd., A1/413-415, GIDC Road, No. 4, Sarigam Gujarat- 396155
3. M/s.Amalgamated Synthetic Moulders,44/14, K.B.Sarani(Mall Road),Kolkatta- 700080
4. M/s. J.D.Rubber Industries, Survey No. 580/A, Ghatkesar (M) R.R. Dist(A.P.)
5. M/s Andhra Polymers Pvt. Ltd., Plot No.2, Phase – 5, IDA, Jeedimetla, Hyderabad – 560055

24. FOOT STEPS

1. M/s. K.G.M. Exports, Plot No. 1 & 2, Sector 59, H.S.I.D.C. Indl. Estate,Faridabad
2. M/s. TV Plastics Ltd., 488, Kamakshipalya New Extension, Bangalore- 560079
3. M/s. Rajvaibhav Enterprises Pvt Ltd., No. 18, KIADB, Industrial Area, Chintamani Road,
Hosakote- 14,Bangalore

25. CLARIFIER BRIDGE

1. M/s.Voltas Ltd., Pumps & Projects,Business Division,2nd Pokran Road,Thane- 400601


2. M/s.EMCO
3. M/s. Triven

26. PIPE COATING

1. M/s. STP Ltd., Mirgadih, Dimna Road, P.O. MGM Medical College, Jamshedpur- 831 018,
Jharkhand
2. M/s Shalimar Tar products- 404,Lloyds Chamber,Block no-2, Mangalwar Peth-Pune-411011
3. M/s MP Tar Products- Plot No 69 and 70 Light Industrial area Bhilai dist- Durg(C.G)
4. M/s A.R. Laminators -497/2, G.I.D.C-Makarpura, Vadodara-390 010-Gujarat,India
5. M/s IWL India ltd-W360, North Main Road-Anna Nagar West-Chennai -600 101-Tamilnadu

27. KNIFE GATE

1. M/s.JashEngineeringLtd.,31,Sector`C‟,IndustrialArea,SanwerRoad,Indore-452015
2. M/s. Indian Valves Pvt Ltd., H.O.- 53, Industrial Estate, Satpur, Nashik- 422007

28. VERTICAL TURBINE PUMPSETS

1. M/s. Fair Banks Morse, 28 A, Site IV, Industrial Area, Sahibabad, Ghaziabad(U.P)
2. M/s. Kirloskar Brothers, Stategic Business Unit-1, Kirloskar Brothers, Kirloskar Wadi, Pune –
416 308
3. M/s. Jyothi Ltd., Nanubai, Amin Marg, P.O. Chemical Industries, Vadodara- 390002
4. M/s. Worthington Pvt. India Ltd., (WPIL), 22, Ferry Fund Road, Panihati-743 176, 24,
Parganas(N), WestBengal.
5. M/s. Worthington Pvt. India Ltd., (WPIL), Macneill & Major Industrial Estate, A-5, Section
XXII, Meerut Road, Ghaziabad- 201 002, UttaraPradesh.
6. M/s. Mather & Platt Pumps Ltd., P.O. Box No.7, Pune-Mumbai Road, Chinchwad, Pune- 411
019.
7. M/s. Voltas Ltd., Pumps & Projects, Business Dvn. 2nd Pokran Road, Thane-400601.
8. M/s.Flowmore Pvt. Ltd., 9th Mile Stone, G.T.Road, P.O. Mohan Nagar, Ghaziabad,U.P.
9. M/s Grundfoss Pumps India Pvt Ltd., 118, Old Mahabalipuram Road, Thorappakkam,
Chennai-60009
50
29. CENTRIFUGAL PUMPSETS

1. M/s.Kirloskar Brothers Ltd., Ujjain Road, Opp. Railway Station, Dewas(MP)- 455001
2. M/s.Beacon Weir Ltd., 28, Industrial Estate (North), Ambattur, Chennai- 600098.
3. M/s. Kirloskar Brothers, Stategic Business Unit-1, Kirloskar Brothers, Kirloskar Wadi, Pune
416308
4. M/s. Flowmore Pvt.Limited, A-292, Mahipalpur Extn., N.H- 8, New Delhi-110037
5. M/s. Jyothi Ltd., Nanubai, Amin Marg, P.O. Chemical Industries, Vadodara- 390002
6. M/s. Worthington Pvt. India Ltd., (WPIL), Macneill & Major Industrial Estate, A-5, Section
XXII, Meerat Road, Ghaziabad- 201 002(U.P.)
7. M/s. Mather & Platt Pumps Ltd., P.B. No.7, Mumbai–Pune Road, Chinchwad, Pune– 411019
8. M/s Grundfoss Pumps India Pvt Ltd., 118, Old Mahabalipuram Road, Thorappakkam,
Chennai-600 097(including boosterpump)

30. SUBMERSIBLE PUMPSETS

1. M/s. Kirloskar Brothers Ltd., Ujjain Road, Opp. Railway Station, Dewas (MP)- 455001
2. M/s. KSB Pumps Ltd., Mumbai – Pune Road, Pimpri, Pune – 411018.
3. M/s. Grundfoss Pumps India Pvt Ltd., 118, Old Mahabalipuram Road, Thorappakkam,
Chennai-600097
4. M/s Aqua pumps and Machinersi pvtltd
5. M/s. Kishore Pumps Pvt. ltd., Enviro Pumps Dvn., 675/2, Pune-Nasik Highway, Kuruli
(Chakan), Pune- 410501.
6. M/s. M.B.H. Pumps Pvt. Ltd., Plot No. 14, GIDC Naroda Industrial Estate,Ahmedabad-
7. M/s Xylem Water Solutions India Pvt ltd--Ground & First Floor,- Vishnu Shivam Mall-Thakur
Village, Kandivali (E)- Mumbai – 400101

31. MONOBLOCK PUMPS

1. M/s. M.B.H. Pumps Pvt. Ltd., Plot No. 14, GIDC Naroda Industrial Estate, Ahmedabad- 382
330
2. M/s. Arihant Pumps Pvt. ltd., Nr. Ladbhi Nala, Deesa Highway, Palanpur, Banaskantha- 385
001
3. M/s. Jyothi Ltd., Nambai, Amin Marg, P.O. Chemical Industries, Vadodara- 390002
4. M/s. Unnati Industrial Corporation, Near Uttar Gujrat Industrial Estate, Opp. Forge & Blower,
Naroda Road, Ahmedabad- 380025
5. M/s Cheran Industries,Coimbatore
6. M/s Waterman Industries Pvt Ltd., 407, Opp New Intas Pharma, Sarkhej Baavla Highweay,
Moraiya, Changodar, Ahmedabad-382213
7. M/s. Mather & Platt Pumps Ltd., P.B. No.7, Mumbai–Pune Road, Chinchwad, Pune– 411019

32. DEWATERING PUMPSETS

1. M/s. MBH Pumps (Gujarath) Pvt.Ltd., No.14, GIDC Naroda, Ahmedabad–382330


2. M/s. Mody Industries (FC) Pvt. Ltd., Plot no. C-41, Road no. 34, Wagle Industrial Estate,
Thane – 400604
3. M/s. Unnati Industrial Corporation, Near Uttar Gujrat Industrial Estate, Opp. Forge & Blower,
Naroda Road, Ahmedabad- 380025
4. M/s. Kishore Pumps Pvt. ltd., Enviro Pumps Dvn., 675/2, Pune-Nasik Highway, Kuruli
(Chakan), Pune- 410501.

33. MOTOR
51
1. M/s. Jyothi Ltd., Nanubai, Amin Marg, P.O. Chemical Industries, Vadodara- 390002
2. M/s.Crompton Greaves Ltd., Pumps Division, Plot No.A/28, MIDC, Ahmednagar-414111.
3. M/s. SIEMENS Ltd., Thane Belapur Road, Kalwa, Thane- 400601.

34. Electrical List of approved makes

DESCRIPTION MAKES
HT SIDE:
COMPACT SUB-STATON ABB / SCHIENDER
RING MAIN UNITS ABB / SCHIENDER / SIEMENS
PLCs ABB / SIEMENS / ALLEN BRADLEY / HONEYWELL
VCB ABB / SCHIENDER / SIEMENS
HT PANELS ABB / SIEMENS / LOTUS POWER GEAR
11kV HT XLPE CABLES UNISTAR / POLYCAB / CCI / KEI
HT CABLE TERMINATION KIT RAYCHEM / BIRLA-3M
OIL FILLED TRANSFORMER UNIVERSAL/ KIRLOSKAR/ VOLT AMP
DRY TYPE TRANSFORMER ABB / VOLT AMP
CHANGE OVER SWITCH ABB / HPL / C&S /INDOASIAN
CURRENT TRANSFORMER KAPPA / AE / PRAGATHI
VOLTAGE TRANSFORMER KAPPA / AE / PRAGATHI
LT SIDE:
BUS DUCT ( AIR INSULATED TYPE) ZETA / ANITA ELECTRICALS / TRICOLITE
BUS DUCT ( SANDWITCHED
CONSTRUCTION) SCHNEIDER ELECTRIC / GODREJ / EMFORM
ACB / MCCB ABB / SCHNEIDER / SIEMENS / L&T
PRAGATHI CONTROLS / LOTUS POWER GEAR /
LT PANELS / AMF POWER CONTROL EQUIPMENTS/ LOAD
CONTROLS
DG SETS CUMMINS / CATERPILLAR
BATTERIES EXIDE / AMCO / AMARON
UPS DELTA / LIEBERT / EMERSON
1.1kV LT CABLES POLYCAB / CCI / SBEE
CABLE GLANDS USHA / CROMPTON / COMET
CABLE LUGS DOWELL/3D
LT CABLE TERMINATION KIT RAYCHEM / SAFE KIT
MCB / MCCB - DBs FOR LIGHTING /
ABB / MDS LEXIC / SCHNEIDER
POWER / EMERGENCY / UPS
BELUK (GERMANY) / ENERCON SYS. PVT.LTD /
APFCR (NUMERIC TYPE)
ALSTOM
CABLE TRAYS PROFAB / INDIANA / OBO BUTTERMAN
RACE WAYS / CABLE MANAGEMENT
SCHNEIDER / LEGRAND / OBO BUTTERMAN
SYSTEM
TELEPHONE CABLE ( INDOOR) DOORAVANI / DELTON / FINOLEX
TELEPHONE CABLE OUTDOOR (JELLY
FINOLEX / KARNATAKA TELECABLES / VINDHYA
FILLED)
TELEVISION CABLE RR KABELS/FINOLEX
INDUSTRIAL TYPE PLUG & TOP
SOCKETS & WEATHER PROOF HENSEL/ LEGRAND
ENCLOSURES
52
DESCRIPTION MAKES
ADVANCED LIGHTNING PROTECTION
ERICO / INDELEC / OBO BUTTERMAN
SYSTEM
METERS / SWITCHES / RELAYS:
STARTERS ABB / SIEMENS / TELEMECHANIC/L&T
TIMERS ABB / LEGRAND / TELEMECHANIC
CAPACITORS UNIVERSAL / MEHER / EPCOS
SELECTOR SWITCHES SIEMENS / L&T / KAYCEE
INDICATING METERS CONZERV
ENERGY METER CONZERV / AE / SECURE
PUSH BUTTONS SIEMENS / L&T / TEKNIC
INDICATING LAMPS SIEMENS / ALSTOM / VAISHNO / BINAY
PROTECTIVE RELAYS ABB / SIEMENS / ALSTOM / EASUN
LIGHT FIXTURES / CONDUITS
LIGHT FIXTURES PHILIPS / HAVELS / BAJAJ
STREET LIGHT POLES SHUBHAM / PIPE CORPORATION / KESELEC
CEILING / EXHAUST FANS GE / KHAITAN / ANCHOR/CG
FRLS PVC CONDUITS VIP / PRECISION / UNIVERSAL
METAL CONDUITS TATA / BHARATH / GB
FRLS WIRES-1100V GRADE RR KABELS / ANCHOR / FINOLEX
LIGHT SWITCHES ANCHOR ROMA / ABB / LEGRAND

35. WATER LEVELCONTROLLERS

1. M/s. Hitech Systems and Services, White House, 119, Park Street, Kolkata- 700016
2. M/s. Nivo Controls Pvt Ltd., 104-115, Electronic Complex, Indore- 452010.
3. M/s. Gujarat Electronics and Controls, (Water level controllers & Water level guards) 7,
Adavani Market, Out side Delhi Gate, Ahamedabad- 380004.
4. M/s. Pune Techtrol, S-18, MIDC Bhosari, Pune - 411026(INDIA).
5. M/s. SBEM, 39, Electronic Co-Operative Estate, Pune Satara Road, Pune – 411009(India).

36. PE FITTINGS (For HDPE Pipes)

1. M/s Al Aziz Plastics Pvt Ltd., No. Plot No.5-14, Achhad Industrial Estate, Achhad,
Tal:Talasari, Dist: Thane(Maharastra)-401606
2. M/s.Glynwed Pipe Systems India Private Ltd., A-208, Kailash Complex, Park Site, Vikhroli-
Hiranandani Link Road, Vikhroli (W), Mumbai -400079.
3. M/s.George Fischer Piping System, Plot No.9-B, 1st Floor, Kopri Village, Above China
Valley, Powai, Mumbai- 400076.

37. TMT BARS / TMT RE-BARS / CRS TMR RE-BARS

1. M/s.Sujana Metal Products Ltd., Survey No.296/7/9, IDA Bollaram, Jinnaram Mandal, Medak
Dist., A.P. India (TMTBars)
2. M/s.SRMB Srijan Ltd., SRMB House, 7 Khetra Das Lane, Kolkata- 700 002. India (TMTBars)
3. M/s.Shyam Steel Industries, Shyam Towers, EN-32, Sector V, Salt Lake, Kolkata- 700 091
(TMT re-bars, CRS TMRre-bars)
4. SAIL, Steel Authority of India limited, Ispat Bhawan, Lodi Road, New Delhi – 110003 PNo.
011 -24300100
5. TATA, Tata Steel Limited Registered Office Bombay House, 24, Homi Mody Street, Mumbai
- 400 001Ph: 91 02266658282
6. Rashtriya Ispat Nigam Limited, Visakhapatnam Steel Plant, Visakhapatnam,AP.

53
38. Ultrasonic Level transmitter & Pressure Transmitter

1. M/s ABB, Prestige Palladium Bayan, Greams Ln, Thousand Lights West, Thousand
Lights, Chennai, Tamil Nadu600006.
2. M/s Siemens, 130, Pandurang Budhkar marg, worli, Mumbai400018.
3. M/s E&H, M-174/175 MIDC Waluj, Aurangabad– 431436.
4. M/s Yokogawa, 115, Mahatama Gandhi road, 2nd floor, Kothari, buildings,
Nugambakkam, Chennai, Tamilnadu, India,600034.
5. M/s Honey well, Mohamadpur Pace City-2, Sector-36, Gurgaon Ho, Gurgaon –122001.

39. Residual Chlorine Analyser

1. M/s E&H, M-174/175 MIDC Waluj, Aurangabad– 431436.


2. M/s Forbes Marshall, A34/35, MIDC Estate, H block, Pimpri, Pune- 411018
3. M/s HACH, 16/1, S.P. Complex, Lalbagh Road, Bangalore– 560027,India.

40. PLC & SCADA System

1. M/s Siemens Siemens Limited, Registered & Corporate Office, 130,


Pandurang Budhkar Marg,Worli,Mumbai 400018.

2. M/s Schneider - Schneider Electric India Pvt. Ltd., 9th Floor, DLF Building
No. 10, Tower C,DLF Cyber City,Phase II,Gurgaon-122002.Haryana,India

3. M/s ABB - Corporate Office and Registered Office;No.26/1,21st Floor,South


Wing, Bangalore
4. M/s.Yokagawa

41. Pressure gauge

1. M/s GIC, 194/195, Gopi Tank Road, Off.Pandurang Naik


Marg, Behind Citylight Cinema,Mahim, MUMBAI-400016.
2. M/s H.Guru Industries, 10 - B HO-CHI MINH SARANI,KOLKATA,WEST BENGAL,INDIA
700
071
3. M/s Baumer, Fourhum Centre, S.No. 112/2/21, 112/2/64 & 112/2/72, Opp. RMD Sinhgad
Institute, Pune-Mumbai Highway, Warje,411058 Pune.
4. M/s H.Guru South, 32, Industrial Suburb, Yeswantpur P.O. , Bangalore - 560 022.India

The specifications as per the relevant codes of provisions conforming to


the best standards shall prevail in case of inconsistency in the above
mentioned specification

54
PART - A :GENERAL SPECIFICATION

1.0 DESCRIPTION OF THE WORKS:

1.1 General

The location of the Works is given in Concept Note.

The principal elements of the Works are;

(a) Head works and pumping station at reservoir;

(b) Raw water pumping main up to treatment plant;

(c) Water treatment plant with associated buildings /facilities;

(d) Contact tank / treated water storage tank and clear water pumping station;

(e) Treated water pumping mains / bulk water transmission mains from WTP up to MBRs
/ ZBTs;

(f) Intermediate booster sumps and pumping stations as necessary;

(g) MBRs / ZBTs for supplying to cluster of Habitations /habitations;

(h) Treated water feeder mains from MBRs / ZBTs to existing / proposed OHTs at all the
Habitations /habitations;

(i) Electro-mechanical, instrumentation and control, automation, IDMS, WMDs, AMS,


RMS etc.

(j) All other works as detailed in Concept Note and Design Criteria;

(k) Operation and maintenance the whole of the entire Works for a period of 60 months.

c) Royalties:
The Employer shall deduct Royalties on materials used in the works from progress payments to
the Contractor at the rates specified in the “Karnataka Minor Minerals Concession Rules 2007” as
published by the Commerce and Industries Department (Mines) and as amended from time to time
till the date of submission of tenders. It shall be responsibility of the Tenderer to ascertain the
applicable rates as on the date of submission of tenders.
d) Rates quoted by the contractor / firm is inclusive of all taxes and duties.
e) The contractor / firm should mandatorily pay by themselves the necessary Entry Tax &
other applicable taxes without fail.

1.2 Scope

The Contractor shall design, manufacture, construct, install, test and commission the
works described in items (a) to (j) above in "Construction Period" under the Contract. The
Employer will take-over the Works after the Contractor has satisfactorily completed this stage
and will subsequently handover the whole Works to the Contractor to conduct 60 months of
operation and maintenance, in "Operation and Maintenance Period". "Operation and
Maintenance Period", the whole Works will be under the possession of the Contractor.
Therefore, the obligation of the Contractor shall have no difference to “the Contractor” as
mentioned in the Conditions of Contract. The Contractor shall be responsible for all
insurances, where the cost of providing that shall be entered in the Schedule of Prices. After
the Contractor has satisfactorily completed the 60 months operation and maintenance works
in "Operation and Maintenance Period", the Employer will take over the whole Works. Both
"Construction Period" and "Operation and Maintenance Period" of the Works contain a 12
months Defects Notification Period. During the Defects Notification Period at "Construction
Period", the Contractor has to rectify all defects and complete all minor outstanding works
that are agreed by the Contractor and the Engineer after the Test on Completion of
"Construction Period". The scope of the tests to be done in the aforesaid Test on Completion
is detailed elsewhere in this General Specification. Prior to handover the whole Works to the
Employer, the Contractor has to conduct and satisfactorily complete the Test on
Completionof "Operation and Maintenance Period". The scope of the tests to be done in this
Test on Completion is detailed elsewhere in this General Specification.

1.3 Design

The Contractor shall take design responsibility for the Works, not withstanding the level
of detail provided in any of the drawings or other items comprising the Employer’s
Requirements.

1.4 Source of Water

The raw water supply shall be derived from reservoir source as detailed in Concept Note
and Design Criteria. The raw water shall be conveyed to the Water Treatment Works via
pipeline.

1.5 Capacity

The design capacity of proposed water supply scheme including WTP shall be as
specified in Design Criteria. During Trial Operation at the Test on Completion for
"Construction Period" of the Works, the Contractor has to demonstrate the above
requirement can be attained, with the output treated water conforming to the treated water
standard stipulated in the Specification.

During "Operation and Maintenance Period" of the Works, the Employer intends to
operate the Water Treatment Plant to produce an output as specified by running all the
pumping stations (raw water and treated water). This treated water quantity per day should
have been used by the Contractor to price the chemical consumption, power consumption,
spare to use, consumables to use, operation and maintenance resources to use etc. in
"Operation and Maintenance Period" of the Works. The Employer has the right to instruct the
Contractor, during "Operation and Maintenance Period", to vary the running hours of the
whole Works in order to produce treated water output lower or higher than the specified.
Used filter wash water shall be recycled to the works inlet as specified.

1.6 Raw water quality

The raw water supply for the treatment works shall be derived from the reservoir at site
as finalized in consultations with Client. The Contractor shall obtain their own raw water
quality data by carrying out water quality analysis during different periods of the year.

1.7 Treated water quality

When operated in accordance with the Contractor's instruction at flows up to the required
maximum throughput, the water treatment works treating raw water from the reservoir shall
be capable of producing a reliable and continuous supply of potable water free of waterborne
pathogenic organisms. The water quality from the works sampled after treatment at the
treated water reservoir outlet or as otherwise stated shall comply with the "Acceptable" limits
as listed in Table - 2.2 and Table - 2.3 of CPHEEO Manual on Water Supply and Treatment.

1.8 Performance Guarantee

Performance guarantees are specified in technical schedules for the following;

• Treated water output;


• Clarified, filtered and treated water quality;
• Guarantee of filter runtime;
• Clarifier sludge discharges;
• Washwater consumption;
• Used washwater return;
• Raw water pumpsets;
• Treated water pumpsets;
• Booster pumpsets;
• Plant control system;
• Chemical consumption;
• Electrical power consumption;
• Overall plant performance including plant and equipment warranty.

1.9 Treatment process

The sequence of treatment processes proposed for the treatment works is summarized
below. Where aluminium sulphate is mentioned as a coagulant the Contractor may use
polyaluminium chloride (PAC) instead at his sole responsibility subject to the approval of the
Engineer.

Location / Process Function


Works Inlet

Cascade Aerator Aeration

Parshall flume Flow measurement

Mechanical mixing with the addition of Coagulation and flocculation


aluminium sulphate

Hydraulic mixing with the intermittent Biological control


addition of oxidizing agent.
Clariflocculator

Settling Removal of Suspended and Colloidal

particulate matter.
Filtration

Rapid sand filtration Removal of colloidal and suspended


impurities
Contact tank

Disinfection Removal of bacteria, virus, pathogens,


cysts etc.
Treated water storage

Mixing with the addition of lime. Final pH correction to give a positive


Langelier Index

Storage in treated water reservoir. Balancing treated water inflow to treated


water pumped outflow for further supply.
Used washwater recovery

Sedimentation of used filter washwater Separation of supernatant for return to


inlet works and sludge conveyed for
further treatment.
Location / Process Function
Sludge thickeners

Thickening of clarifier sludge and sludge Reduction of volume of sludge for further
from used filter washwater treatment

Sludge drying beds

Removal of excess water Increase in dried solids concentration to


facilitate handling for removal from site

1.10 Control and operation of the Works

Overall control and monitoring of the head works, intake structure, raw water pumping
station, the water treatment works, the treated water pumping station, the booster pumping
stations, MBRs / ZBTs, OHTs in Habitations / habitations, etc shall be directed from the
central control room / control center. Operation of plant and treatment processes shall
normally be from local control centres in various buildings associated with the process units
and chemical and disinfection buildings. Instruments shall be used to monitor critical plant
states and alarm plant faults, failures and abnormal operations on local panels. Information
essential to the overall running of the treatment works shall be presented in the central
control room at WTP.

The treatment works shall be arranged for manual operation with the following exceptions;

(a) Automatic Desludging of clarifiers;


(b) Automatic filter flow control;
(c) Automatic filter washing;
(d) Automatic operation of disinfection system;
(e) Automatic operation of, water supply pumps, used wash water transfer pumps and
thickener feed pumps.
(f) Automatic desludging of sludge thickeners;
(g) Automatic operation of some drainage pumps as specified.

All automatic operations shall have manual override facilities as specified.

1.11 Ability of processes to meet variations

The treatment processes are required to deal effectively and efficiently with the variations in
raw water quality and in the through put which are likely to occur, due both to seasonal
changes in the water quality and consumer demands.

1.12 Hydraulics

The hydraulic loss through the Treatment Works for the maximum flow from the normal
TWL at the Parshall flume to the TWL in the treated water reservoir shall not exceed 5.0m.
The height of cascade aerator shall be as per design.

1.13 Unit processes

The unit processes for treatment plant shall be as specified in design criteria. The design
of water treatment plant shall be in accordance with CPHEEO manual on Water Supply and
Treatment and as approved by client.
1.14 Electricity distribution system

(a) General

The power shall be derived from local Electricity Board supply via the provision of
dedicated 33kV feeders at each pumping station such as Intake structures, Water Treatment
plant, Clear Water Pumping Station and Intermediate Booster Pumping Stations etc. the
Contractor shall provide a 33kV sub-station which shall house the 33kV switch board to be
provided as part of this Contract. Local pumping stations with total load less than 50 HP may
be fed from lower voltage feeders.

The 33kV supplies from KPTCL to the pumping stations of Intake Structure, Water
Treatment plant, Clear Water Pumping Station and Intermediate Booster Pumping Stations
will be via overhead lines. Outdoor switch gear shall be for connection to overhead cables.
The 33kV switch boards provided shall be fed from the KPTCL 33kV outdoor switch gears by
underground cables. The Contractor shall be responsible for the supply and installation of
these underground cables. At each of the sites of this Contract, as described above, the
Contractor has to provide a 33kV outdoor switchgear yard with fencing and a metering
house for use by KPTCL. Electricity supplies to the process plant and site infra-structure
shall be as detailed within this Specification.

(b) High voltage Switchgear

High voltage switchgear equipped with vacuum circuit breakers shall be provided as
detailed herein.

(c) Transformers

Transformers shall be of the oil filled and naturally air-cooled type with primary and
secondary cable boxes as detailed in the Standard Specifications. Transformers of rating
below 500kVA located indoor shall be dry-type encapsulated winding cast resin
transformers. Redundant Transformer shall be provided for each pumping station.

(d) Low Voltage switchgear

Switch boards and motor control centres shall be the multi-compartment type
incorporating circuit-breaker or switch dis-connector incomer units, circuit-breaker or fuse-
switch type outgoing units and motor starters as appropriate.

(e) Power factor

The power factor shall be corrected at each load centre by means of individual or
automatically controlled multistage capacitor banks.

(f) Cables

33/11/6.6/3.3kV and 415V cables shall be of the cross-linked polyethylene insulated, single
wire armoured and polyvinyl chloride over-sheathed type of appropriate voltage grade.
Conductors shall be copper.
(g) Earthing

The 433V transformer winding neutral shall be solidly earthed.

The 1600kVA and above rated Transformer winding neutral shall be earthed through
resistance. The selected value of resistance should restrict the earth fault current below the
full load current of the largest drive/motor in the system. Time rating of neutral earthing
resistor shall be 10sec. Necessary provisions in the protection systems shall be made to
avoid adverse impact on sensitivity of protection relays. The works high and low voltage
earthing systems shall be inter connected.

1.15 Power failure

On simultaneous mains power failure on both the independent dedicated feeders, the
works shall shut-down to a safe-mode. On failure of one supply, the second supply shall
automatically supply the complete Works.

2.0 GENERAL REQUIREMENTS:

2.1 Scope

This part of the specification covers certain duties of the Contractor in connection with
the administration of the Contract; it includes also some of the general responsibilities of the
Contractor in carrying out work under the Contract, which are in addition to or in furtherance
of the requirements of the Conditions of Contract. The requirements of any clauses of this
specification herein, or compliance with the requirements of the Engineer, shall not limit any
of the Contractor's obligations or liabilities under the Contract.

2.2 Clause references

Except where stated to the contrary, references herein to Clauses are reference to
Clauses numbered in the Specification.

2.3 Issue of documents

The Contractor will be supplied with one copy of the Contact Documents for his own use.

2.4 Materials: general requirements and manufacturer’s experience

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 Contractor for incorporation in the Works. Except as may be otherwise specified for
particular parts of the Works in other volumes of the specification, the provision of the
standard specifications shall apply to materials general requirements 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. The Contractor shall as far as possible use
materials available in India for the completion of the Works, subject to compliance with the
specification. Materials shall be transported, handled and stored so as to prevent
deterioration, damage or contamination.

The Contractor shall procure pipes from reputed manufacturers with at least 3 years of
manufacturing experience and the respective ISI Certification. For pumps, mechanical and
electrical equipments, at least 10 years of manufacturing experience is required with the
respective ISI Certificate. Experience of collaborators, if any, for satisfying these criteria will
be acceptable, subject to documentary evidence.
2.5 Substances and products

Substances and products used in the Works which may be applied to or introduced into
water which is to be supplied for drinking, washing or cooking shall not contain any matter
which could impart taste, odour, colour or toxicity to the water or otherwise be objectionable
on health grounds. Only substances and products which have been approved by a national
or international regulatory body shall be used. After award of Contract, from time to time, the
Contractor shall submit for the approval of the Engineer a schedule of substances and
products he proposes to use in the Works giving the following information as applicable:

 Item of plant;
 Substance/product in contact with water;
 Manufacturer of plant/substance/product;
 Point of use in the Works;
 Name of the regulatory body, which has approved the substance/product;
 Date of approval (for use on water quality and on health grounds);
 Approval (with respect to water quality and health) reference number.

For all other products and substances to be used in the Works in such situations, the
Contractor shall at his own expense obtain the necessary approval and follow the procedure
set above and obtain the approval of the Engineer before use.

2.6 Plant to be safe in use

The Contractor shall ensure that the Plant is safe in use, and that any safety regulations
imposed by law or by any authorized body empowered to make such regulations are
complied with.

2.7 Design life

"Design life" means the period for which an item is designed to operate at full design
output without major overhaul involving extensive dismantling, serious corrosion or necessity
for substantial renewal of any anti corrosion system, reduction of efficiency in excess of 5%,
or replacement of major components essential to the functioning of the item etc except for
consumables and for any limited-life components explicitly agreed at the time of the Contract
award.

Minimum design lives shall be as follows;

(a) Roads, pipelines including associated pipe work -60years


and valves and other buried or built-in pipe work,
structures of concrete, brick or block work

(b) Structures of steel, exposed pipe work and valves - 30years

(c) Machinery including pumps, valve actuators, -20years


generating sets, transformers, switchgear,
cabling, air blowers, compressors, process plant,
electrical installations, building services, etc

(d) Computer systems - 5years

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All items and systems shall be designed to allow replacement or major overhaul at the end
of the design life without requiring major work or dismantling of other items and systems
which interrupt operation of independent items and systems.

3.0 STANDARDS:

3.1 Reference standards

The Works shall be carried out in accordance with the relevant quality standards, test
procedures or codes of practice, collectively referred to as Reference Standards, listed in the
relevant Part of the Specification. In many places, British Standards or other International
Standards are stipulated. During the submission of that works for the approval of the
Engineer, the Contractor shall also provide one copy of such Standard that the works is
conforming to for the use of the Engineer. The Contractor shall familiarise himself fully with
the requirements of such standards. Applicable Indian Standards may be offered. If no
standard is indicated then the relevant Indian or British Standard or, in the absence of such
standard, internationally recognised standard shall apply. Other national standards may be
considered provided that they are, in the opinion of the Engineer, no less exacting than the
corresponding standard quoted in the Specification. The Contractor shall demonstrate to the
Engineer that the alternative standard is suitable and equivalent to the specified standard,
and shall provide proof of previous successful use. The Engineer will decide whether or not
the use of such alternative will be permitted as a Reference Standard. When an alternative
standard is proposed, the Contractor shall supply the Engineer with a copy of that alternative
standard that the equipment is conforming to and also a copy of the standard as required to
be complied by the equipment in the specification, as part of that equipment submission for
the Engineer's approval.

3.2 Applicable issue

The applicable issue of any Reference Standard shall, unless otherwise stated in the
specification, be the issue current at the date three months preceding the date for
submission of the tenders for the Contract.

3.3 Abbreviations for Reference Standards

The following abbreviations where used in the Specification refer to standards, codes
of practice and other publications published by the organisations listed:

BS British Standards Institution


CP British Standards Institution (Code of Practice)
BIS /IS Bureau of Indian Standards
ISO International Organisation for Standardisation

4.0 CONTRACT ADMINISTRATION

4.1 Contractor's organisation and administration of the Contract

For the purposes of this Contract the term “Project Manager” shall be used instead of
the term "Contractor’s Representative". The Contractor shall submit to the Engineer a
diagram showing the structure of the organisation for his administration of the Contract. This
structure shall include a project managing organisation which may be part of the Contractor's
organisation, or an outside body which shall be named by the Contractor.

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The Project Manager and an assistant capable of deputising for the Project Manager,
both belonging to the Project Managing organisation shall be appointed.

The duties of the Project Manager shall include responsibility for programming, progressing
and co-coordinating:

• all of the Contractor's designs including those of his subcontractors;


• manufacture, erection, testing and commissioning of all plant;
• operation and maintenance of the plant for not less than 60 months after the
satisfactory completion of the final commissioning tests and trial operation;
• construction and testing of all civil works;
• production of Operation and Maintenance Manuals.

The Project Manager shall also be responsible for ensuring that all codes, standards
and any other technical requirements of the Contract are complied with by all sub
contractors. All correspondence and communication between the Engineer and the
Contractor shall be directed through the Project Manager. The structure diagram shall state
the names of the firms to be employed to carry out the following portions of the Works.

• Process plant;
• Mechanical plant;
• Electrical plant;
• Instrumentation, control and automation systems;
• IDMS, WMDs, AMS, RMS etc.
• Civil works;

The specialist firms and the specific engineers to perform the design of the process
plant, mechanical plant, electrical plant, the civil works and the instrumentation, control and
automation systems, IDMS, WMDs, AMS, RMS etc. shall possess, as a minimum, 10 years
of relevant experience in his specialist field for projects similar to the degree and nature of
work as this Contract. The Contractor has to submit relevant details of this specialist firms
and the specific engineers to the Engineer for approval prior to the commencement of any
design work.

Designs, drawings and documents that are required to be submitted to the Engineer for
approval shall be considered as bona fide by the Engineer only if they have been submitted
by the Project Manager. Prior to submission to the Engineer, the Project Manager shall have
reviewed the design, drawing or document. Each item submitted shall be stamped "checked
by Project Manager", dated, and shall be clearly identified as to its final location and
function.

4.2 Progress reports and meetings

Each month the Contractor shall submit to the Engineer three copies of a written detailed
progress report showing the stage reached in the execution of the Works. The report shall
show progress to the end of the preceding month with respect to the approved Contract
programme. The reports shall be accompanied by such additional information in approved
form as may be required by the Engineer.

The reports shall be forwarded promptly so that on receipt the content is not more than
seven days out of date. The report shall show all activities required by the Contract such as
design, drawings, procurement, manufacture, works tests, delivery, erection, testing and
commissioning, operation and maintenance of all items of plant. Delays shall be detailed by
the Contractor, with the proposed action to overcome it. The Engineer/Employer may call

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Meetings in his office, at the Contractor's office, or at the Site, to review the progress
of the Contract. The Contractor's Project Manager shall attend all such meetings.

In addition to the above, the Employer shall convene periodical meetings with Contractor /
Engineer for reviewing progress and for necessary co-ordination among Contractor(s) for
smooth construction implementation and maintain the time schedule.

4.3 Method statements

The Contractor shall prepare and submit to the Engineer detailed method statements for
aspects of his work which may affect the operations of the Employer, the activities of others
outside the site, the work of other contractors on the Site or other potentially hazardous
activities. The method statements shall be submitted for review by the Engineer at least 21
days before the work covered by the method statement is programmed to start. Aspects of
work for which method statements are required include:

• work which may affect access to the Works;


• work which may have an effect on the operation of any existing works;
• work which involves filling any part of the Works with water or passing water through
any part of the Works as part of testing, commissioning, and setting to work;
• work which involves any other aspect of the Contractor's operations, as may be
requested by the Engineer;
• any work which might in the opinion of the Engineer be potentially hazardous;
• Any work pertaining to the installation, testing and commissioning, operation and
maintenance for all equipments to supply under the Contract, which in the opinion of
the Engineer reckon there is a necessity to have a detail method statement.

Each method statement shall comprise a step-by-step schedule of specific operations and
activities with descriptions, dates, times and durations for each step. It shall highlight specific
points in the programme, and include contingency plans for emergency reinstatement of
plant including "point of no return" and "earliest start time" of modified or new plant. The
statement shall clearly state who and what organization will carry out work and precisely
when and what support or provisions are to be made by others outside the Contract. The
statement shall include all supportive detail to enable a clear understanding of the method
and significance of each step of the safely and in accordance with the specification.

4.4 Delivery and storage of plant

4.4.1 Packaging and marking

Upon the successful completion of the prescribed off-Site testing and inspection and
prior to dispatch from the place of manufacture, all items of plant shall be thoroughly
protected against corrosion and incidental damage from any cause. Packaging shall be
carried out to BS 1133 / relevant IS. Items intended to be painted shall receive the treatment
specified and all unpainted parts liable to corrosion (with the exception of the electrical
equipment) shall be thoroughly coated with high melting point grease or other approved
protective substance, which is easily removable. Electrical equipment shall be suitably
protected against corrosion and incidental damage to the satisfaction of the Engineer.
Temporary leads shall be fitted to electrical equipment to enable anti-condensation heaters to
be energised when the plant is in store. The heaters shall be energised by the Contractor
when conditions require. Items shall be packed to withstand rough handling in transit.
Packages shall be suitable for exposure to the atmosphere and storage in the open. The
Contractor shall be responsible for items reaching the destination undamaged. The
Contractor shall provide all necessary packing, cases and crates, properly strengthened.
Packages containing dangerous or breakable goods shall be packed and marked in
accordance with any statutory rules and orders applicable. Crates and packages shall be
correctly and adequately marked as follows;
• Employer's name;
• Title of scheme;
• Title of contract;
• Contractor's name;
• Designation site and item number matching approved schedules;
• Commercial markings;

The Contractor shall keep the Engineer informed of the state of deliveries. The
Contractor shall send copies of all shipping documents to the Employer and to the Engineer.
Shipping documents shall be accompanied by copies of test certificates as required.

4.4.2 Delivery

The Contractor shall be responsible for the safe delivery of items to the Site. Delivery
of items shall comprise any of the following, which may be necessary but not be limited to;

• Obtaining the necessary permits for all plant and equipment from relevant
Authorities;
• Loading and transporting items by whatever means, including insurances;
• Taking charge of items at the port of entry or rail or air terminal in India, including
payment of all handling charges, off-loading at terminal points, reloading and
transporting to the Site;
• Taking delivery of items at the Site, off-loading and temporarily storing in store
buildings or under cover until they are required for installation in the Works.

The Contractor shall examine items to the extent possible at the port or air or rail
terminal, and more thoroughly whilst taking delivery at the Site. If the Contractor discovers
that any item of Plant has been damaged in transit, he shall forthwith inform the Engineer
who will inspect and may give instructions for its disposal. Any item condemned by the
Engineer shall be immediately removed and replaced by the Contractor. Items with short
shelf-life shall be delivered in the shortest possible time before use with the Plant.

4.4.3 Storage

The Contractor shall provide all facilities for the safe storage of Plant as recommended
by the manufacturer. Stored items shall be laid out by the Contractor to facilitate their
retrieval as required. Stacked items shall be protected from damage. No metalwork shall be
stacked directly on the ground. Small items shall be held in suitable storage and shall be
clearly labeled. Items shall be handled and stored so that they are not subjected to
excessive stresses and their protective coatings are not damaged. The Contractor shall
comply with manufacturers' recommendations concerning the use of lifting arrangements.

4.5 Erection of Plant

4.5.1 General

The Contractor's site personnel shall include at least one approved skilled supervising
erector to supervise the erection of the Plant and enough skilled, semi-skilled and unskilled
labour to ensure completion of the Works in the time required. The Contractor shall not
remove any supervisory staff or skilled labour from the Site without the Engineer's approval.
The supervising erector shall mean the engineer in charge responsible to the Contractor for
completion of the erection, installation, setting to work, commissioning, operation
orMaintenance of the Works. Where different engineers are in charge of separate stages or
sections of work, the Contractor shall state their names and responsibilities to the Engineer
in writing.
Plant shall be erected in a neat and workman like manner on the foundations shown
on the approved drawings. The Contractor shall be responsible for setting-up and erecting
Plant to the line and level required and shall ensure that all equipment is securely held and
remains in correct alignment during grouting-in. This responsibility shall not be passed to any
other contractor. Where the Works are associated with are in physical contact with plant
supplied under a separate contract, the Contractor shall satisfy himself that the work carried
out by the other contractor is consistent with the correct operation of the plant. If the
Contractor considers any work being done, or any work completed, to be detrimental to the
plant, he shall report the matter at once to the Engineer. The Contractor shall make all holes
and openings in building structures required for fixing small plant items and shall provide any
associated supports. If any other openings or holes or additional loads applied to the
structures are found to be required, after approval of the drawings prepared by the
Contractor, their locations and sizes and method of cutting shall be submitted by the
Contractor to the Engineer for approval. Approval will be dependent on an assessment by
the Engineer on whether the structural integrity of the building will be compromised and
whether they will be detrimental to the appearance of the finished Works. If the Engineer
refuses permission for these reasons, the Contractor shall make fresh proposals, and shall
have no claim for delay. All additional holes or openings shall be cut by the Contractor at his
own expense.

4.5.2 Foundations

Foundations shall comply with the details shown on the approved drawings. Where
floors and plinths require to be cut away and prepared to accept foundation bolts or
mounting frames and plates, the approval of the Engineer shall be obtained before any work
begins.

4.5.3 Foundation bolts and fixings

The Contractor shall supply all anchor bolts, holding down bolts, fixing bolts, washers,
nuts, straps, supports, brackets, spacers and fixtures, which are needed for the satisfactory
installation of the Plant. All fixing anchors, nuts and washer shall be made of stainless steel.

4.5.4 Fixing to structures

No holes in concrete, brick, timber or structural steel work for fixing devices shall be
drilled without the prior approval of the Engineer. Holes shall preferably be made with a
rotary drill of the non-percussion type. A single-shot cartridge tool may be used only at the
discretion of the Engineer. Any damage caused by the Contractor to any surface during
erection shall be made good by the Contractor at his own expense to the satisfaction of the
Engineer. The Contractor shall be responsible for the provision of any scaffolding required
and the cost shall be deemed to be included in the Contract Price.

4.5.5 Plant protection on Site

Plant shall be adequately protected during and after installation against damage to
finished surfaces and fitted components and against ingress of dust, moisture and the
effects of humidity. Structural finishing operations may have to be done near installed plant
before it is taken-over and the Contractor shall take this into consideration in complying with
the requirements of this Clause. The cost of all protection shall be included in the Contract
Price.

4.5.6 Cleaning and preparing surfaces at Site


On arrival at the Site all Plant shall be examined by the Contractor and the Engineer
for damage to protective coatings. Damaged portions shall be cleaned down, all rust
removed by grit blasting, if instructed by the Engineer, and the coating made good with a
similar paint within four hours of surface preparation. After erection and building-in,
appropriate items of Plant shall be thoroughly cleaned to remove all debris and filled where
necessary.

4.5.7 Protective coatings applied at Site

The Contractor shall apply the protective coatings for the Plant at Site in accordance
with the protective treatment system approved by the Engineer. The first in-situ coat shall be
applied immediately the items of Plant have been erected and built-in. Painting of Plant shall
be completed not later than one month after the satisfaction completion of the trial operation
and prior to proceed to Operation and Maintenance period. Before the end of the Operation
and Maintenance period of the Works all damaged paintwork shall be touched up and the
cost of this shall be deemed to be included in the Contract Price. Where touching up is done,
the result shall be uniform in colour with the original paint. If uniformity of colour is not
achieved after touching up, to the Engineer’s satisfaction, then the entire item shall be re-
painted so that uniformity of colour is achieved. The cost of this work shall be deemed to be
included in the Contract Price.

4.5.8 Connection of electrical power

The Contractor shall check all items of electrical plant for correct phasing and
insulation resistance. Motors shall be dried out in accordance with the manufacturer's
instructions and checks on the insulation resistance shall be made at regular intervals.
Drying out shall continue until the insulation resistance reaches a steady value as
recommended by the manufacturer. After all drying out and checking of insulation resistance
is complete the Contractor shall check that all electrical connections to the plant are correct
and any errors shall be brought immediately to the notice of the Engineer. Electric power
shall only be applied to any plant item after the individual tests specified for the plant have
been done to the satisfaction of the Engineer.

5.0 HEALTH, SAFETY AND WELFARE

5.1 Applicable regulations, acts etc.

The Contractor shall comply with the relevant requirements of all local and the
national health, safety and welfare acts and regulations issued by the Ministry of Labour
(MOL). Compliance with the requirements of acts and regulations by the Contractor shall not
relieve the Contractor from responsibility for the safety of his workers and employees and
those of his sub contractors.

5.2 Failure to comply

In the event that the Contractor fails to comply with the requirements of the regulations
or with the Specification in respect of safe working conditions or practices on the Site, the
Engineer will have the authority to instruct the Contractor to stop work in any particular
location until the unsafe conditions or practices have been rectified to the satisfaction of the
Engineer. The Engineer will issue safety violation notices to the Contractor, informing him
that he is working unsafely and describing the nature of the unsafe working practice, the time
and date and the location. In this event, the Contractor shall be responsible for all costs and
delays resulting from complying with such instruction by the Engineer and for the actual
costs incurred on rectification of the unsafe conditions or practices.

5.3 Contractor's health, safety, welfare and security implementation plan


The Contractor shall prepare and submit to the Engineer for review a Site
implementation plan specific to health, safety, welfare and security practices of the work to
be carried out under the Contract. The Contractor shall carry out all work on the Site in
accordance with the agreed Site implementation plan. The Contractor’s plan shall reflect the
requirement of the local and national requirements. It will include a methodology for carrying
out risk assessments by the Contractor where these are deemed necessary. The plan will be
updated from time to time to reflect any significant changes to laws and regulations or site
activities.

5.4 Contractor's health, safety, welfare and security (HSWS) officer

The Contractor shall appoint a qualified and experienced HSWS officer for the
duration of the Contract. The full time duty of the officer will be to implement the site
implementation plan, to prevent accidents and enforce the requirements of legislation in
force. The name and qualifications of the officer so designated shall be submitted to the
Engineer by the Contractor for approval within two weeks of the commencement of the
Contract. The officer shall attend full time on site during normal working hours and whenever
work is in progress during out of hours working, public and national holidays approved by the
Engineer and available by phone and mobile during nonworking hours. The Contractor shall
engage senior site engineers and foremen that are properly trained in the application of
correct Health and Safety practices. These individuals shall liaise closely with the HSWS to
maintain safety on site at all times. The Contractor shall submit the details of the Health and
Safety qualifications of all such site personnel. The HSWS officer will be responsible for
ensuring all relevant information and posters are displayed at locations throughout the site in
accordance with the site implementation plan.

The HSWS officer will be responsible for keeping a site accident book to record all site
incidents or any major site rescue events. The book will be available for inspection by the
Engineer or any MOL authorised person. Record keeping must also be maintained to comply
with any other legal or regulatory requirements. The HSWS officer will be responsible for
ensuring that every site worker and regular visitor is given site HSWS procedure training
when they first enter the site and refresher training at an appropriate frequency agreed by
the Engineer. All occasional visitors will be trained on arrival and be provided with the
appropriate personal, protective equipment. Records of the training will be kept and available
for inspection by the Engineer.

5.5 Contractor's health, safety, welfare and security committee

The Contractor shall set up a safety committee comprising her full-time HSWS officer,
project manager, site engineers and foremen for the Contract. The committee shall meet
weekly and minutes shall be recorded and a copy shall be submitted to the Engineer. The
Engineer shall be invited to be present at the meetings. The purpose of the meetings will be
to discuss and resolve health, safety, welfare and security aspects of various parts of the
work, including possible areas of conflict or difficulty. Where different contractors are working
in the same area or adjacent areas, or where the work of one may impinge upon the work of
another, the meetings will consider what action needs to be taken to ensure that each
contractor is aware of the safety requirements of others.

5.6 Site health, safety, welfare and security coordinator

The Employer may oversee the health, safety, welfare and security arrangements of
the various contractors working on the Site, to liaise with the Engineer and to draw his
attention to any breaches of Contract requirements or the approved safety plans of the
Contractor.
5.7 First aid facilities
The Contractor shall provide a complete approved first aid kit in his site office. The kit
shall be in the charge of either the Contractor's HSWS Officer or some other responsible
person who will also be on the site during all working hours to ensure that the first aid kit is
available without delay. The Contractor shall also provide a first aid kit in the office for the
Engineer. Kits shall also be provided at all remote sites. The HSWS Officer and adequate
numbers of other senior members of the Contractor's staff shall be trained in occupational
site first aid duties including resuscitation to take account of numbers of site workers located
on the permanent site and mobile site operations.

The Contractor will make arrangements with the emergency and rescue services to
provide adequate support where on site first aid assistance is inadequate to meet the
welfare requirements of all site workers.

The Contractor shall comply fully with all rules and regulations from time to time
issued and orders given by the Health Service of the Government or the local medical or
sanitary authorities.

5.8 Overhead hazards

Overhead protection shall be provided at any location where there is a hazard of


falling objects. This shall particularly be observed around any scaffolding and in
excavations.
“Goalposts‟ shall be erected beneath all overhead lines to prevent the arms or jibs of plant
from approaching such lines. No plant shall be trafficked beneath overhead lines until the
Engineer has inspected and approved the erected goal posts.

5.9 Excavations or underground hazards

Every excavation or underground space into or through which a person may fall shall
be covered by a temporary cover fixed securely in position or guarded by an effective barrier
to prevent falls except where free access is required by work actually in progress. In such a
case where work is in progress, the barrier shall be maintained in position to the extent
possible, and suitable warning signs shall be erected.

5.10 Drowning hazards

Where the work involves filling tanks with water leaving an open surface, the
Contractor shall provide at all times and at suitable locations equipment for promptly
rescuing persons from the water and resuscitating rescued persons. The Contractor shall
take all necessary steps to prevent any such accidents occurring by providing adequate
guarding.

5.11 Slipping hazards

The Contractor shall not suffer or permit an employee to use a passage way, or a
scaffold, platform or other elevated working surface which is in a slippery condition. Oil,
grease, water and other substances causing slippery footing shall be removed, sanded or
covered to provide safe footing.

5.12 Tripping hazards

All passageways, platforms and other places of work shall be kept free from
accumulations of dirt and debris and from other obstructions that may cause tripping. Sharp
projections shall be removed or covered.
5.13 Access to workplace

Temporary stairways, ramps or runways shall be provided as the means of access to


working levels above or below ground except where the nature or progress of the work
prevents their installation, in which case ladders or other safe means shall be provided. The
Contractor shall not assume that access arrangements provided by the Employer will
necessarily remain in place after the time that the Contractor commences work in a
particular area.

5.14 Dust and gases

Dust and gases shall be controlled by ventilation or otherwise so as to prevent


concentrations tending to injure health or obstruct vision or from exceeding safe levels.

5.15 Hazardous and corrosive substances

All alkalis, acids, gases and other hazardous and corrosive substances shall be so
stored and used so as not to endanger employees in accordance with national and state
regulations. Suitable protective equipment for the use of such substances shall be provided.
Clean water supply shall be readily available for washing off any spillage of any corrosive
substance on the employees.

5.16 Eye and ear protection

Suitable eye protection equipment shall be provided for and shall be used by
employees while engaged in welding or cutting operations or in chipping, cutting or grinding
any material from which particles may fly, or while engaged in any other operation which
may endanger the eyes. The Contractor shall ensure that fully equipped eye washing
facilities are available on permanent and mobile site locations. Ear protectors shall be made
available for employees when operating noisy machinery.

5.17 Respiratory and resuscitation equipment

Where required the Contractor shall provide sufficient numbers of respiratory


equipment and the employee shall be trained to use respiratory equipment suitable for the
type of operation for which it is to be used. The Contractor shall maintain such respiratory
equipment in good condition and shall furnish the means for its continued efficient working
condition. The Contractor shall provide regular inspection, cleansing and sterilisation of such
equipment. Such equipment, when not in use, shall be stored in an accessible, closed
container. The respiratory equipment shall be either of the escape set type, where it is
provided for possible emergency use, or working sets where work has to be carried out in
conditions where toxic gases are present or where there may be a deficiency of oxygen
identified by the HSWS officer or his appointed staff when a risk assessment is undertaken
prior to a site operation commencing. Risk assessments will be available for inspection by
the Engineer immediately on request. All persons who may be required to use such
equipment shall be adequately trained and shall have certificates to that effect. Individual
certificates will be available for inspection from all authorised workers by the Engineer.

5.18 Work in confined spaces

Where work is required to take place in a confined space, defined as an enclosed


space or excavation with limited access and where there is no natural ventilation, the
Contractor shall provide equipment for monitoring the quality of the atmosphere within the
space. The equipment will be calibrated to occupational standards to measure the range of
gases and atmospheres identified as part of the risk assessment undertake prior to entry.
The equipment shall be used to check the atmosphere before personnel enter, and shall
remainin place while work is in progress to ensure that the confined space is free of harmful
or noxious gases. The Contractor shall not permit anyone to enter or work in a confined
space, including personnel from other contractors, the Engineer staff or the Employer's staff
if harmful or noxious gases are detected. Under such circumstances, any personnel inside
shall be evacuated immediately. Prior to the commencement of the work, the Contractor will
document a safe system of work which will be available for inspection by the Engineer.

All personnel working in such conditions shall be provided with escape sets. The
Contractor shall provide a "top-man" who shall be stationed immediately outside the
entrance to the confined space, and who shall maintain communication with personnel
working inside the confined space. In the event of a tranverse entry, this may require
additional personnel to be used to facilitate a reliable line of communication if evacuation has
to take place. The top man shall have the means to raise the alarm in case of any
emergency inside the confined space. The Contractor shall provide adequate ventilation for
workers carrying out work inside a confined space, pipeline or chamber or other enclosed
areas by using blowers or other suitable means.

5.19 Personal protective equipment (PPE)

Every site worker and visitor shall be provided with a full set of personal protective
equipment for use at all times including a luminous vest, helmet of a type tested and
approved by the MOL, steel toe-capped boots, gloves and other specific work related
clothing offering ear and eye protection. All site workers and visitors shall be required to
wear PPE while working on the Site, except in the Engineer’s and Contractor's office. The
Contractor shall display a notice on the access to the site stating that entry is for authorised
personnel only, and that PPE is to be worn at all times. Every employee required to work in
water, wet concrete or other wet footing shall be provided with suitable safety, waterproof
boots. Every employee required to use or handle alkaline, acid or other corrosive substances
shall be provided with appropriate PPE.

5.20 Electrical hazards

Before work commences, the Contractor shall ascertain by inquiry or direct


observation, or by instruments, where any part of an electric power circuit exposed or
concealed is so located that the performance of the work may bring any person, tool, or
machine into physical or electrical contact therewith. The Contractor shall post and maintain
proper warning signs to his employees of the location of such lines, the hazards involved
and the protective measures to be taken and shall, if practicable, de-energise the electric
power circuit.

The Contractor shall not suffer or permit an employee to work in such proximity to any part of
an electric power circuit that he may contact the same in the course of his work unless the
employee is protected against electric shock by de-energising the circuit and earthing it or by
guarding it, by effective insulation or other means acceptable to the Engineer. The location
of underground power lines that encroach on the Works shall be confirmed using cable
detectors, the path of the cable shall be clearly marked. If such cables are adjacent to
excavations, the cable location shall be confirmed by finding the cable using carefully
controlled hand-dig methods under the supervision of a senior member of the Contractor’s
staff. No live cables shall be retained within working trenches or other excavations. Any such
cables shall be diverted prior to excavation commencing. The Contractor shall at all times
liaise with the local electricity supplier with regard to the locating and diverting of any
supplies.
5.21 Power driven saws, abrasive wheels and grinders

All portable power-driven hand operated saws, abrasive wheels and grinders shall be
equipped with guards above the base plate which completely protects the operator from
contact with the saw blade when in motion and with self-adjusting guards below the base
plate which completely covers the saw to the depth of the teeth when the saw is removed
from the cut.

5.22 Public vehicular traffic

Whenever any work is being performed over, on, or in proximity to a highway or any
other place where public vehicular traffic may cause danger to men at work, the working
area shall be so barricaded as to direct traffic away from it or the traffic shall be specially
controlled by persons designated for that purpose.

5.23 Site traffic

All vehicles used at the worksite must be roadworthy and registered with the
appropriate authority. No person shall drive a vehicle at the worksite unless they are a holder
of the appropriate driving license or certificate. A site internal access management system
including all appropriate road signs will be submitted by the Contractor to the Engineer for
approval at the commencement of the Contract.

5.24 Stability of structures

No section of the plant or other structure or part of a structure shall be left unguarded in
such condition that it may fall, collapse or be weakened due to wind pressure or vibration.

5.25 Storage of materials and equipment

All materials shall be stored or stacked in a safe and orderly manner so as not to obstruct
any passageway or place of work. Material piles shall be stored or stacked in such a manner
as to ensure stability. Hazardous materials shall be stored in secure areas and the HSWS
shall maintain an up-to-date list of the persons with a key to those areas.

5.26 Disposal of debris

Debris shall be handled and disposed of by a method which will not endanger
persons. Debris shall not be allowed to accumulate so as to constitute hazard.

5.27 Excavations

No employee shall be permitted to enter any excavated area, including areas


excavated by other contractors on the Site, unless sheet piling, shoring or other safeguard
that may be necessary for his protection is provided. In most cases, excavations will be
considered to be confined spaces and the appropriate procedures followed. Where any
employee in an excavation is exposed to the hazard of falling or sliding material from any
bank or side more than 1.5 m high above his footing, adequate piling and bracing shall be
provided against the bank or side to eliminate such hazard. The excavation and its vicinity
shall be checked by a designated person after every rain, storm or other hazard-increasing
occurrence and the protection against slides and caveins increased if necessary. Shoring
adequate to support the overhanging material shall be provided where banks are undercut.

Excavated material and other superimposed loads shall be placed at least 1 m back
from the edge of open excavations and trenches and shall be so shored or retained that no
part Thereof can fall into the excavation, or cause the banks to slip or cause the upheaval of
the excavation bed. Banks shall be stripped of loose rock or other materials which may slide,
roll or fall upon persons below. Open sides of excavations where a person may fall more
than1.5 m shall be guarded by adequate barricades, and suitable warning signs shall be put
up at conspicuous positions. No employee shall be allowed to work where he may be struck
or endangered by an excavating machine with which his activity is not directly related.

5.28 Ladders, step ladders and access platforms

Every ladder, step-ladder and access platform shall be of good construction, sound material
and adequate strength for the purpose of which it is used. Ladders, stepladders and access
platforms shall not stand on loose bricks or other loose packing, but shall have a levelled
and firm footing. Ladders of over 2m in height shall be securely tied to the structure it is
propped against. Free-standing, portable ladders over 4m in height shall not be used.

5.29 Working at height

All site workers who work at height shall be provided with appropriate PPE to prevent an
accident by slipping or falling.

5.30 Positioning of machinery

No person shall be permitted to position or operate machinery in a manner likely to endanger


himself or others.

5.31 Fixed and mobile cranes

Fixed and mobile cranes shall be so constructed, positioned and operated as to be stable.
No crane shall be loaded beyond the safe working load except by an approved person or an
inspector for the purpose of testing such machine. Every crane including all blocks, shackles,
sheaves, wire ropes and the various devices on the mast and jib shall be thoroughly
inspected by an approved person at intervals not exceeding 12 months. Cranes shall be
inspected before being first erected or operated on each job or after any major repair.
Inspection and repair of crane jib shall be made only when the jib is lowered and adequately
supported. Outriggers and counter-weights shall be provided and used as specified by the
manufacturer of the crane or by an approved person. Counter-weights shall be properly
placed and secured. Leveling jacks or other suitable means shall be provided and used with
outriggers of truck-mounted mobile cranes.

Firm and uniform footing shall be provided for cranes. When such a footing is not otherwise
supplied it shall be provided by substantial timber, or other structural members sufficient to
distribute the load so as not to exceed the safe bearing capacity of the underlying material.

Every power-operated crane shall be provided with efficient brake or brakes or other locking
devices which will prevent the fall of the load when suspended and by which the load can be
effectively controlled whilst being lowered. Hand or foot-operated bakes shall be provided
with a substantial locking device to lock the brake in engagement.

No load-bearing part of any crane shall be replaced by another part, and no such machine
shall be modified by the addition thereto or removal there from of any load bearing part,
unless the replacement or modification shall be certified by either the manufacturer or the
approved person who tested the crane. A capacity chart shall be provided for every crane.
Such chart shall be posted and maintained in a place clearly visible to the operator and shall
set forth the safe loads for various lengths of jib at various jib angles and radial distances.
Where outriggers are provided such loads shall be set forth with and without the use
ofOutriggers. Unless furnished by the manufacturer or builder of the crane, a capacity chart
shall be prepared and certified by an approved person. Cranes shall have audible overload
warning alarms. A crane shall not lift any load that exceeds the corresponding safe working
load specified by its capacity chart. Every crane having a jib shall be provided with an
accurate indicator which shows, clearly to the operator, the radius of the jib and the safe
working load corresponding to that radius at all times and gives warning signal when the
radius is unsafe. Before hoisting any load at a new job site, the jib shall be operated to its
maximum height.

Crane cabs shall be locked when the operator is not present and no unauthorised
person shall enter the cab or remain immediately adjacent to any crane in operation. If
locking of a crane cab is impracticable, the operating mechanism shall be locked as to
prevent the crane from being operated by an unauthorised person. No crane shall be
operated in such a location that any part of the crane or of its load in any position of jib or
swing may come within 3 meters of live power line. All the lifting equipment used at site shall
be registered with the appropriate GOI Ministry and shall have a valid certificate at the time
of usage. All crane operatives should be authorised to operate the particular type of fixed or
mobile crane. Valid certificates will be available for inspection by the Engineer. All banks
men will be formally trained to undertake their duties and refresher training will be given at
an appropriate frequency agreed by the Engineer.

5.32 Attachment of loads

Where a sling is employed to hoist long-length material, a lifting beam shall be used to
space the sling legs for proper balance. When load is suspended at two or more points with
slings, the eyes of the lifting legs of the slings shall be shackled together and this shackle or
the eyes of the lifting legs may be shackled directly on the hoisting block or balance beam.
The eyes may be placed on the lifting hook without shackles if the hook is of the safety type.
Each container or receptacle used for raising or lowering filter media or other loose material
of any kind shall be so enclosed, constructed or designed as to prevent the accidental fall of
such material. Crane loads shall be raised vertically so as to avoid swinging during hoisting.
No crane shall travel with a suspended load except upon a safe runway. During travel
without loads, crane’s falls shall be secured or placed so as to prevent accident or damage
by swinging.

5.33 Access and trespass to adjoining property

If the Contractor's work will cause unavoidable interference with access to adjoining
property the Contractor shall first give seven days notice in writing to the occupier of such
property and shall provide temporary means of access for vehicles, animals and
pedestrians. In carrying out the Works due regard shall be paid to the amenities of adjacent
property and to the interests of owners, tenants and occupiers. The Contractor shall take
adequate steps to prevent trespass by his employees and shall be wholly responsible for
making good any loss or damage caused by such trespass. The Contractor shall take all
necessary steps to ensure that the activities of his employees (and those of his
subcontractors) do not have any detrimental effect on the surrounding environment.

5.34 Claims for damage to persons or property (procedure)

Any claim received by the Employer in respect of matters in which the Contractor is
required under the Contract to indemnify the Employer will be passed to the Contractor who
shall likewise inform the Employer of any such claim which is submitted directly to him by a
claimant. The Contractor shall do everything necessary, including notifying the insurers of
claims received, to ensure that all claims are settled properly and expeditiously and shall
keep the Employer informed as to the progress made towards settlement, failing which
theEmployer shall be entitled to make direct payment to claimants of all outstanding
amounts due to them in the Employer's opinion and without prejudice to any other method of
recovery to deduct by way of set-off the amounts so paid from sums due or which become
due from the Employer to the Contractor. If the Contractor receives a claim which he
considers to be in respect of matters for which he is to be indemnified by the Employer under
the Contract he shall immediately pass such claim to the Employer. All information as
aforesaid shall be given in writing and shall be copied to the Engineer's Representative.

5.35 Advertisements

The Contractor shall not except with the written authority of the Engineer exhibit or
permit to be exhibited on the Site any advertisement board. Any such advertisement may
also be subject to the approval of the local planning authority before it is put up and it shall
be removed if the Engineer so demands. Site sign boards shall be erected, typically of 3m x
2m, to bear the logos and text as specified by the Engineer. Costs shall be deemed to be
included in the site establishment items in the Price Schedules.

5.36 Site Welfare

5.36.1 Sanitation

The Contractor shall maintain the Site and all working areas in a hygienic condition
and in all matters of health and sanitation shall comply with the requirements of the local
requirements. The Contractor shall be responsible for providing all sanitary services
necessary to keep all offices and stores in a clean, neat and hygienic condition.

The Contractor shall provide all proper temporary sanitary facilities for the Contractor’s
employees and sub-contractor’s. The sanitary facilities provided within the Site shall be of
the portable type. The Contractor shall provide septic tanks as necessary for the disposal of
sewage. Waste water and septic-tank effluent shall discharge into properly designed French
drains. Where the construction of septic tanks or water-borne sewerage is not feasible, the
Contractor shall construct conservancy tanks and arrange for the removal and disposal of
sewage. All such arrangements shall meet all the requirements as stipulated by the relevant
local Health Authority and the Contractor's proposals shall be submitted to and approved by
the Engineer. In particular, the Contractor shall ensure that his employees (and those of his
subcontractors) only use the toilet facilities provided by him as part of his site establishment.
Any person found urinating or defecating elsewhere on the Site shall be removed from the
Site immediately, and shall not be re-employed on the Site.

The Contractor shall also provide for the removal and legal disposal off the Site of all
rubbish and solid waste from offices and other areas of the Site, with collections being made
at least twice weekly.

5.36.1a General hygiene and medical examination of Contractor’s employees.

Before commencing work on the Site, the Contractor shall ensure that all his
employees are instructed about the necessity for the prevention of pollution. The Contractor
shall immediately dismiss and remove from the Site any of his employees or representatives
who have been polluting or fouling the Site or any of the water supply installations and shall
take appropriate remedial measures to prevent a repetition of the occurrence and to disinfect
the areas concerned all to the satisfaction of the Engineer.During commissioning and
subsequent operations the Contractor shall not employ upon the Site, or on periodic visits
thereto, persons who are known to have any disease which could be water-borne or who is
suffering from an illness associated with looseness of thebowelsor who are carriers of
typhoid bacillus or other potential pathogenic organisms or who are otherwise unsuited on
medical grounds to be employed in or around water supply installations.

The Contractor shall if and when required to do so, arrange for his employees to be
examined and tested in the manner approved by the local medical officer.

The Contractor shall immediately remove from the Site any such employees who as a
result of such examination and testing may in the opinion of the medical officer or the
Engineer constitute a danger to water supplies or who refuse to undergo an examination.

5.36.2Environmental Monitoring Plan

The Contractor shall enforce an Environmental Monitoring Plan during the


construction period and at the 60 months operation and maintenance period, which shall
conform to the requirements as entered in relevant Appendix of this Specification. During the
construction period, the air quality, noise level, plantation conditions, borrow area
management at each site; the raw water quality, the eco-system, soil erosion condition at the
raw water intake shall be monitored. During the operation and maintenance period, the water
quality at the intake and the noise level at the potential noise generation plant, e.g. the
pumping stations, shall be monitored. The measurements stated above, both at the
construction and the operation and maintenance period, shall meet the minimum frequency
and duration as stated in said Appendix. However, under special situation, the Engineer’s
Representative has the discretion to take measurement records in higher frequency than
that stated in said Appendix.

The Contractor shall be responsible for environmental monitoring at the sites


notwithstanding of that, the Contractor shall be responsible for all the necessary rectification
work should any non-compliance of any parameter as entered in Appendix is recorded, and
the causes of such non-compliances are identified to be the responsibility of the Contractor.
The Contractor has to appoint a competent monitoring agency that shall possesses all the
necessary calibrated testing equipment to conduct the measurement as entered in
Appendix, with the presence of the Engineer’s Representative. The Contractor shall submit a
rolling time program to the Engineer and proposes the date and time for each of the
measurement record to be taken. After the time program being approved by the Engineer,
the Engineer’s Representative shall still be entitled to have the final discretion to rearrange
the actual day for the record to be taken to cope with the site activities that is to incur. The
record of the measurement shall be submitted by the Contractor to the Engineer within two
working days after the measurement is completed. Should any non-compliance be recorded,
the Contractor shall provide his remedial measures with this submission. Rectification work
has to be done immediately subsequent to the approval of the proposed remedial measures
by the Engineer.

6.0 PROGRAMME OF WORK:

6.1 Preparing the programme

In preparing the programme required to be furnished the Contractor shall take into
account any restrictions on possession of the Site or of Temporary Working Areas imposed
by the Contract. The Contractor shall also take account of the availability dates for the
different portions of the site.

The programme shall be in the form of a Critical Path Network, together with bar charts.
Particulars to be shown on the programme shall include:
• Submission of designs, drawings and documents
• Engineer's approval procedures/review procedures
• Re-submission of drawings etc as necessary and review
• Civil construction of each major structure
• Placing of orders for Plant
• Plant manufacture
• Plant tests at place of manufacture
• Plant deliveries to Site
• Plant erection
• Plant tests at Site
• Final commissioning tests
• Trial operation
• Plant operation and maintenance for 60 months

The programme shall make reasonable allowance for any work to be carried out by
other contractors employed by the Employer. The Time for Completion of the Works and
Sections thereof shall correspond to the periods prescribed in the Contract. Approval of the
Contractor's programme by the Engineer shall not relieve the Contractor of his duties and
responsibilities under the Contract.

The programme shall be updated monthly and when requested by the Engineer to
show actual progress and any revisions necessary to achieve completion.

6.2 Measurement for payment

All work to be done and goods and services to be provided by the Contractor under
the Contract and other general obligations of the Contractor shall be valued for payment as
per Schedule of Prices. The cost of any work, goods, services and general obligations as
aforesaid which are not so itemized shall be deemed to be included in the rates and prices
for other items in the Schedule of Prices.

6.3 Form of designs and documents

Designs and documents submitted by the Contractor to the Engineer for approval
shall comprise generally;

• Contents list;
• Scope (description of the contents and purpose of the submission);
• Conclusions and recommendations;
• References, Specification requirements, codes, manuals and supporting documents
used, drawing numbers, and titles of drawings which are based on the design;
• Description of design approach;
• Criteria, parameters and methods used;
• Test procedures, analyses and results;
• Calculations and schedules;
• Qualitative description and comments on results;
• Any other relevant information;
• Appendix.

Designs and documents shall be presented on A4 size paper with every page
numbered and bound in order between covers formed of a transparent front and stiff back.
The title of the submission shall be given on the front sheet beneath the transparent cover
together with a reference number, Employer's name, title of scheme, title of Contract,
Contractor's name, Consultant's name title of works location, author's reference, date,
Contractor's signature, revision box and space for Engineer's markings as for drawings and
any other relevantinformation. Drawings submitted as part of the design or document shall
be folded into pockets at the back.

6.4 Programme of submissions

In addition to showing the submission of designs, drawings and documents on his


programme for the works, the Contractor shall submit a specific programme for submitting
designs, drawings and documents to the Engineer for approval. The programme shall
provide for the Engineer's review of the Contractor's submissions to be undertaken at a
reasonably steady rate of working. The programme shall also make reasonable provision for
re-submission of not approved designs, drawings and documents and for the time needed to
transmit such designs, drawings and documents. No designs, drawings and documents will
be accepted by the Engineer for review until the programme for their submission has been
approved by him.

The Engineer may withdraw or modify his approval to an "Approved" design drawing
or document as a result of subsequent submissions. In this circumstance, he will inform the
Contractor in writing of the withdrawal or modification and, upon receipt of such information,
the Contractor shall immediately take the necessary action in regard to the Works and
confirm this to the Engineer in writing. Where appropriate and as agreed between the
Engineer and the Contractor drawings may be submitted in stages of development so as to
allow certain milestones to be achieved or certain elements of the work to be started; the
following stages are quoted by way of example and not as requirements to be met:

Stage1: Sufficient to allow preparation of foundations (floor slab and beams thickness
and levels agreed);

Stage2: Structural outlines shown (sufficient to permit ordering of materials and detail
up planning for building dates);

Stage 3: Structural outlines and details shown (sufficient to accommodate and fix all
plant and to allow building to proceed).The programme for submission of
designs, drawings and documents shall be based on the following general
order, which may need to be adjusted to fit particular circumstances;

• Topographical survey reports;


• Contoured site drawings;
• Site investigation reports;
• Outline design calculations;
• Hydraulic profile;
• Basic design criteria;
• Process and instrumentation drawings(P&IDs);
• General arrangement drawings;
• General civil works drawings;
• Structural designs;
• Structural drawings;
• Foundation drawings;
• Detailed mechanical equipment layouts
• Detailed electrical equipment layouts and drawings;
• Instrument schedules;
• Instrumentation, control and automation system design, documents and drawings;
• Detailed proposal for IDMS, WMDs, AMS, RMS etc. with drawings;
• Vendor data sheets and drawings for all the equipments and machinery;
• Substances and products schedules;
• Functional plans and functional design specifications;
• Fabrication and installation drawings;
• Detailed design calculations;
• General drawings for plant design;
• Plant drawings;
• Architectural drawings.

6.5 Copies for Approval

Drawings submitted for approval shall be submitted as four A1 paper copies, two A3
paper copies, and in electronic format. The Engineer may agree with the Contractor to waive
the requirement for A1 copies for certain submissions, for example where drawings are low
in detail.

In respect of returning drawings, the following shall apply: One A1 and one A3 original
shall be stamped accordingly, signed off and returned, balance A1 original and A3 original
shall be stamped as above, signed off, and retained by the Engineer.

The Contractor shall submit to the Engineer for approval four copies of all other
submissions. Only one copy generally will be returned to the Contractor.

6.6 Copies of Approved Contractor’s Documents

After approval, the Contractor shall submit to the Engineer two A1 copies, and two A3
copies, of all "Approved" drawings with the date of approval marked on the reproducible
against a new revision/issue of the document. The drawing shall also bear an electronic
watermark, or stamp, with the words “AS APPROVED”.

Four copies of all "Approved" designs and documents shall also be submitted.

6.7 Definition of working days for approval of submissions

In the context of time for approval by the Engineer of submissions by the Contractor,
and for no other, "working days" shall mean Monday to Saturday in each week, and shall
exclude any public holidays in Karnataka. The number of working days shall be counted
from the next working day following the day of delivery to the office of the Engineer until the
day before the day of dispatch from the office of the Engineer to the Contractor.

6.8 Working drawings

6.8.1 Hydraulic profile

Hydraulic profile drawings for the treatment works shall show top water levels for all
water retaining structures, chambers and channels from the inlet works to the treated water
storage tank for normal and peak inputs. The drawing shall be supported by detailed
calculations.

Hydraulic calculations shall also be produced for used wash water and clarifier sludge
treatment streams and the overflow system. All formulae and coefficients used with source
references and assumptions made in the calculations shall be detailed. The design shall be
in accordance with CPHEEO manual guidelines.

Detailed hydraulic calculations, drawings and hydraulic profiles shall be submitted for
intake well / channel, connecting pipes, intake structure cum pumping station, raw water /
Treated water transmission mains, intermediate sumps and pumping stations, gravity feeder
main network, MBRs / ZBTs etc.

The hydraulic profile and calculations shall be the first design submission to be made
by the Contractor for the Engineer's approval. Until the Engineer has given the approval to
the hydraulic profile, the Contractor shall not commence any construction work on the site.

6.8.2 Plant working drawings

Drawings for all items of plant constituting an operating system shall be submitted to
the Engineer concurrently and shall include diagrams showing circuit functioning and details
for erection.
Plant working drawings prepared by subcontractors and manufacturers employed by
the Contractor shall be checked by the Contractor for accuracy and compliance with the
Contract as specified, before being forwarded to the Engineer. Working drawings, not so
checked and noted, will be rejected and returned to the Contractor without further
examination.

Working drawings for chemical, process, mechanical, electrical, instrumentation and


similar plant shall include but not be limited to;

• Process and instrumentation drawings(P&IDs);


• Single line diagram for electrical distribution system from point of supply to final plant
connection;
• General arrangement drawings of the Works fully developed to show Plant layout
and dimensions;
• General arrangement drawings for all items of Plant, drawn to scale, fully
dimensioned and showing weights, foundation details and all clearances required for
installation, operation and maintenance;
• Fascia layout drawings of switchboards and instrumentation and control panels
showing controls, instrumentation, mimics and inscription details of all labels;
• Alarm annunciator layout and engraving details;
• Electrical block, circuit and wiring diagrams for switchboards and control boards;
• Supplementary block, circuit and wiring diagrams for integrated control, protection,
metering and other schemes as required for a complete understanding of the
Contractor's proposals;
• Instrument configuration loop drawings which shall identify each element and its
location, all wiring and cable connections, and all inputs to and outputs from
programmable devices. The drawings shall be prepared on A3 size sheets and
presented in book format;
• Block diagrams to show power, control and instrumentation cabling systems with
each cable, cable core and associated equipment terminals identified as in the cable
schedules;
• Installation drawings showing cable routes and cable support system details. For
cables installed in ducts and direct in the ground, the drawings shall include sections
to show their disposition and the position of all marker posts, cable joints and draw
pits;
• Cable schedules, which shall include the cable number, type, voltage, conductor
size, number of cores and route length;
• Cable termination schedules for all power, control, instrumentation and data cable
showing all details of the cable schedule and also incorporate cable core ferrule and
equipment terminal numbers and the diagram number(s) of connected equipment;
• Single line diagram showing the electrical system neutral earthing, earth terminal(s)
and electrode(s), and all circuit protective and equipotential bonding
conductors;Earthing installation layout showing conductor routes and the location of
earth terminal(s), test links, earth electrodes and associated connecting chambers;
• Earth terminal general arrangement;
• Lightning protection system installation drawings showing air termination details, the
location and route of down conductors, the location of bonds, test points and earth
electrodes, and the location of bonding points in reinforced concrete structures;
• Building services installation drawings showing the location of distribution boards,
luminaries, socket outlets, heaters, ventilation fans and ductwork, air conditioning
units, fire detectors and manual call points, intruder alarm switches and detectors,
alarm sounders etc, and associated switches, thermostats, control panels and
distribution board diagrams and/or schedules;
• Installation drawings for chemicals, waste, sludge disposal, water supply, and
sewage and waste water systems;
• Fabrication and installation drawings for metalwork including platforms, floor plates
and frames, hand railings etc;
• Diagrams showing flow paths and circuits, descriptions, dimensions and capacities of
water treatment process units, and piezometric levels corresponding to average and
maximum flow rates and to different or alternative treatment processes, accompanied
by proof of computations;
• Complete and detailed schedules listing all items of plant, instruments and ancillary
equipment to be supplied by the Contractor;
• List of safety signs and drawings;
• Any additional drawings required to supplement those identified above and for other
work not specifically identified;
• Control Room Layout shall include both plan and rendered perspective views of two
alternative control room layout options;
• Instrument Schedule shall list all instrumentation items (including actuated valves)
area by area in loop number order. For each instrument item the Instrument
Schedule shall as a minimum list the size, make, exact model, P&ID reference, range
and calibration, loop diagram reference, service description, and location drawing
reference;
• PLC / Control System I/O (Input / Output) Address Schedules & Field bus segment
assignment lists shall list all inputs and outputs to the PLC / control system. I/O shall
be listed in address order, and grouped into cards or module blocks if applicable. For
each address record, the tag number and service description of the connected
device, the I/O type (4-20 mA analogue input, 24 V DC digital outputs, field bus etc),
the loop diagram/field bus segmentation drawing reference and the P&ID reference
shall be listed. In the case of analogue parameters the corresponding range in
engineering units shall also be listed. Eg 4-20 mA = 0 –100 l/sec. Spare registers
assigned for analogue and digital signals and field bus data shall also be listed;
• Instrument Datasheets shall be supplied for each instrument, identified by instrument
tag number. The datasheet shall list all information required to replace and re-
commission the instrument in the event of damage or failure. This shall include the
final settings of all setup parameters stored in the instrument and process conditions
(pressure, temperature, flow and other applicable variables);
• ICA Panel Layout drawings for each different panel or junction box a detailed drawing
of both the internal and external layout shall be provided. Drawings showing the
internal layout shall clearly show how segregation of 230 V AC and 24 V DC wiring
has been achieved within the panel. Field connection boxes used solely to terminate
flying leads to cables shall not require layout drawings. In the case of multiple
identical junction boxes or field motor stop / start stations, a single typical panel
layout drawings shall be acceptable provided such drawings are clearly labeled as to
all the panels they describe;
• Panel Power Distribution drawings shall clearly show the distribution of power at
different voltage levels within each panel. Drawings should be specific
includingShowing which items are supplied from each fuse or MCB. The drawing
shall also show the instrument earth connection arrangements;
• Instrument Location drawings for all instruments (including control valves) shall show
the location (identified by tag number) of every instrument. The location drawings
shall also show the location of major equipment items and routing of main cable trays
and ducts. In plant areas where a field bus is being used, the instrument location
drawings shall show the field bus segmentation;
• Instrument Loop Diagrams showing all connections, cables, terminals etc for all
devices carrying the same loop number shall be provided for each loop connected
using conventional wiring. The instrument loop diagram shall provide all information
required to troubleshoot a loop i.e. a technician shall be able to trace the electrical
signal from field instrument through any junction boxes and signal isolators to the
input terminals of a controller, any power supplies shall also be shown. The
requirement for loop diagrams is not limited to closed-loop analogue control loops but
applies to all instruments and fold devices. These shall be A3 size drawings;
• Field bus Segment drawings shall be provided for each field bus segment. It shall
show the general segment topology and details of devices on that segment. In
addition it shall show design constraints such as segment and spur length, voltage
drop and current draw, loop execution requirements, and placement of power
supplies, power conditioners, and terminators;
• Instrument installation, wiring and piping hook-up drawings, where applicable, shall
be submitted. These shall be detailed in every respect;
• Logic Diagrams shall provide a detailed record of how the control system has been
configured. That is what sequences and operations the plant performs under both
normal and fault conditions the alarms shall be described in detail. These shall follow
or at least be similar to the SAMA (Scientific Apparatus Makers Association) format;
• Control System Overview Drawing shall depict the general structure of the control
system detailing the various components including detailing the contents of any
control equipment racks (processors, I/O modules etc), any communication links
between racks, operator interface stations (eg SCADA terminals, touch panels, alarm
annunciators). Any communications links shall be labeled as to their protocol and
parameters (eg baud rate, parity, stop bits);
• Control System Software Listing showing a full printout from the proprietary control
system programming tools shall be provided. This shall include but not be limited to a
listing of used and spare addresses, PLC program listing, report generation listing
and database listing. The electronic data files (ie. code and documentation
databases) necessary to maintain or modify the system configuration shall be
supplied with the as-built drawings;
• I/O Connection Diagrams for control system I/O connected to non-field devices (eg to
MCC.s), connection diagrams meeting the same requirements as Instrument Loop
Diagrams shall be provided.

6.9 Operation and maintenance manuals

The Contractor shall submit the operation and maintenance manuals for approval by
the Engineer. Submission to, and approval, subject to comments, by the Engineer of the
operation and maintenance manuals shall be a mandatory necessary condition precedent to
the allowance of the Contractor to proceed to "Operation and Maintenance Period", even the
Contractor has satisfactory completed the final commissioning tests and trial operation. Draft
operation and maintenance manuals shall be available for the Engineer’s use prior to the
start of the final commissioning tests.

The operation and maintenance manuals shall cover the setting to work,
commissioning, testing, operation and maintenance of the Works. The greatest importance is
attached to completeness and clarity of presentation. Its shall be` users friendly bearing in
mind theTraining and abilities of the Contractor’s and Employer’s personnel responsible for
operating and maintaining the Works at "Operation and Maintenance Period" and the time
there after respectively.

The preparation of the manuals shall be carried out by personnel who are trained and
experienced in the operation and maintenance of the Plant described and are skilled as
technical writers to the extent required to communicate essential data and are competent to
prepare the required drawings and documentation.

A collection of standard pamphlets of a general nature unaccompanied by drawings


and descriptive matter relating to items of plant as installed, will not be acceptable. In
particular, information supplied by sub-contractors and manufacturers employed by the
Contractor shall be co-ordinate into the comprehensive manual. Cross-referencing of
descriptive matter, drawings and spare part lists must be complete.

The manuals shall be in English, shall be securely bound, and pages shall be of A4
size to ISO 216 or folded to that size in a loose-leaf hardcover binder, using not more than
70% of the binder capacity.
The format of the manuals shall be white paper for typed pages with neatly typewritten
text except for manufacturers' printed data. Drawings shall be provided with a punched
reinforced binder tab for binding into the text. Drawings shall be so sized that they may be
folded to the size of the text pages.

All pages shall be clear, legible and permanent. Offset printing or multi lith is
preferable, but electrostatic or photocopies will be acceptable if clear and permanent.

Each volume of the manual shall be identified both on the front cover and on the
spine, with the typed or printed title "OPERATION AND MAINTENANCE INSTRUCTIONS",
the title of the project, including the Contract reference number, and the identity of the
general subject matter covered in the manual. The text and drawings shall be placed in
commercial 4-ring binders with durable and cleanable plastic covers. When multiple binders
are used, the instructions shall be correlated into related consistent groupings.

The front cover and spine of each volume, shall also bear the Employer’s logo, details
of which will be provided by the Engineer. The background colour for the cover shall be
proposed by the Contractor and agreed with the Engineer.

Each O&M manual volume shall contain a neatly typewritten table of contents
arranged in a systematic order giving: name of Contractor, address and telephone number, a
list of each item of Plant included, an index to the contents of the volume and a list of each
plant item with the name, address and telephone number of any sub-contractor or installer.
Only the manufacturer's printed data which is pertinent to the specific Plant shall be
included. Each sheet of manufacturers' instructions shall be annotated to identify clearly the
specific item or part installed and the instructions applicable to that item or part of the Plant.
All inapplicable information shall be deleted. Plant data shall be supplemented with drawings
as necessary to illustrate clearly component parts of equipment and systems, control
diagrams, flow diagrams, and test procedures covered in the manual. Written text shall be as
required to supplement the Plant data for that particular installation. Written text shall be
organised into a consistent format under separate headings for different procedures and in
a manner to provide a logical sequence of instructions for each procedure.

The operation and maintenance manuals shall describe the installation as a whole
and shall give a step-by-step procedure with assembly drawings for any operation likely to
be carried out during the life of each item of plant, including its erection,
commissioning, testing,Operation, maintenance, dismantling and repair. Manuals shall
identify and cover aspects liable to affect other installations and shall include all health and
safety precautions to be taken.

Maintenance instructions shall include charts showing lubrication, checking, testing


and replacement procedures to be carried out daily, weekly, monthly and longer intervals to
ensure trouble-free operation. Where applicable, fault location charts shall be included to
facilitate tracing the cause of malfunction or breakdown.

A separate section of the manuals shall be devoted to each size and type of
equipment and to each item of Plant. It shall contain a detailed description of its construction
and operation and shall include all relevant pamphlets, and a list of parts with the procedure
for ordering spares.

The detailed sections of the manual, if necessary, shall contain further maintenance
instructions and fault location charts. Subject to the foregoing, the manual shall generally
comply with the recommendations of BS 4884 parts 1 and 2.(Technical Manuals - Content
and Presentation) / relevant IS.

Any additions, alterations or deletions which may be required by the Engineer


following the experience gained during the periods of running and further maintenance shall
be incorporated in these copies in the form of additional or complete replacement pages and
the cost of these amendments shall be deemed to be included in the Contract Price.

The Contractor's attention is drawn to the need to ensure that the following items are
included in the operation and maintenance manuals;

• All health and safety instructions for chemicals and any precautionary measures
necessary for ensuring health and safety and avoidance of misuse;

• General description of the scope, purpose and manner of working of each system or
apparatus forming part of the Works, and the final functional design specification
(FDS);

• Schedule of equipment supplied giving manufacturers' name and appropriate make,


model/catalogue number, description of unit and component parts identified on
drawings;

• Maintenance procedures for regular maintenance and preventative maintenance,


including frequencies of routine operations, guide to fault diagnosis, fault finding
charts, step-by-step procedures for dismantling, cleaning, servicing, part replacement
and reassembling, including recommended clearances and tolerances;

• Maintenance procedures for the flushing of chemical tanks, pumps and dosing lines
and procedures for dealing with leakages and spillages including neutralisation;

• Schedule of spare parts with ordering reference numbers and parts identified on
equipment drawings;

• Schedule of tools;

• Schedule of changeover frequencies for duty/standby equipment;

• Sectional arrangement drawings of major items of plant with dismantling instructions;


• Plant layout drawings showing the "as erected “installation;

• P&I drawings for "as installed “processes;

• Schedules for "as installed “instrumentation;

• Electrical system single line diagrams;

• Electrical system protection grading characteristics and setting data;

• General arrangement and circuit diagrams for switchboards and control panels "as
installed";

• Diagrams of all "as installed" connections between electrical plant and


instrumentation systems;

• Operating procedures including step by step instructions for pre-start, starting up,
including start up following emergency shutdown, normal operation and normal and
emergency shutting down of the Plant;

• "Do's" and "Don’ts" in plant operation with attention drawn to all operations
considered to be hazardous to personnel or likely to damage plant;
• Data on general setting of controls associated with controlling design conditions,
monitoring instruments and switchgear, together with the details of initial settings of
all adjustable items;

• Test certificates for works and site tests carried out on plant, for site tests carried out
on pipe work, electrical and instrumentation installations and other items where
appropriate;

• Pump performance and calibration characteristics as tested and system


characteristics;

• Manufacturers' printed operating and maintenance instructions;

• Lubrication instructions including frequency of application and schedule of


recommended lubricants and their equivalents, which must be readily obtainable;

• Typical log sheets for recording plant operating information for each process and
chemical plant with instructions for identifying departures for normal behavior;

• Typical log sheets on which operating staff can record their service/maintenance
checks on essential equipment and at periods recommended by the Contractor;

• Instrumentation, control and automation equipment operating instructions for normal


procedures in a step by step format including flow charts, control operations,
requests for display or printing of data, performance monitoring, response to alarms
or failures, changing of operation parameters, and manual data entry;

• Description of the plant control philosophy (a layman's guide for operator assistants)
including plant trips and interlocks;

• A schedule of alarms, giving cause and action to be taken;


• Procedures for calibration of instruments, dosing pumps etc;

• Data sheets for process and chemical plant giving design parameters;

• Data sheets for pumps, compressors etc giving capacities.

All drawings incorporated in the manuals shall be presented in such a way that they
can be easily referred to whilst reading the associated description in the text.

The Contractor shall submit for the Engineer's approval, not less than one month in
advance of the time at which any item of Plant is delivered to Site, two copies of instructions
appropriate to the erecting, testing, operation and running maintenance of that item of Plant.
These instructions shall form a draft of the relevant parts of the operation and maintenance
manual.

Two complete draft copies of the manual for the Works shall be submitted to the
Engineer at least one month before the commencement of the final commissioning tests.
These copies may be the same copies as those submitted in sections in accordance with the
previous paragraph. In this case the Contractor shall check and certify that these two copies
are complete before the commencement of the trial operation.

The trial operation shall not be started if the complete draft manual has not been
submitted to the Engineer.

All copies of the manual shall be amended as necessary by the Contractor during the
period of testing, commissioning and setting to work of the Plant. Following this updating, the
Contractor shall check and certify that the copies of the amended manual are the final draft
of the manual.

The Engineer will review the final draft manual and advise the Contractor of any
changes required. This review will be completed by the Engineer within 35 working days of
the certification by the Contractor that the final draft manual is complete.

Final copies of the manual shall be submitted not later than three months after the
commencement of "Operation and Maintenance Period". The text of the manual shall also be
submitted on CD ROM disc.

If any further revisions are necessary as a result of operational experience during the
"Operation and Maintenance Period", all copies shall be revised by the Contractor within a
period of thirty days of the need for revision becoming apparent.

A third copy of the draft manual shall also be provided by the Contractor for use by the
operating staff during the period between the commencement of "Operation and
Maintenance Period" and receipt of the final manual. The manual shall be clearly marked
"draft". This copy shall also be amended as for the copies provided for the Engineer, and
may, after checking and certification of its correctness by the Contractor, form one of the
sets to be provided to the Board under the Contract.

Upon approval of the Draft O&M manuals, the Contractor shall submit six sets of the
final O&M manuals, two sets of CD ROM discs and pdf/html format to be loaded onto the
Workstations of the SCADA system.
6.10 Hazard and operability study

The Contractor shall carry out a hazard and operability study (HAZOP) in accordance
with the recommendations of Chapter 2 of "HAZOP and HAZAN, Notes on the Identification
and Assessment of Hazards" by Trevor A. Kletz, published by the UK Institution of Chemical
Engineers / Relevant Indian Standards. The study shall be applied to the process and
instrumentation diagrams produced under the Contract prior to the submission of the same
for approval.

The HAZOP study sessions shall be held at the Contractor's site office and shall be
attended by his Project Manager and the persons responsible for the design of the subject
matter. The Contractor shall appoint one of his team to act as secretary responsible for
recording, typing and issuing copies of the minutes to each person present at the meeting. A
representative of the Engineer will act as chairman.

6.11 Manufacturers' and Contractor's certificates

Where certificates are required by the Specification or relevant Reference Standard,


the original and one copy of each such certificate shall be provided by the Contractor, unless
otherwise specified. The original and copy certificates shall be submitted to the Engineer.

Certificates shall be clearly identified by serial or reference number where possible to


the material being certified and shall include information required by the relevant Reference
Standard or Specification clause.

Unless otherwise specified, the timing for submittal of certificates shall be as follows:

(a) Manufacturer's and supplier's test certificates shall be submitted as soon as the tests
have been completed and in any case not less than seven calendar days prior to the time
that the materials represented by such certificates are needed for incorporation into the
Permanent Works.
(b) Certificates of tests carried out during the installation of plant and equipment or on
completion of parts of the Permanent Works shall be submitted within 7 days of the
completion of the test.

7.0 INSPECTION AND TESTING OF PLANT DURING EXECUTION OF THE WORKS

7.1 Off-Site inspection and testing

7.1.1 General

The Contractor shall offer all items of Plant for inspection by the Engineer at all stages
of manufacture and shall include for the testing of all Plant as required by the Specification.
The Engineer/Employer/Third Party Inspection Agency may witness any test, at his sole
discretion.

The Contract Price shall include for the costs of all inspection and off-Site tests
including temporary assembly and subsequent dismantling, labour, materials,
instrumentation, chemicals and consumable items, provision of test certificates, certified
records and curves.

The off-Site tests shall normally be carried out at the manufacturer's works but if the
tests are beyond the resources of the manufacturer, the Contractor shall make
arrangements for tests to be carried out elsewhere. The off-site testing may be witnessed by
the Engineer or by inspectors appointed by the Employer. All travel and out of pocket
expenses, e.g. airTickets, accommodation, allowances, professional charges, etc. incurred
by the inspectors in attending any test will be paid by the Contractor and be reimbursed
under an item in the PROVISIONAL SUM. Details of Inspection Agency and the details of
agreement between Third Party Inspection Agency and the Employer will be notified to the
Contractor.

No Plant or materials for inclusion in the Works shall be dispatched from any
manufacturer's works without the written permission of the Engineer. Any Plant or materials
dispatched without permission shall be returned and tested in accordance with the
Specification at the Contractor's expense.

If during off-site testing, any Plant or materials fails to meet the requirements of the
Specification, the defects shall be rectified forthwith. The rectified item shall be offered for re-
inspection and witness testing, and all resulting additional costs incurred shall be borne by
the Contractor.

The Contractor shall carry out all applicable tests required by the Specification and the
Reference Standard, together with such tests as are necessary, in the opinion of the
Engineer to demonstrate that the Plant or materials comply with the Specification.

When the Contractor is ready to carry out any off-Site test, he shall submit a detailed
test procedure to the Engineer. The proposals shall give values, such as test parameters
and make reference to Reference Standards, any other standards and manufacturer's
literature. The proposed format for the test sheets shall be submitted at the same time. The
testing shall not start until the Contractor's proposals and test sheets have been approved by
the Engineer. After receiving approval, the Contractor shall notify the Engineer of the place
and time of the proposed tests giving not less than fifteen working days notice.

The Contractor shall carry out every off-Site test at the time and place notified. If the
Engineer does not attend any test, then the Contractor shall carry out the test in the absence
of the Engineer and the certified copies of the test results shall be deemed to be a correct
record. The Contractor shall provide the Engineer with three certified copies of the test
results within two weeks of completing the tests. Enough information, including the Contract
number and title, shall be given on each test certificate to enable the Engineer to check for
compliance with the Specification.

No inspection or approval by the Engineer of the Plant or materials covered by the


Contract shall release the Contractor from any of his obligations under the Contract.

Where items of Plant are of identical size and duty the Engineer may elect not to
witness all tests, but the Contractor shall assume that the performance tests on all items will
be done prior to offering any Plant for witnessed testing.

7.1.2 Calibration of instruments

All instruments used for testing purposes shall have been calibrated by an
independent accredited testing authority and shall have a valid calibration certificate.

The calibration validity period shall not be longer than 12 months. Instruments used
for tests at site shall have been calibrated not more than 3 months before the start of testing.

The Contractor shall provide the Engineer with three copies of calibration certificates
and correction graphs etc at the time of testing.

Any test instruments shall be recalibrated if requested by the Engineer.


7.1.3 Test procedure

The procedure and requirements for all tests off-Site on all Plant or materials shall be
in accordance with the requirements of the Specification and shall in addition be in
accordance with the requirements of the Reference Standards applicable to the item being
tested.

7.1.4 Guaranteed performance

The figures entered in the Schedule of Technical Particulars or stated in the Contract
for performance and efficiency shall be guaranteed by the Contractor in respect of the Plant
offered at the duties specified. These figures will be binding and may not be varied except
with the written approval of the Employer. No tolerances are permitted on these figures.
Testing to the relevant standards and to prove guarantees given will be required for all Plant
and materials and the complete Works.

7.1.5 Test records

For any test required by the Contract, the Contractor shall produce a written record, in
a form approved by the Engineer, certifying that the test has been completed. The
Contractor's representative at the test shall sign the test record. The tests witnessed by the
Engineer's Representative shall be certified by the Engineer's Representative on the same
test record.

7.1.6 Certificates

Certificates of test in triplicate shall be provided by the Contractor for all off-Site tests.
These shall incorporate all test results, calculations, performance graphs and curves and
shall be signed by representatives of the manufacturer, Contractor and Inspector. These
certificates shall be provided within two weeks after completing the test. Copies of all test
certificates shall be included in the operating and maintenance manual.

7.1.7 Notification
Following any inspection or testing of Plant or materials, the Engineer shall notify the
Contractor in writing either that:

• the item has passed the tests;

• the item on any part thereof is defective;

• the item is not in compliance with the Specification; or

• The item has not met guaranteed performance or efficiency requirements not in
compliance with the Specification.

The Engineer shall state the grounds on which the decision is based.

7.2 Site inspection and testing

7.2.1 Inspection

During erection of the Plant the Engineer will inspect the installation from time to time
in the presence of the Contractor to establish conformity with the Specification. Any
deviations found shall be corrected forthwith to the satisfaction of the Engineer.
As soon as the Engineer is satisfied that the erection of the Plant in an installation has
been completed and the Plant found to be in good working order and that the associated civil
works have been substantially completed to an extent permitting the proper operation of the
plant, the Contractor shall start testing at Site.

7.2.2 Testing –general

The scope of the “Test on Completion” at the Site shall be as follows;

• Individual tests (also called pre-commissioning tests) which shall be at the first
opportunity after installation of the Plant;

• Final commissioning tests which shall be on whole systems to demonstrate to the


Engineer that a section of the Works is ready to undergo trial operation;

• Trial operation.

Before any testing involving water entering supply, disinfection of all Plant items in
contact with water to be supplied shall be undertaken by the Contractor. The disinfection of
structure and pipe work shall be generally in accordance with relevant clause and subject to
the approval of the Engineer.

When water is discharged to waste, the Contractor may, subject to such conditions as
the Engineer and Employer may lay down, operate and adjust the Plant as necessary in
order to test the operation of the Plant. No water shall be put into supply except with the prior
authorisation of the Engineer and Employer and under such conditions as they may lay
down.

No part of the Plant shall be set to work until it has been inspected and accepted by the
Engineer.

7.2.3 Testing programme

The Contractor shall submit to the Engineer for his approval a programme for testing
up to the commencement of the trial operation, at least 28 days in advance of the proposed
start of testing and shall agree the timing with the Engineer and Employer not less than one
week before the start of testing.

The programme shall show the quantities of raw water, chemicals and power required.
Details of the proposed test procedures shall be submitted by the Contractor, including the
manner and order in which each item of Plant and process will be tested. Associated flow
rates and durations shall be submitted, and log sheets shall be prepared for recording plant
information and other operating, water quality parameters, and presentation and
interpretation of test data.

The programme shall be subject to approval by the Engineer and shall take into
consideration the extent of progress on other contracts, the availability of water, chemicals
and power, and the Employer's requirements for disinfection and discharges either to supply
or to waste.

The Contractor and any specialist sub-contractor shall be available to attend meetings
at the Site to discuss the testing programme, the test details and the test results.
7.2.4 Labour, materials, water, electricity and chemicals for tests

For individual tests, final commissioning tests and trial operation, the Contractor shall
provide all necessary labour, materials, chemicals, electricity, water, fuel, stores, apparatus,
instruments and indicators necessary to carry out the tests. If it is permitted by the Employer,
the Contractor may be allowed to use the permanent electricity supply registered under the
name of the Employer. However, the Employer has the final discretion to decide whether
such permission will be given. If the Employer permits the Contractor to do so, all electricity
tariff expense that is to incur to the Employer has to be reimbursed by the Contractor.
Electricity used for the tests shall be recorded on suitable meters provided by the Contractor,
which shall be read by the Engineer in the presence of the Contractor at appropriate times.
Electricity consumed as a result of testing activities shall be paid for by the Contractor. The
Engineer will from time to time deduct the cost of supplying electricity to the Contractor from
the Contractor’s monthly progress claims. The Contractor has to make arrangement for
water for carrying out all necessary tests.

During testing and trial operation of the Plant, until completion of the Works being
taken over by the Employer, the Contractor shall be responsible for all work, plant and costs
in connection with the commissioning and the trial operation of the Works.

All measuring instruments used for testing purposes shall comply with relevant clauses.

The Contractor shall prepare test record sheets for recording of all test results for the
approval of the Engineer at least one month before the programmed date for the tests. Three
copies of each approved sheet shall be provided to the Engineer not less than one week
before the start of testing.

7.2.5 Individual tests

Individual tests shall be in the presence of the Engineer and shall include the following;

• Leakage tests for structures and tanks;


• Leakage tests for pipe work.

Leakage tests shall be carried out on all pipe work. Where pipe work is to be built in,
these tests shall be carried out after erection and before concreting. The Contractor shall
ensure that the pipe work is suitably anchored and supported to sustain the pressure in the
not-built- in condition.

Pipelines and valves shall be pressure tested to one and a half times working
pressure unless otherwise specified.

Pipe work and valves through which oil or gas is to be conveyed shall be thoroughly
inspected then tested with the oil with which they are to be used or an inert gas and the
whole checked for leakage. Hydraulic tests using water shall NOT be applied to this pipe
work.

Tests on all items of Plant and materials in accordance with the requirements of the
Specification shall also be in accordance with the requirements of the Reference Standard
applicable to the item being tested.

• Electrical tests to demonstrate compliance of the electrical installation with specified


and statutory requirements;
• Operational test for all valves;
• Running test for all pumps, blowers, compressors, etc.;
• Noise and vibration levels measurements shall be carried out for all rotating
equipment.

7.2.6 Functional test of all protective devices.

All individual tests on items of plant or equipment making up a complete system shall
be completed to the satisfaction of the Engineer, before starting the final commissioning
tests on that system.

7.3 Final commissioning tests

The Contractor shall carry out such tests and retests on complete systems as are
required to demonstrate to the satisfaction of the Engineer that substantial portions of the
Works are ready to undergo the trial operation with a minimum of interruption in regular
operation.

The final commissioning tests shall demonstrate satisfactory performance of the items
of Plant under normal operation and their response to abnormal and emergency conditions.

Each process system shall be set to work under manual control and final
commissioning tests shall be carried out for such time as is agreed by the Engineer as being
appropriate. Subsequently the automatic control equipment shall be set to work and further
final commissioning tests shall be done.

The tests shall include simulation of the full ranges of alarm conditions over the full
ranges of operation and include tests of emergency shutdown procedures including
electricity power failure.

The period of final commissioning tests shall finish after the Plant has been
satisfactorily operated by the Contractor, as certified by the Engineer, for a continuous
period of fourteen days or for such extended period in excess of 14 days as may be required
by the Engineer to make up for interruptions in operation. However, the Contractor will not
be required to run the Plant under the provisions of this clause more than once for one
continuous fourteen day period.

The Contractor shall use the 14 day period to optimise the water treatment process.
During the 14 day period or after the trial operation as decided by the Engineer, the
Contractor shall demonstrate the hydraulic capacity of the works and overflows at the
maximum works through put with:

- all process units in service


- one clarifier out of service,

- two filters out of service,

- one compartment of contact tank out of service, and

- One compartment of treated water reservoir out of service.

- One thickener out of service.

During the hydraulic capacity tests, the Contractor shall measure water levels at various
points corresponding to the points where levels are identified on the approved hydraulic
profile drawing and shall also measure the free board at these points and at overflow points.

7.4 Trial operation

7.4.1 General

The Contractor shall start the trial operation when the following conditions have all been
completed:

• Final commissioning tests have been successfully completed;


• the Plant is ready;
• draft operating and maintenance manuals have been submitted; and
• The Contractor and Employer's operation and maintenance staff have received full
training as specified.

Trial operation shall be carried out on Sections of the Works and on the Works as a whole,
as appropriate.

In addition, certain tests to demonstrate compliance with guaranteed or specified


performance of particular items of Plant or parts of the Works shall be carried out
independently from the trial operation for the Works or Section of Works. Apart from the
results of the trial operation, these independent tests shall also be a condition precedent to
the allowance of the Contractor by the Engineer to proceed to the "Operation and
Maintenance Period" and the taking-over of completion of the Works by the Employer.

The trial operation shall demonstrate that the Works can fulfill all the mechanical,
electrical, instrumentation, control and automation and process requirements of the
Specification in the ambient conditions prevailing, using the raw water available at the time.

The Works shall be tested for performance for a continuous period of 30 days, of
which at least the last 15 days shall be uninterrupted by other tests. During the 30 days tests
the Works shall be operated at the maximum output for at least 15 days as instructed by the
Engineer. The object of the tests shall be to obtain a comprehensive set of data to show that
treatment performance meets the Specification and performance guarantees specified over
a range of flows within the design capacity limits. Following each flow change and after a
period of plant stabilisation all process and water quality parameters shall be measured and
recorded for comparison against the Specification and performance guarantees relating to;

• Works output;
• Clarified water quality;
• Filtered water quality;
• Treated water quality;
• Filter run duration;
• Clarifier sludge discharge;
• Filter wash water consumption;
• Thickener supernatant turbidity;
• Any other parameter.

During the 30 day performance trial period, the Contractor shall collect samples and
carry out analyses for the parameters listed in accordance with the sampling schedule at the
end of this section of the Specification.

Every sample taken shall be divided into three equal portions; one portion shall be
used for analysis by the Contractor's chemist, in accordance with the schedule. This analysis
shall be witnessed by the Employer's chemist. The second portion may be used by the
Employer for analysis at the discretion of the Employer. The third portion shall be retained as
a check sample. The sample volume shall be at least 3 liters.The Employer may, at its own
discretion, carry out additional sampling and tests at its own laboratories or accredited
laboratories as it deems necessary.

The methods to be used to analyse the listed parameters shall be as given in Standard
Methods for the Examination of Water and Wastewater; APHA-AWWA-WPCF, latest edition,
as follows;

Parameter Method Reference


Turbidity 2130-B
Colour 2120-C
PH 4500-H+B
Alkalinity 2320-B
Aluminium 3500-AlE
Iron 3500-FeD
Manganese 3500-MnD
Bacteriological quality 9222-B and D

Any deficiencies or deviations from the guaranteed or specified performance of plant


disclosed by the tests shall be corrected by the Contractor and tests shall be repeated as
necessary until acceptable results are achieved to the satisfaction of the Engineer.

These tests shall require provision of facilities and man-power, organisation and a
high degree of co-operation between the Contractor and the Employer and it shall be
deemed that this has been taken into account in the rates and sums entered in the
Schedules.

The Contractor shall be responsible for collecting and collating all data and test results
and shall carry out all necessary calculations to confirm compliance with the Specification
and Performance guarantees. A report comprising test data, results, calculations and
conclusions shall be submitted within one week of the date of completion of the tests, or set
of tests.

Satisfactory completion of the trial operation is a prerequisite for the Employer to


takeover completion of the Works and the allowance of the Contractor to commence the
"Operation and Maintenance Period".

The test procedures to be used for the trial operation during the specified periods shall
be as follows:

(a) Works output

The Works output shall be the difference between the clarified water flow and the filter
wash water flow. Clarified water flow shall be measured at the common clarifier outlet using
the flow meter in the pipe connecting the clarifiers and the filters totalised during the period
when the works is operated at the maximum flow. Filter wash water flow shall be measured
in the wash water outlet pipe from the wash water holding tank totalised during the period
when the works is operated at maximum flow.

(b) Water quality

Samples of clarified water, filtered water and treated water shall be taken at the specified
frequencies and tested by the methods listed in the Specification. Sampling at clarified water
and filtered water shall be separated by about two hours and that between filtered water and
treated water by about one hour to ensure that the same parcel of water is sampled in one
sampling event. The failure of one or more of water quality parameters in filtered water and
treated water shall be deemed to be a failure of the water quality test.
(c) Clarifier sludge discharge

Works input shall be monitored at the inlet flow meter to the works and shall be totalised
throughout the test. Losses due to clarifier Desludging shall be the works input less the
clarified water flow as defined above.

(d) Filter wash water consumption

The total quantity of wash water used during the test period measured at the wash water
flow meter divided by the total quantity of the Works input as defined above for the same
period, multiplied by 100 shall be not greater than the filter wash water consumption as
stated in the Schedule of Guarantees.

(e) Works chemical consumption

The chemical consumption on the plant to achieve the specified water quality guarantees
during the test period shall be not greater than the chemical consumptions stated in the
Schedule of Guarantees.

(f) Works energy consumption

The electrical energy consumption of the Works comprising raw water pumping plant,
treatment plant, treated water pumping plant and intermediate booster pumping stations over
the test period shall be evaluated on the basis of maximum demand and units used and shall
be divided by the volume of raw water treated over the same period. The electrical energy
consumption of the Works shall not be greater than the electrical energy consumption stated
in the Schedule of Guarantees.

7.4.2 Test failures

If the performance during the tests of the Works (or any parts thereof) fails to comply
with the Specification or with the Contractor's performance guarantees, the Contractor shall
submit his proposals for meeting the requirement of the Specification and the guarantees to
the Engineer for his approval and shall carry out at his own expense, whichever measures
may be necessary to achieve the specified requirements. Such measures may include
improvements, alterations or additions to the plant and/or civil works and the Contractor shall
bear the whole cost of such modification including any changes to the civil, electrical,
instrumentation or mechanical works. The tests shall be completely repeated and shall be
continued until the Engineer is satisfied that the requirements of the Specification and the
guarantees have been met. Failure of any item of equipment or part of the Works which is
tested for performance as a separate exercise during the final commissioning tests will
require the Contractor to repeat the complete final commissioning test, as specified. Failure
of any one or more of the tests which forms part of the overall Works trial operation will
require the Contractor to repeat the complete trial operation. The duration of repeat trial
operation shall be not less than 15days.

In case of repeated failure of the trial operation, the Contractor shall continue to make
adjustments to the Plant and repeat the tests until full compliance is reached, or until the
Employer, at its sole discretion, decides to accept the Plant, despite the failure of the final
commissioning tests or the trial operation. In this event the Contractor shall pay liquidated
damages as a result of failure to achieve the guaranteed values of chemical consumption
and electrical energy consumption and delay damages to the Employer, in the amount as
guaranteed by the Contractor in the Schedule of Technical Particulars.
Sampling Schedule

Parameters Minimum sampling freq/24hrs


Raw water
Turbidity Every six hours
Colour (true) Every six hours
Iron Every six hours
pH Every six hours
Conductivity Every six hours
Alkalinity Every six hours
Manganese Every twenty four hours
Total coliforms Every twenty four hours
Aerated water (where applicable)
Iron Every four hours
pH Every four hours
Alkalinity Every four hours
Clarified water
Turbidity Every one hour
Aluminium Every four hours
pH Every four hours
Alkalinity Every four hours
Filtered water
Turbidity Every two hours
Aluminium Every four hours
Iron Every four hours
Treated water
Turbidity Every two hours
Colour Every eight hours
pH Every two hours
PHs Every twelve hours
Aluminium Every eight hours
Iron Every eight hours
Manganese Every twenty four hours
Bacteriological quality Every twenty four hours
Thickener supernatant
Turbidity Every twelve hours

7.5 Cleaning and sterilisation of structures

The greatest care shall be taken to ensure that all process unit tanks are kept free from
contamination.

In addition the following structures shall be sterilised in accordance with the procedure
set out below;

• Pipes, channels and mixers from filter outlets to treated water reservoir;
• Contact tank and treated water reservoir;
• Pipe feed to treated water pumping station;
• Treated water pumping station pipe work;
• Treated water surge vessels (where applicable);
• Treated water pumping main connecting to MBRs /ZBTs;
• MBRs /ZBTs;
• Pipe main connecting the MBRs / ZBTs to OHTs;
• Existing / proposed OHTs in each village /habitation;The Contractor shall subject all
workmen who will be engaged in sterilising structures to a medical examination by a doctor
Approved by the Employer. Only workmen considered fit by the examining doctor shall be
permitted to enter the structure for carrying out any work associated with the sterilisation
procedure. The Contractor shall keep a separate register of all such labour and shall forward
a copy to the Engineer prior to commencing such work. The Contractor shall maintain strict
supervision over all workmen entering the tanks. The Contractor shall provide rubber boots
and means for the workmen to wash their boots clean and sterilise them before entering the
structure.

The Contractor's sterilisation procedure shall strictly adhere to as set out in relevant IS /
International Standards. The Employer will carry out the necessary sampling in the
presence of the Contractor, and the subsequent physical and bacteriological analysis. The
Engineer will advise the Contractor of the results. Should the tests fail the procedure shall be
repeated as many times as may be necessary to achieve satisfactory results.

The Contractor shall make all arrangements necessary for conveying the water from the
source to the point of filling and such arrangements shall be subject to the approval of the
Engineer. The Contractor shall provide all hoses, pumps and other equipment necessary to
carry out the tests. The Contractor shall also provide all water and chemicals necessary to
sterilise structures, which shall be of a type and from a source Approved by the Engineer.

The Contractor shall note that these structures are Confined Spaces as defined in the
Specification and that during the sterilisation process the levels of chemical in the
atmosphere may exceed acceptable occupational exposure limits. The work shall be subject
to the specified requirements for entry and working in Confined Spaces, and the Contractor
shall provide all necessary trained personnel and equipment as specified.

8.0 TESTING OF PLANT

8.1 General

The requirements for testing shall be as specified below.

8.2 Pumps, valves and pipe work and general purpose machinery

8.2.1 Off-site inspection and testing

(a) Pumps

Pumps shall be individually tested in accordance with relevant IS standards and the tests
shall be with clean water. Site conditions shall be simulated as nearby as possible including
the NPSH condition. Pumps shall be tested with their own prime movers. Where it is
impracticable to include the full length of the connecting shaft, the Contractor shall state the
allowances to be made for the losses incurred by its omission and shall demonstrate the
accuracy of the allowances to the satisfaction of the Engineer.

Pumps shall be tested at the guaranteed duty point and over the full working range from the
closed valve condition to 20 percent in excess of the quantity when a single pump runs alone
at minimum head. The tests shall provide information for performance curves to be drawn for
head/quantity, efficiency/quantity, power absorbed/quantity and net positive suction head /
quantity. Readings shall be taken at a minimum of seven points in addition to shut-off
condition. Each pump shall also be run at its duty point for at least 30 minutes.
Positive displacement pumps shall be tested in accordance with relevant IS.
For eccentric helical rotor pumps the tests shall provide information for performance
curves to be drawn for pump speed/flow, input power absorbed/flow differential
pressure/flow and pump efficiency/flow.

Pump casings shall be subject to a pressure test at 1.5 times the pressure obtained
with the delivery valve closed. The positive suction head when installed shall be taken into
account in determining this pressure. During the test, the casing and joints shall show no
signs of leakage, distortion or defect.

In addition to confirming the specified hydraulic performance of the pump set, the test
shall demonstrate that vibration is within the specified limits, the mechanical performance is
satisfactory and the noise level is within the specified limit.

Additionally chemical dosing pumps shall be tested in accordance with API standard 675
and the specified flow linearity, steady state accuracy and flow rate shall be demonstrated.

(b) Valves and Penstocks –General

Valves and penstocks specified as operated by actuators shall be tested with their own
actuator. For valves and penstocks fitted with power operated mechanisms, the test shall be
carried out to demonstrate correct manual and power operation.

(c) Gate valves

Gate valves shall be tested in accordance with BS EN 1171 or BS 5163 and BS 6755 Part 1
as relevant / relevant IS. Whichever applies, valve seat tests shall be made under open-end
conditions, the test pressure being applied to each face of the valve in turn.

(d) Butterfly valves

Butterfly valves shall be tested in accordance with BS EN 593 and BS 6755 Part 1 / relevant
IS. The seat test shall be for tight shut-off and low leakage. Valves shall be tested under
maximum unbalanced water test pressure in either direction.

(e) Air valves

Air valves shall be water tested for drop-tightness at all pressures from 0.2 bars in steps of 2
bars up to the specified pressure. The valve body shall be water tested at 1.5 times the
specified pressure, at which pressure no damage or permanent deformation of the valve
body, ball or seat shall occur.

Two valves of each type and size incorporating large orifices shall be tested for exhaust of
air at a differential pressure up to 1 bar in steps of 0.1 bar and for inflow of air at a differential
pressure up to 0.5 bars in steps of 0.1 bar. During the tests the air flow rates shall be
measured by orifice plates in accordance with BS 1042 / relevant IS. Pressures (positive or
vacuum) shall be measured by Bourdon tube gauges or by mercury-in-glass manometers.
The temperature of the flowing air shall be measured in accordance with relevant parts of BS
1041 / relevant IS. The barometric pressure shall also be measured.

If the manufacturer provides results of independently witnessed air flow tests similar to
those specified and these are accepted by the Engineer, the specified airflow tests shall be
deemed to be completed.
(f) Check valves

Check valves shall be tested in accordance with the requirements of BS EN 12334 and
BS 6755 Part 1 / relevant IS.

(g) Pressure and flow control valves

Pressure and flow control valves shall be tested hydrostatically as follows;

Body strength: closed-end test, valve open, test pressure 1.5 times working pressure;

Valve element strength: open-end test, valve closed, test pressure of 1.5 times working
pressure applied to each end;

Leak tightness: open-end test, valve closed, test pressure of the working pressure applied to
inlet end, no visible leakage permitted.

(h) Ball float valves

Ball float valves shall be tested hydrostatically in the closed position and a pressure of
1.5 times the working pressure applied to the inlet end.

Valves shall be tested for drop-tightness at the working pressure.

(i) Plug valves

Plug valves shall be subject to hydrostatic shell and seat tests in accordance with BS
5158 and BS 6755 Part 1 / relevant IS.

(j) Diaphragm valves

Diaphragm valves shall be tested in accordance with BS EN 13397 and BS 6755 Part 1 /
relevant IS.

(k) Ball valves

Ball valves shall be tested in accordance with BS 5159 and BS 6755 Part 1 / relevant IS.

(l) Globe valves

Globe valves shall be tested in accordance with BS EN 13789 and BS 6755 Part 1 / relevant
IS.

Seating shall be tested hydrostatically at 2400 kN/m2 and the valve shall be tested for 1500
kN/m2 working pressure.

(m) Penstocks

Penstocks shall be operated from fully closed to fully open positions to verify correct
operation.

Penstocks shall be tested in accordance with BS 7775 and AWWA C501 as relevant /
relevant IS.
(n) Electric actuators

Electric actuators shall be tested in accordance with the Reference Standards.

Compliance with the specified functional and performance criteria shall be demonstrated.

(o) Pneumatic actuators

Pneumatic actuators shall be tested in accordance with the Reference Standards.

Compliance with the specified functional and performance criteria shall be demonstrated.

(p) Pipe work

Pipe work shall be tested in accordance with the appropriate Reference Standards.

(q) Castings

Castings shall be tested hydrostatically to 1.5 times the maximum working pressure for a
minimum period of 1 hour.

(r) Surge vessels

Surge vessels shall be tested in accordance with the Reference Standards.

(s) Cranes

Cranes shall be completely assembled and tested for all operations in accordance with
BS 466 / relevant IS. All slings, ropes, shackles and other lifting equipment shall be tested at
1.25 x their Safe Working Load.

(t) Weighers

All weighing equipment shall be tested for accuracy with standard weights and shall be load
tested at 1.25 times the safe working load.

(u) Automatic in-line strainers

Automatic in-line strainers shall be tested in accordance with the Reference Standards and
with manufacturer's own requirements.

(v) Air supply plant

Tests shall be carried out on all items of plant, vessels, pipe work and valves to
demonstrate compliance with the criteria specified and with relevant standards. Unless
otherwise specified the tests shall be in accordance with the Reference Standards including
BS 6754 for dryers, BS 6759 Part 2 for safety valves, BS 1123 Part 1 for fusible plugs, BS
3274 for after coolers, BS 5169 for air receivers, BS 1571 for compressors and BS 5500 for
pressure vessels and the manufacturer's own procedures / relevant IS.

Noise level of all the compressors and blowers shall be tested and shall not exceed the
specified limit.

For package units.functional tests of the fully assembled system shall be carried out to
demonstrate correct operation with respect to sequence and pressure.
8.2.2 Individual tests

The following Site inspections and tests shall be carried out as appropriate:

(a) Inspection to check the assembly of the Plant and conformity with the Specification
and consented drawings;
(b) Rotational checking of all electric motors;
(c) Hydrostatic testing of all gravity flow pipe work systems and penstocks at the
maximum head or differential head that can occur in service. Leakage from
penstocks shall be measured and recorded but shall not exceed the maximum value
stated in the AWWA C501 or BS 7775 or otherwise required for safe operation /
relevant IS;
(d) Hydrostatic testing of all pressurised pipe work systems at 1.5 x maximum working
pressure for a period of at least one hour; during this time the pressure shall not
change;
(e) Functional testing of each pump, compressor and blower to prove correct operation,
absence of fluid leaks, correct bearing temperatures and absence of undue vibration
and noise for a period of not less than four hours;
(f) Functional testing of auxiliary items including automatic in-line strainers and valve
actuators;
(g) Functional testing of valves to demonstrate correct orientation and operation;
(h) Overhead cranes and slings, ropes, shackles and other lifting equipment shall be
tested with a load of 1.25 x Safe Working Load and results recorded in accordance
with the Reference Standards. Additionally each complete system shall be tested for
all functions including overload safety device;
(i) All weighers shall be tested with standard weights for accuracy and shall be load
tested at 1.25 x the Safe Working Load;
(j) The following tests shall be carried out on the installed air supply systems:

• The air pipe work system shall be tested for 1 hour at 1.5 x maximum working
pressure using dry air or nitrogen;
• Pressure safety valve operation shall be demonstrated;
• Performance tests shall be carried out on all machinery, coolers and dryers
for a minimum period of 48 hours with air demand simulated by purging at
measured rates downstream of all plant subject to testing; the purging rates
shall correspond to zero demand, maximum demand and at least one
intermediate value.
• The tests shall prove correct operation, absence of fluid leaks, correct
operating pressures, temperatures and dew point and absence of excessive
vibration and noise with due regard to any containment and attenuation
provisions.

8.3 Mixers, flocculators and scrapers

8.3.1 Off-site inspection and testing

The complete mixer, flocculator and scraper system shall be checked for accuracy of
dimensions against construction drawings and all welds inspected.

8.3.2 Individual tests

The following Site inspections and tests shall be carried out as appropriate:

(a) Inspection to check the assembly of the plant and conformity with the Specification
and approved drawings;
(b) Rotational checking of all electric motors;
(c) Tip speed and flight speed, as applicable;
(d) Rotation speed;
(e) Functional testing of the mixers, flocculators and scrapers;
(f) Scraper torque overload protection device;
(g) Head loss across static mixers at maximum works throughput.

8.3.3 Final commissioning tests

The testing shall incorporate the following requirements.

The performance of the static mixers shall be tested for compliance over a 30 minutes
period by dosing the chemical corresponding to each mixer at the specified doses and
concentrations. Alternatively a solution of sodium chloride shall be injected continuously at a
fixed dose in the range 10 to 20 mg/l or a fluoride solution at 1.0 mg/l as F. The injection
velocity shall not be greater than that applicable to the specified chemical dosing. The mixer
performance shall be determined by measuring either the conductivity or the chloride or the
fluoride ion concentration. The background conductivity value or chloride or fluoride ion
concentration shall be monitored during the test. The water shall be sampled continuously at
the prescribed sampling points from at least four different positions along a diameter of the
pipe using a sampling system specially designed for the purpose.

8.4 Filters

8.4.1 Off-site inspection and testing

Upon preliminary approval of sources of filter material supply and within two months of
the award of Contract, the Contractor shall submit to the Engineer a 10 kg of representative
sample of each filter material for testing and approval as specified.

Filter material (sand and gravel) shall be tested by the Contractor before dispatch from
source in accordance with the following schedule. Certificates for all tests shall be delivered
to the Engineer for approval or rejection before the material is dispatched.

(a) For a volume equivalent to the volume in each filter Grading curve, effective size and
uniformity coefficient.
(b) Additionally for a volume equivalent to the volume in 2 filters Specific gravity and
losses of weight on acid washing and ignition.
(c) Additionally every 500 m3 or every batch, whichever is the smaller Loss due to
abrasion.

A method of identification shall be employed to enable test certificates to be related to


shipments of media delivered to Site.

8.4.2 Individual tests

The following Site inspections and tests shall be carried out as appropriate:

(a) On delivery to Site, one kg of filter material shall be taken from a selection of bags
until 12 kg is obtained. The samples shall then be mixed and quartered before testing
as follows;

(i) Gravel: a sample shall be taken from each delivery to Site as described
above and graded. Samples shall be examined to ensure they are similar to
the initial 10kg sample.
(ii) Sand: samples shall be taken from each delivery to Site as described above.

Tests shall include a sieve analysis and preparation of grading curves, and shall give
effective size, uniformity coefficient and specific gravity. A visual inspection shall also
be carried out to ensure it is similar to the initial 10 kg sample.

In addition to the above tests, certificates for each load equal to one filter volume
shall include tests to determine loss on acid washing and ignition as applicable to the
filter material.

(b) Inspection to check the assembly of plant and conformity with the Specification and
approved drawings;

(c) Pumps and valves shall be tested as specified;

(d) Functional testing of each air blower for correct operations, absence of fluid leaks,
correct bearing and gearbox temperature and absence of undue noise and vibration;

(e) Relief valve operation and blower unloading device shall be demonstrated.

8.4.3 Final commissioning tests

Testing shall incorporate the following requirements:

(a) Filter under drain

Filters shall be tested as follows before any filter material is placed and additionally, in the
case of pipes lateral system before placing concrete on the pipes;

(i) Air distribution test

The empty filter bed shall be filled with water to a level 150mm above the top of the nozzles.
Air shall then be passed into the under drain system at such a rate that the system can be
seen to pass air thorough the nozzles over the whole filter area. Any discrepancies in
distribution shall be rectified and the test repeated.

(ii) Pressure test wit water

All the nozzle outlets shall be plugged. The filter under drain system shall then be filled with
water and a pressure of (a-b+c) applied to the underside of the filter floor or to the piped
lateral system as applicable where:

a = twice the normal peak pressure during a combined air and water filter wash, or separate
air and water filter wash as applicable to the design, measured under the filter floor or in the
filter laterals;

b = the downwards pressure on the floor due to the weight of media and water which would
be present during air scouring;

c = the pressure due to any water present in the filter above the floor during the test.

Any pressure relief pipe on the wash water supply pipe work shall be blanked off during this
test. The test pressure shall be maintained for one hour. Any leaks detected shall be
corrected and the test repeated.
After placing the material in the filters and backwashing to remove fines the Contractor
shall take samples of the material from each filter and carry out sieve analysis and the
results along with grading curves shall be submitted to the Engineer for approval. Only when
the Engineer has given approval to the samples, shall the Contractor bring the filters into
service.

(b) Manual and automatic backwashing sequence shall be demonstrated

The sampling of sand in the individual filters shall be repeated in the twelfth month of the
Defects Notification Period for compliance with the Specification. The results shall be
submitted to the Engineer for approval.

8.5 Aluminium sulphate plant

8.5.1 Off-site inspection and testing

Tests shall be carried out on all items of plant, vessels, pipe work and valves to
demonstrate compliance with the criteria specified and with relevant standards and tests
specified. Unless otherwise specified, the tests shall be in accordance with the Reference
Standards and the manufacturers' own procedures.

8.5.2 Individual tests

The following Site inspections and tests shall be carried out as appropriate;

• Inspection to check the assembly of the plant and conformity with the Specification
and approved drawings;
• Rotational checking of all electric motors;
• Functional testing of all auxiliary items including mixers;
• All tanks shall be filled to overflow level and inspected for absence of leaks;
• Hydrostatic testing of all pipe work systems at 1.5 x maximum working pressure for a
period of at least one hour; during this time the pressure shall not change;
• Relief valve operating pressure shall be demonstrated;
• Functional testing of each pump to prove correct operation, absence of fluid leaks,
correct gearing and gearbox temperatures and absence of undue vibration and
noise.

8.5.3 Final commissioning tests

Testing shall incorporate the following requirements;

• Functional testing (without aluminium sulphate) of the batching system to


demonstrate correct operation with respect to sequence, time, and levels;
• Functional testing of the batching system with aluminium sulphate to demonstrate
correct operation and calibration;
• Dosing equipment calibration shall be demonstrated and specified accuracies shall
be confirmed.

8.6 Hydrated lime plant

8.6.1 Off-site inspection and testing

Tests shall be carried out on all items of plant to demonstrate compliance with the criteria
specified, with relevant standards and tests specified.
Unless otherwise specified, the tests shall be in accordance with the Reference Standards
and manufacturers own procedures.

8.6.2 Individual tests

The following Site tests shall be carried out as appropriate;

• Inspection to check the assembly of the plant and conformity with the Specification
and approved drawings;
• Rotational checking of all electric motors;
• Functional testing of all ancillary items including mixers;
• The slurry tanks and saturators shall be filled with water to overflow level and
inspected for absence of leakage;
• Water and slurry pipe work and all components up to the point of application shall be
tested hydrostatically for one hour at 1.5 x maximum working pressure;
• Relief valve operating pressure shall be demonstrated;
• Functional testing of each pump to prove correct operation, absence of fluid leaks,
correct beaming and gearbox temperatures and absence of undue vibration and
noise.

8.6.3 Final commissioning tests

Testing shall incorporate the following requirements;

• Functional tests shall be performed on the solids handling systems with


demonstration of correct operation of safety devices including silo pressure relief
valves, all prior to charging with hydrated lime;
• Functional tests (without hydrated lime) shall be performed on the slurry batching
systems and saturators demonstrate correct operation with respect to sequence, time
and levels;
• Functional tests shall be performed on the solids handling and slurry batching
systems with lime to demonstrate correct operation and calibration when handling
hydrated lime;
• Functional tests shall be performed on the slurry dosing systems to demonstrate
correct operation and calibration when handling hydrated lime and specified
accuracies shall be confirmed in operation.

8.7 Water sampling equipment

8.7.1 Off-site inspection and testing

Tests shall be carried out on all items of plant to demonstrate compliance with relevant
standards. Pumps shall be tested as specified.

Unless otherwise specified, the tests shall be in accordance with the Reference Standards,
the manufacturers' own tests where applicable.

8.7.2 Individual tests

The following Site inspections and tests shall be carried as appropriate;

• Inspection to check the assembly of the Plant and conformity with the Specification
and approved drawings;
• Sample water pipe work and components shall be tested hydrostatically for 1 hour at
1.5 x maximum working pressure or 5 bar whichever is greater. During the test the
pressure shall not change;
• Drain pipe work shall be flushed and inspected visually for absence of leaks;
• Water quality monitoring instruments shall be tested as specified.

8.7.3 Final commissioning tests

Testing shall incorporate the following requirements;

• Functional testing of the sampling system (including water quality monitoring


instruments);
• Sample lines shall be flushed and delivery rates checked for example by timing water
into a calibrated vessel against a stopwatch.

8.8 Works water supply system

8.8.1 Off-site inspection and testing

Tests shall be carried out on all items of plant to demonstrate compliance with the criteria
specified, with relevant standards and tests specified.

Unless otherwise specified, the tests shall be in accordance with the Reference Standards
and manufacturers own tests where applicable.

8.8.2 Individual tests

The following Site inspection and tests shall be carried out as appropriate;

• Inspection to check the assembly of the Plant and conformity with the Specification
and approved drawings;
• Rotational checking of all electric motors;
• Hydrostatic testing of all pipe work systems at 1.5 x maximum working pressure for a
period of at least one hour during which the pressure shall not change;
• Service water storage tank shall be filled to overflow level and inspected for absence
of leaks;
• Testing of safety showers and eye baths for correct operation.

8.8.3 Final commissioning tests

Testing shall incorporate the following requirements;

• Functional testing of the hydropneumatic system to demonstrate correct operation


with respect to sequence, pressure and level;
• Functional testing of the system including the elevated water storage tank with
respect to sequence and level.

8.9 Miscellaneous tests

8.9.1 General

Miscellaneous tests shall include tests for hydraulic pallet trucks, safety equipment, and
contact tank and access equipment.
8.9.2 Off-site inspection and testing

Tests shall be carried out on all items of plant to demonstrate compliance with the criteria
specified, with relevant standards and tests specified.

Unless otherwise specified the tests shall be in accordance with the Reference Standards
and the manufacturer's own procedures.

8.9.3 Individual tests

The Site inspection and testing shall incorporate the following;

• Pallet trucks shall be tested to 1.25 x Safe Working Load;

• Testing of access equipment for stability;

• Inspection of safety equipment to check sufficiency of supply and satisfactory


installation.

8.9.4 Final commissioning tests

The testing shall incorporate the following requirements;

• Chemical tracer tests using sodium chloride at a concentration of about 20 mg/l(with


either conductivity or chloride concentration measurements) or fluoride at
concentration less than 1.0 m/l as F (using specific ion electrode for concentration
measurement) shall be carried out to demonstrate that the specified effective contact
time in the contact tank has been satisfied at the maximum works throughout;

• Time to completely drain a clarifier from full.

8.10 Switchgear and control gear

8.10.1 Off-site inspection and testing

Tests shall be carried out to demonstrate compliance with the Reference Standards
and the specified functional and performance criteria.

Unless otherwise specified, the tests shall be Routine Tests in accordance with the
Reference Standards and the following additional tests as appropriate to demonstrate;

(a) 415V switchboards and MCCs

(i) High Voltage & Meggar test of busbars with circuit breaker connected;
(ii) The interchangeability of withdraw able equipment;
(iii) The correct operation of electrical and mechanical interlocks;
(iv) The correct and accurate functioning of current and voltage operated
protection relays by primary and secondary current injection and voltage
application;
(v) The correct polarity between current and voltage elements of power operated
protective devices, instruments and metering;
(vi) Meters do not creep with the removal of either the current or voltage supply.
(vii) The correct operation of control circuits, indications and alarms;
(viii) Where necessary a suitable test panel shall be provided for simulation of
external controls and signals during such tests;
(ix) The calibration of ammeters Voltmeter, KW meter, PF meter, Hz meter etc at
0.25, 0.5 and full scale deflection by secondary current injection;
(x) The calibration of transducers;
(xi) Type and special tests shall be carried out when specified.

(b) 33kV/11kV/6.6kV/3.3kV switch boards

(i) Power frequency high voltage pressure test with all breakers racked in and
closed, between phases and from phase to earth;
(ii) Pressure test on secondary small wiring circuits;
(iii) Milli-volt drop tests - Milli-volt drop (Ductor) test across circuit breaker
contacts and between extreme terminals on individual panels, (for
comparison purposes, the manufacturer shall state design values for each
size and rating of equipment);
(iv) Operational closing tests - These tests are to ensure the operation of closing
coil or spring release coil and satisfactory closing of the circuit-breaker with
the voltage on the coil down to 80% of its rated voltage and to ensure that
mal-operation does not occur, with a voltage at the coil of 120% of its rated
voltage;
(v) Operational opening tests - These tests are to ensure the satisfactory
operation of the shunt trip circuit, and the tripping of the circuit-breaker at no
load conditions with the trip coil energised at 50% of its rated voltage;
(vi) Mechanical tests - All mechanical interlocks on the switchgear panels shall be
thoroughly tested to ensure their correct operation, together with mechanical
tripping, opening and isolating devices;
(vii) Interchangeability – With drawable circuit-breaker panels of identically
equipped units shall be capable of inter-changing of circuit-breaker trucks.
This facility shall be proved. A check shall also be carried out to ensure that
the inter- changeability shall not be possible between incoming and outgoing
feeder circuit-breaker trucks;
(viii) Heat run tests - Heat run tests will not be required on panels manufactured
under this Contract provided type test figures for heat runs carried out on
identical panel types are made available for inspection by the Engineer;
(ix) General operation tests;
(x) In addition to the tests given above, tests shall be conducted, where
applicable, for the following purposes;
• to ensure satisfactory tripping of the circuit-breakers with the closing
coil energised;
• to prove satisfactory mechanical behaviour of the circuit-breaker when
the closing coil is energised with the tripping coil also energised;
• to prove that the operation of the power closing device when the
circuit-breaker is already closed causes neither damage to the circuit-
breaker nor danger to the operator;
• Protection and control circuits;
• For all forms of current transformer protection, the following
information shall be made available to the Engineer prior to the time of
inspection;
• Current transformer magnetising curve;
• Recommended relay setting;
• Calculated primary operating current at this setting;
• Calculated through fault stability values, where applicable;
• Values of any stabilising and setting resistors employed in the
scheme.
(xi) As far as possible, based on the completeness of the circuits in the final
manufactured form within the manufacturer's premises, the satisfactory
operation of associated control and protection circuits shall be proved by the
following tests;
• to ensure the correct operation of all current operated protection relays and
direct acting coils at the recommended setting by current injection;
• to ensure the correct polarity between current and voltage elements of power
relays, meters and instruments;
• to ensure the correct operation of control circuits at normal operating voltage
by operation of local control switches and simulation of operation from remote
control positions.

Note: The checking of the operation of all protection relays and control circuits is to be
carried out with all closing and tripping circuits energised at their normal rated
voltage.

(xii) Instrument and metering equipment;

• Indicating ammeters shall be checked for calibration at 0.25, 0.5, 0.75 and full
scale deflection by primary current injection testing;
• Indicating voltmeters shall be checked for normal voltage readings by voltage
application;
• Frequency, power factor and kilowatt meters shall be tested for accuracy of
indication;
• Integrating kWh meters shall be tested for correct rotation. Creep tests shall
be carried out to ensure that the meter is inoperative with voltage alone, if the
secondaries of current transformers are left connected with the primary
current interrupted;
• All transducers shall be tested for at least 5 different points in the complete
working range of each unit.

(xiii) Current transformers;


(xiv) Verification of terminal markings;
(xv) High voltage power frequency withstand test on primary and secondary windings;
(xvi) Over-voltage inter-turn tests;
(xvii) Test for accuracy;
(xviii) Voltage transformers;
(xix) Verification of terminal markings;
(xx) High voltage power frequency dry withstand test on primary windings;
(xxi) Test for accuracy;
(xxii) Visual inspection;
(xxiii) Inspection of paint work and measurement of paint thickness shall be carried out.

Dimensional checks shall be also carried out.

8.10.2 Individual Tests

The following Site inspections and tests shall be carried out as appropriate;

(a) 415V Switchboard and MCC

(i) Insulation resistance of main connections and secondary wiring using an approved
insulation tester. The test shall be carried out between phases and phase to earth. All
circuit-breakers, switches and contactors shall be in circuit and closed;
(ii) The correct operation of electrical and mechanical interlocks shall be demonstrated;
(iii) The correct and accurate operation of current and voltage operated protection relays
shall be demonstrated by primary and secondary current injection and voltage
application. At least two points shall be demonstrated for each relays. Simulation test
on the operation of thermal overload relay for motor shall not be acceptable. Actual
test on thermal overload relay for motor shall be carried out;
(iv) The stability of unit protection systems shall be demonstrated by primary current
injection;
(v) The correct operation of control circuits, indications and alarms shall be
demonstrated;
(vi) The continuity of all protective conductors shall be checked;
(vii) The correct operation of inter tripping circuits shall be demonstrated;
(viii) Demonstration of accurate operation at 50% and 10% of working range on all
measuring devices, meters and transducers;
(ix) Any tests required by the electricity supply company.

(b) 33kV/11kV/6.6kV/3.3 kV Switch board

(i) Pressure testing - Power frequency pressure test shall be carried out on equipment for
use on systems above 1000 volts. For systems up to 1000 volts the insulation resistance of
the equipment shall be tested with a 500 volt Megger hand generator. These tests shall be
carried out with all circuit phases and phase to earth. All secondary small wiring circuits shall
be similarly tested;

(ii) Mechanical tests - All mechanical tests specified and carried out at Manufacturer's
premises are to be re-checked to ensure satisfactory operation of the Works in the final
erected state;

(iii) Interchangeability - On withdraw able circuit-breaker panels identically equipped units


such as incoming and outgoing panels shall be capable of inter-changing of circuit-breaker
trucks. This facility is to be proved;

(iv) Protection and control circuits - The satisfactory operation of all current operated
protection circuits over their whole operating range and correct connection of CT wiring shall
be tested by primary current injection;

(v) The checking of the operation of all protection relays and control circuits shall be carried
out with all tripping circuits energised;

(vi) The satisfactory operation of all inter-tripping circuits shall be tested;

(vii) The satisfactory operation of control circuits shall be tested from local and from remote
positions;

(viii) Indicating ammeters - Indicating ammeters shall be checked for calibration at 0.25, 0.5,
0.75 And full scale deflection by primary current injection testing;

(ix) Indicating voltmeters - Indicating voltmeters shall be checked for normal voltage reading
by voltage application;

(x) Integrating kWh meters - Where possible kWh meters shall be tested for correct rotation.
Creep tests shall be carried out to ensure that the meter is in-operative with voltage alone, if
the secondaries of current transformers are left connected with the primary current
interrupted;
(xi) Other indicating meters - Other indicating meters including frequency, power factor and
kilowatt meters shall be tested for accuracy of indication;

(xii) Transducers - All transducers shall be tested for at least 5 different points in the
complete working range for each unit;

(xiii) Current transformers - Current transformers shall be tested for the following;

• verification of terminal markings;


• high voltage power frequency withstand test on primary windings;
• test for accuracy;

(xiv) For all forms of current transformer protection the following information shall be made
available to the Engineer prior to the time of testing;

• current transformer magnetising curve;


• recommended relay testing;
• calculated primary operating current at this setting;
• calculated through fault stability values where applicable;
• values of stabilising and setting resistors;

(xv) Voltage transformers - Voltage transformers shall be tested for the following;

• verification of terminal markings;


• high voltage power frequency withstand test on primary windings;
• test for accuracy;

(xvi) Operational sequence tests - Tests shall be carried out on all starter panels to test
operational sequence and operation of protection devices. Sequential tests for pump- motor
shall be able to carry out when putting the VCB at “Test” position without required to modify
any control circuit;

(xvii) Continuity of earth conductors - Continuity tests shall be carried out on the earth
conductor of the switchboard, such tests being by current injection;

(xviii) This does not include the earth resistance test of the station earthing system which
shall be tested as detailed elsewhere in the Specification.

8.11 Electric motors

8.11.1 Off-site inspection and testing

Motors shall be inspected and tested to show that they are compliant with the
Specification and approved drawings.

Tests shall be in accordance with BS 4999: Part 143 / relevant IS. For low voltage
standard production motors for general use, the tests shall be routine checks. For high
voltage and low voltage motors for main drive application, the tests shall be duplicate.

If the test to determine the locked rotor current of cage induction motors is carried out
at reduced voltage, allowance shall be made for the effect of saturation when adjusting for
rated voltage. The estimated value of locked rotor current at rated voltage shall be stated on
the test certificate.

A Polarisation Index test shall be carried out for high voltage motors.
The requirement for "basic" or "special" tests shall be as specified.

8.11.2 Individual Tests

Each motor shall be inspected prior to site testing for;

• Absence of damage during transportation and erection;


• Absence of moisture or other contamination;
• Ventilation openings and drain holes are free of debris;
• Cable glanding and core terminations for tightness and identification;
• Free rotor rotation;
• Free movement of brush gear;
• Remote start/stop / E.stop control box wirings and arrangement;
• Starting interlocks

Unless otherwise specified the following tests shall be carried out on each motor before
energising;

• Winding insulation resistance;


• Polarisation Index for high voltage motors;
• Insulation resistance between motor and heater windings and ancillary devices;
• Calibration of winding and bearing temperature monitoring devices and the. operation
of alarm and trip initiating contacts;
• Continuity and resistance of winding thermistors;
• Bearing insulation integrity;
• Brush pressure.

Any other tests recommended by the manufacturer or stipulated in the Reference


Standards. On the satisfactory completion of the inspection and tests listed above, motors
shall be energised to check for correct direction of rotation, noise and the vibration levels are
within the specified limits. The tests shall be carried out with the motor uncoupled from the
driven plant.

8.12 Transformers

8.12.1 Off-site inspection and testing

Transformers shall be inspected and tested to show that they are fully compliant with the
Specification and approved drawings and shall include the following tests as a minimum;

• Routine tests;
• Measurement on winding resistance;
• Ratio, polarity and phase relationship;
• Impedance voltage;
• Load loss;
• No-load loss and current;
• Insulation resistance;
• Induced over voltage withstand;
• Separate source voltage withstand;
• Magnetic circuit voltage withstand
• Transformer tank oil leakage test (1 kg/cm2 for 24hours);
• Transformer noise level measured in accordance with methods and procedures
detailed in IEC 551 -Noise level shall not exceed 65dBA;
• Tap changer switching, mechanical and electrical tests according to BS4571 /
relevant IS;
• Zero sequence impedance measurement;
• Type tests;
• Impulse voltage withstand test;
• Temperature rise test;
• On load tap changer panels;
• Operational tests;
• Sequence tests.

Unless otherwise stated by the Engineer at the time of placing the order, evidence of
records of satisfactory type test carried out on identical transformers to those ordered will be
accepted in lieu of actual tests on transformers manufactured under this Contract for impulse
voltage withstand test. Temperature rise test shall be carried out on one transformer of each
size and type. The guaranteed no-load and load losses of each transformer shall be verified
at the manufacturer's works. The positive tolerances stipulated in BS 171 / relevant IS shall
not be accepted. The Board reserves the right to reject any transformer which does not
achieve its declared guaranteed values.

8.12.2 Individual Tests

The Site inspections and tests to be carried out are as follows;

• Ratio, polarity and phase relationship;


• Impedance voltage;
• Insulation resistance;
• Oil and winding temperature gauges shall be calibrated and tested;
• Pressure gauges and oil level indicator relays shall be tested with pilot cables
connected by mechanical operation of contacts;
• Tap changer equipment including protective devices shall be tested to ensure correct
operation;
• Oil tests;

Samples of insulating oil shall be taken and subjected to dielectric strength tests. If the
insulating oil fails the site test, the Contractor shall carry out the drying of oil to remove the
moisture content or replace the oil and then carry out the oil tests again to comply with BS
148 / relevant IS.

8.13 DC Supply Units

8.13.1 Off-site inspection and testing

The correct operation of the charger in the float and boost modes and the alarm functions
shall be checked.

The following tests shall also be carried out;

• Insulation resistance test;


• Load stability test;
• Incoming supply line test;
• Ripple voltage measurement with battery disconnected;
• Noise level measurement;
• Dropper diodes functional test;
• Charger automatic changeover test;
• Charger manual changeover test;
• Battery discharge test;
• Burn-in test at 110% load for 8 hours;
• Visual inspection shall be carried out to check the dimensions, paintwork, paint
thickness and components inside the enclosures.
8.14 Cabling

8.14.1 Tests at manufacturers 'works

Unless otherwise specified cables shall be subject to Routine Tests in accordance with the
Reference Standards.

8.14.2 Individual Site tests

The following inspection and tests shall be carried out on the completed cable installation as
appropriate;

• Insulation resistance between cores and core to earth using an approved insulation
tester compatible with the voltage grade of the cable under test. For high voltage
cables, the test shall be carried out at the highest voltage compatible with the voltage
grade of the cable under test. Where cables are jointed, the test shall be repeated
after each joint has been completed;
• For multicore and multipair cables, continuity of each core and correct identification
and ferruling;
• Supports and cleating arrangements are fitted;
• For power cables, correct phasing and phase colouring;
• Correct bonding and earthing of cable metallic sheaths, core screens and armouring;
• Sealing of cable entries against water and vermin ingress;
• Mechanical glands have been correctly fitted;
• For high voltage cables pressure tests shall be carried out in accordance with the
Reference Standards using high voltage d.c. Wherever possible cables shall be
energised after the satisfactory completion of the pressure test;
• For high voltage cables, additional checks and tests to the manufacturers' specific
instructions shall be carried out;
• For low voltage cables, additional tests as required by the Reference Standard;
• Loop resistance test for each pair of conductors in multipair instrumentation and
telephone distribution cables;
• Attenuation test for each pair of conductors in telephone distribution cables;
• Measurement of cross talk across pairs of conductors in telephone distribution cables
over a minimum frequency band of 0.5 to 20kHz. The conductors connected to a
resistive load equal to that of their characteristic impedance. The injected signal shall
have a sinusoidal waveform at a level equivalent to the intended operating level of
the modems to be connected (-3dBm).

8.15 Earthing

8.15.1 Individual Site tests

On completion of the earthing installation tests shall be carried out in accordance with the
Reference Standards and the following requirement;

• Resistant of each earth point shall be measured;


• Resistant value of the overall earthing system after the connection of linking tapes;
• The earth contact resistance and the earth conductor continuity from each major
piece of the Works, i.e. main switchboards and transformers etc., shall be measured
by using an earth loop impedance tester and auxiliary return conductor.
8.16 Building services

8.16.1 Individual Site tests

The building services installations shall be inspected and tested in accordance with the
Reference Standards.

8.17 Lightning protection

8.17.1 Individual Site tests

The lightning protection installation shall be inspected and tested in accordance with the
Reference Standards and the following requirement;

• Resistant of each earth point shall be measured;


• Resistant value of the overall earthing system after the connection of linking tapes.

9.0 TRAINING

9.1 Training requirements

Training shall be provided on site and at the Employer’s premises as applicable, and
shall commence at such time as directed by the Engineer/Employer. Training of the
Employer’s personnel shall aim at achieving optimum operation of the Works including
maximum efficiency of plant, optimum use of chemicals, minimum loss of water, and
minimum numbers of operating staff. The Employer’s personnel shall be trained in all
aspects involved including management, operation of plant, water quality tests, laboratory
procedures, control of chemicals, routine and periodic maintenance of every item of
equipment and plant, health and safety at work, security and in all other subjects as may be
required for satisfactory operation and maintenance of the Works.

The training shall comprise three main aspects:

(a) Formal classroom and practical training in-groups;


(b) “Hands-on” training to the Employer’s operation and maintenance staff while the
Contractor is conducting equipment erection and pre-commissioning;
(c) "Hands-on" training to the Employer’s operation and maintenance staff during the
first 12 months and the last 12 months of "Operation and Maintenance Period" while
the Contractor's operation and maintenance staff are operating the Works and
carrying out maintenance of the Works.

During the period of classroom and practical training, the Employer will make available
selected staff for the Contractor to train in the safe and efficient operation and maintenance
of the installed plant. The Contractor shall allow for comprehensive training in at least two
separate sessions for each of the following disciplines and designed to accommodate the
Works shift (24 hour, 3 shift) pattern.

• Staff discipline;
• Management staff;
• Operational staff including Works chemist and laboratory personnel;
• Electrical and ICA maintenance staff;
• Mechanical maintenance staff.

The exact number of personnel attending the training sessions will be finalized prior to
the training. During the last 12 months hands-on training period, the Contractor shall remain
fully
responsible for the operation and maintenance of the Works, but shall utilize the Employer's
staff to the fullest extent possible, commensurate with their proficiency at the time, with a
view to providing a smooth transition of responsibility for operation and routine maintenance
from the Contractor to the Employer. During installation of the Plant, the Contractor shall
produce videos (CD ROM format) where necessary illustrating all essential aspects of plant
installation and testing for use during training of the Employer's personnel.

The Contractor shall provide an experienced training manager (with a minimum of ten years
training experience and five years experience in a similar capacity) to organize and
supervise the training programme. He shall be based on site and shall remain on site from
the commencement of the training programme until the completion of the first 12 months of
"Operation and Maintenance Period".

Training shall be performed by specialist personnel specifically allocated to the task.


Such training shall be specific to the trainee's position and discipline and shall be
appropriate to staff with the basic skills related to their grade.

The Contractor shall ensure that, training on individual items of plant, equipment or
systems such as chemical facilities, instrumentation, control and automation systems (ICA)
and similar shall be carried out by the manufacturer or specialist sub-contractor. Provision
shall be made for both classroom and hands-on-training in this respect. The Contractor shall
be responsible for ensuring that such training is properly co-ordinate into the overall
programme, and that the quality of the training is of the type, quality and standard specified.
The Contractor shall submit details of the number of training specialists he shall assign to
each phase of training together with details of their duties, qualifications, capabilities and
experience to the Engineer for approval.

The Contractor shall maintain a register of attendance at training sessions and the
subjects covered and shall carry out assessments jointly with the Engineer and the
Employer’s representative to monitor the effectiveness of training. Based on the
assessments, the Contractor shall offer technical advice, organize and conduct special
tutorial sessions for any personnel who have jointly been assessed and needing them and
ensure that they carry out operations and procedures correctly. Training shall be based on
the relevant approved operating and maintenance manuals and record drawings including
P&I Diagrams and flow sheets, which shall be available before training commences.

Training shall be provided for management, operating and maintenance staff and shall
cover in detail the areas listed below. At least six months prior to the start of training the
Contractor shall provide a draft syllabus of the proposed training and shall then develop in
liaison with the Engineer and the Employer an approved syllabus, training programme and
training methodology. The approval syllabus programme and methodology shall be
submitted to the Engineer at least one month prior to the agreed start date for training. The
syllabus to be provided by the Contractor shall be based upon, but not limited to, the
following;

(i) Health and safety procedures, with particular respect to toxic and hazardous gas
areas, chemical handling, electrical plant use, maintenance, entry/working in
confined spaces and similar;
(ii) General plant description:

• General process description and treatment objectives;


• Process design parameters;
• General description of electrical equipment;
• General description of mechanical equipment;
• General description of ICA system.
(iii) Detailed description and demonstration on operation of individual process units,
including process chemistry, sampling and laboratory procedures specific to the
treatment processes adopted on the Works;
(iv) Detailed description, including operation principles/mechanism and demonstration on
operation and control of all electrical, mechanical and ICA equipment;
(v) Operating instructions, including normal operation, actions necessary under varying
conditions and abnormal conditions, start-up and shut-down procedures for individual
process units;
(vi) Process optimisation;
(vii) Routine inspection and maintenance instructions;
(viii) Fault finding and correction;
(ix) Dismantling and re-assembly of plant, and replacement of consumable parts;
(x) Emergency procedures, including process aspects such as start up after power
failure and gas leaks and chemical spillages;
(xi) Set up and calibration of each control, protection, measuring and process equipment
/ System;
(xii) Spares - strategic and consumables;
(xiii) Special tools;
(xiv) Trouble shooting and programme modifications to ICA systems, PLC and PC
software and use of management systems provided under the Contract;
(xv) Review of relevant drawings, P&IDs and O&M manuals.

9.2 Training methodology

The method of delivery shall be structured to include theory, group discussion and part
practical elements supported by audio-visual aids, hand outs, demonstrations and
appropriate assessments. Hand outs shall include extracts from operating and maintenance
manuals supplemented by specially prepared material and shall be prepared so as to be
collated to form a set of course notes for use by attendees for future reference. Audio-visual
aids shall include relevant video presentations prepared by plant and equipment
manufacturers, as well as those prepared during plant installation and testing.

9.3 Training duration

Classroom Training shall start at an appropriate time during the erection of plant and
shall be completed before the commencement of the trial operation of the Works. “Hands-
on” training as specified elsewhere shall start prior to the commencement of any final
commissioning test of the equipments and shall be completed before the commencement of
the trial operation of the Works. During "Operation and Maintenance Period", the Contractor
shall provide "hands- on" training, as specified, and full direction and supervision of the
Employer's staff, so that by the last twelve months period of operation and maintenance by
the Contractor during "Operation and Maintenance Period", the Employer’s personnel are
sufficiently proficient so as to take over the operation and maintenance of the Works with
minimal supervision by the Contractor. The extent/length of training provided shall also take
into account the numbers of Employer’s personnel involved, shift patterns and scope of
training or the like. As a minimum requirement the following number of 8 hour, day shifts
shall be allowed for each course in the scope of training (excluding the “hands on” training
to be given during the erection and pre-commissioning testing):

Subject Days
Process chemistry 2
Operation of all plant including safety aspects of chemical and
10
other plant
Electrical maintenance 4
Mechanical maintenance 4
ICA maintenance 5

The number of trainees per theory and group discussion class shall not exceed ten and the
number of trainees per practical and/or “hands on” training session shall not exceed five.

9.4 Training assessment

The training shall be monitored continuously by the Contractor jointly with the
Engineer and / or the Employer’s representative and each trainee will be required to
demonstrate their understanding of the instruction received. In order to achieve an
acceptable standard of competence, the Contractor shall build into the training, a two-step
assessment monitoring programme as set out below or a comparable assessment method
approved by the Engineer:

(a) Each session shall include small groups of trainees being given a task/scenario, which
will require them to use the knowledge learnt during the session to feed back and
demonstrate understanding in such a manner as to promote trainee participation without
putting individuals under pressure. This type of assessment shall be adopted for both
theoretical and practical sessions and time shall be built into the course programme for this
purpose.

(b) Each trainee shall be issued with a training task book which will include sections for
recording attendance at individual classroom, practical and "hands-on" training sessions.
Each section of the task book shall relate to a session undertaken during the training and will
be signed off by the Contractor, Engineer and the Employer on completion of the training
session.

9.5 Training material

A comprehensive overall training manual shall be produced by the Contractor


covering all disciplines and shall be submitted to the Engineer for approval six months before
the commencement of the training programme. Three copies of the approved manual shall
be submitted at least one month before the commencement of training. The presentation
requirements of the manual shall be the same as those for the operating and maintenance
manual. The manual shall also be submitted in CD ROM with interactive web page format.
The manual shall be updated as necessary throughout the training programme. In addition,
each trainee shall receive one set of bound documents including the following:

(a) Course notes;


(b) Training information from the overall training manual appropriate to their particular
skill areas (e.g. management, chemist, operator, electrical and mechanical
maintenance);
(c) Training task book for recording training and for individual assessment;
(d) Functional task book, to be issued to each trainee shall include a comprehensive
schedule of daily tasks to be carried out by the trainee staff member in their allotted
position in maintaining satisfactory operation of the plant.

The training material shall be in a user-friendly style and shall cover in general terms the
main technical procedures and activities associated with the Plant. The documents shall be
in a format suitable for use in future training of Employer’s personnel up to operating shift
supervisor level. Training documents shall be securely bound in such a manner that
individual pages can be added or replaced so that the documents can be kept up to date. On
completion of the training programme, the training manual and other documentation,
Updated to take account of changes during the performance of the programme, shall be
submitted to the Engineer in CD ROM format (IBM PC compatible).

9.6 Training programme

The Contractor shall provide an outline training programme indicating target dates for the
following associated activities:

(a) Submission of draft training plan, draft training manual, training task book and draft
functional task book;
(b) Submission/agreement with the Engineer and the Employer of detailed training plan
and syllabus. This shall include agreement of the assessment structure for trainees,
training manual, training task books and functional task books;
(c) Submission/agreement with the Engineer and the Employer of training development
programme. This will include aspects such as duration of training courses, dates,
training venue/arrangements, training content, training materials, confirmation of
numbers involved;
(d) Training review updates;
(e) Two week “familiarisation” programme;
(f) Number, dates and duration of courses/sessions within overall training programme;
(g) Relative dates for start of plant tests;
(h) Date for availability of draft operating and maintenance manuals.

9.7 Training review update

The Contractor shall make available suitable personnel to carry out training updates
and assessments at six months from the start of the "Operation and Maintenance Period"
and at six months prior to the end of the "Operation and Maintenance Period".

9.8 Training support

Following satisfactory completion of "Operation and Maintenance Period", the


Contractor shall handover his operation and maintenance responsibilities to the Employer’s
personnel who will carry out the operation and maintenance of the Works. In the last 12
months of "Operation and Maintenance Period", the Employer’s operation and maintenance
staff should be conducting the operation and maintenance of the Works for the Contractor,
who is still taking full responsibility of the operation and maintenance of the Works.
Therefore, throughout the "Operation and Maintenance Period", the Contractor shall advise
the Employer’s personnel on the proper running of the Works, and provide technical support
to the Employer to overcome operating and maintenance difficulties.

The Contractor shall attend to all requests for advice and assistance, both oral and
written, made by the Employer’s personnel and shall keep a written record of these requests
with a copy submitted to the Engineer monthly.

Any advice or technical support given by the Contractor to the Employer’s personnel,
as a result of requests from them, and the action taken by them as a result of such technical
support shall be recorded by the Contractor and copies shall be submitted to the Engineer
monthly.

9.9 Training record

The Contractor shall keep a complete record of Plant formal training carried out in the
classroom and on the plant on DVD (MPEG2 format) and at the end of the training period
shall submit to the Engineer four copies on DVD disks (MPEG2 format).
10.0 SPECIAL TOOLS, SPARE PARTS, TOOLS AND TEST EQUIPMENT

10.1 Special Tools

As well as the workshop tools specified, the Contractor shall provide special tools or
appliances which he considers necessary for erection, dismantling or testing, operation and
maintenance for any part of the Works during the life of the Works. Special tools provided
shall not be used for the erection of the Plant unless the Engineer instructs the Contractor to
demonstrate the effectiveness of any special tool. The special tools shall be handed over to
the Employer in a new and unused condition. Should the Contractor require any special tools
at Site for erection, he shall provide his own. Tools for each different type of equipment shall
be contained in a suitable box clearly marked or labeled with its description. Each tool shall
be identified and a list of tools shall be fixed to the inside of the box lid. Each set of tools
shall be supplied with the equipment it serves.

10.2 Spare parts

The Contractor shall submit a complete list of spares recommended for continuous
operation of all items of Plant and the Works for "Operation and Maintenance Period", in
Schedule of Technical Particulars. The list shall be based on average servicing requirements
and prevention of breakdown for continuous operation of the Plant. Following detailed design
of the Plant, the list submitted at the time of tender shall be updated. The list shall contain a
description of the spare parts, ordering reference numbers, with parts identified on
equipment drawings, quantities, unit price and the total price. The prices entered in this list
shall be the prices quoted, except where the items listed at that time have been superseded
by the requirements of detail design of the Works. The list shall be re-submitted in a single
submission for the approval of the Engineer before any items are ordered.

The sum included in the Contract for provision of those spare parts listed in the Price
Schedules is provisional, and the Employer reserves the right to order spares in accordance
with the recommendations of the Contractor, or to vary the list and quantity of items to be
ordered, or not to order spare parts through the Contract. Should additional quantities be
ordered from the Employer, the Contractor shall be obliged to supply based on the unit rates
being entered in the Schedules of Technical Particulars.

Any spares that are specified elsewhere as part of any plant item shall be provided
and the cost shall be deemed to be included in the lump sum for the plant item. The final
approved spare parts schedule shall be submitted in hard copy and CD ROM format. It shall
show part numbers, ordering references and equipment drawings showing the spare parts.
Spare parts shall be new original manufacturers' spares. They shall be packed separately
from the main Plant in packages or containers designed to preserve the spares from the
effects of long term storage under the ambient conditions at the Site. Any items which
cannot be packed in this shall be protected from corrosion by applying temporary protective
coatings and shielded from mechanical damage. All items shall be clearly labeled with brief
descriptions and part numbers, and shall be cross referenced to the approved spare parts
list.

Spare parts shall be delivered to the Site prior to the commencement of "Operation
and Maintenance Period". Spare parts being ordered additionally by the Employer for their
use after they take over the operation and maintenance of the Works shall be delivered to
the Employer 6 months prior to the completion of "Operation and Maintenance Period".
Whether the Contractor can achieve this requirement can be a prerequisite condition for the
Employer to issue the Taking-Over Certificate of "Operation and Maintenance Period".

The Contractor shall not use any of the spare parts for construction, commissioning or
rectification of defects without written permission from the Engineer. Parts so used shall be
Replaced free of charge by the Contractor prior to the commencement of "Operation and
Maintenance Period". The Contractor shall not use any of the spare parts additional ordered
by the Employer for them to carry out future operation and maintenance of the Works without
written permission from the Employer or the Engineer. Parts so used shall be replaced free
of charge by the Contractor prior to the issue of the Taking-Over Certificate of "Operation
and Maintenance Period". All packages may be opened for such examination as the
Engineer may require and packing’s shall be designed to facilitate opening and thereafter
repacking.

10.3 Tools and test equipment

The Contractor shall supply two sets of all the standard workshop hand tools
necessary for the dismantling and repair of the Plant.

Tools and test equipment for each different type of equipment shall be contained in a
suitable hardwood, floor mounted cabinet clearly marked or labeled with its description.
Each item test equipment and tools shall be identified and a list shall be affixed to the inside
of the cabinet door.

Each set of tools and items of test equipment shall be supplied with the equipment it serves.

11.0 OPERATION AND MAINTENANCEPERIOD

11.1 General

Following the Engineer to accept the Contractor has satisfactorily completed the
individual tests, final commissioning tests and trial operation of the Works, the Engineer shall
issue a “minor outstanding works and defect list”. This “minor outstanding works and defect
list” is to provide the details of the defects to be rectified and works that are still outstanding
which the Employer can accept the Contractor to finish those works after the Employer has
taken-over the Works completed. The Contractor shall acknowledge to complete these minor
outstanding works and rectifies the identified defects within the Defects Notification Period of
"Construction Period". Under this pre-requisite condition and other necessary conditions
specified elsewhere in the Contract, e.g. to receive from the Contractor the Performance
Security for "Operation and Maintenance Period", the Engineer will issue the Taking-Over
Certificate for "Construction Period" and a letter to the Contractor to permit "Operation and
Maintenance Period “to commence. The Defects Notification Period of "Construction Period",
which is of 12 months duration, shall commence on the same day.

The Employer and the Engineer will arrange handover of the whole Works to the
Contractor, for them to commence the operation and maintenance of the whole Plant. The
duration of "Operation and Maintenance Period" will be 60 months.

A Test on Completion for "Operation and Maintenance Period" has to be satisfactorily


completed by the Contractor to demonstrate to the Employer that the whole Works is in good
operative condition. The Engineer/Employer will issue a “minor outstanding works and defect
list” that the Contractor has to accept to complete in the Defects Notification Period of
"Operation and Maintenance Period". Under such scenario, the Employer will take-over the
whole Works and will allow the Contractor to access all the Plants to rectify the defects
identified and completes all the outstanding works in the Defects Notification Period.
11.2 Contractor's obligations during the first twelve months of "Operation and
Maintenance Period"

During the first twelve months of "Operation and Maintenance Period", which is also
the Defects Notification Period of "Construction Period", the Contractor shall be responsible
for the following;

(a) Operation and routine maintenance for the whole of the Works, including the
provision of all necessary skilled supervisory staff and unskilled workers necessary
for full operation and maintenance of the works. The Contractor shall provide at least
five persons per shift. In addition, the day shift shall include a supervisor for the
whole of the plant, intake structure, pumping stations, booster stations and water
treatment plant, a process chemist, ICA system subcontractors, and a maintenance
supervisor. The additional day shift staff shall be available on a "call out" basis to
deal with any problems, which may arise outside the specified day shift period.
During this twelve month period the Contractor shall provide `hands-on' training to
the Employer's operating and maintenance personnel, who will be trained to carry out
their future duties under the direction and supervision of the Contractor. The
Contractor shall be responsible for the work of the Employer’s personnel during this
period;

(b) Rectifying defects in accordance with the requirements entered in the “minor
outstanding works and defect list” issued by the Engineer for "Construction Period",
including the provision of all supervision, labor, parts and materials including
chemicals, fuel and lubricants excluding electricity power charges. All defects of the
Works in "Construction Period" shall be rectified by the Contractor in this Defects
Notification Period and the Contractor shall prove to the Engineer or Employer of
that;

(c) The supply of all spare parts required for maintenance of plant as specified
elsewhere in the Contract; and

(d) Carrying out amendments to the operating and maintenance manuals based on
experience gained in the Employer operating the plant.

11.3 Contractor's obligations after the first twelve months and before the last twelve
months of "Operation and Maintenance Period"

(a) Same scope of work as (a) above, except that formal “hands-on” training is not
required in this period. In this period, the Contractor shall provide advice to the
operation and maintenance staff of the Employer at the Works for the queries they
raise, based on the experience the Contractor obtained during the course of their
operation and maintenance work;

(b) Same scope of work as (c) and (d) above.

(c) Provision of all materials including chemicals, fuel and lubricants excluding electricity
power charges for the operation of the Works.

11.4 Contractor's obligations during the last twelve months of "Operation and
Maintenance Period"

After satisfactory operation of the Works during the first four years of "Operation and
Maintenance Period", the Contractor shall be responsible for the following:

100
(a) Advising on operation of the whole of the Works to the Employer's personnel for the
remainder of the "Operation and Maintenance Period", who will be conducting
operation and maintenance of the Works under the direction and supervision of the
Contractor. The Contractor shall provide all necessary skilled advisory staff and
providing necessary training. The staff shall be provided on a day shift basis on
weekdays only and shall number at least three, including the overall plant supervisor,
ICA sub-contractor's supervisor and a maintenance engineer. The staff shall also be
available on a "call out" basis to deal with problems arising outside the specified day
shift period. The Contractor shall be responsible for the work of the Employer’s
personnel during this period;

(b) During this twelve month period the Contractor shall provide `hands-on' training to
the Employer's operating and maintenance personnel, who will be currently carrying
out operation and maintenance of the Works under the direction and supervision of
the Contractor. The Contractor shall supplement the “hands-on” training material
being used in the training mentioned above by those experience the Contractor
gained in operation and maintenance of the Works in the first four years of
"Operation and Maintenance Period";

(c) Conducting studies as required by the Engineer on water treatment processes to


optimise operations;

(d) The supply of all spare parts required for maintenance of plant as specified
elsewhere in the Contract;

(e) Carrying out amendments to the operating and maintenance manuals based on
experience gained in the Employer operating the plant.

(f) Provision of all materials including chemicals, fuel and lubricants excluding electricity
power charges for the operation of the Works.

11.5 Employer’s responsibilities

During the "Operation and Maintenance Period", the Employer will provide and be
responsible for the following in respect of the operation of the Works;

(a) All manpower to be trained to operate and maintain the Works under the direction of
the Contractor;
(b) Electric power;
(c) All manpower to operate and maintain the Works in the last twelve months of
"Operation and Maintenance Period", under the direction and supervision of the
Contractor.

11.6 Periodic visits

The installation shall be visited during the eleventh month, twenty-third month, thirty
fifth month, forty-seventh month and fifty-ninth month of "Operation and Maintenance Period"
by a competent engineer or other specialist representative and training manager of the
Contractor. He shall inspect all Plant provided under the Contract, ensure that servicing,
adjustments and recalibrations as necessary are being carried out on all those items
requiring attention and assess the competence of the Employer's personnel. The Contractor
shall obtain the Engineer's or the Employer’s approval at 14 days prior to each visits and
shall supply a full service report within 14 days after each visit.

101
12.0 TEST ON COMPLETION FOR OPERATION AND MAINTENANCE PERIOD OF
THEWORKS

Test on Completion at the end of "Operation and Maintenance Period" shall be carried
out to show that the Works are in complete and satisfactory working order. The tests shall be
agreed in detail with the Employer and be carried out to an agreed programme which shall
be submitted to the Employer at least 28 days prior to the start of the tests.

The tests will include functionality, leakage and any structural tests necessary to prove
that the Works are in full and compliant order, and are fit for purpose.

The Test on Completion shall be similar to those set down for Trial Operation for
"Construction Period" as in above clause. The continuous period the Works, to be tested on
handover, shall be 7 days. The tests shall be designed to prove that the Works and
treatment performance meets the Specifications and Performance Guarantees entered in
the Schedule of Technical Particulars. Additionally, the following specifications and
Performance Guarantee aspects shall also be included:

• Works Output
• Classified Water Quality
• Treated Water Quality
• Filter run duration
• Clarifier Sludge discharge
• Filter Wash water Consumption
• Thickener supernatant turbidity
• Any other Parameters

The procedures to be used for the Test on Completion during the specified period
shall be as listed in items (a) to (f) inclusive of relevant above clause. All Mechanical Plant
and Pumping equipment shall be inspected during operation, and tested for functionality and
performance. The contractor shall prove to the Employer that plant as installed and operated
complies fully with specified performance.

All those defects and outstanding works identified in the Tests on Completion, that the
Employer considers shall be completed prior to allowing the Defects Notification Period for
"Operation and Maintenance Period" to commence, the Contractor shall carry out the
rectifications works promptly. Repeated tests shall then be conducted.

After all the critical defects and outstanding works be completed and the necessary
repeated tests be satisfactorily completed, the Employer will furnish to the Contractor a
"defects and minor outstanding work list". The Contractor shall rectify all those defects and
complete all the minor outstanding works in the list during the Defects Notification Period of
"Operation and Maintenance Period".

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PART - B: PARTICULAR SPECIFICATION

1 CAPACITY OF THEWORKS:

1.1 Capacity of Works


The design capacity for various components of proposed water supply scheme
including intake well and connecting pipes / intake channel, intake structure, pumping
station, raw water rising mains, WTP, clear water transmission mains, BPT, intermediate
booster sumps and pumping stations, MBRs / ZBTs, clear water feeder mains up to village
OHTs etc. shall be as specified in "Design Criteria".
1.2 Treatment works
The treatment plant capacity shall be as given in design criteria. The water produced in
the washing of the filters (hereafter called used wash water) shall be discharged to wash
water recovery tanks from which the supernatant shall be returned to the treatment works
inlet. The returned supernatant shall be included in the throughput of the works. Sludge
from the used wash water recovery tanks and sludge from the clarifiers shall be discharged
to sludge thickeners from which the supernatant shall be discharged to a nallah and
thickened sludge will be discharged to sludge drying beds. Therefore, the mean output to
the treated water reservoir will be the treatment works input less the water discharged as
sludge from the clarifiers and from the used wash water recovery tank and less service
water used for flushing, irrigation or domestically. Mean losses from the works excluding
service water used for flushing, irrigation or domestically shall not exceed 2.5% of the input.
The hydraulic capacity of the process units, the interconnections between units and to
the treated water reservoir including overflows shall be designed for the relevant mean
throughput of the works plus an allowance of 25%.
1.3 Variation in throughput
It is not possible to forecast accurately the extent or the frequency of variations in
demand and therefore the throughput. In general the range of hourly variations in demand
will be met by the storage in the treated water reservoir but there may also be short term
variations in the input to the treatment works. Such variations shall be introduced slowly so
as not to upset the performance of the treatment processes. Diurnal and seasonal
variations in demand will be met by adjustments to the input to the treatment works.
1.4 Range of output
The treatment works will be continuously operated for number of hours of operation as
specified in Design Criteria.
1.5 Hydraulic capacity of the treatment works
In addition to the requirements as specified above, the hydraulic capacity of the process
units and the relevant inter connections shall include provision for the maintenance of the
works throughput with the following operational conditions present;
1.5.1 One clarifier taken out of service for maintenance;
1.5.2 Two filters out of service, one for washing and one for maintenance;
1.5.3 One compartment of the treated water reservoir out of service for maintenance;
1.5.4 One compartment or one unit, as appropriate, out of service for maintenance of all
other units and inter connections that are necessary for the operation of the water
treatment works at the required throughput.
Overflows shall be provided between all critical treatment process units for discharge to
the site drainage system during emergencies or during commissioning of the treatment
works without affecting the operation of process units upstream of the overflow.
1.6 Forwarding pumping plant
Forwarding pumping plant in the Contract includes the raw water pumps at the intake,
the treated water pumps at the water treatment works and the treated water pumps at the
intermediate booster pumping stations.
1.7 Raw water quality
The Contractor has to take his own samples of raw water that will be adequate for
conducting a comprehensive treatability study. The result of this study shall be submitted to
the Engineer.
1.8 Treated water quality
When operated in accordance with the Contractor's instruction at flows up to the
required maximum throughput, the water treatment works treating raw water from the
reservoir shall be capable of producing a reliable and continuous supply of potable water
free of waterborne pathogenic organisms. The water quality from the works sampled after
treatment at the treated water reservoir outlet or as otherwise stated shall comply with the
"Acceptable" limits as listed in Table - 2.2 and Table - 2.3 of CPHEEO Manual on Water
Supply and Treatment.

2 PUMPING STATIONS AND MECHANICALWORKS:


2.1 General
The Contractor is required to conduct detail design for all the pumping stations
including raw water pumping, treated water pumping, intermediate booster pumping etc.
and other mechanical works as per requirements as specified and as per detailed
specifications.
2.2 Scope of Mechanical Works
The Works to be undertaken by the Contractor include but not be limited to the following;
- Design, procurement, construction, testing and commissioning of all pumping
stations and other mechanical plant,
- Design, procurement, construction, testing and commissioning of Water
Treatment Works and pumping station including raw water and clear water
transmission system and feeder mains,
- Design, procurement, construction, testing and commissioning of booster
pumping stations including and transmission system,
- Design, procurement, construction, testing and commissioning of BPTs, MBRs /
ZBTs etc.
- Undertake all necessary site investigations, surveys and testing related to the
above works.

Each of the above pumping stations and mechanical plant shall include all necessary
systems, plant, equipment, structures and protections allowing safe and undisrupted
operation and maintenance. These systems and plant may not be expressively mentioned
in the specifications but it shall be Contractor’s responsibility to undertake relevant study
and analyses and propose systems suitable for stipulated conditions and requirements.
2.3 Drawings
The Contractor shall prepare all relevant drawings as specified elsewhere for execution
of the works. The Contractor shall prepare the drawings duly considering available space,
location of site and based on detailed site survey. The equipment / machinery layout shall
be prepared duly considering sizes of proposed plant and equipment, hydraulic
calculations, etc. The submissions shall include detailed designs, drawings, procedures
and method statements required for construction of the pumping stations, all associated
systems and mechanical plants.
2.4 Works, systems and equipment common to all pumping stations
Valves and pipe work – general requirements
Pump, valves, pipe work, and their supports shall be designed to withstand the
maximum stresses imposed by any operating condition, including the shock resulting from
pump starting when the advancing inrush of water strikes the closed non-return valve.
The design maximum velocity through the valves and pump branch pipe work shall
not exceed 2.0 m/s.
The design pressure rating of valves and pipe work shall be 1.5 times the pump shut
valve pressure or 16 bar, whichever is greater.

2.4.1.1 Valves
Each pump shall be provided with a delivery non-return valve, a delivery isolating valve,
and an automatic air inlet / release valve. The air valve shall be fitted to the delivery pipe
work near to the discharge bend and upstream of the non-return valve.
A main suction isolating valves shall be provided. The valve shall be of the same nominal
size as the suction manifold. Valve shall be resilient-seated butterfly valves, fitted with
electric actuators. Air valves shall be made of ductile iron and all other valves shall be
made of cast steel. Valve operation when manual shall be by hand wheel through integral
reduction gearing. Valve operation when manual shall be by hand wheel at the level of
valve installation or from the platform / walkway at higher level (usually ground level) by
headstock. The position to operate the valve manually shall provide the highest operation
convenience to the future operators. The Contractor shall submit their proposal for the
approval by the Engineer.
Pump suction isolating valve shall be resilient-seated butterfly valves, fitted with electric
actuators. Valve operation when manual shall be by hand wheel through integral reduction
gearing.
Pump delivery isolating valves shall be resilient-seated butterfly valves, fitted with electric
actuators. Valve operation when manual shall be by hand wheel through integral reduction
gearing.
Non-return valves shall be of the swing-check type, designed for rapid closing as soon as
forward flow stops. If any closure-rate control is needed, full details shall be as provided in
the Technical Schedules at the time of Tender.
A main isolating valve shall be provided. The valve shall be the same nominal size as the
delivery manifold.
The valve shall be butterfly type with resilient seating, and manually operated by a hand
wheel through integral reduction gearing.
The valve shall be the same pressure rating as the delivery manifold.
All valves size DN250 and above, installed in the chambers within pumping station
compound shall be fitted with electric actuator. Valve operation when manual shall be by
hand wheel through integral reduction gearing in the chamber and by T key from the
chamber cover.
2.4.1.2 Pipe work
Pump suction and delivery pipe work shall be fabricated steel, with flanged connections.
Pressure ratings shall match those for valves as given above.
Dismantling joints shall be incorporated wherever needed to facilitate the removal of
pumps and valves.
Pipe work shall be protected from corrosion as detailed for exposed steel pipes
elsewhere in the Specification
2.4.1.3 Pump common delivery manifold
The pump deliveries shall be joined to a fabricated-steel delivery manifold, with flanged
connections. The manifold shall be of nominal diameter as per design. The term pipe work
shall include all necessary supports, saddles, slings, fixing bolts and foundation bolts
required to support the pipes and its associated equipment.
The pipe work shall be laid out and designed so as to facilitate the erection, painting in-
situ, dismantling of any section for maintenance and to give a constant and uniform flow of
working fluid with a minimum head loss. Positions of flanges shall take in to account any
necessary steel and concrete pipe supports or thrust blocks.
Flexible joints shall be provided where necessary to allow for differential settlement of
building structure. Wherever practical, flexible joints shall be provided with tie bolts or other
means to transfer longitudinal thrust along the pipe work as a whole. Wherever possible
standard fittings shall be used in preference to fabricated or special fittings. Facilities shall
be provided for draining the pipe system and releasing air. The drainage fluid shall be
piped into the building drainage system and the period of time for drainage shall not exceed
30minutes.
The pipe work layout within pump stations shall have the approval of the pump
manufacturer. Wherever the pipe enters and leaves the building through walls, a pipe
sleeve should be used and proper sealing to be done to make it fully water tight.
Valves, strainers and other devices mounted in the pipe work shall be supported
independently of the pipes to which they are connected.
The manifold design pressure rating shall be 1.5 times the pump shut valve pressure or
16 bar, whichever is greater. Protection shall be as specified for pump delivery pipe work.
The reducers on inlet and delivery branches shall suit the pump branch sizes and
corresponding inlet and delivery pipe branch sizes shown. Inlet reducers shall be eccentric
with flat tops.
2.4.2 Electric overhead travelling crane (EOT)
An electric overhead travelling crane shall be provided in each of pumping stations and
shall be designed to serve the pumps and all the plant installed in the motor hall, and for
water intake pumping station to lift and lower the skips provided for de-silting the pump
wells. Enough hoisting cable shall be incorporated to lower skips to the bottom of the pump
well. EOT crane shall be provided for clear water pumping stations and booster stations
also as specified in Design Criteria.
The Contractor shall determine the Safe Working Load required for the crane and capacity
shall be as specified in specifications. The pendant control shall be designed for operation
from the motor hall floor.
Crane operating speeds shall be as follows:
2.4.2.1 Long travel: Not more than 40 m /min
2.4.2.2 Cross travel: Not more than 25 m /min
2.4.2.3 Hoisting and lowering: Not more than 10 m /min

A fixed ladder with safety hand railing shall be provided for access to the crane for
servicing, and to access the maintenance platform for use when servicing high-level
lighting and ventilation units mounted in thereof.

2.4.3 Surge protection system


Hydraulic and Surge analysis

The Contractor shall carry out comprehensive steady state hydraulic analysis and
pressure (transient) surge analysis on the complete pumping system at all the pumping
stations and along the pipelines under all operating conditions. The surge analysis shall be
undertaken by independent specialist Subcontractor using a proven computer programme.
The surge analysis shall identify the most adverse transient operational conditions. The
analyses shall include but not be limited to the following conditions:
- Complete power failure to the pumping stations with all duty pumps running at
maximum capacity.
- Start up of the pumps under the specified control system
- Shut down of the pumps under the specified control system

In addition to the delivery pipeline the surge analysis shall include consideration of the
length of pipeline(s) between the pumping stations and the pressure vessel(s), and the
suction condition(s).
The objective of the surge analysis is to recommend surge protection equipment which
ensures maximum and minimum pressures under all conditions within the allowable surge
rating of the pipelines as indicated below:
- Maximum pressures shall not exceed the capabilities of the pipes and fittings on
the system.
- Minimum pressures in the system shall not fall below atmospheric pressure and
subsequently rise above atmospheric pressures again during the same transient
event. Pressures below atmospheric pressure will only be permitted as the
systems drain down through supply connections during extended periods of
pump shutdown.
The recommended solutions should include sensitivity checks to show that it is still valid
with possible variations in system parameters such as wave speed, friction factor and
system demands.
The solution should include but not be limited to the following recommendations:
- Size and details for delivery air pressure vessel (Surge Vessel)
- Details for controlling the air volume in the above vessels
- Details and alarms for monitoring the air volume in the above vessel.
- Recommendations for controlling “slam” on the pump delivery non-return valve
that may adversely affect the lifetime or operation of the valve and the system

The Contractor shall determine the required air pressure vessel capacity as per detailed
engineering, according to the transient surge analysis.
In addition to surge vessels of total capacity as arrived by calculations, the Contractor shall
install at least one standby surge vessel (for each pumping station) of the same type and
size as the proposed ones. Such surge vessel shall provide stand by capacity in a case of
releasing one of duty vessel for maintenance.
The Contractor shall furnish the surge analysis report to Engineer for approval. The report
shall include computer printouts and graphs showing maximum and minimum pressure
envelopes. The report shall also include time-flow and time pressure plots at critical points.
Surge protection may be by pressure vessel or feed tank, but flywheels to add to the pump
rotating inertia shall not be used.
Surge Vessels shall be compressed air type, designed, constructed, installed and tested as
detailed elsewhere in the Specification.
Surge vessel(s) shall be installed near, as practically possible, to the pumping stations.
2.4.4 Provision of safe access
Steel access platforms and ladders shall be provided wherever needed. The
arrangements shall ensure that all parts of the plant are made readily accessible in safety
for operation and maintenance.
2.4.5 Ventilation system
Each of the pumping stations shall be provided with a ventilation system designed to limit
the air temperature rise to not more than 5 deg. C, above the ambient, when the plant is
operating. The system shall be designed to provide uniform ventilation throughout the
pumping station to promote plant cooling and eliminate pockets of stagnant air.
The system shall be sized based on the maximum number of motors operating together,
with all the lights switched on, and with three operating personnel present, but the design
maximum air extraction rate shall be not less than ten air changes hourly for the complete
pump hall.
The system shall comprise a number of roof-mounted air extraction fans and manually
operated air inlet louvers. The fans shall be fitted with non-corrodible protective cowls and
all other protective measures needed to make them weatherproof in the climatic conditions
at the Site, including monsoon winds combined with heavy rainfall. Louvers shall be
manually operated and comprise as a minimum of removable anti-insects stainless steel
mesh and sand trap.
The air extraction units shall be designed so that routine servicing can be from the
maintenance platform on the crane and access from the roof is not needed.
Fans shall be controlled from wall-mounted contactors, accessible from pumping station
floor level.
2.4.6 Sump Pump and Discharge Pipe work

Each pumping station shall be equipped with a minimum two submersible sump pumps
(one duty and one stand by) pumping water from the sump to the location approved by the
Engineer. The sump pump shall have an integral vertical level switch and all principal
components and shall be fabricated from Grade 304 stainless steel. Pump shall be capable
of pumping solids up to 10 mm diameter.
The sump pump shall be supplied with all mechanical, electrical, I & C components,
ancillaries and materials required for installation and normal operation.
Capacity of each of the sump pumps shall be minimum 100 l/min. The pump head
shall be as per hydraulic design.
Sump pump control and electric systems shall be designed in such a way that allows both
pumps operation at the same time in a case of emergency.
Sump pump discharge pipe work within the pumping station and above ground shall be
of galvanized carbon steel and incorporate a check valve and isolation valve (as minimum)
to prevent back syphonage. Below ground, pipe work shall be made of rigid material.
2.5 RAW WATER PUMPINGSTATION
2.5.1 General
The Contractor shall design the plant to be installed in the raw water pumping station. The
arrangement shall be as per specifications.
2.5.2 Sump Model Study
To improve the performance of pumps, the Contractor shall perform sump model tests
with various pumping combinations. The sump model study shall have to be taken up and
completed before the finalization of sump design. The tests shall be conducted considering
the design parameters.
2.5.3 Mechanical plant included
Mechanical plant to be installed at the intake structure and the raw water pumping station
shall include but not be limited to the following;
2.5.3.1 inlet gratings for intake well (in case of intake well and connecting pipes)
2.5.3.2 intake screens / trash racks constructed in two levels (in case of intake channel);
2.5.3.3 set of stop logs and lifting beams;
2.5.3.4 manually operated overhead crane for intake screens and stop logs;
2.5.3.5 penstocks;
2.5.3.6 raw-water pumps;
2.5.3.7 pump delivery valves and pipe work, including delivery manifold with isolating
valves;
2.5.3.8 delivery pipe work with isolation and throttling / control valve, flow meter, and flow
meter bypass;
2.5.3.9 electric overhead travelling crane for the pump hall;
2.5.3.10 two submersible drainage pumps with flexible hose;
2.5.3.11 two sump pumps;
2.5.3.12 de silting plant and tools;
2.5.3.13 pump well ventilation system;
2.5.3.14 pump hall ventilation system
2.5.3.15 pump hall fire fighting system and other auxiliary systems,
2.5.3.16 surge protection system including surge vessels, air compressors (duty and
standby):
2.5.3.17 provision for safe access

2.5.4 Intake screens / trash racks and stop logs (in case of intake channel)
Bar screens shall be provided to protect each inlet. Screens shall be designed for easy
cleaning by manual raking. The screen free area provided shall be not less than five times
the area of the inlet which is protected.
Bars shall be spaced not more than 25 mm apart, and the screens shall be sized so that
themaximumheadlossshallnotexceed50mm.Screenbarsshallbeprovidedwithstiffeners for
reinforcement and the stiffeners shall be designed and installed to avoid impeding raking.
Rakes shall be provided, each designed for use by one man. Rake handles shall be of
non- corrodible lightweight tubular alloy. Rake tines shall fit the screen apertures and shall
be of softer material than the screen bars to ensure bars are undamaged by raking.
Raking containers shall be provided, designed for ease of handling and lifting. They shall
be free draining, with mesh apertures not larger than 25 mm square. They shall be fitted
with lifting handles designed for use by hand or with the hoist.
Stop log slots to be provided in structures and shall be fitted with channel-section inserts,
built-in to the structure during construction. Materials used for the inserts shall be corrosion
resistant and designed for long life in installed conditions at site. The slot inserts shall be
designed to ensure effective sealing with stop logs.
Manually operated overhead travelling crane shall be provided to raise the containers to
the structure top level for safe disposal as well as for lifting stop logs. The hoist shall be
fitted with a suitable hook, designed for quick attachment and release, and shall be
designed for operation by one-man.
2.5.5 Penstocks (Sluice Gate) for isolating the inlets
Manually-operated penstocks shall be installed inside the pumping station pump well to
shut off each of inlets. Each penstock shall be provided with a headstock, mounted at the
floor level, complete with extension shaft and couplings.
Penstocks and their frames shall be cast iron, and the frames shall be provided with cast
iron mounting spigots (thimbles), for building-in the frame to the structure. Penstocks shall
be the off-seating type, with rising spindles.
Apertures shall be rectangular, sized to provide a clear opening to match the inlet port
size. Penstocks shall be designed for the maximum pressure to which they could be
subjected in service.
2.5.6 2.5.6 Raw water pumps
As per requirements and specifications as specified elsewhere
2.5.7 2.5.7 De-silting plant and tools
The plant and tools to be provided for de-silting shall include:
2.5.7.1 4 No. long-handled shovels;
2.5.7.2 4 No. handpicks;
2.5.7.3 4 No. skips for loading with recovered silt.

Tools shall be of first-class commercial quality, designed for rough handling and frequent
use. Shovel blades and pick heads shall be steel, and handles of best quality ash or
hickory wood.
Skips shall be robustly built of fabricated steel, designed for hard ware and protected from
corrosion by painting. They shall be designed for emptying by tipping. They shall be
provided with handles suitable for hand carrying and for safe lifting without tipping when
using the station crane.
The total weight of each skip when fully loaded with silt shall not exceed 50 kg.

2.5.8 Pump well ventilation system


2.5.8.1 General
A ventilation system shall be provided to supply fresh air to the bottom of the dewatered
pump well during de-silting, to promote safe working. De-silting is expected to last for up to
24h, and to be needed not more often than once every 10 months. The design shall
provide not less than five air changes hourly (ACH) for pump well.
The system shall include at least two (or more) wall-mounted electric fan units, designed
to draw fresh air from outside the pumping station, and to deliver it to the pump wells
through fixed and flexible ducts.
2.5.8.2 Fans
Fan motors shall be rated for continuous operation. Fan inlets shall be protected from
ingress of harmful foreign matter by robust grilles at the inlets.
2.6 CLEAR WATER PUMPING STATION AND BOOSTER PUMPINGSTATIONS
2.6.1 General
The Contractor shall design the plant to be installed in the Water Treatment Works
pumping station.
The Treated Water pumping station shall draw water from the two chambers of the treated
water reservoir. From each chamber, an inlet pipeline shall be installed to connect to
suction manifold. Individual pump discharge line and discharge manifold in pump hall shall
be as per design. Main flow meter (and the bypass) shall be located in separate chambers
outside the pump hall.
2.6.2 Mechanical plant included
Mechanical plant to be installed at the pumping station shall include but not be limited to
the following;
2.6.2.1 Suction incoming lines with motor operated isolation valves;
2.6.2.2 Suction manifold which can be isolated with the motor operated butterfly valve;
2.6.2.3 Treated water pumps;
2.6.2.4 Pump delivery valves and pipe work, including delivery manifold with isolating
valves;
2.6.2.5 Electric overhead travelling crane;
2.6.2.6 Submersible sump pumps;
2.6.2.7 Pump hall ventilation system;
2.6.2.8 Pump hall fire fighting system and other auxiliary systems,
2.6.2.9 Surge protection system including surge vessels, air compressors (duty and
standby):
2.6.2.10 Provision for safe access:
2.6.2.11 Plant and equipment for the workshop.

2.6.3 Treated water pumps


As per requirements and specifications as specified elsewhere
2.6.4 Pumping Station Workshop
As per requirements and specifications as specified elsewhere

3 WATER TREATMENT WORKS


3.1 Treatment processes
The sequence of treatment processes proposed for the treatment works is summarized
below. Where aluminium sulphate is mentioned as a coagulant the Contractor may use
poly aluminium chloride (PAC) instead at his sole responsibility subject to the approval of
the Engineer.
Location Process Function
Works Inlet
Cascade aerator Aeration
Parshall flume Flow measurement
Mechanical mixing with The addition of Coagulation.
aluminium sulphate.
Hydraulic mixing with the intermittent Biological control.
addition of oxidizingagent.
Clariflocculator
Sedimentation Tank

Sedimentation Removal of Suspended and Colloidal

particulate matter.
Rapid gravity filtration
Filtration through sand media. Removal of flocculated particulate matter
carried over from clarifiers.
Disinfection Disinfection system proposed shall be as
per WHO standards for drinking water
Treated water storage
Hydraulic mixing with the addition of lime. Final pH correction to give a positive
Langelier Index
Storage in treated water reservoir. Balancing treated water inflow to treated
water pumped outflow
Used wash water recovery
Sedimentation of used filter wash water. Separation of supernatant for return to inlet
works and sludge discharged for further
treatment.
Sludge thickeners
Thickening of clarifier sludge and sludge Reduction of volume of sludge for further
from used filter wash water Treatment
Sludge drying beds
Removal of excess water. Increase in dried solids concentration to
facilitate handling for removal from site.
Plant Road and drains All units shall be provided with access road
for vehicular movement, hard stand area.
Proper drainage system for effective
drainage of storm water shall be provided.

3.2 Treatment works


The complete water treatment works comprising the specified processes and such other
additional or alternative processes as the Contractor may consider appropriate, together
with the associated plant shall comply with the following clauses of the Particular
Specification.
3.3 Control of the treatment works
3.3.1 Control
Overall control and monitoring of the raw water pumping station, clear water pumping
station, booster pumping stations and the water treatment works will be directed from the
control room in the filter building. Operation of plant and treatment processes will normally
be from local control centres in various buildings associated with the process units and
chemical and disinfection buildings.
Facilities in the form of instruments shall be provided to monitor critical plant states and
alarm plant faults, failures and abnormal operations on local panels as specified.
Information essential to the overall running of the treatment works shall be presented in the
control room in the filter building.
3.3.2 Operation
The treatment works shall be arranged for manual operation with the following exceptions:
3.3.2.1 Automatic Desludging of clarifiers;
3.3.2.2 Automatic filter flow control;
3.3.2.3 Automatic filter washing;
3.3.2.4 Automatic operation of disinfection system;
3.3.2.5 Automatic operation of, water supply pumps, used wash water transfer pumps
and thickener feed pumps.
3.3.2.6 Automatic Desludging of sludge thickeners;
3.3.2.7 Automatic operation of some drainage pumps as specified.

All automatic operations shall have manual override facilities as specified.


3.3.3 Ability of processes to meet variations
The treatment processes shall be capable of dealing effectively and efficiently with the
variations in raw water quality and in the throughput which are likely to occur, due both to
seasonal changes in the water quality and consumer demands.
3.4 Hydraulics
3.4.1 Hydraulics
The hydraulic loss through the Treatment Works for the maximum flow from the normal
TWL at the Parshall flume to the TWL in the treated water reservoir shall not exceed 5.00
m. The height of cascade aerator shall be as per design.
3.4.2 Overflows
The Contractor shall design and install all overflow systems complete with necessary pipe
work and channels from the point of overflow to a point of safe discharge.
All overflows shall be designed for the safe evacuation of the maximum flow at the point of
discharge resulting from the following conditions:
3.4.2.1 Restriction to water flow, e.g. excessively clogged filters.
3.4.2.2 Total obstruction to water flow, e.g. inadvertent closure of filter inlet penstocks.
3.4.2.3 Commissioning and testing of the water treatment works, and shall be provided
At the following locations;
- Inlet to the clarifiers;
- Inlet to the filters;
- Treated water reservoir;
- Used wash water holding tank;
- Clarifier sludge balance tank.

At the maximum overflow rate, the head over any overflow weir shall not be greater
than 250 mm and at the maximum design treatment flow, taking into account conditions
when the specified number of process units are not in service, the upstream overflow level
shall be at least 100 mm below the crests of the overflow weirs. Each overflow shall be
served by a level probe arranged to initiate an alarm state when the water level rises to
within 20 mm of the overflow weir level.
The hydraulic profile of the works shall be such that overflow occurs at the point in
the process stream immediately upstream of the condition causing the overflow, so that
water does not back up to other upstream overflow locations and so that no more than one
overflow occurs in the water treatment process at any time. The tanks, chambers and
channels shall be designed to accommodate the head necessary to evacuate the
maximum flow at overflows with a freeboard of at least 200mm.
The sludge balance tank overflow shall be discharged to the sludge drying beds. All
other overflows shall be discharged to the site drain.
3.4.3 Drainage
All water retaining structures and interconnecting channels and pipes shall be provided
with facilities for complete dewatering. Where practicable, provisions shall be made to allow
draining of individual process units, compartments, sections of channels and lengths of
pipes without interrupting the operation of the treatment works.
Dewatering shall be either by gravity (direct or via a sump) or using pumps or by both.
Where pumped drainage is proposed adequately sized pump sumps with portable pumps
of the submersible type shall be provided as specified
A site drainage system discharging to an approved nallah off the site of the water
treatment works shall be provided. All drainage not discharging to a specified location shall
be directed to the site drainage systems.
3.5 Inlet works
3.5.1 General
Raw water shall be delivered by pipeline from the intake pumping station through a MS /
DI pipe to the treatment works, terminating at an upturned bell mouth at the cascade
aerator. The raw water shall flow over steps of cascade aerator and shall be conveyed
through inlet channel. The inlet works shall consist of an inlet channel, a Parshall flume and
a clarifier flow division chamber unless flow division is incorporated in the clarifier block.
3.5.2 Mixing Tank
A flash mixing tank shall be provided with mechanical mixer for the dosing of aluminium
sulphate or poly aluminium chloride and oxidising agent.
3.5.3 Clarifier flow division chamber
A clarifier flow distribution chamber shall be provided unless provision for the uniform
distribution of flow from the clarifier inlet channel to individual clarifiers is incorporated in
the clarifier block.
The clarifier flow distribution chamber shall distribute flow to the clarifiers using a system
of free-fall weirs. The design of the system shall ensure that equal division of flow is
effected between the clarifiers in service at all flows up to the hydraulic capacity of the
clarifiers.
Weir penstocks (also called weir gates) on the flow division weirs shall be provided for
isolating the individual clarifiers at the flow division chamber or other equivalent
arrangements shall be incorporated in the clarifier inlet channel. The flow division weirs
could be provided in sections to enable weir penstocks to be accommodated. The
arrangements for isolation shall be provided with access.
3.5.4 Access and drainage
All structures of the inlet works including the flume and clarifier flow division chamber shall
be provided with stair access and platforms complete with hand railing for operation and
maintenance of the plant. Where structures are connected by channel, a walkway complete
with hand railing shall be provided along the side of the channel.
The clarifier flow division chamber shall also be provided with access from the top of the
clarifier.
At least one hydrant point and a high pressure hose of 20 m length complete with
hose reel, hose connector and nozzle shall be provided central to the clarifier flow division
chamber for washing and cleaning purposes.
The inlet works shall be provided with facilities for completely dewatering the pipelines,
conduits, chambers and where applicable individual compartments independently.
3.6 Mixing of chemicals
3.6.1 Location of dosing points
The points of application of chemicals shall be as specified.
3.6.2 Mixing -general
Mixing of chemicals at all dosing points shall be by high speed impellor. Hydraulic energy
for mixing at the relevant points of chemical application shall be derived from a device
which produces a head loss adequate for mixing.
Mixing of chemicals at each point shall produce the most uniform dispersion of the
chemical into the body of the water as quickly as possible. Chemical solutions shall be
diluted with an adequate amount of carrier water before dosing into the point of greatest
turbulence at the mixer.
3.6.3 Design criteria
Design requirement for each mixing point shall be as specified in CPHEEO manual.
All free-fall weirs shall be ventilated below the nappe to prevent a depressed or clinging
nappe and shall have a downstream freeboard of not less than 50 mm under the maximum
flow condition.
3.6.4 Mixing chambers
Mixing chambers at the contact tank and treated water reservoir inlets shall be fully
covered and ventilated and access to dosing facilities shall be sealed with removable
water-tight covers. All mixing chambers shall be provided with facilities for completely
draining of all water and sludge. Drainage shall be by either gravity or pumped to the site
drainage system and for gravity drainage each chamber shall be supplied with a 150 mm
diameter outlet valve and pipe work. Valves shall be provided with extension spindles and
supporting brackets and shall be operated by hand wheel.
Where gravity drainage is not feasible, facilities shall be provided for pumped drainage and
shall consist of pump sumps within the chamber.
3.6.5 Chemical dosing at mixers
Aluminum sulphate shall be dosed by an injection pipe / coagulant distributor terminating
close below the eye of the impellor. Dosing of lime shall be by perforated distributor
channel.
All distributors shall be designed to minimize clogging and provide uniform distribution.
The coagulant distributor shall be provided with removable end caps to give access for
cleaning. Two flexible wire brushes shall be supplied to serve the pipe distributors.
A hydrant and a hose complete with hose reel, hose connector and nozzle shall be
provided at mixing points for cleaning and washing down purposes.
Means of access shall be provided at the mixing points for operation of valves, flushing and
cleaning of distributors and for maintenance purposes.
All chemical injection devices at each point of application shall be provided in duplicate (1
duty, 1 standby) to allow one to be taken out of service for cleaning, without interrupting
chemical dosing.
3.6.6 Protection against chemical attack at dosing points
At locations where aluminum sulphate and other chemicals are distributed the concrete
surfaces within 0.5 m upstream and 2.5 m downstream of the dosing point, both above and
below the water surface shall be protected against chemical attack by a suitable protective
coating.
3.7 Clariflocculator
Clariflocculator design shall be as given in CPHEEO manual.
3.8 Filtration
3.8.1 General
The treatment works shall be provided with minimum number of filter units as specified in
design criteria. The filters shall be of the duplex type comprising two equal size beds
separated by a central used wash water collection channel and operating at constant rate
on the principle of influent flow division and constant water level. The under drain system
shall comprise nozzles set in a plenum concrete floor.
The filters shall be arranged in two banks located on either side of a covered central
gallery containing a walkway and filter wash consoles at high level and filter pipe gallery
and filtered water channel complete with walkway at low level.
The banks of filters shall be served by an adjoining filter building which shall house the air
scour blowers, compressors and any other equipment required for the operation of the
filters. The filter building shall also accommodate administration facilities for the works,
which shall include offices, the control room, laboratory, toilets and mess facilities. Air
blower and compressor rooms shall be sound proofed to reduce the sound level in offices
on the floor above to less than 65 dB(A).
3.8.2 Layout and design considerations
Layout and design of the filters shall comply with the following;
3.8.2.1 All filters shall be identical in dimensions and designed for combined air and water
washing using filtered and disinfected water.
3.8.2.2 Filtration shall be through sand media with depth of bed and effective size as per
manual.
3.8.2.3 Filter media shall be supported by a layer of gravel of specified depth and which
shall be placed in graded layers so as to be stable under the simultaneous
application of air and water wash unless the filter nozzle system is specifically
designed to operate with a lesser depth of gravel under the simultaneous
application of air and water wash.
3.8.2.4 The depth of water in the filter above the top of the media shall be as specified.
3.8.2.5 The design shall minimize any tendency to develop negative head in the filters;
filter outlet shall be arranged to discharge filtered water over a weir into the
filtered water channel with weir crest set at about the top level of the sand layer.
3.8.2.6 Filter run length shall be not less than 24hours.
3.8.2.7 The design shall minimize any tendency to scour the media, particularly during
filling or surface flush and to carry-over of media particularly at the start of the air
scour.
3.8.2.8 Filters shall be arranged for slow start by opening the outlet in a step wise manner
over 30 minute period.

The filter works shall be designed to facilitate sections being taken out of service for
inspection, cleaning of filters and channels and maintenance, without total loss of supply.
Stop logs shall be provided at the inlet channel to each bank of filters for isolation.
The filter design shall have been proved in service in existing installations in the tropics for
a minimum period of five years in at least three drinking water treatment works.
3.8.3 Filter media
The loss of media in the first year of operation shall be not be greater than 1% of the total
media in the filters.
Spare media shall be provided to replace that lost in the first 5 years of operation following
issue of the Performance Certificate.
The minimum quantity supplied shall be 50 m3 and shall be packed in bags and stored on
2 - way entry close boarded pallets in a location to be advised by the Engineer. Pallets
shall be shrink wrapped and shall be stacked two high.
3.8.4 Filter flow control
The filter control shall be of the equal inlet flow division, constant water level type.
The inflow to the filters shall be divided equally between filters using the pre-set overflow
weirs in the inlet to each filter. The control system shall be arranged to maintain the level of
water in each filter constant irrespective of the inflow and the head loss by modulating the
filter outlet flow control valve as necessary.
The filtration rate shall be as uniform as possible between filters any variation shall be
limited to plus or minus 5%. The water level variation in the filter shall be limited to 50 mm
during the complete filtration cycle.
3.8.5 Filter inlet and flow division
The inlet flow division weir to each filter shall be provided with a stainless steel weir plate
set in stainless steel frame with an adjustable height of at least 150 mm and an
pneumatically actuated penstock / valve for filter isolation and shall be arranged to feed the
filter by way of a central washout channel. A flow stabilising baffle shall be provided at the
inlet to each weir.
3.8.6 Filter outlet valve
The outlet pipe of each filter shall be provided with a flow control valve of the butterfly type
with a pneumatic actuator and shall be arranged to discharge into the filtered water channel
via a chamber containing an outlet weir.
3.8.7 Filter level
Each filter shall be provided with a level electrode system for terminating the drain down of
a filter and for the execution of any other operations during the wash and for initiating any
level alarms.
3.8.8 Loss of head indicators
Each filter shall be provided with a loss of head transmitter and local indicator. The unit
shall be designed and installed to eliminate air entrainment and sand ingress. The
transmitter signal shall be utilized to initiate remote indication and alarm annunciation.
In addition, each filter shall be provided with piezometer tappings to monitor head loss
across the media and outlet valve. The system shall be provided complete with all
necessary puddle pipes, strainers, manometer tubes (diameter 50 mm) and floats,
mounting boards, scales calibrated in 0.10 m minor divisions and 1 m major divisions to
show water levels, interconnecting pipes, valves and fittings.
3.8.9 Filter washing
The method of cleaning filters shall be by simultaneous application of air and water
followed by a water rinse.
Filter washing shall be automatic following manual initiation. Filter valves and
penstocks which require to be operated as part of the wash sequence shall be fitted with
pneumatic actuators of the double acting type. Except where specified the time to
open/close penstocks/valves shall be less than one minute.
It is an essential requirement of the Contract that only proven wash systems, materials and
procedures be used. Particular care shall be exercised in ensuring equality of pressure and
flow to the nozzle floor system bearing in mind the high velocities of air and water. The
Design shall incorporate such devices as may be necessary for converting velocity head to
pressure head.
Wash rates proposed shall be those of the Contractor's own proven design, but in any case
shall meet the requirements as given in CPHEEO manual.
Air supply for air scour shall be provided by Root type rotary air blowers. One or two
duty blowers and at least one standby blower of equal capacity to one duty blower shall be
provided. Air blowers shall be provided with acoustic enclosures.
Each filter shall be provided with an air release if the Contractor considers it is
necessary to remove any residual air from the plenum floor.
Disinfected water shall be used for washing filters and shall be drawn under gravity
from an elevated storage tank.
The scour air and wash water pipes shall be laid in a ring main.
The wash water supply to the filters shall be provided with a flow meter of the
magnetic type. The rate of wash water flow shall be controlled by a butterfly valve located
downstream of the flow measuring element. Operation of the valve shall be manual by
hand wheel unless the Contractor requires it to be automated for applying two different
rates for combined air-water wash and the water only rinse. The valve shall be provided
with a position indicator and a locking device where applicable. The maximum velocity
through the control valve shall not exceed 5 m/s. The valve shall be provided with access
for operation and maintenance.
The rate of flow shall be indicated local to the control valve.
Wash water shall be removed from above the media by a side weir arrangement. The
system shall be designed to:
- Remove wash water evenly from the filter and as rapidly out of the filter as
possible.
- Prevent the loss of filter media, particularly at the start of the air scour.
- Incorporate means for removal of residual solids at the end of the rinse phase.
- Be free draining on completion of the backwash.

Suspended troughs over the media surface for wash water removal will not be accepted.
Surface flush (also known as cross-wash) using clarified water may be provided and
the manner in which it is introduced onto the filter shall be such that scouring of the filter
media at the points of entry is avoided. The quantity of surface flush water used shall be
included in the computation of the wash water consumption.
It shall be possible to drain a filter, in emergencies, to waste via the wash water outlet
valve instead of draining it to supply. This is defined as a `dump' and will amount to the
volume of water formed by the full depth of water over the sand media down to the washout
weir sill. Used wash water including `dump' water shall gravitate to the used wash water
holding tanks. Dump water is not required to be included in the computation of the wash
water consumption.
3.8.10Filter sampling
Each filter shall be provided with facilities for taking a filtrate sample, which shall be
brought to an accessible point in the lower walkway gallery. Each sampling point shall be
provided with a sink complete with a drain.
3.8.11Filter performance
When operated in accordance with the Contractor's instructions at the rated throughput
using all filters less one out of service for maintenance and one washing individual filters
working together with clarifiers shall perform to the standards as specified elsewhere.
Filters shall achieve the filtrate quality specified with a minimum length of filter run of 24
hours.
Water used in washing filters (i.e. wash water and surface flush water) averaged over a 24
hour period shall not exceed 2.5% of the works input averaged over the same 24 hour
period.
3.8.12 Drainage
The filter building shall be provided with a drain sump to collect and evacuate drainage in
the filter pipe gallery.
If drainage by gravity is not practicable the sump shall be provided with two drain pumps
arranged to operate on automatic level control as duty and `duty assist'.
Pumps shall be fitted with quick release couplings and lifting chain and shall be supplied
complete with delivery and non-return valves and pipe work.
All filter plant drainage shall be discharged to the used wash water channel or to the site
drainage system.
3.8.13 Access
Access shall be provided on top of the filters as follows:
- Along filter inlet channels
- Between pairs of filters leading to the upper filter gallery
- Covered walkway between the two banks of filters.

Access shall also be provided from the filter building to the lower and upper filter galleries
and also to the opposite end of the upper filter gallery. Lower filter gallery shall be provided
with stair access from the upper filter gallery from the opposite ends. Filter wash control
panels shall be located opposite each filter in the upper filter gallery. Upper filter gallery
shall be provided with glass panels to observe the filters from the central walkway.
All access ways where necessary shall be provided with hand railing.
3.9 Used wash water disposal plant
3.9.1 General
Filter wash water after use shall be discharged to a filter wash water recovery tank from
which supernatant will be returned to the treatment works inlet at a rate not greater than
5% of the rated throughput.
3.9.2 Used wash water recovery tank
One used wash water holding tank shall be provided. The tank shall be provided with two
equal sized compartments interconnected by a penstock, to allow one to be taken out of
Service for settling of the used wash water or for maintenance, whilst the other remains
available to receive used wash water. Each compartment shall be rectangular in plan with
the floor laid to a fall and terminating in a pump sump. The capacity of each compartment
of the tank shall be adequate to store as a minimum, the wash water from two consecutive
filter washes. In sizing the tank and the draw-off systems the Contractor shall assume that
all filters will be washed consecutively spaced at 30 minutes apart.
The used wash water shall flow into an inlet channel and then through penstocks into
the compartment in use.
The inlet channel to the tank shall be provided with an overflow discharging to the
site drainage system.
Each compartment shall have a floating draw-off arm which shall be design to
remove settled water from the upper part of the tank. The floating arm shall be connected
to the draw-off connection by an articulated pipe or suitable arrangement. A restraint
system shall be provided to prevent excess movement of the floating draw-off arm and
articulated pipe during filling and when the compartment is fully emptied.
Each compartment shall have a sludge draw-off connection with a downward facing
bell mouth in the sump.
Each compartment of the used wash water recovery tank shall be provided with level
monitoring equipment for filter wash inhibit and pump control.
The Contractor shall include sufficient pedestrian access-ways in reinforced concrete,
which shall be fitted with hand railing and kick-plates on both sides of the tank and on the
common wall throughout their full length, to enable the operational staff to have ready
access around each compartment and to the inlet channel.
Means of access shall be provided into each compartment of the wash water recovery
tank.
3.9.3 Used wash water return
After a period of settling the supernatant shall be returned to the works inlet from the used
wash water recovery tank at a rate not exceeding 5% of the raw water inflow to the
treatment plant. The water remaining shall be pumped to the sludge balancing tank.
The supernatant discharge pipe at the works inlet water tank shall terminate in a
nozzle to give an exit velocity of not less than 2.5 m/s to promote mixing of the water with
the raw water. The flow in the pipe shall be measured.
The wash water recovery pump house shall be arranged as a dry basement having a
common wall with the wash water recovery tank.
Separate pumps (one duty, one standby) shall be provided for supernatant and for
sludge. Pumps shall be located below the minimum sludge level in the wet wells to ensure
that they are fully primed and operate under positive suction head at all times. Drive from
the motor to pump shall be direct and motors shall be mounted at a suitable level to avoid
the risk of flooding.
Pumps shall be of the vertical spindle, volute type arranged to draw supernatant or
sludge directly from the tank. Pump volute casing shall have integral suction and delivery
branches
And shall be constructed to permit the removal of the rotating assembly without disturbing
the branch connections.
The suction connections form each compartment shall be interconnected so that the
duty and standby pumps can draw from either compartment. The pump delivery
connections shall be manifold to a single delivery main in each case.
Operation of the pumps shall be controlled by level probes in each compartment of
the used wash water recovery tank. Pumps shall be arranged for automatic changeover
from duty to standby on the failure of the duty pump.
The sludge pumps shall be installed to minimise ingress of sand originating from the
filters. Pump design and materials shall be selected to minimize damage to the pump due
to sand in the sludge.
The installation shall be provided with all pipe work, valves, fittings, level detectors and
penstocks. Sludge pipe work shall be arranged with easily detachable joints and isolating
valves to allow any blockages to be easily cleaned.
3.9.4 Tank cleaning
At least two hydrant points shall be provided near the used wash water recovery tank for
washing down purposes. The Contractor shall provide a high pressure hose of length 20 m
complete with hose reel, connector and nozzle to serve the two hydrant points.
3.10 Sludge treatment
3.10.1General
Sludge from the clarifiers and from the used wash water recovery tank shall be thickened
before disposal to the drying beds.
Sludge works shall include the following treatment stages and plant;
3.10.1.1 Sludge balance tanks.
3.10.1.2 Thickener feed pumps.
3.10.1.3 Sludge thickeners.
3.10.1.4 Thickened sludge tank.
3.10.1.5 Supernatant and thickened sludge discharge system.
3.10.1.6 Sludge drying beds.

3.10.2Sludge balance tanks


The function of the balance tanks is to balance the intermittent sludge discharges from the
clarifiers and from the used wash water recovery tank, to provide a well mixed uniform
sludge to the thickeners and to act as a sump for the thickener feed pumps. The tanks shall
be sized to balance the intermittent flow while it is withdrawn at a steady rate and
concentration to the thickeners. The minimum criteria for sizing shall be all clarifiers
Desludging consecutively for a predetermined period every hour plus emptying of sludge
from the used wash water recovery tank.
One tank with two equal compartments of combined capacity adequate to balance sludge
discharges shall be provided.
At least one submersible mixer shall be provided in each tank and shall be designed to
maintain solids in suspension and keep the sludge fully mixed. The mixers shall comprise a
Drive unit and propeller integrated into a compact installation with guide rails, lifting chains
and davits.
Each balance tank shall be provided with level measuring equipment for pump control, to
ensure a minimum submergence required for the mixer is maintained, to prevent dry
running of the pumps and for clarifier and wash water recover tank desludge inhibit and
alarm initiation.
Balance tank compartments shall be provided with an overflow discharging to the sludge
drying beds.
A hydrant shall be provided on the tanks for washing down purposes. The Contractor shall
provide a high pressure hose of length 20 m complete with the hose reel, connector and
nozzle to serve the hydrant point. Facilities shall be provided for completely draining the
balance tank.
3.10.3Thickener feed pumps
The sludge thickener feed pump house shall be arranged as a dry basement having a
common wall with the sludge balance tanks.
The pumps shall be located below the minimum sludge level in the wet wells to ensure that
they are fully primed and operate under positive suction head at all times. Drive from the
motor to pump shall be direct and motors shall be mounted at a suitable level to avoid the
risk of flooding.
Pumps shall be of the vertical spindle, volute type arranged to draw sludge directly from the
tank. Pump volute casing shall have integral suction and delivery branches and shall be
constructed to permit the removal of the rotating assembly without disturbing the branch
connections.
Each thickener shall be provided with two pumps (one duty, one standby). The duty
pump of each pair of pumps shall be arranged to draw sludge from the two balance tanks
separately and pump to the respective thickener.
However the outlets of all the pumps shall be manifolded to allow two duty pumps
feed one thickener when the other thickener is out of service for maintenance. Each feed
pump shall have an output equivalent to at least the thickener scraper capacity.
Operation of the pumps shall be controlled by level probes in each sludge balance
tank compartment. Pumps shall be arranged for automatic changeover from duty to
standby on the failure of the duty pump.
The sludge thickener pump basement shall be provided with a drain sump and
pumps to collect and evacuate drainage in the pump area. There shall be two pumps
arranged to operate on automatic level control as duty and `duty assist'.
All drainage form the pump basement shall be discharged to the sludge balance tanks.
3.10.4 Sludge thickeners
Two thickeners of the continuous flow type suitable to thicken the sludge feed to a
concentration greater than 1.5% w/v (15 g/l) without the aid of polyelectrolyte shall be
provided. The thickener shall be designed to accept polyelectrolyte conditioned sludge in
the future and thicken it to 3% w/v (30 g/l).
The thickeners shall be sized for a nominal design surface loading rate of 0.75 m 3/h. m2 at
the maximum feed rate with both thickeners in service. Each thickener shall be
hydraulically designed to a surface loading rate of 1.5 m 3/h. m2 to permit the maximum feed
rate to be passed through one thickener.
The process design of the thickener shall be based on a proven method for continuous
thickening of coagulant sludges with and without polyelectrolyte conditioning.
Thickeners shall comprise a feed channel or pipe discharging to a central feed well, a
scraper mechanism driven by a fixed speed motor for moving sludge to a central hopper
and a peripheral launder for collecting the supernatant. The floor of the thickener shall be
laid to a minimum fall of 7.5%.
Hydrant points and a high pressure hose of length 20m complete with hose reel, hose
connector and nozzle shall be provided for washing down and cleaning purposes.
Each thickener shall be provided with facilities for complete draining.
Thickeners shall be provided with bypass facilities to allow part or all of the clarifier sludge
to be discharged directly to drying beds.
Thickeners shall be provided with access to the top of the thickener to enable cleaning of
supernatant launders and operation and maintenance of scraper drive unit to be carried
out.
3.10.5Thickened sludge collection and disposal
Sludge from the thickeners shall be discharged to the sludge drying beds by gravity. Each
thickener sludge outlet pipe shall be provided with a pneumatically operated valve arranged
to operate on timer control. Each power operated valve shall be provided with a guard
valve. Valves shall be provided with access for maintenance. Where chambers are
provided access shall be by stairs.
The thickener bypass and the overflow from the site septic tank shall also be discharged to
the sludge drying beds.
3.10.6Sludge valves
All sludge valves shall be of the eccentric plug or ball type and where specified shall be
arranged for pneumatic power operation with manual override. Each power operated valve
shall be spring loaded and arranged to fail close and shall be provided with a manually
operated guard valve.
3.10.7Flushing system
Flushing points complete with isolating valves and terminating in hose connectors shall be
provided on sludge pipe work and on both sides of all isolating valves on thickener feed
and thickened sludge withdrawal systems.
A pressure water supply complete with high pressure hoses, hose reels, nozzles and hose
connectors shall be provided.
3.10.8Thickener supernatant
Supernatant from the sludge thickeners shall be discharged by gravity to a nallah.
3.10.9Sludge drying beds
Reusable type sludge drying beds shall be provided to accept sludge from the thickeners
of concentration up to 1.5% w/v (15 g/l) without polyelectrolyte and up to 3% w/v (30 g/l)
with polyelectrolyte and dewater to a concentration greater than 15% w/w dry solids.
Dewatering shall be by settling and supernatant decanting followed by evaporation drying
and under floor drainage.
The capacity of the drying beds shall be based on the time to settle sludge, time to decant
supernatant and rainfall and time to evaporate or drain water from the sludge and rainfall in
the wettest month of the year. The capacity of the drying beds shall be adequate at least to
accommodate sludge produced over the longest cycle time of all the sludge drying beds at
the maximum rate of production of sludge. Drying beds shall be of equal or similar capacity.
Where the space available does not lend itself to drying beds of equal capacity, the
capacities shall be proportioned accordingly. A minimum of eight drying beds shall be
provided and shall be used in rotation each being in various stages of filling, dewatering
and emptying. Drying beds may be set at different levels.
The floor of the drying beds shall be comprise a graded filter and collector pipe system to
remove water from the area of the drying beds with minimum loss of efficiency. The
decanting and under-drainage systems shall discharge by gravity to a nallah at a location
to be approved by the Engineer. Sludge will be removed by mechanical or manual
scraping. Concrete strips shall be incorporated in the floor to permit the passage of plant
and to provide a bed reference level which will facilitate the removal of the sludge without
damage to the drainage layer.
Individual beds shall be separated by reinforced concrete walls which shall provide a
minimum of 300 mm freeboard when the higher of adjacent drying beds is overflowing.
The decanting system shall include manual weir penstocks which shall be accessible
at all times and which shall also serve as overflows. The weir penstocks shall be located on
the side opposite to that on which the inlets are located and shall discharge to a common
collection channel.
The inlet pipes shall discharge onto splash slabs so that there is no damage to the beds.
The under-drainage of each drying bed shall discharge to a manhole on the drainage
collection system so that the flow from individual drying beds can be inspected.
Concrete access ramps into the drying beds shall be provided. Ramps shall be at least
3 m wide and set at a maximum gradient of 20%. Slope transitions shall be provided at the
top of the ramps. Road access shall be provided around the area of the drying beds for
transportation of the sludge by tipper trucks to remote landfill sites.
3.11 Chemical treatment
3.11.1List of chemicals
The chemicals to be used shall be as specified elsewhere in the document.
3.11.2Chemical building -layout
The facilities comprising storage, handling, slurry/solution preparation and dosing for
chemicals shall be housed in the chemical building or buildings as per requirement. The
flowing description applies to the provision of one building, which shall be a separate self-
contained building comprising the following;
3.11.2.1 A segregated area on the ground floor for aluminium sulphate and hydrated lime
storage if required.
3.11.2.2 An area in the basement for aluminium sulphate solution and hydrated lime
slurry preparation and transfer area.
3.11.2.3 An area on the first floor for lime saturators if required and aluminium sulphate
constant head tank and metering equipment.
3.11.2.4 An electrical switch room.
3.11.2.5 Toilet, wash room and shower room.

If separate buildings are to be provided then the requirements shall be the same except
that the buildings shall be specifically for aluminium sulphate or hydrated lime.
A separate building shall be provided for disinfection system.
3.11.3Chemical building - storage and reception
Aluminium sulphate and lime will be manually unloaded from delivery vehicles on to
pallets for conveying to storage.
The basis for sizing storage space for bags of lime shall be that they will be stacked on
pallets to a height not more than 1.5 m. Aluminium sulphate shall be stored loose on the
floor in bunkers of width about 3 m to an average height of about 1 m. Transfer of bags and
blocks from delivery vehicle to storage area shall be by pallet truck. Movement of bags and
blocks in the storage area and to slurry/solution preparation area shall be by pallet truck.
The storage space for aluminium sulphate and lime shall be estimated on the basis of
average dose x maximum throughput x 30 days.
The aluminium sulphate storage area floor and the walls up to the storage height shall be
protected by a 5 mm thick trowel applied epoxy mortar.
3.11.4Chemical building -drainage
Slurry/solution preparation and stock tanks shall be located in the basement of the
chemical building. Floor drains shall be provided to collect overflow, spillage leakage and
drainage from the tanks and discharge by gravity to a chemical waste holding tank in the
basement of the chemical building. The drains shall be provided with open mesh flooring of
GRP construction.
The contents of the chemical waste holding tank shall be pumped to the clarifier sludge
balance tanks. There shall be two pumps arranged to operate on level control as duty and
duty „assist'. The pumps shall be arranged for control on level in the tank using a system of
level electrodes.
The basement floor, plinths, drains and waste holding tank and the walls up to 300 mm
shall be protected by a 5 mm thick trowel applied epoxy mortar.
3.11.5 Chemical handling
Equipment provided for handling chemicals shall include the following;
3.11.5.1 Hand powered hydraulic pallet trucks each with a lifting capacity of not less than
1500 kg and 10 Nos 4-way entry open deck reversible pallets of approximate size
1200 x 1200 mm for transfer of lime and aluminium sulphate.
3.11.5.2 2 - Way entry closed deck non-reversible type pallets for lime bag storage, each
of timber construction and approximate size 1200 x 1200mm.
3.11.6Chemical plant safety
The following safety equipment shall be provided to serve the chemical building:-
3.11.6.1 One safety shower (complete with eyebath)
3.11.6.2 20 Face masks each containing disposable dust masks for lime handling area.
3.11.6.3 Protective clothing as specified.
3.11.6.4 Goggles.
3.11.6.5 First aid boxes.

3.12 Aluminium sulphate


3.12.1General
Aluminium sulphate shall be stored in the chemical building, transferred to saturator tanks
and drawn by pumps as a saturated solution which shall then be diluted to a 10% w/v (100
g/l) solution in stock tanks, transferred to constant head tank for metering under gravity to
the point of application. The plant for storage, solution preparation, solution transfer and
dosing shall be provided.
3.12.2Saturators
Saturators constructed in concrete shall be provided. The tanks shall be lined with fiber
reinforced plastic.
The water shall be introduced along the length of the saturator by a spray bar and
the inlet shall be provided with a float operated isolating valve and a guard valve. The time
to fill a saturator with water from empty to full shall be not more than one hour. Each
saturator shall be provided with piped saturated solution collection system placed in a layer
of gravel.
The outlet shall be provided with a manual isolating valve and a strainer and the
recirculation return pipes shall be provided with a manual isolating valve. Saturators shall
be provided with a drain discharging to the waste holding tank in the chemical building. The
outlet pipe shall be provided with a flushing connection to back flush the gravel bed in the
saturator via the overflow to waste.
The float valve and any other fittings shall be located within stainless steel
compartments inside the saturators to protect them against damage from blocks of
aluminium sulphate.
3.12.3Saturated solution recirculation and transfer
Two pumps (one duty, one standby) shall be provided for recirculation and transfer of
a saturated solution and the pumps shall be of the centrifugal type.
The pumps shall be arranged to draw a saturated solution of aluminium sulphate
from any selected saturator downstream of the strainer and return to the same saturator.
Each pump shall be sized to turn over the solution in a saturator (making an allowance for
the solid present) in less than 2.5 hours. The pumps shall also be arranged to transfer the
solution from one saturator to another. The capacity of each pump shall be not less than 11
m3/h.
The same pumps shall be used to transfer aluminium sulphate from the saturators to the
stock tanks.
The transfer pumps shall be provided with all necessary isolating and non return valves,
pressure gauges and facilities for flushing the pumps.
3.12.4 Stock tanks
The saturated solution containing approximately 70% w/v (700 g/l) of solid as 15.2% w/w
Al2O3 shall be diluted in the stock tanks to a concentration of 10% w/v (100 g/l).
The dilution process shall comprise transfer of a known volume of saturated solution to the
stock tank followed by the addition of water to the maximum level in the tank and mixing of
the contents.
Two GRP lined concrete tanks shall be provided. Each tank shall be equipped with a
mixer. The tanks shall be arranged to operate on a rotational batch basis.
The stock tanks shall be provided with a water supply for in-tank dilution.
The water inlets, solution inlets and solution outlets shall be provided with manually
operated isolating valves. Tanks shall be provided with a valve drain. A strainer shall be
provided on each outlet.
Each solution tank shall be provided with level probes for monitoring the level in the tanks,
level sensors for measuring the volume of contents in the tank and sight glass type
contents monitoring device calibrated in litres.
3.12.5 Diluted solution feed to constant head tanks
Two feed pumps (one duty, one standby) of the centrifugal type arranged to draw the
chemical from any one of the selected stock tanks and feed a constant head tank shall be
provided. The pumps shall be rated at least 15% in excess of the maximum aluminium
dosing flow rate.
The feed pumps shall be provided with all necessary isolating and non return valves,
pressure gauges and facilities for flushing the pumps.
3.12.6 Constant head tank
One constant head tank of fiber reinforced plastic construction shall be provided. The tank
shall be arranged to operate as a constant head tank by providing a supply of aluminium
sulphate solution in excess of the maximum outflow from the tank for the coagulation
process and discharging the excess as overflow to the stock tanks.
The tank shall be provided with a high level return pipe arranged to return the excess flow
(the difference between the inflow and the outflow) to the duty stock tank and thereby
maintaining a constant head in the tank. The return pipe shall be provided with a manual
isolating valve on each branch to the stock tanks. In addition, the tank shall be provided
with an overflow discharging to the chemical house drainage sump.
The tank shall be located at such a level to ensure gravity dosing of aluminium sulphate to
the point of application.
The tank shall be also provided with an outlet complete with a strainer and an isolating
valve and a valved drain.
The tank shall be provided with level probes for monitoring the level in the tank.
3.12.7Aluminum sulphate dosing
Aluminium sulphate solution from the constant head tank shall be conveyed to the point of
application by gravity. The point of application shall be provided with a minimum of one
duty variable area flow meter.
Flow meters shall be provided with inlet isolating valves and outlet flow regulating valves.
The flow meters shall be man folded on the upstream side. The manifold shall be provided
with flushing facilities. One dosing line shall be provided and shall be terminated in two
perforated distributor pipes provided complete with isolating valves and flushing connection
at the point of application.
3.13 Hydrated lime
3.13.1General
Lime shall be stored in the chemical building, manually emptied into tanks for preparing a
5% w/v (50 g/l) slurry and then transferred by pumps to lime saturators for metering to the
points of application.
The plant for lime storage, handling, slurry and solution preparation, metering, and transfer
shall be provided.
3.13.2Slurry preparation tanks
Vertical concrete tanks shall be provided. The concentration of lime slurry prepared in the
tanks shall be 5% w/v (50 g/l).
Each tank shall be provided with a cover complete with a dust filter sock and a hinged
access hatch. A bag loader sized for taking bags up to 50 kg capacity shall be provided on
each tank. Tanks shall be equipped with slow speed paddle type or similar mixers for
mixing lime and keeping lime in suspension.
The tanks shall be provided with a water supply. Water inlet and slurry outlet shall be
provided with isolating valves. A valve drain shall also be provided on each tank.
Each slurry tank shall be provided with level electrodes for level monitoring.
3.13.3Slurry transfer pumps
Lime slurry transfer pumps shall be of the open impeller centrifugal type. Two pumps (one
duty, one standby) shall be provided. Each pump shall be arranged to draw lime from any
selected slurry tank and pump separately to a selected saturator. Each delivery pipe shall
be provided with a magnetic flow meter with local and remote indication.
Pumps shall be provided with pressure gauges Flushing connections shall be provided on
pumps, pump suction manifold, pump delivery saturator manifolds and the manifolds at
each saturator.
3.13.4Saturators
Saturators shall be designed to prepare a saturated solution of lime. The concentration of
a saturated solution is about 1.53 g/l at 30oC. In practice, the concentration of lime that can
be expected from a saturator is estimated to be about 85% of the theoretical value. The
Contractor shall use his previous experience in similar applications to arrive at a design
value for the lime concentration from a saturator.
Vertical steel saturators shall be provided for meeting the pre and post lime dosing
requirements. One set saturators shall be assigned for pre-lime dosing and set saturator
shall be assigned for the post lime dosing points. The use of inclined plates in the saturator
to increase the surface loading rate of the saturators will not be acceptable.
The saturators shall be located on the first floor of the chemical building.
All pipe work conveying lime solution desludging of the saturators shall be manual.
Sludge shall be conveyed by open channel to a pit outside the chemical building for manual
removal and offsite disposal. The overflow from the pit shall be discharged to the drying
beds via the site drainage system.
The proposed saturator design shall have been proved in service in existing installations
operating on similar quality of lime at the specified or higher rates for a minimum period of
five years.
3.13.5Lime dosing
Lime solution from the saturators serving each dosing point shall be combined as
applicable and shall be metered to the points of application by gravity. Each point of
application shall be provided with a minimum of one duty variable area flow meter. An
equal number of standby flow meters of equal capacity to the duty flow meters shall be
provided for each application.
Flow meters shall be provided with inlet isolating valves and outlet flow regulating valves.
The flow meters serving each point of application shall be separately manifolded on the
upstream side. The manifolds shall be provided with flushing facilities. Each dosing point
shall be provided with dosing lines which shall be terminated in two perforated distributor
channels provided complete with isolating valves and hosing down connection at the point
of application.
The Contractor is at liberty to propose proven alternative methods for manual lime dose
control.
3.14 Sampling and monitoring
Facilities shall be provided for taking and conveying continuous samples from the following
locations on the plant to the laboratory:
3.14.1 Raw water (inlet to the inlet flume).
3.14.2 Dosed water (inlet to the clarifier).
3.14.3 Clarified water (clarified water pipe to the filters).
3.14.4 Filtered water (filtered water pipe to the contact tank).
3.14.5 Treated water (inlet to the treated water reservoir after lime addition)
3.14.6 Final water to supply (treated water reservoir outlet).

Each sample point shall be provided with means of extracting the sample at a rate not less
than 2.5 l/minute, a sample pump (where necessary) of the centrifugal type and pipeline of
nylon or flexible reinforced PVC construction for conveying the sample to the laboratory. All
sample lines shall be laid in trenches provided with covers and protected from the sun light.
Pumps shall where possible be located under cover in the nearest building. Where this is
not possible the pumps shall be located in a weather-proofed kiosk. A standby sample
pumps are not required. One spare pump common to all installed pumps shall be provided
and kept in store.
A sink shall be provided in the laboratory dedicated for receiving the samples. Each
sample tap shall be appropriately labeled.
Treated water quality at (e) above shall be continuously monitored for pH and turbidity. The
instruments shall be mounted on a backboard and shall be located in the laboratory. Each
Instrument shall be provided with local indicators. The Contractor is at liberty to derive the
sample to the instruments from the sample delivered to the laboratory, provided the sample
flow to the instruments is not influenced by the sample flow to the laboratory.
3.15 Treatment works water supply system
3.15.1General
A treated water supply shall be provided to serve the treatment works service water supply
requirements include the following:
3.15.1.1 Process water for the preparation of chemical solutions /slurries.
3.15.1.2 Motive water
3.15.1.3 Safety showers.
3.15.1.4 Water for flushing chemical and sludge pipelines.
3.15.1.5 Water for washing down purposes.
3.15.1.6 Domestic potable water for all buildings and the laboratory.
3.15.1.7 Irrigation water.

Sufficient pressure shall be maintained in the system at all times for all service conditions
by means of an elevated storage tank, but if necessary also by pumps or hydro pneumatic
booster system. The elevated storage tank specified for storage of filter wash water shall
be used to store the site service water requirements specified above.
3.15.2Elevated water storage tank
A fully covered storage tank of concrete construction shall be provided. The tank shall
have two interconnected compartments of equal capacity with isolating facilities to enable
one compartment to be taken out of service for cleaning and maintenance.
The capacity of the tank shall be adequate to provide water for two consecutive filter
washes, all continuous water requirements and the simultaneous use of one flushing point,
two washing down points and two safety showers.
The supply to each compartment shall be provided with an isolating valve. Each
compartment shall be provided with a level transmitter and level switches for monitoring /
measurement. The two compartments shall be provided with overflows and valved drains.
Each compartment shall be provided with separate outlets for filter washing and site water
supply.
The tank shall be located independently supported on RCC framed structure. The
elevation of tank shall be adequate for the requirements of backwashing.
Access shall be provided to the tank, around the tank in particular to the level monitoring
equipment, drains and isolating valves.
3.15.3Works water supply pumps
Two pumps of the horizontal radial flow type (one duty, one standby) shall be installed in
the treated water pump station, arranged to draw treated water from the treated water
reservoir.
The capacity of each pump shall be sized on the assumption that all the filters will be
washed consecutively spaced at 30 minutes apart and shall not be less than 5% of the
maximum works input.
The operation of the pumps shall be automatic, controlled on level using a system of level
probes in the storage tank.
The pumps shall be provided with all necessary suction and delivery pipe work, isolating
and non return valves, pressure gauges and instrumentation and control system.
3.15.4Works water supply boosting system
Water for flushing and hosing down duties shall if necessary be boosted by using either
booster pumps (one duty, one standby) or a hydro-pneumatic type boosting system.
The hydro-pneumatic system shall consist of two booster pumps (one duty, one standby)
drawing water from the works water supply system and operating in conjunction with a
precharged diaphragm pressured air/water vessel of suitable capability.
The boosting system shall be designed to satisfy conditions of maximum water demand as
would occur in the event of simultaneous flushing of all duty dosing/feeder/transfer pumps
and the operation of at least four hosing down points. The start/stop operation of the
booster pumps shall be on pressure in the air/water vessel, controlled by a pressure switch
in the supply water line.
The system shall be supplied as a package unit, complete with all necessary valves,
pressure gauges, control switches, starters, fuses and other associated electrical
equipment, all contained in a composite control panel; volt free contacts shall be provided
to indicate unit in operation and unit failure alarm on a remote panel.
The high pressure system if provided shall be separated from the low pressure process
water system.
3.15.5Loop system
The main supply system shall be in the form of a loop or loops, with arrangements made to
ensure continuity of supply in case of a break or interruption at any point. Pipe diameters
shall be amply sized to permit maximum flows under service conditions.
3.15.6Pipe work
All pipes shall be laid underground with 1 m minimum cover. Valves and air valves shall
be provided in drained chambers where required. Valve wash water branches with effluent
drain systems shall be provided at low points in the main system to permit sections of the
loop to be emptied when necessary.
Service connections shall be provided from the main system to all buildings and points of
individual demand or likely demand, and where required for washing down, e.g. chemical
building, clarifiers and filters, and for general purposes. Branch lines shall be connected to
points of demand by properly designed assemblies, with backflow and excess pressure
protection and by-pass draining. The number of washing-down points to serve a particular
area shall be determined on the basis of a maximum hose length of 20 m. Washing-down
points for each area shall be provided with the required number of hoses complete with
hose reels, connectors and nozzles all suitably mounted and shaded from sunlight.
3.16 Laboratory equipment
3.16.1General
The works shall be provided with a laboratory equipped for routine monitoring of
parameters necessary for process control including setting of chemical doses as follows:
3.16.1.1 pH value;
3.16.1.2 Turbidity(NTU);
3.16.1.3 Colour (true);
3.16.1.4 Total alkalinity
3.16.1.5 Aluminium concentration
3.16.1.6 Jar testing.
3.16.1.7 Specific gravity of chemical solutions
3.16.1.8 Bacteriological quality

3.16.2Laboratory equipment
The following equipment shall be provided:
• 1 No. Laboratory pH meter with combination electrode and temperature
compensation;
• 1 No. Spare combination electrode for the pH meter above;
• 1 No. Laboratory turbid meter to cover the range 0.1 to 1000 NTU including six
o sample cells and standards (Hach 2100N or equivalent);
• 1 No. Laboratory Spectrophotometer to cover wavelength range of at least 330
to 900 nm, with facility to accept cells from 10 to 100 mm. Single beam
instrument with microprocessor control. To include spare tungsten-halogen
lamp, cell holders as appropriate for 10 and 40 mm cells and 2 pairs of each of
10 mm and 40 mm cells. (Hach DR/4000 or similar)
• 1 No. Lovibond type Nessleriser with integral comparator including six sample
tubes (50 ml) and disc for colour (0 to 70 Haze units);
• 2 Nos. Comparator (Lovibond type) with twenty sample cells for analysis by
DPD method, discs for the range 0.1 to 1.0 mg/l and 0.1 to 4.0 mg/l residual
chlorine;
• 3 Nos.Hydrometers calibrated in specific gravity units with the range1.000 to
1.200 for measuring lime slurry of concentration at 50 g/l;
• 1 No conductivity meter complete with a graph of conductivity against
concentration at 30oC to measure saturated limewater concentration;
• 3 Nos Hydrometers calibrated in specific gravity units with the range1.000 to
1.400 for measuring saturated aluminum sulphate concentration;
• 3 Nos Hydrometers calibrated in specific gravity units with the range1.000 to
1.200 for measuring diluted aluminum sulphate of concentration 100 g/l;
• 1 No. Jar tests apparatus of the 4 jar unit type with adjustable speed control,
illumination and timer including 10 No. 1 litre jars;
• 1 No. Water deionization unit of capacity 10litres/hour;
• 1 No. Aspirator, heavy duty high density polyethylene (HDPE) construction, with
screw in tap; 50 litre capacity;
• 1 No. Aspirator, heavy duty HDPE construction, with screw in tap; 10 liter
capacity;
• 10 Nos. Plastic sample bottles with screw caps of capacity 500m;
• 10 Nos. Plastic sample bottles with screw caps of capacity 1000ml;
• 4 Nos. Plastic buckets of capacity 10litres;
• Beakers, Pyrex, low form with spout (10 Nos. capacity 100 ml., 5 Nos. capacity
250 ml. and 5 Nos. capacity 1000ml);
• 5 Nos. Wash bottles capacity 600ml;
• Filter Papers (Whatsmann) 15 cm diameter (10 Nos. boxes No. 1 Grade and 10
No. boxes No. 42Grade);
• 10 Nos. Funnels, plain glass, conical, 75 mm diameter;
• Beakers, low form with spout; (5 Nos. 100 ml; 5 No. 250 ml; 5 Nos. 600 ml; 4
Nos. 1000 ml; 2 Nos. 2000ml)
• Burette, schellbach, Class B, with interchangeable PTFE key (2 Nos. 50ml)
• Retort stand base, stainless steel, 210 x 130 x 8 mm; with threaded retort rod,
750 x 12.5 mm. (2 Nos. of each).
• Retort stand boss and clamp (5 Nos. of each)
• Measuring cylinders, polypropylene with spout (5 Nos. 25 ml., 5 Nos. 50 ml., 5
Nos. 100 ml. and 2 Nos. 1000ml.);
• Volumetric flasks BS 1792 Class B type, with poly stop (5 Nos. 100 ml., 5 Nos.
250 ml., 5 Nos. 500 ml. and 5 Nos. 1000ml.);
• Erlenmeyer flask, DIN 12387 (5 Nos. 200ml)
• Pipettes, straight sided BS 700, Class B, graduated to deliver fast flow (10 Nos..
1 ml., 10 Nos.. 2 ml., 10 Nos. 5 ml. and 10 Nos. 10ml.);
• Pipettes, bulb, Class B, BS 1583 (2 Nos. 10 ml; 2 Nos. 25ml.)
• 2 Nos. pipette fillers;
• Nessler tubes (20 pairs 50 ml. and 5 pairs 100ml.);
• Racks for Nessler tubes (5 Nos. 50 ml. and 2 Nos. 100ml.);
• Bacteriological test equipment;

Chemical Reagents
• Aluminum standard solution; 1000 mg/l 2 x 500ml
• Ammonia 35% solution 4 x 1000ml
• DPD tablets No 1 (comparator) 2000No.
• DPD tablets No.3 (comparator) 2000No.
• Hexamine 4 x 500g
• Hydrochloric acid (2N) 6 x 1000ml
• Hydroxyl ammonium chloride 2 x 500g
• Indicator solution, BDH 4.5 2 x 500ml
• 1, 10 Phenanthroline hydrochloride 6 x 5g
• Pyrocatechol violet 2 x 5g
• Sulphuric acid, 0.02 N (0.01 M), CONVOL 3 carton x 6ampoules

All chemicals to be of Analytical Reagent (AR) or equivalent grade


The Contractor shall provide step by step procedures for carrying out the determinations
for pH, turbidity, aluminium, alkalinity, and jar tests. Hydrometers shall be provided with
graphs for specific gravity against concentration in g/l and %w/v.
3.16.3 Room Specifications
The laboratory room shall be provided with the appropriate benching and furniture suitable
for use in the laboratory environment. Cupboards shall be provided for storage of
glassware, equipment and other items.
There shall be two sinks each provided with a water supply terminating in swan neck taps
and draining board. A further sink shall be provided to receive water samples pumped from
the process as specified. The deionization unit shall be provided with a separate water
supply.
There shall be at least four twin power points located at bench top level distributed around
the laboratory.
Drainage from the laboratory shall be discharged to the site drainage system.
3.17 Miscellaneous requirements
3.17.1Compressed air plant
A plant to supply compressed air for actuation of filter valves, clarifier Desludging valves
and thickener Desludging valves shall be provided and located in the filter building. The
plant hall comprises one duty and one standby compressor and one duty and one standby
receiver. The plant shall be supplied as necessary with air dryers, filters and lubricators.
3.17.2Lifting equipment
The Contractor shall supply lifting equipment such as gantries, hoists, cranes, shear legs,
davits etc for the operation and maintenance of all mechanical and electrical plant and
equipment, pipe work, stop logs etc. provided both in buildings and outside in the open.
The lifting equipment such as monorail/hoists in pumping stations and chemical building
shall be permanently installed. The lifting equipment for external plant shall only be
permanently installed if the equipment is not portable.
Storage facilities shall be provided for portable/mobile lifting equipment and stop logs.
Trolleys, trucks, containers etc shall be provided for transporting plant/equipment which are
heavier than 50kg or bulky to be man handled between user points or workshop and
storage facilities.
3.17.3Access equipment
The Contractor shall provide all necessary mobile/portable access equipment for
operation and maintenance of plant where permanent access is not provided. The
equipment shall include but not be limited to safety steps, safety ladders and access
platforms.
3.17.4Spacer pieces for flow meters
The magnetic flow meters of each size shall be provided with a spacer piece of pipe of the
same length to enable works to be operated when flow meters have to be removed for
maintenance.
3.17.5Portable submersible pumps
A minimum of two portable submersible pumps of different capacities shall be provided for
dewatering chambers and sumps which cannot be drained by gravity.
3.17.6Plant identification
All plant, equipment, instruments, panels, pipe work and valves and manholes shall be
identified and safety signs shall be provided where appropriate
4 PARTICULAR SPECIFICATIONS – ELECTRICAL WORKS
4.1 Scope of Works
This section covers the particular requirements for the provision of electrical site works for
the raw water intake works, raw water pumping stations, water treatment plant, treated
water pumping station, booster pumping stations etc.
The Contract shall include the design, manufacture, testing at manufacturers' works,
delivery to Site, off-loading, storage, erection, testing, commissioning and setting to work
the complete electrical works for all sites including but not limited to;
4.1.1 KPTCL Electricity supplies including dedicated express feeder mains
4.1.2 High voltage switchboards, motor control centers and motor starters;
4.1.3 Low voltage switchboards, motor control centers and motor starters;
4.1.4 Battery units for switchgear operation;
4.1.5 Power factor correction equipment;
4.1.6 Local control units including emergency stop and start/stop or open/close
pushbuttons, local control panels, cable marshalling boxes and cable termination
boxes;
4.1.7 Uninterruptible power supply units;
4.1.8 Power, control, instrumentation, network and telephone cabling installations;
4.1.9 Earthing system and lightning protection installations including soil resistivity
survey;
4.1.10 Harmonic filtering equipment if necessary for complying with local Codes,
Regulations and KPTCL's requirements;
4.1.11 All cabling, termination and cable containment works;

The electrical plant, cabling and earthing installations shall comply with Standard
Specifications and the following clauses herein. Where the Drawings, Standard
Specification and Particular Specification differ, the latter shall take precedence.
4.2 General electrical requirements
4.2.1 Design considerations
The Contractor shall design the electrical installation taking into consideration the following;
4.2.1.1 Location and maximum power demand of all loads;
4.2.1.2 Availability and reliability of supply;
4.2.1.3 Prospective short-circuit current;
4.2.1.4 Environment in which electrical plant is located;
4.2.1.5 Ambient temperature, humidity and its effect on the rating of switchgear,
transformers, cables and generating plant;
4.2.1.6 Method of cable installation;
4.2.1.7 Cable transient and steady state volt-drop on motor starting;
4.2.1.8 Transient volt-drop on motor starting at point of supply;
4.2.1.9 Electrical protection discrimination;
4.2.1.10 Ground earth resistivity;
4.2.1.11 Overall system power factor shall be minimum0.95;
4.2.1.12 Total harmonic distortion;
4.2.1.13 Effective operation, control and monitoring of plants;
4.2.1.14 Easiness and effectiveness of maintenance.
4.2.2 Environmental conditions
All Plant shall be designed and manufactured for continuous operation under the specified
climatic and environmental conditions as detailed elsewhere within the Specification.
4.2.3 Estimated power requirements
The Tenderer shall submit estimated installed and running loads and distribution
schematic diagram with rating of major equipment for each site and calculate the estimated
available load required as part of his Tender submission.
Load computations for sizing all equipment/cables shall consider present load, future
expansion and 20% design margin on the total value.
The Contractor shall update the preliminary load schedule during the detailed design stage,
finalize plant ratings and submit all calculations to the Engineer for approval.
4.2.4 Electrical distribution system
The electrical distribution systems shall be designed to provide;
4.2.4.1 Redundant transformer shall be provided for supplying switchboards and MCCs
for each pumping station. Each transformer of a transformer pair shall have the
capacity to support the maximum connected duty load. The connected loads shall
be shared evenly by the transformer pair during normal operation.
4.2.4.2 Switchboards and MCCs shall be provided with a bus coupler to enable change
over in case any one of the transformer failed.
4.2.4.3 Operational flexibility.
4.2.4.4 Ease of maintenance with minimum operational disruption to the operation of the
works.

The Contractor shall determine the equipment quantity, equipment rating, equipment
location, and suitable distribution network and protection scheme.
The configuration of the main distribution system and sub distribution system shall be
determined by the Contractor.
4.2.5 Electricity supply
`The high voltage electricity supply to each pumping station, booster station and water
treatment works shall be drawn by dedicated feeders from local Electricity Boards via 33/11
kV overhead lines as detailed herein.
The Electricity Board contract interface shall be the 33/11kV metering panels incoming
cable boxes or termination chambers at the switchgear of Electricity Board. The cables
connecting to the switchgear of Electricity Board from the incomer switchgear of the
Electrical Works of this Contract shall be provided by the Contractor.
All liaison works for the procurement of the Electricity Board supplies shall be included
within the Contract Price.
4.2.6 Electricity Board supply system data
a) Voltage: 33/11/6.6kV
b) Frequency: 50Hz
c) Voltage tolerance: plus or minus10%
d) Frequency tolerance: plus or minus5%
e) Neutral earthing: direct
f) Three phase maximum fault level: Based on Actual tapping conditions.

4.2.7 Liaison with Electricity Board


The Contractor shall be responsible for;
4.2.7.1 Confirming short-circuit and earth fault current data.
4.2.7.2 Finalizing supply capacity and supply scheme.
4.2.7.3 Establishing any special Electricity Board requirements.
4.2.7.4 Finalizing protection relay characteristics, settings and co-ordination.
4.2.7.5 Agreeing procedures and responsibility for connection of incoming feeder
cables to the metering panel and pre-commissioning testing.
4.2.7.6 Responsibility of co-ordination with Electricity Board for overhead line work.

Liaison with the Electricity Board shall be by the Contractor through the Engineer.
4.2.8 Liaison with Electrical Inspectorate
The Contractor shall be responsible for all the works required for obtaining all design
approvals necessary from the local Electrical Inspectorates / Chief Officer as well as
obtaining a sanction for energizing the new supplies. All liaison with the Electrical
Inspectorate shall be by the Contractor through the Engineer.
4.2.9 Electricity Board Metering Requirements
The Contractor shall be responsible for coordinating all designs with Electricity Board.
The Contractor shall provide metering CTs, electricity maximum demand watt meter and
testing terminals in accordance with the requirements of Electricity Board as detailed
below. Meter shall conform to standards IEC 1107, IEC 1000-4, IEC 255, IEC 60687 in
concurrence with IS 13779 and IS 14697. All metering equipment including VTs and CTs
shall be housed in HV metering panels which shall be fully sealed and self-contained to
ensure Electricity Board metering seals can be installed. Prior to procurement of any
equipment, the Contractor shall submit full technical details of the proposed plant to
Electricity Board.
(a) Metering Voltage Transformer (VTs)
VTs shall be provided for the main switchboard. Tappings from each VT compartment shall
be used to provide a supply to the separate Electricity Board metering compartment.
(b) Metering Current Transformer (CTs)
Separate metering summation CTs shall be provided. The CTs shall have an accuracy
class of better than 0.5. In any case total metering error shall be less than 1%.
(c) Electricity Maximum Demand Wattmeter
The Contractor shall provide electricity maximum demand watt meter located within the
metering panel. The meter shall be programmed in accordance with Electricity Board
requirements. Prior to procurement of the meter the Contractor shall confirm latest
requirements of Electricity Board.
4.2.10 Utilisation voltages
(a) High voltage 33kV, 11kV, 6.6kV or 3.3kV three phase to suit plant
rating. 33kV incomer for capacity demand above
5MVA in accordance with the Distribution Code of
Electricity Board.
(b) Low voltage 415V three phase
(c) Control Low Voltage - AC, 415, 3phase, 4 wires, 50Hz.
Lighting & space heating - AC, 230V, 3phase, 4
wires, 50Hz.
AC Control - 240V single phase for anti-
condensation heater, instrumentation and LV motor
starter control, motor starter control and indication
lamps. .
UPS Supply - AC, 110V(filed Instruments and PLC
system)
DC Supply -110V for high voltage switchboard
control, protection, circuit breaker motor charging

4.2.11 Neutral Earthing


The 415V transformer winding neutral shall be solidly earthed.
The 1600kVA and above rated Transformer winding neutral shall be earthed through
resistance. The selected value of resistance should restrict the earth fault current below the
full load current of the largest drive/motor in the system. Time rating of neutral earthing
resistor shall be 10 sec. Necessary provisions in the protection systems shall be made to
avoid adverse impact on sensitivity of protection relays. The works high and low voltage
earthing systems shall be interconnected.
4.2.12 System voltage drop
(a) Steady state
Under normal service conditions the volt-drop at the terminals of the fixed current using
equipment shall not be greater than 4% of the nominal voltage of the supply except where
a lower value is necessary for the:-
- satisfactory operation of the equipment;
- compliance with the volt-drop criteria for motors during the starting period.

(b) Transient
During motor starting periods the following criteria shall apply:-
- Under minimum supply voltage conditions specified earlier, the voltage at the
motor terminals shall not be lower than 85% of the motor rated voltage;
- The voltage drop at the point of supply shall not be greater than 10% of the
rated voltage.

4.2.13 Protection co-ordination and protection relays


The Electricity Board and protection devices provided as part of this Contract shall be
capable of coordination so that on the occurrence of a fault only the affected section is
disconnected from the system.
The Contractor shall carry out a protection co-ordination design study for the different types
of faults occurring at different points in the system under maximum and minimum fault
conditions. The proposed relay characteristics shall be submitted to the Engineer for
approval.
Unless otherwise approved by the Engineer, all relays shall be of the microprocessor based
numerical type and shall have a front of panel test facility. Relays shall be tropicalised.
Relays shall have hand reset operation indication for each element.
Front of panel mounted relays shall have a clear polycarbonate cover providing a degree of
protection not less than that of the switchboard or motor control centre on which they are
mounted. The Contractor shall provide all necessary computer connections and software
including actual relay settings for the re-programming of these devices including a
hardcopy of the protection setting for each device.
4.2.14 Electrical Safety
The Contractor shall provide adequate safety labels for the safe operation and
maintenance of all electrical equipment.
An A1 framed single line diagram shall be provided on each switch room wall.
Each electrical switchboard shall be provided with all necessary safety equipment including
operating gloves, full length rubber safety mat, a minimum of 2 No CO2 portable fire
extinguishers, fire bucket and any other equipment required by the Authorities.
An emergency first aid kit and safety procedure shall be provided in each switch room.
4.3 High voltage switchboard and motor control centre
The Contractor shall design the high voltage power distribution to meet the requirements of
the proposed plant.
The high voltage switchboard/motor control centres shall be of the floor mounting metal
clad cubicle type equipped with VCBs, vacuum contactors and motor starters as
appropriate. All compartments shall be provided with and designed for withdraw able type
switchgear.
The switchboard shall be provided with the protection and metering as shown on the single
line diagram. Cable entry shall be located at the bottom with suitable gland plates.
Cable openings in the base of switchboards and motor control centres shall be fitted with
plates to prevent the entry of vermin.
Switchboards and motor control centres shall be extensible to cater for the future designed
development. The Contractor shall take this requirement into account when designing
switch rooms and control rooms.
Rubber insulation floor mat of 9mm thickness shall be provided at the front of each switch
board and motor control centre. The mat shall extend over the full depth of switch boards
and motor control centre plus 800mm minimum at each end.
Test plugs and tools shall be provided to facilitate switchboard testing.
(a) Technical requirements
Rated voltage: 36/12/7.2/3.6kV
Rated short circuit:
breaking current Based on Actual tapping conditions.
Rated short-circuit: current withstand Not less than 1 second.
time

• Incoming circuit breakers and bus-couplers shall be motorized to allow


automatic operation of the circuit breakers on loss of power on any incomer;
• Switch-disconnector, earth switch and circuit-breaker operating mechanisms
shall be of the independent manual type and shall have positively driven
position indicators;
• Operating mechanisms shall be padlock able in all positions;
• Control functions shall be centralized on the module front;
• Bus bars shall be insulated;

(b) Incomer units


All incomer units shall be 3 pole.
Circuit-breaker type incomer units shall be equipped with the following minimum facilities:-
- Voltage transformer and voltmeter with phase to phase selector switch.
- Indicator lights shall be provided to indicate voltage presence;
- Power meter/load manager shall be provided to monitor kVA, kW, kWh, power
factor, voltage and current with provisions for RS485 communication port. The
outputs shall be wired to the ICA system;
- Over current and earth fault protection relay/release as indicated in single line
diagram.
- The relay characteristics shall be selected to co-ordinate with upstream and
downstream protection devices.
- Auxiliary relay with hand reset operation indicators for transformer winding
temperature high alarm, transformer oil temperature high alarm and circuit-
breaker trip initiation (for incomers derived from transformers only)
- Phase failure and under voltage relay/release for circuit-breaker trip initiation,
alarm annunciation and remote indication. The relay shall be connected on the
busbar side of the circuit-breaker.
- High voltage inter-trip receive relay (for incomers derived from transformers
only).
- Trip circuit supervision relay.
- Current transformers of appropriate accuracy class and limit factor and output
for instrumentation and protection.
- Status Indicator lights for:-
o Circuit-breaker open
o Circuit-breaker closed
o Circuit-breaker trip supply healthy
- Push-buttons for:-
o Circuit-breaker open
o Circuit-breaker close
o Circuit-breaker trip supply test
(c) Motor starters
Motor starters shall be provided for all plant specified in the Specification.
Motor starter types shall be direct-on-line, star-delta, solid state soft starter, variable speed
drives, auto-transformers or other equivalent reduced voltage type as required to suit the
plant operation and to comply with the specified transient voltage drop criteria. For the raw
water pumps, treated water pumps and booster pumps the starters shall be able to ramp up
and down the speed of these pumps gradually, in order to minimize any water pressure
surge to induce to the pipelines and other equipments.
Motor starter control and protection facilities shall include but not be limited to:
- Staggered start circuits shall be provided to prevent more than one motor
starting at the same time;
- All necessary interlocks/safety devices as described in the mechanical
specification to prevent the pump sets being re-started until the pump pipe
column has stopped draining;
- All necessary interlocks/safety devices for the proper operation and effective
protection of the pump set;
- Motor thermal overload and single phase protection;
- Start and Stop pushbuttons;
- Hours Run meter;
- Indicating ammeter;
- Individual power factor correction capacitor;
- Microprocessor based comprehensive numerical type motor protection relay.
The relay shall have thermal overload, phase unbalance/single phasing, reverse
phase sequence and earth fault protection functions. The earth fault trip function
shall be co-ordinate with the short-circuit protection device and contactor current
breaking current;
- Control selector switch -Local/Off/Remote;

Motors provided with variable speed drive or soft starter shall be provided with the following
additional facilities:
- Drive Fault Indicator;
- Motor Speed Indicator;
- Variable Speed Controller (door-mounted).
- Cooling facility shall be provided for dissipating heat generated by the variable
speed drive or soft starter in accordance with the manufacturer’s
recommendations.

(d) Control and operation


A local control panel shall be provided adjacent to each pump set for accommodating pump
set instrument transmitters and pump status indicators for effective monitoring of the pump
set.
(e) Interlocking
The switchboards/motor control centres with incomers derived from two separate sources
shall have circuit breakers for the two incomers and bus-coupler. The switchboard shall be
Provided with an electrical and mechanical interlocking scheme to allow only two out of
three circuit breakers to be closed at any one time. The normal operation of the
switchboard will have the two incomers closed and the bus-coupler open, with the load
equally distributed between the two incomers. On power failure of one incomer, the bus
coupler will be closed automatically and the complete plant operating from one supply as
shown in SLD.
Interlock shall be provided to prevent access to cable termination enclosure unless the
associated earth switch is closed. Alternative interlocking arrangements, which are
standard to a particular switchgear manufacturer, shall be submitted to the Engineer for
approval
(f) Feeder units
Feeder units shall be provided as required on each switchboard and motor control centre.
(g) Lamp test
Each switchboard and motor control centre compartment shall be provided with a lamp test
facility when fitted with indicating lamps.
(h) Anti-condensation heaters
Anti-condensation heaters shall be provided for each panel.
(i) Auxiliary contacts
Voltage-free changeover type contacts shall be provided for remote status and alarm
indications as follows:-
- Each incomer(mains/generator)
Circuit-breaker/switch open;
Circuit-breaker/switch closed;
Circuit-breaker tripped on fault;
Transformer winding temperature high;
Transformer oil temperature high;
Supply healthy;
- Each bus-coupler
Circuit-breaker/switch open;
Circuit-breaker/switch closed;
- Each motor starter
Motor available
Motor running
Motor fault (common)
The contacts shall be wired to a common marshalling terminal in the associated LCP.
(j) Switch room design considerations
Switch room floor flatness and concrete insert shall be provided to the requirements of
switchboard manufacturer. Space shall be provided within the switch room to permit two
circuit-breaker panels to be added to one end of the switchboard. Front clearance shall be
not less than 1500 mm.
For switchboards and motor control centres designed for rear access, a clear space of
not less than 800 mm shall be provided at the rear of the panel.
Where floor trenches for cabling is provided it shall extend over the full depth of witch
boards and motor control centres plus 800 mm minimum at each end. Trench depth shall
be not less than 1000 mm. A galvanized steel supporting framework shall be provided for
switchboards and motor control centres.
Galvanised steel or aluminium chequer plate cable trench covers shall be provided.
Doorways shall be dimensioned to permit the entry of the largest section of
switchboards and motor control centre’s in its upright position.
An identification label shall be fitted to the outside of the building adjacent to the access
door. The label shall identify voltage and substation location. The label material shall be
plastic laminate or other material approved by the Engineer and the size of characters and
numerals shall be not less than 50 mm. The label description shall be subject to the
approval of the Engineer. The label shall be fixed to the building using non-ferrous screws.
Mechanical ventilation shall be provided for the switch room. Ventilation fan sizing
calculation taking into account of equipment heat dissipation rate shall be provided for
Engineer’s approval.
The minimum air change rate for switch room shall be 10 air changes per hour.
Transformer
Service Transformer
Main transformers shall be oil filled and naturally air cooled outdoor type with winding
temperature indicator incorporating alarm and trip contacts for remote indications, pressure
relief device with trip contacts and primary/secondary cable boxes.
Dry type cast resin indoor transformers shall be provided for the auxiliary loads below
500kVA.
The transformers shall be sized for total duty loads of the Works plus the following
additional capacities:
• 3% for system losses
• 10% for future expansion works

Main transformers shall be provided with an on-load tap changing (OLTC) facility as
shown on single line diagram. All other auxiliary transformers shall be provided with offload
tap changing facilities. On load tap changer panels shall provide automatic adjustment of
voltage level with facility of manual operation.
The transformers shall be fitted with a removable link to connect the low voltage
winding neutral point to earth. The link shall be accommodated in the low voltage cable box
and shall be fitted with a label inscribed LV WINDING NEUTRAL EARTH LINK.
Transformers using open type bushings shall not be accepted.
Each transformer shall be provided with an emergency trip push button in the secondary
voltage switch room or as agreed with the Engineer.
Remote control unit for OLTC
The OLTC control equipment shall be housed in an indoor sheet steel cubicle located in the
adjacent HV switch room. It shall conform to degree of enclosure protection IP 54 or better
and shall comprise the following but not be limited to:
• Control switch: Raise / off / Lower (spring return to normal type)/automatic or
independent pushbuttons.
• Tap position indicator.
• Facia type alarm annunciators with “accept”, “lamp test” facilities and hooter /
buzzer for alarms.
• Necessary auxiliary relays.
• Lamp indications for tap change in progress, lower limit reached, upper limit
reached etc.
• 240 V rated panel space heater with thermostat.
• Fluorescent type interior lighting fixture with lamp and door switch.
• Voltage sensing and voltage regulating devices
• Line drop compensator with adjustable R and X elements.
• Timer 5-25 seconds for delaying the operation of the tap changer in the first step
for every tap change operation.
• Adjustable dead band for voltage variation.
• Volt free contacts for alarms for a. c. supply failure drive motor auto tripped and
other protective purpose considered essential by the Contractor shall be wired
to a common terminal rail. The Contractor shall cable the outputs to the ICA
compartment of the adjacent switchboard/motor control centre.

Transformer Compounds
The transformers shall be housed in a compound surrounded by 2.4 m high chain
link fencing or similar approved. Each transformer shall be provided with a double leaf gate
not less than 2.4 m wide. The transformers shall be shaded from direct sunlight.
A minimum clearance of 1500 mm shall be provided to all sides of the transformer.
Transformers shall stand on reinforced concrete plinths surrounded by an oil retaining
sump. The sump shall be filled with suitable single size (nominally 40 mm) rounded stones.
The capacity of the sump when filled with stones shall be suitable to hold the total oil
content of the transformer plus 15%. The sumps shall be connected to a separate chamber
to permit the removal of standing water and oil.
Trenches and ducts entering the oil-retention area shall be sealed after the cable
installation.
The compound shall be provided with a name plate identifying the transformer number
and rating. The name plate shall be plastic laminate or other material approved by the
Engineer
And the size of characters and numerals shall be not less than 50 mm. The name plate
shall be fixed to the access gate using stainless steel fixings.
Each transformer compound shall be provided with adequate portable firefighting
equipment accordingly to Statutory Requirements.
4.5 415V switchboard and motor control centre
The Contractor shall design the low voltage power distribution to meet the requirements
of the proposed plant. The Contractor shall generally provide motor control centres at each
process area including the chemical house, clarifier works, individual pumping station, the
filter building, the sludge treatment plant and the chlorine plant. The motor control centre’s
shall be supplied from the main works switchboard which shall then feed the sub
distribution switchboards/ motor control centre’s. The Contractors design should not derive
feeders from one sub-distribution switchboard to another sub-distribution switchboard.
The 415V switchboard/motor control centre’s shall be of Form 4 construction, floor
mounting metal-clad cubicle type equipped with ACBs, MCCBs, fuse-switches and motor
starters as appropriate. Cable entry may be top or bottom with panel access to the front to
suit the requirements of the site layout drawings.
Cable openings in the base of switchboards and motor control centres shall be fitted with
plates to prevent the entry of vermin.
Provision shall be made on switchboards and motor control centres for supplying building
and external electrical & mechanical services.
Supplies to process plant and instrumentation shall be derived from a separate process/
instrumentation services distribution board and not derived from building services
distribution boards.
Switchboards and motor control centres shall be extensible to cater for the future designed
development. The Contractor shall take this requirement into account when designing
switch and control rooms.
Rubber insulation floor mat of 9mm thickness shall be provided at the front of each
switchboard and motor control centre. The mat shall extend over the full depth of
switchboards and motor control centre plus 800 mm minimum at each end.
Test plugs and tools shall be provided to facilitate switchboard testing.
(a) Technical requirements

Rated voltage: 430V


Three phase symmetrical: The maximum let-through current of the
short-circuit current supply transformer or feeder protective
device but not less than 50kA for 1600A
bulbar
Rated short-circuit: Not less than 1 second.
current withstand time
(b) Incomer units
Incoming supplies and associated bus-couplers rated at 800Amps and above derived
from transformer secondary circuit shall be controlled by withdraw able air-break circuit
breakers. All other incoming supplies of similar case shall be controlled by withdraw able
type MCCBs.
All other supplies derived from other switchboards shall be terminated on switch
disconnectors.
In a distribution system ACB/MCCB of upstream side shall either be followed by switch
disconnector or with-draw able type MCCB.
All incomer units shall be 4 poles.
Circuit-breaker type incomer units shall be equipped with the following minimum facilities:-
- Voltmeter with phase selector switch.
- Ammeter with phase selector switch.
- Power meter/load manager shall be provided to monitor kVA, kW, kWh, power
factor, voltage and current with provisions for RS485 communication port and
selectable pulsed outputs. The outputs shall be wired to the ICA compartment of the
switchboard/motor control centre (for incomers derived from main transformers
only);
- Over current and earth fault protection relay/release as indicated in single line
diagram. The relay characteristics shall be selected to co-ordinate with upstream
and downstream protection devices.
- Phase failure and under voltage relay/release for circuit-breaker trip initiation, alarm
annunciation and remote indication. The relay shall be connected on the busbar
side of the circuit-breaker.
- Trip circuit supervision relay for incomer circuit breakers.
- Current transformers of appropriate accuracy class and limit factor and output for
instrumentation and protection.
- Status Indicator lights for:-
- Circuit-breaker open
- Circuit-breaker closed
- Circuit-breaker trip supply healthy
- Push-buttons for:-
o Circuit-breaker open
o Circuit-breaker close
o Circuit-breaker trip supply test
o Lamp test
- Switch-disconnector type incomer units shall be equipped with the following
minimum facilities:
o Voltmeter with phase selector switch.
o Ammeter with phase selector switch.
o Phase failure and under voltage relay for alarm annunciation and remote
indication.

The relay shall be connected on the busbar side of the switch-disconnector.


- Current transformers of appropriate accuracy class and limit factor and output for
instrumentation.

(c) Motor starters


Motor starters shall be provided for all plant specified in the Process and Mechanical
Specification.
Motor starter types shall be direct-on-line, star-delta, solid state soft starter, variable speed
drives, auto-transformers or other reduced voltage type as required to suit the plant
operation and to comply with the specified transient voltage drop criteria.
Motor starter control and protection facilities shall include but not be limited to:
- Motor thermal overload and single phase protection;
- Start and Stop pushbuttons;
- Available, running, fault tripped lamps;
- Fault reset push-button;
- Hours Run meter;
- Indicating ammeter for motor above5kW;
- Individual power factor correction capacitors shall be provided for motor rating
above35HP.
- Motor starters above 22kW shall be fitted with a microprocessor based
comprehensive numerical type motor protection relay. The relay shall have thermal
overload, phase unbalance/single phasing, reverse phase sequence and earth fault
protection functions. The earth fault trip function shall be co-ordinate with the short-
circuit protection device and contactor current breaking current;
- Control selector switch – Starters shall be provided with a Hand/Off/LCP selector to
determine the control location. Starters with field start/stop push-buttons shall be
provided with an additional selector for Field/MCC;
- Auxiliary relays and indicating lamps for direct pump/motor mounted protection
facilities, covering no flow, winding temperature, bearing temperature, motor
exhaust air temperature, gland seal monitoring, oil leakage, motor water ingress,
motor vibration detection, coolant failure detection and lubricant failure detection.

Motors provided with variable speed drive units shall be provided with the following
additional facilities:
- Drive Fault Indicator;
- Motor Speed Indicator;
- Variable Speed Controller (door-mounted).

Cooling facility shall be provided for dissipating heat generated by the variable speed drive
or soft starter in accordance with the manufacturer’s recommendations.
(d) Control and operation
Control and operational requirements for motor starters shall be as specified herein. All
control and instrumentation equipment shall be located within the ICA section of each
switchboard/motor control centre.
(e) Interlocking
The main switchboards/motor control centres with incomers derived from two
transformers shall have ACBs for the two incomers and bus-coupler. The switchboard shall
be provided with an electrical interlocking scheme to allow only two out of three circuit
breakers to be closed at any one time. The normal operation of the switchboard will have
the two incomers closed and the bus-coupler open, with the load equally distributed
between the two incomers. On power failure of one incomer, the bus-coupler will be closed
automatically and the complete plant operating from one supply as shown in SLD.
Main switchboards/motor control centers with incomers derived from a generator and
transformer shall be provided with two incomers electrically interlocked to prevent the
paralleling of the incoming supplies or an automatic (with manual over-ride) changeover
switch.
(f) Feeder units
Feeder units shall be provided as required on each switchboard and motor control centre.
(g) Lamp test
Each switchboard and motor control centre compartment shall be provided with a lamp test
facility when fitted with indicating lamps.
(h) Anti condensation heaters
Anti condensation heaters shall be provided for each panel.
(i) Auxiliary contacts
Voltage-free changeover type contacts shall be provided for remote status and alarm
indications as follows:-
- Each incomer(mains/generator)
o Circuit-breaker/switch open;
o Circuit-breaker/switch closed;
o Circuit-breaker tripped on fault;
o Supply healthy;
- Each bus-coupler
o Circuit-breaker/switch open;
o Circuit-breaker/switch closed;
- Each motor starter
o Motor available
o Motor running
o Motor fault(common)
o Individual fault signal

The contacts shall be wired to a common marshalling terminal in the associated ICA
section of the switchboard/motor control centre.
(j) Socket outlet
A 240V 5A single phase socket outlet shall be provided within the ICA compartment of
each switchboard and motor control centre.
(k) Location
The switchboards and motor control centres shall be located as per approved Drawings.
(l) Switch room design considerations
Switch room floor flatness shall be finished to the requirements of switchboard
manufacturer. Switchboards and motor control centres shall be extensible to cater for the
future designed development. The Contractor shall take this requirement into account when
designing switch and control rooms. Front clearance shall be not less than 1500mm.
For switchboards and motor control centres designed for rear access, a clear space of
not less than 800 mm shall be provided at the rear of the panel. For front access
switchboards a nominal 150 mm clear space shall be provided at the rear of the panel.
Where floor trenches for cabling is provided it shall extend over the full depth of
switchboards and motor control centres plus 800mm minimum at each end. Trench depth
shall be not less than 1000 mm. For switchboards and motor control centres designed for
front cable access the trench shall extend not less than 600mm from the front face. A
galvanized steel supporting framework shall be provided for switchboards and motor
control centres.
Galvanised steel or aluminium chequer plate cable trench covers shall be provided.
Doorways shall be dimensioned to permit the entry of the largest section of switchboards
and motor control centres in its upright position.
An identification label shall be fitted to the outside of the building adjacent to the access
door. The label shall identify voltage and substation location. The label material shall be
plastic laminate or other material approved by the Engineer and the size of characters and
numerals shall be not less than 50mm. The label description shall be subject to the
approval of the Engineer. The label shall be fixed to the building using non-ferrous screws.
Mechanical ventilation shall be provided for the switch room. Ventilation fan sizing
calculation taking into account of equipment heat dissipation rate shall be provided for
Engineer’s approval. The minimum air change rate for switch room shall be 10 air changes
per hour.
4.6 Electrical ancillary equipment
4.6.1 Power factor correction
The power factor at each load centre shall be corrected to no less than 0.95 lagging. The
correction may be by means of capacitors connected to individual items of plant or by
automatically controlled multistage capacitors connected to each busbar section.
For multistage power factor correction, capacitor ratings shall be selected to ensure that
motors are not subjected to leading power factor conditions or abnormal operating
conditions due to the effect of self-excitation when switched off.
Multistage capacitors shall be controlled by contactors via an automatic capacitor
controller with target power factor setting adjustment and manual override facilities. The
contactors shall be de-rated to compensate for zero power factor switching duty, the
permitted capacitor positive tolerance and the presence of harmonic currents.
Capacitors shall incorporate a discharge circuit and shall not contain polychlorinated
biphenols.
Each of the HV main pump motors shall be provided with an individual power factor
correction unit to the highest value obtainable without the self-excitation of the motor.
Power factor correction units shall comprise one or more three phase capacitor banks and
a set of three fuses, housed in an enclosure and connected through fuse gear and an
isolating link by cable to the motor starter such that it is permanently connected across the
motor windings. A manually operated mechanical key interlock system shall be provided to
ensure that the enclosure cannot be opened until the associated motor starter breaker is
open and in the "earthed “position.
Calculations corroborating capacitor kVAr ratings shall be submitted to the Engineer for
approval.
4.6.2 Switchgear battery units
(a) 110V Battery and battery charger
The Contractor shall provide battery charger units with adequately sized batteries and
battery chargers for the HV switchboard and motor control centre. Each battery supply unit
shall incorporate two float and boost chargers with auto changeover facility in case of
failure of one.
The batteries shall have adequate capacity to operate HV switchboard control and relay
system, monitoring devices, circuit breaker charging, OLTC etc. The sizing calculations
shall be submitted to the Engineer for approval.
(b) Battery and battery charger for 415Vswitchboard
Battery units of the appropriate voltage and capacity shall be provided for 415V
switchboard circuit-breaker tripping, control, indication and alarm supplies.
Battery capacity calculations shall be submitted to the Engineer for approval.
4.6.3 Uninterruptible power supplies
An uninterruptible power supply (UPS) unit or units shall be provided where it is necessary
to maintain a no-break supply to instrumentation, control, PLCs, servers, computer
workstations, telecommunication systems, network systems and alarm systems as detailed
in the ICA section of the site works specifications.
The UPS system with fully charged batteries shall, on loss of mains supply, be capable of
supplying the connected loads for a minimum period of 2 hour.
Battery capacity calculations shall be submitted to the Engineer for approval.
4.6.4 Emergency stop push-buttons
An emergency stop push-button shall be installed adjacent to all motors.
4.6.5 Local Control Units (LCU)
Each motor shall be capable of being manually operated from a local operating position.
Where motor starters are provided at remote locations, the Contractor shall provide a local
control unit (LCU) in a safe and accessible operating position adjacent to the motor. Each
LCU shall be of robust construction suitable for the environmental conditions. The LCU
shall be provided with a start/stop or open/close pushbutton.
Local control units installed externally shall be protected from the sun with sun covers and
constructed with an IP rating of IP65
The Contractor shall submit drawings identifying the locations of the LCUs for the
Engineer’s approval.
4.7 Cabling
(a) General
The Contractor shall provide a complete cabling installation comprising power, control,
instrumentation, communications and telephone cables and all accessories including cable
glands, terminations, cable markers, support systems, clips, fittings and fixtures to:-
- Interconnect all Plant provided under the Contract;
- Interconnect Plant provided under the Contract to the Electricity Board point of
supply;
- Interconnect ICA signals to the regional telemetry outstation; and
- Interconnect existing plant with the Plant provided under the Contract.

All calculations to corroborate current carrying capacity and compliance with the volt-drop
criteria specified herein shall be submitted to the Engineer for approval.
The power, control and instrumentation cabling shall interconnect the entire Plant including
but not limited to:
- Valves actuators, pump sets ,etc;
- Switchgear and distribution boards;
- Motor control centers;
- Local control panels, PLCs, intelligent outstations;
- Regional telemetry outstation;
- Local control units; and
- Measuring instruments and sensors.

(b) Cable grouping


The cables shall be grouped as follows:
- power cables
- control cables
- Signal cables - process signals
- data cables - modulated signals (e.g. serial data communication signals);and
- Fiber optic cables - if required.

(c) Cable types


HV cables shall be 3 core, 33/11/6.6 kV, XLPE type with stranded aluminium conductors &
GI armouring. Minimum size of cable shall be selected based on the short circuit
considerations.
LV power cables shall be 1.1 kV PVC/ XLPE type with stranded aluminium conductors & GI
armouring for sizes 16sqmm and above and stranded Copper Conductors & GI armouring
for sizes below 16sqmm. No. of cores shall be as per requirement.
(d) Installation
External belowground
Unless otherwise approved by the Engineer all cables shall be installed in ducts and
concrete trenches.
Duct systems shall be provided with draw chambers at the point of entry into buildings, at
changes in direction and at suitable intervals in straight runs to permit the installation of
cables without exceeding the manufacturers' recommended maximum tensile stress. Draw
chambers shall be generously dimensioned to enable cables to be pulled without damage
or excessive stress due to bending.
Where high voltage and low voltage cables are installed in a common trench, they shall be
on opposite faces. Cables in trenches shall be installed on tray and/or ladder systems.
External above ground
Cables on structural surfaces shall be installed on tray and ladder systems or in trunking
and conduit as appropriate. Cable tray on structural surfaces shall be fitted with covers.
Internal
Cables on structural surfaces shall be installed on tray and ladder systems or in trunking
and conduit as appropriate. Cables in trenches shall be installed on tray and/or ladder
systems.
Cable tray, ladder and trunking systems
Cable tray, ladder and trunking systems shall be heavy duty galvanized steel. Cable tray on
external structural surfaces shall be fitted with covers.
Installations in the chemical and chlorine buildings shall be heavy duty PVC or GRP
systems.
Conduit systems
Conduit shall be heavy duty galvanised steel. Installations in the chemical and chlorine
buildings shall be heavy duty PVC or GRP systems.
4.8 Earthing
(a) General
A complete and fully interconnected earthing installation comprising earth electrodes,
earthing terminals and all earthing, protective and equipotential bonding conductors shall
be designed and provided by the Contractor.
The Contractor shall co-ordinate the earthing design with the KPTCL earthing
requirements.
As a minimum, material for buried earthing conductors shall be of Mild Steel (MS) and for
earthing conductors laid above ground/open to air shall be of Galvanised Steel (GS) tape
or insulated copper cable. Connection between MS conductor buried in ground and GS
conductor above ground shall be welded type made by bringing the MS conductor above
ground. Connection between earth leads and equipments shall be of bolted type.
(b) Earth electrode system
The Contractor shall carry out a ground resistivity survey for each site and design and
install the earth electrode systems to provide an overall resistance to earth not greater than
1 ohm and subject to a maximum hand-to-hand touch voltage of 116V for 1 s. The earthing
system shall ensure effective operation of protective devices for timely isolation of fault.
The earth electrode system shall comprise at least two separate groups of rods located at
agreed locations to allow for testing of one earth electrode system whilst the other is
connected to the system. The main earth bar shall be provided with test links to enable
independent testing of each group of earth electrodes.
Design calculations for the earth electrode system shall be submitted to the Engineer for
approval.
(c) 415V system neutral earthing
The low voltage winding star point of the transformer shall be connected to earth via a
removable link located in the associated transformer low voltage cable box.
(d) Earthing terminals
Earthing terminals shall be located adjacent to the associated switchboard or motor control
centre. The earth terminals shall be interconnected.
(e) Bonding to structural steelwork
Structural steelwork including concrete reinforcement bars shall be bonded to the earthing
system. The method of connection to reinforcement bars shall be subject to the approval of
the Engineer.
All metallic pipe work and other extraneous conductive parts shall be provided with positive
earthing terminals and provided with equi-potential bonding.
(f) Instrumentation earthing
The Contractor shall provide insulated earth cables to connect the instrumentation earth
bars in each LCP to the station earth system. The instrumentation signal earth cables shall
have different outside insulation colour to the power earth cables in order to make them
easily identified. Earthing system design shall comply with local regulations.
4.9 Lightning Protection
A lightning protection system shall be provided on all main structures. Air terminations and
down conductors shall be copper.
The Contractor shall also provide all terminating equipment for all I/O and communications
signals transmitted between buildings on a copper cable with lightning protection barriers.
The barrier shall be installed in a barrier panel which shall be located adjacent to the main
cable entry point into the building or in a small enclosure adjacent to the transmitter. The
barriers shall be earth bonded in accordance with manufacturers‟ recommendations and
the Standard Specification.
The lightning protection installation shall comply with Standard Specifications.
5 PARTICULAR SPECIFICATIONS – CIVILWORKS

PREAMBLE TO CIVIL WORKS SPECIFICATION

This volume contains the Particular Specification for the civil engineering works. The
Particular Specification contains a description of the civil works to be designed and
constructed including any applicable design criteria that have to be met. The general civil
Specification is contained separately, and includes the standards to be met in the design
and construction of the works. Civil works shall comply with all other relevant provisions
elsewhere in the Specification.

CIVIL PARTICULAR SPECIFICATION

5.1 Scope

5.1.1 This section describes the civil works to be designed and constructed under
the Contract. This includes intake well / channel, connecting pipes, intake
structure cum pumping station, WTP, intermediate booster sumps and pumping
stations, MBRs / ZBTs etc.

5.1.2 The principal units include: intake well / channel, intake structure cum pumping
station, intermediate booster sumps and pumping stations, MBRs / ZBTs,
treatment plant units / buildings and other works necessary for the completion
of the Contract. The civil works include associated structures and buildings,
water supply system, overflows, drainage, roads, compound wall, staff housing,
plant compound walls, landscaping, pipe bridge and other associated works
necessary for the Contract.

5.1.3 Mechanical plants shall be provided as per the Mechanical Specification of the
Particular Specification. Electrical plants shall be provided as per the Electrical
Specification of the Particular Specification. Lighting and small power shall be
provided as per the Building Services Specification of the Particular
Specification. Instrumentation, Control and Automation plants shall be provided
as per the ICA Specification of the Particular Specification.

5.1.4 The Contractor shall prepare and submit all the necessary designs and
drawings for each of the works. Civil works shall comply with all the basic
criteria given in this Particular Specifications and the Standard Specification as
given elsewhere.

5.1.5 The Contractor shall provide all the civil works necessary for the Works under
the Contract notwithstanding any omission in the Particular Specification.

5.1.6 The civil works shall be sufficient to provide for all the requirements of the
plant specifications.
All structural design shall be conducted by the Contractor and all design calculation shall be
submitted to the Engineer for approval. The structural design shall confirm to all relevant
Indian Standard. The grade of concrete for all water retaining structure shall beM30.

5.1.7 Payment shall be against the Schedule of Prices in the Contract.

5.2 Intake Works/Raw Water Pumping Station Structure

5.2.1 The structures shall be designed to take account of all possible load
combinations. Part of the structures that may be submerged shall be designed
to withstand the most onerous combination of uplift, differential head across the
structure, wave action, wind and seismic forces. Design shall include an
analysis of the vibration cause by the mechanical plant and appropriate
mitigation.

Supports shall be well founded on solid strata using piles and anchors as
necessary. Principal load bearing members shall be of reinforced concrete. All
engineering metalwork for ladders, handrails and platforms shall be of
aluminium alloy. Water retaining structures shall be reinforced concrete with
sloped or screeded floors at not less than 0.5% to drainage channels and
sumps. As far as possible drainage shall be by gravity, otherwise sumps for
submersible pumps shall be provided.

Other structures may have reinforced concrete frames and brick infill for non-
load bearing walls.

All roofs shall be flat with a minimum fall of 1 in 250. On no account shall water
retaining structures be formed of concrete with a cement render (plaster) finish.

5.2.1 The pump well shall be of reinforced concrete.

5.2.2 The plan area and shape of pump well shall be in accordance with approved
codes of practice. The Contractor shall design the wells in collaboration with the
pump supplier to ensure that the flow conditions approaching the pumps under
all operating conditions are smooth and uniform and that the angle of the swirl
entering any pump inlet does not exceed 5 degrees or such value as is deemed
acceptable by the pump supplier in order that the guarantees he has provided
with respect to efficiency and maintenance are met. In addition the sump design
must ensure that no air, entrained by flow plunging into the sump or by other
features of the proposed design, is carried through to pump inlets. The
Contractor shall demonstrate the appropriateness of the design to meet these
requirements using physical modeling or other means that may be agreed with
the Engineer.
5.2.3 The pump well shall have a cover slab and safe, easy access via a manhole
cover and staged ladders. The Contractor shall provide a cradle for lowering
operatives into the well via this manhole. The cradle shall be sized to fit through
the manhole opening and carry two operatives in safety to the bottom of the well.
The cradle shall be stable even when unevenly loaded, have safety rails and
safe, secure means of access. The cradle shall be capable of carrying at least
300 kg and shall bear a plate stating the safe working load.

5.2.4 The Contractor shall provide skips and other accessories, as mentioned for silt
removal. The system shall be appropriate for handling manually and with the
overhead crane. The skips shall be designed to be moved, lowered and raised
using the overhead crane.

5.2.5 Manhole covers shall be raised at least 50 mm above floor level. The raised area
shall be profiled smoothly down to the floor to avoid making trip hazards.

5.2.6 The plan area and shape of the motor hall should generally follow standards.
Enough space shall be provided between adjacent motors and between a motor
and the wall such that the maintenance staff can have sufficient room to perform
the dismantling and subsequent reassembly work of the pumps, motors, valves,
pipe work etc. Sufficient space shall be provided to enable the dismantled
pumps, motors, valves, pipe work etc to be moved into the loading bay using the
overhead travelling crane. The structure shall have enough head clearance to
accommodate an overhead travelling crane that can lift the largest piece of plant
with at least 0.5 m clearance from any obstruction. The motor hall shall be a
clean, well lit, well ventilated, rainproof structure with adequate access to all
items of the Plant. Raised platform of removable floorings shall be provided
above the pipe work to provide clear, easy access to valve actuators, penstock
actuators and pump motors, should the operating actuators/hand wheels of
these valves, penstocks and any parts of the motors that required operation and
maintenance are not conveniently accessible with operators standing at the floor
of the motor hall. These raised platforms shall be provided with access ladders,
hand railings and the like. The structure shall be provided with external
navigation lights.

5.2.7 The building shall incorporate a loading bay in the motor hall. The overhead
travelling crane shall be designed to travel into the loading bay and place the
largest piece of plant directly onto the back of a suitable vehicle. The loading bay
shall have a roller shutter door and be sized to accommodate a suitable
vehiclethatwouldbeusedtotransportthelargestpieceofPlant, withatleast 1.0m
clearance on either side and to the end of the roller shutter when it is completely
opened.
5.2.8 A high-voltage switchgear room shall be provided near intake well, large enough
to house the switchgear and allow easy access for removal and maintenance.
The general arrangement of the room shall make provision for incoming and
outgoing power and control cabling, by either placing the switchgear on raised
flooring or providing cable trenches.

The room shall have adequate provision of space for removal of switchgear. It
shall be possible to remove any panel from the room or install additional panel
with the same size as the installed panels into the room through the door of the
room, without the need to temporarily shifting the installed panels.

5.2.9 A separate low voltage switchgear room shall be provided for the equipment
other than the pump motors, including small power, lighting, ventilation etc. The
room shall have enough space to house the switchgear and allow easy access
for maintenance and removal of the panels, in a way same as that mentioned
above.

5.2.10 The structure shall be provided with adequate facilities for rainwater drainage
and wastewater removal. The structure shall have a flat roof falling to gutters that
shall empty the collected rainwater to the reservoir via downpipes. Wastewater
shall be connected to a septic tank inside the Plant area.

5.2.11 An outdoor intake electrical sub-station and a metering house shall be provided
for the HV metering panels and HV switchgear of KPTCL. Outdoor transformer
bays shall be provided for transformers, ancillary plants and associated control
systems. Those structures that are to be used by the KPTCL and the cable
ducts/draw pits/cable trenches for KPTCL's incoming cable shall be constructed
to conform to their requirement. Individual transformer bays and HV switch
rooms shall comply with Electrical Specification.

5.2.12 Staff housing shall be provided for the operators, helpers and watchers as
specified.

5.2.13 The works and the outdoor electrical sub-station shall be fenced off from the
exterior by compound walling of, not less than, 2 m height. A double leaf access
door, the main gate, for vehicles and a single leaf access door, the side gate, for
operation personnel shall be provided at the compound wall. The main gate and
the side gate shall be positioned adjacently. The distance in between the gate
and the roller shutter of the pumping station shall be enough for the vehicle to
transport the largest piece of the Plant to turn freely after it enters the Plant with
the main gate closed behind.

Compound walling shall be rendered brickwork with painted finish in


accordance with the standard detail. The main and side gates shall be anti-
intruder painted steel gates.
5.2.14 The works shall be linked with other facilities in the whole Plant by walkway and
access roads. Access roads shall be of minimum width as specified elsewhere in
the document. The design of these walkways and access roads shall be
submitted in conjunction with the layout of the whole Plant for the approved of
the Engineer. Provision shall be made for safe turning for delivery vehicles. Road
areas shall contain space for manoeuvring large vehicles. Covered parking shall
be provided for building. Roads and parking areas shall be surfaced with
bituminous macadam.

5.2.15 Landscaping of the final site shall be provided including tilling and seeding soil
and planting suitable species of trees and shrubs as agreed with the Engineer.
All grassed areas shall be irrigated.

5.2.16 All land around the compound walling disturbed by the works shall be reinstated
upon completion of the civil works by tilling the topsoil and seeding with grass
mix as per the Specification.

5.3 Raw Water / Clear Water Transmission Mains

5.3.1 The civil works for the transmission mains shall include provision, laying, jointing,
backfilling and reinstatement.

5.3.2 The pipes shall be of material as specified.

5.3.3 The pipeline route and exact locations of fittings and chambers shall be agreed
on site between the Contractor and the Engineer following a preliminary survey
to be done by the Contractor. The Contractor shall provide the design for all pipe
supports, anchor blocks, pipe bridges etc. The main shall have a washouts at the
lowest points.

5.3.4 The pipelines diameter and wall thickness shall be in accordance with the
Specifications.

5.3.5 The pipelines shall be commissioned with a complete programme of pressure


testing, swabbing/flushing, and disinfection.

5.3.6 The Contractor has to conduct all trench excavation and all other necessary
work, as specified in Specification.

5.4 Water Treatment Works

5.4.1 The civil works for the treatment works shall include all earthworks to form the
site area to appropriate levels, and all the structures necessary. All structures
shall be reinforced concrete unless otherwise stated.

5.4.2 The Contractor shall provide all the earthworks and any associated structures
such as retaining walls needed to establish the formation levels.
5.4.3 Structures for the treatment processes shall be designed to meet the
requirements given in the water treatment works specification. Water retaining
structures shall be reinforced concrete with sloped or screeded floors at not less
than 0.5% to drainage channels and sumps.

As far as possible drainage shall be by gravity, otherwise sumps for


submersible pumps shall be provided. Other structures may have reinforced
concrete frames and brick infill for non load bearing walls. All roofs shall be flat
with a minimum fall of 1 in250.

On no account shall water retaining structures be formed of concrete with a


cement render (plaster) finish.

5.4.4 Water retaining structures shall be designed to resist water loading due to
external water level at ground level. Uplift forces on reservoirs, tanks and pipes
shall be calculated assuming that they are empty and the factor of safety against
flotation in this condition shall be not less than1.1.

5.4.5 All open tanks shall be provided with handrail protected access walkways all
around at the top level of the tank walls. Ladders shall only be provided within
chambers. Steps shall be provided to all external access platforms unless it can
be demonstrated that steps are impracticable and ladders are absolutely the only
alternative. All engineering metalwork for ladders, handrails and platforms shall
be of aluminium alloy.

5.4.6 All covered tanks shall be provided with approved ventilation cowls. All chambers
shall be provided with manholes and approved hinged covers. Manhole
openings shall be 750 x 750 mm minimum. Chambers and tanks shall be
provided with aluminium ladders. Ladders over 3 m long shall have cages.

5.4.7 Where a standard Drawing is provided for an item, such as handrails, ladders
etc, that item shall comply with that standard detail unless the Contractor
submits an alternative detail that is subsequently approved by the Engineer.

5.4.8 All pipe work shall be laid in trenches complying with the standard details
provided in the Drawings. All valves on buried pipelines shall be in chambers
unless otherwise stated. All stop valves shall be butterfly valves unless otherwise
stated.

5.4.9 The inlet work design shall suit the requirement of Water Treatment Plant
Specification of the Particular Specification. It shall, as a minimum, consists of a
Cascade Aerator, Raw Water Channel, Parshall flume channel for measuring the
inlet flow to the treatment plant, mixing chambers and the flow diversion
chambers to the clarifiers.
5.4.10 The flow division chamber shall have weirs dividing the flow. The weirs shall
discharge into separate chambers feeding separate clarifiers.

5.4.11 Clariflocculator shall be provided as per design.

5.4.12 Rapid gravity filters shall be provided. The filters shall be of the duplex type
comprising two equal size beds. Space shall be left for adding additional units in
the future to meet ultimate year requirement. The filters shall have a covered
central gallery accommodating filter wash consoles, pipe work and filtered water
channel. The filter walls shall be tiled, tiles to be approved by the Engineer.

5.4.13 A two storey filter building shall be provided to house air scour blowers, air
compressors, electrical switchgear, store room and separate ladies. And men’s
toilet / washrooms at ground level.

The filter building shall be provided with a covered area for the transformers
adjacent to the electrical switchgear rooms. The air blower and compressor
room shall be adequately soundproofed. The building shall have a flat roof
accommodating an elevated water storage tank. The upper floor shall have a
floor area sufficient to accommodate office and laboratory. The layout shall be
as approved by the Engineer. The Contractor shall provide all the necessary
furniture, which shall include but not be limited to:

5.4.13.1 1 No. writing desk-1.5x0.7x0.75mhigh;


5.4.13.2 1 No. table of similar dimensions;
5.4.13.3 6 Nos. wooden or metalwork chairs suited to the desk and tables;
5.4.13.4 2 Nos. wooden shelving units-1.8m high x0.9m wide x0.4m deep-with four shelves
per unit;
5.4.13.5 1 No. lockable filing cabinet with four drawers;
5.4.13.6 1 No. wall mounted white board, 2m wide x 1m high, with colored marker pens;
5.4.13.7 1 No. Washbasin and mirror.

5.4.14 Offices shall have at least one window on each exterior wall, of individual area
not less than 2 m2. Rooms shall be painted to a colour scheme approved by the
Engineer and windows shall have curtains to match the colour scheme. Floors of
rooms and corridors shall be tiled with polished stone tiles, type and colour to be
approved by the Engineer. A first aid station shall be placed in the mess room
with posters giving basic first aid guidance.

5.4.15 A works water supply pump house shall be provided for works water supply
pumps located adjacent to the filters and contact tank. The motors and
switchgear shall be at a suitable level to avoid flooding.
5.4.16 A contact tank / treated water storage tank shall be provided adjacent to the
filters. The design of the same shall comply with stated standards. The tank shall
be divided in half lengthwise by a central wall.

5.4.17 Flow shall discharge to the treated water reservoir via weirs with adjustable weir
plates. The roofs shall be coated internally with approved epoxy paint. The roof
surface shall have a waterproof membrane and shall be covered with a 150 mm
layer of 10 mm clean gravel chippings.

5.4.18 A sludge balancing tank shall be provided to receive sludge from the clarifiers.
The design of the sludge balancing tank shall comply relevant Clause. One tank
with two equal compartments of combined capacity adequate to balance sludge
discharges shall be provided.

The two compartments shall be interconnected by low level aperture no less


than 0.3 x 0.3 m with isolating gate and external operating mechanism.

5.4.19 A sludge pump house shall be provided for sludge thickener feed pumps. The
pump house shall have a common wall to the sludge balancing tank. Motors and
switchgear shall be at a suitable level to avoid flooding. The design of the sludge
pump house shall comply with relevant Clause.

5.4.20 Circular sludge thickening tanks shall be provided. Each shall have an inwardly
sloping floor to a central well, and a peripheral launder. Tanks shall be provided
with rotating mechanical scrapers. The design of the sludge thickening tanks
shall comply with relevant Clause.

5.4.21 A rectangular tank shall be provided for used filter wash water. The design of the
used filter wash water tank shall comply with the requirements entered in
relevant Clause. It shall have two interconnected compartments, being isolated
by a penstock with low level aperture no less than 0.3 m x 0.3 m with isolating
gate and external operating mechanism. The capacity of each compartment of
the tank shall be adequate to store as a minimum, the wash water from two
consecutive filter washes.

The Contractor shall include sufficient pedestrian access-ways in reinforced


concrete, which shall be fitted with hand railing and kick-plates on both sides of
the tank and on the common wall throughout their full length, to enable the
operational staff to have ready access around each compartment and to the
inlet channel. Means of access shall be provided into each compartment of the
wash water recovery tank.
5.4.22 A chemical building shall be provided for storage, handling, slurry or solution
preparation and dosing of aluminium sulphate and hydrated lime. The design of
the building shall comply with relevant Clause. It shall include lime and
aluminium sulphate storage, aluminium sulphate solution preparation and dosing
plant, lime slurry preparation and dosing plant, lime saturator and aluminium
sulphate head tank, a switch room and a washroom with washbasin, toilet and
shower head. Safety showers and eye baths shall be provided in the
solution/slurry preparation area.

5.4.23 The elevated water storage tank shall be provided for filter backwash and service
water. It shall be fully covered and have two interconnected compartments of
equal capacity with isolating facilities to enable one compartment to be taken out
of service for cleaning and maintenance. Each compartment shall have a high
level inlet and low level outlet. The tank shall have an overflow.

The roofs shall be coated internally with approved epoxy paint. Access to the
inside shall be provided via a manhole with inclined aluminium ladder 2.4 m
long, to a reinforced concrete platform with aluminium hand railing. Reinforced
concrete steps shall be provided down to the floor. Platform and steps shall
have approved non-slip surface finishes.

5.4.24 Number of sludge drying beds shall be provided as per design and shall be used
in rotation each being in various stages of filling, dewatering and emptying. The
design of the drying beds shall comply with relevant Clause.

5.4.25 The sludge drying beds shall be constructed to the levels as per approved
design and drawings.

Individual beds shall be separated by reinforced concrete walls which shall


provide a minimum of 300 mm freeboard when the higher of adjacent drying
beds is overflowing. The height of the drying beds shall be designed such that
the capacity of the drying beds shall comply with the design requirements. The
drying beds shall be of water retaining concrete structure

5.4.26 Site drainage, drainage from water retaining structures, overflows, basements
and under drains shall be discharged to the point specified outside the site
boundaries. A septic tank shall be provided for domestic wastewater.

5.4.27 The site shall have access roads of minimum width as specified to connect all
the units. Provision shall be made for safe turning for delivery vehicles. Road
areas shall contain space for manoeuvring large vehicles. Covered parking shall
be provided adjacent to buildings for vehicles. Roads and parking areas shall be
surfaced with bituminous macadam.
5.4.28 Under drains shall be provided below reservoir floors and other water retaining
structures as necessary. Outlets from under drains shall be designed so that
leakage can be easily identified.

Flows from under drains shall be collected in sumps and pumped to drainage
or overflow system.

5.4.29 Buildings shall have all necessary provisions for services such as trenches,
ducts, cable trays, racks etc. External service trenches shall be provided for
cables and chemical dosing and sampling lines, which shall be neatly arranged
on racks to be visible and easily accessible. Where several services run in
parallel they shall normally be grouped in a common trench with provision for
man access, except that chemical lines shall not be run in the same trench as
cables. Trenches in roads shall be provided with continuous removable covers
designed to withstand vehicle loading. Trenches shall be clearly identifiable and
shall not be covered with road surfacing.

5.4.30 The Contractor shall provide permanent signboards for all the works including
treatment works. The signboards shall bear text and logos as defined by the
Engineer. The signboard shall typically be 2.5m wide by 2m deep. The sign shall
be corrosion resistant, weatherproof and mounted on painted steel posts set in
concrete. The design shall be approved by the Engineer.

5.4.31 An outdoor electrical sub-station and a metering house shall be provided for the
HV metering panels and HV switchgear. Outdoor transformer bays shall be
provided for transformers ancillary plants and associated control systems. Those
structures that are to be used by the KPTCL and the cable ducts/draw pits/cable
trenches for KPTCL incoming cable shall be constructed to conform to their
requirement. Individual transformer bays and HV switch rooms shall comply with
Electrical Specification.

5.4.32 Staff housing shall be provided for the operators, helpers and watchers.

5.4.33 All the structures of the Treatment Plant as mentioned including the outdoor
electrical sub-stations and also the Treated Water Pumping Station shall be
fenced off from the exterior by compound walling of, not less than, 2 m height. A
double leaf access door, the main gate, for vehicles and a single leaf access
door, the side gate, for operation personnel shall be provided at the compound
wall. The main gate and the side gate shall be positioned adjacently and the
main gate shall be positioned to at a location as agreed with the Engineer.
Compound walling shall be rendered brickwork with painted finish in accordance
with the standard. The main and side gates shall be anti-intruder painted steel
gates.

5.4.34 Landscaping of the final site shall be provided including tilling and seeding soil
and planting suitable species of trees and shrubs as agreed with the Engineer.
All grassed areas shall be irrigated
PARTICULAR CIVIL & STRUCTURAL REQUIREMENTS

Part-A: Standard Basic Specifications


The “Standard Basic Specifications for Civil and Structural Works” set out the
specifications that shall be followed for construction of General Works. Specifications for
additional specialized items of civil and structural works are as set out in Particular
Technical Specifications, of this Section.
In the event of any discrepancy between the provisions of the Standard Basic
Specifications and the Particular Technical Specifications, the provisions of the Particular
Technical Specifications will prevail.
Part-B: Particular Technical Specifications
5.5 Design Submissions
Before proceeding with design and drawing preparation the Contractor shall submit
detailed general philosophy of design (Design Basis Report) of various parts of (all) the
structures and equipment foundations along with explanatory sketches for review. Only
after the review and incorporation of comments on the general philosophy, as offered
during the review, the Contractor shall submit any design document and/or drawing for
review and approval for construction.
5.5.1 Design Philosophy
Following are the details which are to be included in the general design philosophy
document submission:
5.5.1 Design assumptions/philosophy for Liquid Retaining Structures with various
boundary conditions as applicable
5.5.2 Design assumptions/philosophy for buildings
5.5.3 Design assumptions/philosophy for all other structures
5.5.4 Standard General Notes shall include material properties (grade, strength, unit
weight etc.), development lengths, lap/splice lengths, Anchorage lengths under
tension and compression, clear cover, water proofing specifications, legend used
etc.

5.5.2 Standard Details


Following typical details shall also be submitted for approval prior to proceeding with
detailed design:
1. Reinforcement detail showing the development length at Column/Footing
intersection, Column and Roof beam intersections, Walls and Base slab
intersections; Walls and cover slab intersections
2. Detailing of the reinforcement for columns, beams, beam/column intersection,
footing/column intersection, and Slabs as per relevant code
provisions/requirements depending upon the assumptions made in the design as
applicable.
3. Reinforcement detail for cut-outs in slabs and walls with maximum size of cut-outs
4. Reinforcement detail at top of RCC trench walls showing edge/seating angles
5. Pouring sequence of concrete and standard details for construction joints,
expansion joints, contraction joints, etc.
6. Details of Manholes and Rungs to be placed in the tanks
7. Detail for rain water drainage down takes at terrace slab and water proofing at
roof/sunken slabs
8. Detail for storm water drain, plinth protection and entrance ramps to buildings
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9. Detail for Handrails and fixing detail of handrail to concrete, Steel Ladders and
fixing detail of ladders to Walls/Concrete, Cage ladders, Boundary walls, Fencing
and Gates, etc.,
10. Material Specifications and application methodology for
Anti- Corrosive Internal Coating/Lining protection of Concrete Surfaces.

Complete detailed design calculations of foundations and superstructure together with


general arrangement drawings and explanatory sketches shall be submitted by the
Contractor to the Engineer. Separate design calculations for foundations or
superstructures submitted independent of each other shall be deemed to be incomplete
and will not be accepted by the Engineer.
Submissions of detailed design calculations and Good for Construction drawings shall
include the following as a minimum:
A. Detailed Design Calculations
1. One (1) Copy of a Compact Disc (CD) containing electronic files relevant to
the structure’s modeling, analysis and design calculations (Microsoft Excel,
Staad Pro, etc.). Files submitted shall be in editable format.
2. Print copy (6 Copies) of the contents as submitted in the Compact Disc.

B. Good for Construction Drawings


1. One (1) Copy of a Compact Disc (CD) containing AutoCAD files (Civil General
Arrangement, Structural Dimensions and Reinforcement Details) pertaining to
the structure. Files submitted shall be in editable format.
2. Print copy (6 Copies) of the contents as submitted in the Compact Disc. Prints
to be submitted on A1 Size Sheet as a minimum or A0 Size Sheet when
required by the employer.
3. Bar-bending schedule indicating the number, shape and size of the re bars
shall be submitted as part of the Reinforcement Details
4. Detailed drawing showing the location, number and depth of inserts shall be
included for any structural steel inserts/Metal inserts in the structure such as
rungs, bolted connections for ladders/railings, etc.
5. Location of Construction Joints and pour sequence shall be included on the
drawing for base slabs, walls and top slabs.
6. Revised drawings shall be submitted by clouding at the location with the latest
revision number and also show the history of revisions in a table format just
above the title block.

The design considerations described hereunder establish the minimum basic requirements
of plain and reinforced 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 Contractor shall also take care to
check the stability of partly completed structures.
5.6 Design Standards
All the designs shall be based on the latest Bureau of Indian Standard (BIS) 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 Engineer. In case of any variation or
contradiction between the provisions of the BIS Standards or Codes and the specifications
given along with the tender document, the provision given in this Specification shall be
followed.
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All Reinforced Concrete structural design/details shall conform to the following recently
published publications of the Indian Standards Institution:

(i) I.S.456 : Code of Practice for plain and reinforced concrete


(ii) I.S.875 : Code of Practice for design loads for buildings and structures (Part I to V)
(iii) I.S.3370 : Code of Practice for concrete structures for the storage of liquids (Part I
to IV)
(iv) I.S.1893 : Criteria for earthquake resistant design of structures
(v) I.S.2911 : Code of Practice for design and construction of Pile foundations
(vi) I.S.2974 : Code of Practice for design and construction of machine foundations
(Part1to4)
(vii) I.S.4326 : Code of Practice for Earthquake Resistant Design and Construction of
Buildings
(viii) I.S.13920: Ductile Detailing of Reinforced Concrete Structures subjected to Seismic
forces-
Code of Practice
(ix) IRC:6 : Standard specification and Code of Practice for road bridges Loads and
Stresses
(x) SP:16 : Design Aids for Reinforced Concrete to IS456
(xi) SP:34 : Hand book on Concrete Reinforcement and Detailing

All Structural steel design shall conform to the following recently published publications of
the Indian Standards Institution:

5.6.1 I.S.800 : Code of Practice for general construction in steel


5.6.2 I.S.806 : Code of Practice for use of steel tubes in general
building construction
5.6.3 SP:38 : Handbook of Typified Design of Structures with Steel
Roof Trusses
5.7 Design Life
The design life of all structures and buildings shall be 60 years.
5.8 Design Loadings
All buildings and 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, and dynamic loads:
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.
Dead loads shall be in general as per I.S. 875 Part (I). However, the following minimum
loads shall be considered in design of structures:

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(i) Weight of water : 10kN/m 3
Weight of soil (irrespective of strata
available at site and type of soil used for
(ii) filling etc).However, for checking stability : 20.00kN/m3
against uplift, actual weight of soil as
determined by field test shall be
considered
(iii) Weight of concrete : 24.00kN/m3
(iv) Weight of reinforced concrete : 25.00kN/m3
20.00N/m2per mm thickness of
(v) Weight of Brickwork(exclusive of plaster) :
Brickwork
Weight of Solid Concrete Block 24.00N/m2per mm thickness of
(vi) : block work
work (exclusive of plaster)
(vii) Weight of plaster to masonry surface : 18.00N/m2per mm thickness
Weight of granolithic terrazzo finish
(viii) : 24.00N/m2per mm thickness
or rendering screed, etc.
(ix) Weight of MS chequered plates : 78.5N/m2per mm thickness of
plates
Live Load
Live Load (LL) shall include the superimposed loads due to the use/occupancy of
the structure/building not including dead, wind or earthquake load. Live loads shall be in
general as per I.S. 875 Part (II). However, the following minimum live loads shall be
considered in the design of structures:

5.8.1 Live load on roofs : 1.50kN/m2


5.8.2 Live load on floors
supporting Equipment such
as pumps,
valves,
Blowers, Compressors etc. : 10.00kN/m2

(iii) Live load on all other floors


walkways, stairways and : 5.00kN/m2
Platforms

(iv) Live load on Toilet are as : 2.00kN/m2


(v) Live load Surcharge for Structures : 15.00kN/m2

In the absence of any suitable provisions for live loads in BIS Codes or as given
above for any particular type of floor or structure, assumptions made must receive the
approval of the Engineer prior to starting the design work. Apart from the specified live
loads or any other load 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.
Wind Load
Wind loads shall be as per I.S. 875 Part (III).

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Earthquake Load
Seismic forces shall be as per I.S. 1893.

Dynamic Load
Dynamic loads due to working of plant items such as pumps, blowers, compressors, switch
gears, travelling cranes, etc. shall be considered in the design of structures.

Vehicular Wheel Load


For any structure or pipeline below the roads, Class A loading of IRC 6 shall be considered.

5.9 Joints
Movement joints such as expansion joints, complete contraction joints, partial contraction
joints and sliding joints shall be designed to suit the structure. However, contraction joints
shall be provided at specified locations spaced not more than 7.5 m in both right angle
directions for walls and rafts.
Expansion joints of suitable gap at suitable intervals not more than 30 m shall be provided
in walls, floors and roof slabs of liquid 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. PVC water stops of 150 mm width shall be used for walls and
230 mm width for base slabs.

5.10 Design Criteria for Underground or Partly Underground Liquid Retaining


Structures
All underground or partly underground liquid containing structures shall be designed for the
following conditions:
5.10.1 Liquid depth up to full height of wall: no relief due to soil pressure from
outside to be considered;
5.10.2 Structure empty (i.e., empty of liquid, any material, etc.): full earth pressure
and surcharge pressure wherever applicable, to be considered;
5.10.3 If water table exists, earth pressure to be considered for submerged soil
conditions with reference to the geotechnical recommendations;
5.10.4 Partition wall between dry sump and wet sump : to be designed for full liquid
depth up to full height of wall;
5.10.5 Partition wall between two compartments: to be designed as one
compartment empty and other full;
5.10.6 Structures shall be designed for uplift in empty conditions with the water table
as indicated in geotechnical report. The Stability of the structure shall have a factor
of safety of 1.2 against uplift with appropriate safety factor to the characteristic dead
load shall be considered as applicable.

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5.10.7 Walls shall be designed under operating conditions to resist earthquake
forces from earth pressure mobilization and dynamic water loads (Hydrodynamic
Impulsive Pressure);
5.10.8 For general retaining walls and large sized tanks where the walls are
designed as retaining walls, sliding check shall also be performed along with over
turning checks. Overturning: The stability of a structure as a whole against
overturning shall be ensured so that the restoring moment shall be not less than the
sum of 1.2 times the maximum overturning moment due to the characteristic dead
load and 1.4 times the maximum overturning moment due to the characteristic
imposed loads. In cases where dead load provides the restoring moment, only 0.9
times the characteristic dead load shall be considered. Restoring moment due to
imposed loads shall be ignored.
5.10.9 Sliding: The structure shall have a factor against sliding of not less than 1.4
under the most adverse combination of the applied characteristic forces. In this case
only 0.9 times the characteristic dead load shall be taken into account.
5.10.10 All the liquid retaining structures shall be designed for maximum design crack
widths of 0.1mm for direct tension and flexure.
5.10.11 In case of Large and Deep Underground Tanks such as Wet Wells, the
analysis can be carried by Finite Element Method using STAAD.Pro or any other
equivalent software predominantly used and accepted in the industry.

5.11 Foundations
5.11.1 The minimum depth of foundations for all structures, equipments, buildings
and frame foundations and load bearing walls shall be as per IS 1904 but in any
case this shall not be less than 1.0 meter in the original soil.
5.11.2 Maximum safe bearing capacity of soil strata shall be taken as determined by
the Contractor through his own independent investigations. Geotechnical reports of
proposed STP sites covered under the contract are provided with the Bid
Documents. It may be used by Contractor as part of, in addition to, or in lieu of such
investigations at his own risk.
5.11.3 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 Employer.
5.11.4 Special attention is drawn to danger of uplift being caused by the ground
water table. All underground structural slabs shall be designed for uplift forces due to
ground water pressure.
5.11.5 EGL (Existing ground level) and FGL (Finished ground level) shall be marked
on all drawings showing foundation/sub-structure details and related design
documents.
5.11.6 Machine / static equipment foundations shall be separated from adjoining
parts of buildings, other foundations and floor/pavement slabs. Joints at
floor/pavement slabs shall be suitably sealed.
5.11.7 Foundations and structures for machines subject to vibrations shall be so
proportioned that the amplitude and frequency of the foundation/structure are within
the permissible limits as per relevant BIS codes (or as required by the machine
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vendor).
5.11.8 Machine foundations shall be designed and detailed as per IS: 2974. All
appendages to such foundations shall be reinforced suitably to ensure integral
action.
5.11.9 Pile Foundations - Design, Testing and Execution of piles shall be considered
as per provision of relevant codes (conforming to latest version of IS: 2911), and in
compliance with the Geotechnical report recommendations as applicable.
5.11.10 Foundations for plant structures in Swampy/Waterlogged areas, for lightly &
medium loaded structures and relevant Ground Improvements shall be considered in
compliance with the relevant Geotechnical Investigation Report recommendations as
applicable. Also to enlist the services of an experienced & specialized agency for all
related design aspects considerations, equipment specifications, and implementation
methodology, etc., as an advice for the same.

5.12 Design Requirements


The following are the design requirements for all reinforced or plain concrete structures:
a) Allblindingandlevelingconcreteshallbeaminimum100mmthickinconcrete
gradeM10.
b) All liquid retaining reinforced concrete structures, concrete shall be of a
minimum M30 grade with a maximum 20mm aggregate size for all –
structural members and for Buildings, reinforced concrete shall be of a
minimum M25 grade (Footings, Plinth Beams, Columns, Slab and beams,
etc., i.e. which are other than liquid retaining structures) with a maximum
40mm aggregate size for footings and base slabs and with a maximum
20mm aggregate size for all other structural members. Further, if there are
any liquid retaining RCC tanks coming up with in the buildings, concrete shall
be of minimum M30 grade for such RCC tanks also.

c) The reinforced concrete for all structures shall have a minimum cement
content of 360kg/m3 with a maximum 20mm size aggregate for liquid
retaining structures and 320kg/m 3 for non liquid retaining structures.
Reinforced concrete shall have maximum slump of 100mm with maximum
water cement ratio of0.45.

d) As a design consideration to control crack, though general requirements of


IS3370 shall be followed, All liquid retaining structures shall be designed
based on the service ability crack width limit state (i.e. 0.2mm crack width)
and other limit state requirements also to ensure an adequate degree of
safety and serviceability.

e) The minimum cover to the main reinforcing bars for different members for:
1. Non-liquid retaining structures shall be as follows unless stated
otherwise:
Slab (Floor, Roof, Canopy, Chajjas and Staircase)
25m
m Beams (Sides, Bottom& Top)
40m
m
Lintels (all-around) 30mm
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Columns
i) For columnwidth200 40mm
ii) For column width 230&above

iii) 50m
m Pedestals (in contact with earth)
50mmBasementwall, retaining walls
i) Face in contact with earth 50mm
ii) Interior face 40mm
Foundations (Top, Bottom and sides) 50mm

2. Liquid retaining structures shall be as follows unless


stated otherwise:
Walls-Face in contact with Water 45mm
Base Slab in contact with Water 45mm
Base Slab in contact with Soil 50mm
Launders/Gutter Slabs 25mm
f) In general, reinforcement for buildings and sewage treatment units shall be
HYSD-CRS (Corrosion Resistant Steel) of Grade Fe500. All physical and
chemical properties of this Fe500 grade steel shall conform to IS: 1786-2008.
Welded wire fabric shall conform to IS: 1566 as shown or specified on the
drawing. The CRS (corrosion resistant steel) index shall be at least 1.35 when
tested for Salt Spray test as per “ASTMB 117–2009 test procedure for 120
hours when compared with the Fe500 normal reinforcement bars and with
same bar diameter. All test results (including physical and chemical properties
and salt spray tests) have to be produced for the respective bar diameter for
each consignment of steel delivered at site and at a frequency of every 20
Metric Tons.
Reinforcement bars and structural steel to be procured only from Primary steel
producers / Integrated Steel Plants such as TATA/SAIL/RINL/JSW/SHYAM
STEEL using iron or the basic raw material and having in-house iron making
facilities. No Re-rolled material / secondary steel will be accepted or allowed
for any structural works.
The steel manufacturing company should have latest ISO accreditation for
Quality Management System.

g) The minimum amount of reinforcement in each of the two direction sat right
angles within each surface zone should be provided as per clause 8.1 of
IS3370 (Part2): 2009. Definition of surface zones is clearly shown in Figure-1
and Figure-2 of IS3370 (Part2): 2009. For slabs, minimum of 10 mm dia bars
shall be used to avoid any deformation of lesser diameter bars under loads
prior to construction.

h) All buildings shall have a minimum 1meter wide, 100mm thick plinth protection
pavinginM15gradeconcreteorstoneslabs/tiles.Allplinthprotectionshallbe
supported on well compacted strata.

i) All pipes and ducts lay below the structural plinth and roadwork’s shall be
surroundedwithconcreteofgradeM15havingminimum150mmthickconcrete or
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D/4(D=outer dia of pipe) thickness whichever is more.

j) Use of pressure relief valves to reduce uplift pressure due to ground water
table shall not be allowed.

k) Detailing of the reinforcement shall be considered as per latest Indian code of


practices and special publications as applicable.

l) Sliding layer or slip layer shall be provided between sub base and structural
slab (Raft). Polythene sheets of 500 microns shall be provided as sliding layer
as per IS specification.

m) Water tightness testing of water retaining structures shall be done in


accordance with IS:3370, (Part-I) - 2009. It is described in Clause5.26 of this
document. The depth of water for testing shall be up to the soffit of the
covering slab.
Columns
i) For columnwidth200 40mm
ii) For column width 230&above 50mm
iii) Pedestals (in contact with earth) 50mm
iv) Basement wall, retaining walls
Face in contact with earth 50mm
iii) Interior face 40mm
iv) Foundations (Top, Bottom and sides)50mm

2. Liquid retaining structures shall be as follows unless stated otherwise:


Walls-Face in contact with earth 50mm
Walls-Face in contact with Water 45mm
Base Slab in contact with Water 45mm
Base Slab in contact with Soil 50mm
Launders /Gutter Slabs 25mm

n) In general, reinforcement for buildings and sewage treatment units shall be


HYSD-CRS (Corrosion Resistant Steel) of Grade Fe500. All physical and
chemical properties of this Fe500 grade steel shall conform to IS: 1786-2008.
Welded wire fabric shall conform to IS: 1566 as shown or specified on the
drawing. The CRS (corrosion resistant steel) index shall be at least 1.35 when
tested for Salt Spray test as per “ASTMB117–2009 test procedure for 120
hours when compared with the Fe500 normal reinforcement bars and with
same bar diameter. All test results (including physical and chemical proper ties
and salt spray tests) have to be produced for the respective bar diameter for
each consignment of steel delivered at site and at a frequency of every 20
Metric Tons.

Reinforcement bars and structural 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. No Re-rolled material / secondary steel will be accepted or
allowed for any structural works.

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

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o) The minimum amount of reinforcement in each of the two direction straight
angles within each surface zone should be provided as per clause 8.1 of IS
3370 (Part-2): 2009. Definition of surface zones is clearly shown in Figure-
1and Figure-2 of IS 3370 (Part2):2009. For slabs, minimum of 10mm dia bars
shall be used to avoid any deformation of lesser dia meter bars under loads
prior to construction.
p) All buildings shall have a minimum1meter wide, 100mm thick plinth protection
paving in M15 grade concrete or stone slabs/tiles .All plinth protection shall be
supported on well compacted strata.

q) All pipes and ducts laid below the structural plinth and road works shall be
surrounded with concrete of grade M15 having minimum 150mm thick
concrete or D/4(D=outer dia. Of pipe) thickness whichever is more.

r) Use of pressure relief valves to reduce up lift pressure due to ground water
table shall not be allowed.

s) Detailing of the reinforcement shall be considered as per latest Indian code of


practices and special publications as applicable.

t) Sliding layer or slip layer shall be provided between sub base and structural
slab (Raft). Polythene sheets of 500 microns shall be provided as sliding layer
as per IS specification.

Water tightness testing of water retaining structures shall be done in accordance with IS:
3370, (Part-I)-2009. It is described in Clause5.26 of this document. The depth of water
for testing shall be up to the soffit of the covering slab.
The following minimum thicknesses shall be used for different reinforced concrete members,
irrespective of design requirements:

(i) Walls for liquid retaining structures : 200mm


(ii) Roof slabs for liquid retaining structures : 150mm
(Other than flat slabs)

(iii) Bottom slabs for liquid retaining structures : 200mm


(iv) Floor slabs including roof slabs, walkways,

Canopy slabs : 125mm

(v) Walls of cables / pipe trenches,

Underground pits etc. : 150mm

(vi) Column footings : 200mm


(vii) Parapets, chajja and all fascias : 75mm
(viii) Pre-cast trench cover : 75mm
(ix) Column Dimensions
a) Exceptional case(Based on any specific requirements)

i)To match with width of Block masonry wall : 200mm

ii)To match with width of Brick masonry wall : 230mm

b)In general case : 300mm

(x) Beams(To match with width of Block masonry wall) : 200mm


xi) Launder Base Slab : 200 mm

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(xii) Launder Vertical Wall, Baffle Wall, Gutter Slab : 150 mm
(xiii) Grade Slabs : 150 m

5.13 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
Contractor for incorporation in the Works.
Except 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 Contractor
shall inform the Engineer 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 Engineer which
may be withheld until samples have been submitted and satisfactorily tested. The Contractor
shall thereafter keep the Engineer 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.

5.14 Samples and Tests of Materials


The Contractor shall submit samples of such materials as may be required by the Engineer
and shall carry out the specified tests directed by the Engineer at the Site, at the supplier's
premises or at a laboratory approved by the Engineer.
Samples shall be submitted and tests carried out sufficiently early to enable further samples
to be submitted and tested if required by the Engineer.
The Contractor shall give the Engineer seven days' notice in writing of the date on which any
of the materials will be ready for testing or inspection at the supplier's premises or at a
laboratory approved by the Engineer. The Engineer 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 Contractor, failing which the test may proceed in his
absence unless instructed by the Engineer to carry out such a test on a mutually agreed
date in his presence. The Contractor shall in any case submit to Engineer within seven days
of every test such number of certified copies (not exceeding six) of the test results as the
Engineer may require.
Approval by the Engineer as to the placing of orders for materials or as to samples or tests
shall not prejudice any of the Engineer's powers under the Contract.
The provisions of this clause shall also apply to materials supplied under any nominated
sub-contract.

5.15 Standards
Materials and workmanship shall comply with the relevant Indian Standards (with
amendments) current on the date of submission of the tender.

Where the relevant standard provides for the furnishing of a certificate to the Engineer, at his
request, stating that the materials supplied comply in all respects with the standard, the
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Contractor shall obtain the certificate and forward it to the Engineer.
The specifications, standards and codes listed below are considered to be part of this
specification. All standards, specifications, codes of practices referred to herein shall be the
latest editions including all applicable official amendments and revisions.
In case of discrepancy between the Specification and the Standards referred to herein, the
Specification shall govern.
a) Materials
IS:269 - Specification for 33 grade ordinary Portland cement
IS:278 - Specification for Galvanized Steel Barbed wire &Fencing
IS:383 - Specification for coarse and fine aggregates from natural
sources for concrete
IS: 428 - Specification for distemper, oil emulsion, coloras required
IS: 432 - Specification for mild steel and medium tensile steel bars and
hard drawn steel wire for concrete reinforcement (Parts1&2)
IS: 455 - Specification for Portland slag cement
IS: 458 - Specification for precast concrete pipes (with and without
reinforcement)
IS:650 - Specification for standards and for testing of cement
IS:651 - Specification for salt glazed stone ware pipe sand fittings
IS:808 - Specification for dimensions for hot rolled steel beam, column
channel and angle sections
IS:814 - Specification for covered electrodes for manual metal arc
welding of Carbon and Carbon Manganese steel
IS:1003 - Specification for timber paneled and glazed shutters(Parts1&2)
IS:1038 - Specification for steel doors, windows and ventilators
IS:1077 - Specification for common burnt clay building bricks
IS:1398 - Specification for packing paper, water proof, and bitumen
laminated.
IS:1489 - Specification for Portland pozzolana cement(Parts1&2)
IS:1566 - Specification for hard drawn steel wire fabric for concrete
reinforcement.
IS:1580 - Specification for bituminous compounds for waterproofing and
caulking purposes
IS:1786 - Specification for high strength deformed steel bars and wires for
concrete reinforcement
IS:1852 - Specification for rolling and cutting tolerances for hot rolled
steel products
IS:1948 - Specification for aluminum doors ,windows and ventilators
IS:1977 - Specification for Low Tensile structural steel (Ordinaryquality)
IS:2062 - Specification for steel for general structural purposes(Hot

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Rolled Low, Medium and High Tensile Structural Steel).
IS:2185 - Specification for concrete masonry units(Parts1,2&3)
IS:2202 - Specification for wooden flush door shutters(Parts1&2)
IS: 2645 - Specification for integral cement water proofing compounds IS:
2721 - Specification for Galvanized Steel Chain Link Fence Fabric IS: 2750
- Specification for steel scaffoldings
IS:2835 - Specification for flat transparent sheet glass
IS:3384 - Specification for bitumen primer for use in water proofing and
damp proofing
IS:3502 - Specification for steel chequered plates
IS: 4021 - Specification for timber door, window and ventilator frames IS:
4350 - Specification for concrete porous pipes for under drainage IS:
4351 - Specification for steel door frames
IS:4990 - Specification for plywood for concrete shuttering work
IS:8112 - Specification for 43 grade ordinary Portland cement
IS:9862 - Ready mixed paint, brushing, bituminous, and black, lead
free, acid, alkali, water and chlorine resisting
IS:10262- Recommended guidelines for concrete mix design
IS:12269- Specification for 53 grade ordinary Portland cement
IS:12330- Specification for sulphate resisting Portland cement
IS:12709- Glass fiber reinforced plastics (GRP) pipes, joints and fittings for
use for potable water supply

b) Tests
IS:516 - Method of test for strength of concrete
IS: 1182 - Recommended practice for radiographic examination of fusion-
Joints in steel plates
IS: 1199 - Methods of sampling and analysis of concrete
IS: 2386 - Methods of test for aggregates for concrete (Parts1to8)
IS: 2720 - Methods of test for soils (Parts1 to 39)
IS: 2911 - Code of Practice for design and construction of Pile foundations
IS:3025 - Methods for sampling and test(physical and chemical) for water
Wastewater (Parts1to56)

IS:3495 - Method of test for burnt clay building bricks(Parts1to4)


IS:3613 - Acceptance tests for wire flux combination for submerged arc
welding
IS:4020 - Methods of tests for wooden flush doors shutters: Type tests
IS:4031 - Methods of physical tests for hydraulic cement(Parts1to15)
IS:5807 - Method of test for clear finishes for wooden furniture(Parts1to6)

177
IS:7318 - Approval tests for welders when welding procedure approval is
not required (Parts1and2)
IS: 13311 - Methods of Non-destructive testing of Concrete - (Part1 & Part2)

c) Codes of Practice for design /detailing

IS:456 - Code of practice for plain and reinforced concrete


IS:783 - Code of practice for laying of concrete pipes
IS:800 - Code of practice for general construction in steel
IS:806 - Code of practice for use of steel tubes in general building
construction
IS:816 - Code of practice for use of metal arc welding for general
construction in mild steel
IS:817 - Code of practice for training and testing of metal arc welders
IS:875 - Code of practice for design loads (other than earthquake)for
building structures (Parts 1 to5)
IS:1081 - Code of practice for fixing and glazing of metal (steel and
aluminum)doors, windows and ventilators
IS:1172- Code of practice for basic requirements for water supply,
drainage and sanitation
IS:1477- Code of practice for painting of ferrous metals in buildings
(Parts1&2)
IS:1597- Code of practice for construction of stonemasonry(Parts1&2)
IS:1742- Code of practice for building drainage
IS:1893- Criteria for earthquake resistant design of structures
IS:1904- Code of practice for Design and Construction of Foundation in
Soils: General Requirements.
IS:2065- Code of practice for water supply in buildings
IS:2212- Code of practice for brickwork
IS:2338- Code of practice for finishing of wood and wood based materials
(Parts1&2)
IS:2394- Code of practice for application of lime plaster finish
IS:2395- Code of practice for painting, concrete, masonry and plaster
surfaces(Parts1&2)
IS:2470- Code of practice for installation of septic tanks(Parts1&2)
IS:2502- Code of practice for bending and fixing of bars for concrete
reinforcement
IS:2571- Code of practice for laying in-situ cement concrete flooring
IS:2595- Code of practice for radiographic testing
IS:2751- Recommended practice for welding of mild steel plain and
deformed bars for reinforced construction

178
IS:2911- Code of practice for design and construction of Pile foundations
IS:2974- Code of practice for design and construction of machine
foundations (Parts1to4)
IS:3114- Code of practice for laying of Cast Iron pipes
IS:3370- Code of practice for concrete structures for the storage of
liquids(Parts1to4)
IS:3414- Code of practice for design and installation of joints in buildings
IS:3558- Code of practice for use of immersion vibrators for consolidating
concrete
IS:3658- Code of practice for liquid penetrate flaw detection
IS:3935- Code of practice for composite construction
IS:4000- Code of practice for High strength bolts in steel structures
IS:4014- Code of practice for steel tubular scaffolding(Parts1&2)
IS:4111- Code of practice for ancillary structures in sewerage system
(Parts1to5)
IS:4127- Code of practice for laying of glazed stoneware pipes
IS:4326- Code of practice for Earthquake Resistant Design and
Construction of Buildings
IS:4353- Recommendations for submerged arc welding of mild steel and low
alloy steels
IS:5329- Code of practice for sanitary pipe work above ground for
buildings

IS:5334- Code of practice for magnetic particle flaw detection of welds


IS:5822- Code of practice for laying of welded steel pipes for water
supply
IS:7215- Tolerances for fabrication of steel structures
IS:9595- Recommendations for metal arc welding of carbon and carbon
manganese steels
IS:10005- SI units and recommendations for the use of their multiples and
of certain other units
SP:16 - Design Aids for Reinforced Concrete toIS-456
SP:34 - Handbook on Concrete Reinforcement and Detailing
SP:38 - Handbook of Typified Design of Structures with Steel Roof
Trusses
d) Construction Safety
IS:3696- Safety code for scaffolds and ladder(Parts1&2)
IS:3764- Safety code for Excavation work
IS:7205- Safety code for erection of structural steelwork

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5.16 General Arrangement of Plant
The following general guidelines shall be followed in the preparation of general arrangement
of Plant:
- Sufficient room shall be allowed between items of plant and adjacent Plant or fixed
structures to permit safe and convenient access for operation and maintenance;
- An area adjacent to all mechanical Plant shall be provided as maintenance lay down
area;
- fixed runways, lifting eyes or other means shall be provided to permit the removal of
Plant that may be required to be removed during the course of its normal operational
life for maintenance or any other purpose;
- areas where leakage is likely to occur whether in normal use or during maintenance
shall be provided with covered drainage channels which shall direct spillage either to
a suitable plant drain or to a sump from where it can be pumped to plant drain;

5.17 Orientation
The works shall be laid out within the confines of the Site in order to interface to the existing
infrastructure of roadways and inlet and outlet pipe work. Underground services requiring to
be relocated in order to accommodate the proposed site layout shall, with the approval of the
Engineer, be relocated by the Contractor.
5.18 Buildings and Structures
All the building and structure works shall generally comply with the following
Employer’s Requirements unless otherwise specified elsewhere:
1. All building works shall be of reinforced concrete framework (Concrete Grade of M25 as
aminimum).
2. All external walls shall be in solid cement concrete blocks of concrete grade M15 and
shall be provided as per IS: 2185 (Latest Revision) and shall be 200 mm thick.
3. All internal partition walls shall be in solid cement concrete blocks of concrete grade
M15 and shall be provided as per IS: 2185 (Latest Revision). All internal walls shall be
200mm thick except for toilets. Toilet partition walls shall be in 100 mm thick solid
concrete block.
4. (a) Finishes to concrete liquid retaining structures shall
be: F1 - External surfaces, buried
F2 - External surfaces exposed and up to 300 mm below ground level
F2 - Internal surfaces
(b) Finishes to other concrete structures shall
be: F1 - Buried
F1 - Exposed, where plastering is specified
F2 - Exposed

5. All internal masonry and ceiling 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.
6. 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
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approved make and quality shall be added to the cement mortar in proportions as
specified by the manufacturer.
7. 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.
8. Toilet areas, walls and ceilings, shall have one coat of primer and two coats of plastic
emulsion paint.
9. 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.
10. The finished floor level in toilet areas shall be 25 mm below general finished floor level
elsewhere in the building.
11. The flooring in all areas except toilets, staircases, pumping stations, chlorination
building, centrifuge building, workshop, D.G.Room 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.
12. The flooring in the pumping stations, chlorination building, centrifuge building,
workshop, D.G.Room shall be 60mm thick cement flooring with Metallic concrete
hardener topping, under layer of 42mm thick cement concrete 1:2:4 (1 cement :
2coarse : 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.
13. The flooring in operator’s 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.
14. 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.
15. 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
cudapa support as directed and the edges of granite is to be embedded into the wall.
16. The toilet facilities shall include at least:
(i) 2 Nos. Water closets with white porcelain Orissa pan minimum 580 mm long with
low level flushing cistern of 10 litres capacity.
(ii) 2 Nos. Urinals of sizes 600 mm x 400 mm x 300 mm flat back type in white
porcelain separated by a marble partition of size 680 mm x 300mm.
(iii) 2 Nos. wash basins of size 510 mm x 400 mm in white porcelain with inlet, outlet
and over flow arrangements.
(iv) 2 Nos. mirror of size 400 mm x 600 mm wall mounted type fitted over washbasins.
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(v) 2 Nos. plastic liquid soap bottles
(vi) 2 Nos. chromium plated brass towel rails minimum 750 mm long.
(vii) All stopcocks, valves and pillar cocks shall be heavy duty chromium plated brass.
(viii) All fittings such as ’P’ or ‘S’ traps ,floor traps ,pipes, down take pipes etc.
(ix) The sewage from toilet blocks shall be led to the wet well of terminal sewage
pumping station if present or included under this contract or to the closest gravity
sewer.
17. 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 aluminium 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.
18. Stairways shall be provided to permit access between different levels within buildings.
Staircase shall be minimum 1000mm wide, minimum Tread = 250 mm, maximum
Riser
= 175 mm and maximum 15 number of steps per flight unless specified otherwise.
Staircases in general shall not be steeper than 40°. Staircases having space constraints
may be steeper than400. The maximum vertical run for a single flight of stairs shall be
3.0 M.
19. 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 Engineer to access areas not frequently visited.
Steel staircases shall be constructed of standard channel stringers with M.S. grating
treads 25mm thick with non skid nosing. Steel Ladders shall be minimum 600mm
wide and shall not exceed 6m of straight run. The ladders shall be painted with epoxy
paint.
20. All hand railing shall be provided with 6063-T6 Aluminium Alloy with an ultimate
tensile strength of at least 207 MPa and yield strength of at least 172 MPa. The
minimum height of hand railing shall be 1m and maximum spacing of verticals shall be
1.5 m. Number of horizontal rails shall be 3 (1 top, 1 intermediate and 1 bottom) OR 2
rails ( 1 top, 1 intermediate) with a 100 x 6 toe plate at the bottom.
21. The reinforced concrete roofs shall be made waterproof by application of an approved
roof polythene / bitumen membrane / brick bat coba. The finished roof surface shall
have adequate slope to drain quickly the rain water to R.W down take inlet points.
22. 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
23. For roofing drainage, cast iron or uPVC rainwater down takes with C.I. bell mouth or
uPVC 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.
24. 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 rainwater.
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25. Building plinth shall be minimum 450 mm above average finished ground level around
building or high flood level whichever is more.
26. 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
windows shall be provided to prevent the rain water splashing into the building. Chajja
shall be projected 150 mm on either sides from size of doors/windows/rolling shutters.
27. All windows and ventilators shall have 25 mm thick Kota stone sills bedded in cement
mortar(1:3).
28. 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 and340).
29. 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 aluminium doors
& windows shall be as follows

I. Single Glazed Window: (Weights indicated shall be aluminium)


a) Open able
Outer Frame : Weight 0.70kg/Rmt
Shutter Frame :
Weight0.97kg/Rmt Intermediate Mullion:
Weight0.97kg/Rmt Beading:
Weight0.31kg/Rmt Fixing Louvers
windows/ventilators
Outer Frame : Weight 0.46kg/Rmt
II. Double Glazed Window
Outer Frame : Weight 0.72kg/Rmt
Shutter Frame :
Weight0.97kg/Rmt Intermediate Mullion:
Weight0.98kg/Rmt Beading: Weight
0.31kg/Rmt

III. Sliding Windows


Bottom &Top Frame :
Weight0.70kg/m Shutter Frame :
Weight0.42kg/m Interlocking Section :
Weight 0.47kg/m

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IV. Aluminium Door
Outer Frame : Weight 2.508kg/Rmt
Shutter Frame : Weight 2.508kg/Rmt
Bottom Stile :
Weight2.508kg/Rmt
Glazing shall be 5.5 mm thickness.
30. Openings of the windows & ventilators shall be minimum 25% of the external wall area.
31. Ventilator shall be provided where height of floor is more than3m.
32. All windows and ventilators shall have wire mesh. Frame of doors, windows and
ventilators shall be of aluminium of standard rolled section. Doors, Windows and
Ventilators shall be of size as per schedule to be submitted by the Contractor for
approval of Engineer. The minimum size shall be as per below:
Door of opening size 1.2m x 2.1m
Door of opening size 0.75m x 2.1m for
toilets Glazed windows of minimum size
1.2m x 1.2m Ventilators of minimum size
0.6m x 0.6m
33. 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 MCC cum
panel room, chlorine tonner shed, at entry and exit of the pump house for access to
pumps, motors, valves, panels and as wherever required.
34. All concrete channels and ducts used for conveying liquid shall have inside finish of
type F2. The width of concrete channels shall not be less than 500 mm. All open
channels shall be provided with Aluminium hand railings (3-rail) or concrete walls to a
minimum height of 1 m from the access surface elevation. All concrete surfaces of
structures conveying raw sewage or primary effluent upstream of the aeration tanks
shall be protected from corrosion with an approved internal lining as specified in
Clause 5.25of this document.
35. 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 than150mm.
36. 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.
37. 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.
38. All rooms in the treatment plant buildings shall be provided with appropriate sign
boards indicating the function of the rooms involved written in Kannada and English
Languages.
39. 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 paneling shall be kept to a minimum and preference given to wall openings
protected by weather canopies.
40. Emergency exit doorways shall be provided from all buildings in order to comply with

184
local and international regulations .Stairways and paved areas shall be provided at the
exit points.
41. 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.
42. All the walkways shall have minimum 1 m width and shall be covered with mosaic
tiles. Walkways to be provided with 6063-T6 Aluminium Alloy hand railings.
43. Anaerobic Sludge Digesters and Sludge Tank with Gas Holders shall be built in RCC.
A top dome of digesters and Gas Holders shall be made of Steel with full Epoxy
Coating as per the specification given in Clause 5.25of this Part-10 and top surface
Ring Beam and top 2m wall of the digester shall also be coated with Epoxy Coating.
Contractor may submit his proposal for the alternative materials which can be used for
digester dome and gas holder along with all technical details. Employer will approve
the type of material which shall be used for the construction of gas holders and
digester domes depending upon the durability, corrosion resistivity, strength, ease in
operation, functional requirements, economy, etc.(if included in this contract)
44. All concrete structures in contact with sewage and/or sludge upstream of the Aeration
Basins shall be provided with full interior corrosion protection linings and/or coatings of
appropriate material and thickness to be approved by client. This also applies to all
concrete structures in contact with any type of sewage sludge anywhere in the plant.
For Aeration Basins, interior lining shall extend from the top of wall down to 1.0 meter
below the lowest operating water level.
45. 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 calculated at high flood level and
peak plant flow. The top level of internal plant roads and approaches shall be at least
0.5m above the site High Flood Level.
46. If the High flood level is more than Ground Level then road shall be constructed on the
Earthen Embankments/Engineered Embankment. Earthen Embankments/ Engineered
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. Good quality of filling materials can be used for
embankment construction as approved by Engineer/as suggested in relevant
Geotechnical Investigation Report recommendations as applicable.
47. Engineered Embankments for plant structures in Swampy/Water logged areas shall
be considered in compliance with relevant Geotechnical Investigation Report
recommendations as applicable.
48. All requirements for Engineered Embankments and all other associated works
connected to this system (i.e. like, all controlled filling requirements, Type & suitability
of materials, Methodologies, Testing, Protective systems, Aprons, Proper slopes,
Stability, Specifications, Quality control, and all other requirements pertaining to this
system of works, etc.,) shall be considered in compliance with relevant Geotechnical
Investigation Report recommendations as applicable. Also to enlist the services of an
experienced & specialized agency for all related design aspects considerations,
equipment specifications, and implementation methodology, etc., as an advice for the
same (Refer to 46 &47).
49. Suitable River flow training systems/Flow diversion to be adopted at required
locations/places in compliance with relevant Geotechnical Investigation Report
recommendations as applicable.
185
5.19 Roadways, Pathways & Hard standings
A comprehensive network of roadways shall be provided around the treatment plant to
link in with the existing road network and permit access to the plant for necessary
maintenance, delivery of consumables and personnel access. All roads shall be of
asphalt macadam having minimum 5.5 metres wide. 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.
Paved pedestrian access ways shall be constructed to provide a network of logical
routes interlinking plant areas. Damage to any existing roads on account of their use
by the Contractor shall be made good to the satisfaction of the Engineer.
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. The road system shall be designed such that vehicles involved
in the delivery of consumables can follow a continuous route through the works and
out again.

5.20 Site Drainage


The Contractor shall provide a site drainage system. The system shall comprise of the
following:
- Storm Water Drainage
- Foul Drainage

Storm Water Drainage


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 be450mm.
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.
Foul Drainage
The foul drainage system shall accept discharge from toilets, washrooms, offices and the
laboratory. The foul drainage system shall be conveyed to either wet well of the terminal
sewage pumping station wherever exist or proposed under this contract or nearest public
sewer wherever exist.
5.21 Cable and Pipe work Trenches
Cable and pipe work trenches shall generally be constructed in reinforced concrete.
All floor cut-outs and cable ducts, etc. shall be covered with M20 precast concrete
covers (Heavy Duty) or MS grating as per direction of Engineer in outdoor areas and
M.S. chequered plates, suitably painted of adequate thickness 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.
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 Engineer while planning the works.
5.22 Pipes and Ducts
186
R.C.C ducts for drainage shall have minimum 1 metre 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.
All drains (except storm water drains adjacent to roads) shall be covered and designed
structurally for appropriate loads.
5.23 Boundary wall & Main Gate
5.24 Boundary wall / Compound wall
Compound wall shall consist of RC precast slab panels (M25), RC post at regular
intervals including plinth beam as supports for the panels and necessary RC foundation
system for the same along with barbed wire stretched between MS angles fixing at the
top of the precast panels with necessary fixtures etc.,
All structural designs and Specifications shall confirm to relevant codal provisions.
5.25 Main Gate
Each proposed treatment plant shall have 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 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 Engineer. The gate shall have all necessary hinges,
locking arrangement, rolling arrangement and painting complete, as approved by the
Engineer.
5.26 Landscaping
The site shall be landscaped once the Works are substantially complete. Landscaping
area shall be marked in the layout plan of STP site.
Landscaping shall include planting of suitable 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 Engineer. Medicinal and fruit trees shall be avoided. Landscaping shall be
maintained in good condition till the completion of the contract.
Area for landscaping will be equal to total area of project site minus area for the
treatment plant units and the area required for roads, sidewalks and drains.
5.27 Tree Planting
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 shall be planted in each pit. A guard made of bamboo with
wire mesh or bricks or M.S. ring as approved by Engineer, shall be provided.
5.28 Hydraulic Testing of Liquid Retaining Structures
In addition to the structural test of structures as applicable, the liquid retaining structures
shall also be tested for water tightness test at full supply level as described in clauses
12.1,12.1.1, 12.1.2 and 12.1.3 of latest version of IS 3370 (Part I).
On completion of the structure and before its commissioning, the Contractor shall carry
out a water tightness test for the maximum water head condition i.e. with the water
standing at Full Supply Level (FSL). This test shall be carried out preferably in dry
season and prior to internal coating/lining in accordance with the procedure given
below:
The water tightness test shall be carried out when the construction of liquid retaining
187
structure is done and when it is possible to fill the structure and ensure that uniform
settlement of the structure as a whole or as directed by the Engineer. Before the filling
operations are started the structure shall be inspected by the Engineer and the
Contractor's Representative and the condition of surfaces of walls, contraction joints
shall be noted and it shall be ensured that the jointing material filled in the joint is in
position and all openings are closed. The Contractor shall make necessary arrangement
for ventilation and lighting of the structure by way of floodlights, circulators etc. for
carrying out proper inspection of the surfaces and inner conditions if so desired by the
Engineer. Records of leakages starting at different levels of water in the reservoir, if
any, shall be kept.
The liquid retaining structure once filled shall be allowed to remain so for a period of
seven days before any readings of drop in water level are recorded. The level of the
water shall be recorded against the subsequent intervals of 24 hours over a period of
seven days. The total drop in surface level over a period of seven days shall be taken
as an indication of the water tightness of the structure, which for all practical purposes
shall not exceed 40 mm. Also there shall be no indications of the leakages around the
opening or on the walls.
If the structure does not satisfy the condition of test and the daily drop in water level is
decreasing, the period of test may be extended for a further period of seven days and it
the specified limit is then reached the structure may be considered as satisfactory.
The external faces of structure shall not show any signs of leakage and shall remain
apparently dry over the period of observation of seven days after allowing a seven day
period for absorption after filling.
In case the drop in level exceeds the permissible level limit and signs of leakage with
the stipulated period of test, the Contractor shall carry out such additional works and
adopt such measures as may be directed by the Engineer to reduce the leakage within
the permissible limits. The entire rectification work that shall be carried out in this
connection shall be at the Contractor's cost. The water required for subsequent testing
shall be supplied to the Contractor free of cost, if the same is available near the site.
Contractor shall have to make arrangement for filling emptying the structure at his own
cost.
If the test results are unsatisfactory, the Contractor shall ascertain the cause and make
all necessary repairs and repeat the water retaining structures test procedures, at his
own cost. Should the re-test results still be unsatisfactory after the repairs, the structure
will be condemned and the Contractor will dismantle and reconstruct the structure, to
the original specification, at his own cost.
During testing and during defect liability period the impression marks created due to
seepage shall be rectified and made good.
No separate payment shall be made for water tightness test and the cost thereof shall
deem to be covered in the rates quoted of different items of work of Treatment Plant.
5.29 Non Destructive Testing of RCC Structures
Non Destructive Testing (NDT) shall be carried out as per latest version of IS: 13311
codes as per the instruction given by Employer.

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6 PARTICULAR SPECIFICATIONS – BUILDING SERVICESWORKS

BUILDING SERVICES
6.1 Scope
The Contractor shall design, supply, delivery to Site, off-loading, storage, erection, testing
and commissioning the complete building services installations at all the works including but
not limited to;
(a) Internal main and emergency lighting;
(b) External lighting and floodlighting;
(c) Roadway lighting;
(d) Small power;
(e) Ventilation and ceiling fans;
(f) Telephone lines and handsets;
(g) Plumbing and drainage.

The building services installation shall comply with Standard Specification and the following
clauses herein and local Codes and Regulations. Where the drawings, standard
specification and particular specification differ, the latter shall take precedence.
6.2 Lighting
6.2.1 Internal main lighting
Internal lighting shall be designed to provide the following minimum service luminance,
measured at floor level:-
6.2.1.1 Process plant/pump hall areas : 200lux
6.2.1.2 Chemical and disinfection areas : 300lux
6.2.1.3 Switch rooms : 200lux
6.2.1.4 Control room : 350lux
6.2.1.5 Workshop areas : 300lux
6.2.1.6 Laboratory : 350lux
6.2.1.7 Offices : 300lux
6.2.1.8 Staff rooms : 150lux
6.2.1.9 Toilets, washrooms, mess rooms, corridors and staircases : 100lux

LED type Luminaries shall be provided and fixed directly to, or suspended from the
underside of roof slabs, ceilings or fixed to walls as appropriate.
Pump halls areas shall be provided with LED high or low bay energy efficient lighting. The
Contractor shall provide all necessary equipment to ensure lighting maintenance can be
performed in a safe and efficient manner. Where special provision would have to be made
for accessing luminaries supported from the underside of the roof slab for maintenance,
luminaries shall be wall mounted.
LED type Luminaries for the control room and offices shall be designed to minimize glare
and shall be suitable for VDUs.
Light switches shall be located adjacent to doorways. Multi-way switching shall be provided
for rooms and areas with more than one point of access. For large area light switching or
high/low bay lighting, contactors shall be provided to switch lighting in blocks from each entry
point.

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Luminaries and associated electrical accessories installed in chemical plant rooms shall be
protected to IP 65 minimum.
6.2.2 Internal emergency lighting
Emergency lighting shall be provided and shall comprise exit and escape route luminaries to
facilitate safe movement of personnel in or from any building or major dry structure in the
event of a mains supply failure. Exit luminaries shall be provided above all doors leading to
or accessible to an outdoor area.
Emergency lighting shall be provided in areas where essential operations may be required
during a mains supply failure, for example, switch room and control rooms. Exit luminaries of
emergency lighting shall be powered by integral battery units.
6.2.3 External walkway areas
LED type Luminaries shall be provided to illuminate all external personnel walkway areas
around buildings and structures. The lighting shall be designed to provide an even minimum
service illuminance measured at ground level of 15 lux.
Lighting shall be switched at personnel access doors. Multi-way switching shall be provided
where there is more than one point of access.
Luminaries and associated electrical accessories installed in outdoors shall be protected to
IP 65 minimum.
6.2.4 Flood lighting
LED type Floodlighting shall be provided for the entrance to the sites all site pumping
stations and loading / unloading areas. Floodlighting shall also be provided at all locations
requiring inspection.
Floodlights shall be mounted on galvanised steel poles or on structure walls as appropriate.
Floodlighting shall provide a minimum service illuminance of 50 lux measured at the working
plane.
Floodlighting shall be locally switched. Luminaries and associated electrical accessories
installed in outdoors shall be protected to IP 65 minimum.
6.2.5 Lighting for Booster Stations & MBRs / ZBTs site and general roadway
lighting
Lighting for Booster Stations & MBRs / ZBTs site and general roadway lighting at all plants in
this Contract shall comprise tubular steel columns with semi cut-off high pressure sodium
type luminaries complete with control gear, which shall in general conform to the Standard
Drawing. The lighting shall provide a minimum illuminance at ground level of 25 lux.
Concrete mass base and skirting, in conceptual design as per design shall be installed. Each
lamp pole shall be structurally sound to withstand, as a minimum, 160 knots without causing
any damage. The height of the lamp pole for general roadway lighting shall be not less than
4.5 m and that for MBRs / ZBTs shall be not less than 8 m. Lamp poles of mild steel
construction shall be hot dip galvanized to BS 729. The poles shall be finished overall with at
least two coats of primer and two coats of finishing paint after erection. The colour of the
finishing paint shall be as directed by the Engineer.
Minimum of 4c x 6sq mm, 1.1 kV, Cu., PVC, Armoured cables shall be used for power
supply from distribution board up to the individual junction boxes of each street light pole.
From the junction boxes up to the luminaries 2.5sq mm Cu flexible wire shall be used.

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External Roadway lighting control shall be integrated with timer control and DB for the same
shall be kept in security cabin / control room.
Luminaries and associated electrical accessories installed in outdoors shall be protected to
IP 65 minimum.
6.3 Small power
Industrial switched type 240Vac socket outlets with residual current devices for the
connection of electric tools shall be installed in convenient places in all plant and workshop
areas.
Suitable rated 415Vac/240Vac socket outlets with residual current device shall be provided
for all water retaining structures for the water treatment works, intake structure and raw
water pumping station. The socket outlets shall be located in an IP65 weatherproof
enclosure fixed to the structure wall.
For process plant areas, industrial type socket outlets shall be so spaced so that any
location within the area is no greater than 20m from an outlet. A minimum of two socket
outlets shall be provided in each area.
Commercial type 240V 16A and 6A socket outlets shall be installed throughout all
administrative office areas including the associated corridor areas. A minimum of two socket
outlets shall be provided in each room to allow each desk to be serviced with a power supply
without the need for extension leads. Additional socket outlets to suit the particular
requirements of the main control room and the laboratory shall be provided.
6.4 Local area network
The Contractor shall provide a local area network for all offices including control room and
laboratory within the filter building in accordance with the standard specification. As a
minimum two RJ45 connections shall be provided in each office, laboratory and control
room. The Contractor shall submit details of the proposed network for the Engineer’s
approval.
6.5 Ventilation
Ventilation system shall be as specified elsewhere in the document.
6.6 Ceiling fans
All administrative areas such as the control room, all offices and building entrance areas at
the water treatment works and each water pumping station shall be provided with ceiling
fans to provide 4 ACH. The fans shall be provided with local speed controllers and switches
adjacent to each individual unit.
6.7 Distribution boards
Each individual building or facility shall be provided with suitably sized distribution board
dedicated for building services. The distribution board shall provide distribution to lighting,
socket outlets, heating, ventilation and air conditioning. Circuits shall be arranged to provide
a balanced load on each phase of the supply. Each distribution board shall be provided with
20% spare ways.

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6.8 Wiring
Internal wiring on concrete and block work surfaces shall be carried out using single core
PVC insulated non-sheathed cables installed in surface mounted heavy duty galvanised
steel conduit and / or trunking. Wiring in plastered and tiled areas shall be installed in
concealed steel conduit.
External wiring shall be carried out using single core PVC insulated non-sheathed cables
installed in heavy duty galvanised steel conduit or PVC covered mineral insulated copper
sheathed cables.
Wiring associated with lighting and ventilation fans in the chemical buildings shall be carried
out using heavy duty PVC or GRP conduits / trunking and/or cable tray/ ladder as necessary.

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7 PARTICULAR SPECIFICATIONS – INSTRUMENTATIONWORKS
7.1 General
All pumping stations and water treatment plant shall be designed for automatic operation
with programmable logic controller (PLC) and HMI / SCADA with facility to operate each
process unit manually if need arises.
The control system shall be designed to recover the plant fully to the normal operational
mode on the restoration of power (either from utility supplier or the generator) within the
predefined (programmable) time of power recovery without any manual intervention. If
power outage is for more than the above predefined time, then the same shall be treated as
fresh start and the system shall follow the fresh starting sequence selected by operator and
the timing shall be logged with real time data in the report format.
Local manual controls shall be located adjacent to equipments wherever required for manual
operation. The system envisaged shall be compatible for continuous operation of the plant.
The entire electrical control systems and instrumentation systems of the plant shall be
interfaced. The automation system proposed shall not be limited to only process / equipment
control but shall also cater to the energy monitoring system of all the areas including
substation and generator. All data shall be logged on real time basis including hours of
generator operation, total power produced and supplied to the plant etc. Data shall also be
logged for the power used from Electricity Board.
7.2 Control System
The control system hardware to be located in control room and near each plant areas, MCC,
pump / power, distribution areas shall consist of;
7.2.1 Plant Control Panel(PLC)
7.2.2 Local 10.4” TFT Colour Screen HMI
7.2.3 Power Supplies
7.2.4 PC based MMI / SCADA System (2 Nos.) at Central Control Room(CCR)

Dynamic MIMIC showing the status of all equipments (at CCR)


The MMI / SCADA at CCR shall have the following facilities;
7.2.5 Auto / Manual Selection
7.2.6 Physical display of measured value
7.2.7 Alarms for each drive
7.2.8 Interlocking and protection of equipment
7.2.9 Selection of duty drive

The Central Control Room shall also have screen printed dynamic MIMIC with transparent
acrylic cover showing the plant flow diagrams and dynamic status using multi coloured LED
lamps and digital meters for flow, level etc. MIMIC shall also have buzzer along with alarm
display, window type or message display unit type. All PLC panel and instrument / PC
supply shall be provided through UPS with at least one hour backup time.
The field instrumentation process forms an integral part of control system. Hardwired
interlocking shall be provided for safety circuits such as motor protection, dry run protection,
emergency stop circuitry and rotation monitor.

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7.3 Process Instrumentation
The process instrumentation includes instruments for Control, Operation and Monitoring.
The contractor shall list all the process instruments proposed in the scheme.
Ultrasonic signal shall be interfaced with PLC for SCADA and control functions and float type
switches signal shall be as a backup to transmitter signal for protection of dry run or over
flow condition.
7.4 Process Units Control
7.4.1 General
The WTP shall be divided into sections depending on the operational requirements. A
hierarchical structure shall be adopted throughout the plant for fault annunciation.
The highest alarm level shall be at the central point MMI which shall annunciate general
alarms like disinfection fault, mixing fault, sludge dewatering fault, chemical dosing fault,
backwashing fault, and other specific alarms related to the plant. However, information shall
be made available up to the lowest level fault by selecting the drive details on SCADA
screen.
The next lowest level shall be the alarms matrix associated with each area. This shall
indicate non drive specific alarms on MIMIC panel.
The next lowest level shall be the alarm annunciated on each drive starter module. This will
annunciate every alarm associated with that drive. The same information shall be made
available on SCADA and also on the popup screen of particular drive.
Thus the operator noting the fault at the Central MIMIC panel shall go to the specific alarm
matrix to determine the correct nature of fault, in case of SCADA not operational.
7.4.2 Motor Control Centers
The MCC shall be provided with Local Remote Selector Switches and Auto Manual Selector
Switches for operation of the motors from various locations.

 Auto Mode

Motors shall be operated from the PLC when the selected mode is Auto of Auto
Manual Selector Switch.

 Manual Mode

Motors shall be operated from the Motor Control Centre when the mode selected in
the MCC is “Manual” from Auto / Manual Selector Switch and “Local” from Local /
Remote Selector Switch.

 Remote Mode

Motors shall be operated from the Local Push Button Stations of the corresponding
motor kept near the motor.

 Local Mode

Motors shall be operated from the Motor Control Centre.

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7.4.2.1 Main Substation
Higher load feeders shall be provided (in the MLTP) with energy meter for each of those
feeder with pulse output to interface with PLC. Detailed single line diagrams shall be
furnished with the proposal. Also typical detailed feeder single line diagram shall be
submitted. These provisions shall be for the feeders above 15 HP.
7.4.2.2 Local Man Machine Interface
Local HMI shall be provided in all PLC panels for controlling and monitoring of the status of
all the pumps, mixers, air blowers etc.
Typically with local HMI the operator shall be able to do;
7.4.2.2.1 Start and Stop control
7.4.2.2.2 Auto Manual Selector Switches
7.4.2.2.3 Pump - Motor start - stop pushbuttons
7.4.2.2.4 Discrete Controls to provide selection of duty pumps
7.4.2.2.5 Indicating lamps

The start, stop and trip alarms of all associated motors MCCs shall be indicated in the HMI.
The Contractor to include all the alarms as necessary for the satisfactory operation of the
pumping stations and WTP in his proposal. The list shall also indicate parameters of offered
MCC feeders of each area.
In order to make PLC function properly and accurately, the point of power and control shall
be from one point. Junction boxes shall be provided at approximate locations on signal
concentration to avoid multiple cables.
7.4.2.3 Central Man Machine Interface (SCADA)
The MMI / SCADA at the central control shall have the following facilities:
7.4.2.3.1 Auto - manual selector switches
7.4.2.3.2 Pump motor start stop pushbuttons
7.4.2.3.3 Indicating Lamps
7.4.2.3.4 Alarm annunciators
7.4.2.3.5 HMI of PLC Panel (for selecting sequence of duty – standby pumps)
7.4.2.3.6 MIMIC

The Central MIMIC including annunciator panel shall be provided to meet the requirements
of entire pumping station and WTP. The MIMIC which shall be approximately 2 m x 1 m
shall comprise of following:
7.4.2.3.7 A MIMIC providing a colour representation of the Plant Flow Diagram WTP
dynamic status.
7.4.2.3.8 Physical displays of measured values of levels, flows, totalized flows etc.
7.4.2.3.9 An alarm matrix for displaying general fault alarms.

All the alarms shall be provided in alarm annunciation in the identified windows of area of
fault.
7.5 Instrumentation and Control System
7.5.1 Instrumentation System
The offered system shall provide all the necessary protection devices to protect electrical
equipments. The scraper mechanism, turbine mixers etc. shall be provided with electronic
type torque overload devices to trip the drive to ensure safety of the equipment. The

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Arrangement shall include necessary electronic speed monitoring equipment for monitoring
the movement of equipment and shall give alarm in the event of stoppage.
All the tanks level shall be measured using ultrasonic level sensors / transmitters. As
detailed in process description necessary flow monitoring instruments shall be provided and
all these transmitters to be integrated with PLC for monitoring and interlocking.
Contractor shall provide a list of equipments / instruments proposed for approval giving
details of instrument / equipment, numbers, location etc. in a format as indicated in Table - 1
below.
TABLE - 1
SAMPLE FORMAT FOR INSTRUMENT LIST
Sl. Type of Instrument Area of Plant Location Quantity
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
…..

7.5.2 Control System


The entire pumping station and WTP shall be designed to operate in Auto mode. However,
if need arises the plant can be operated on manual mode also.
The control system shall comprise 1 No. of PLC based I / O locations as detailed below:
The PLC shall communicate on Ethernet with MODBUS / any other patented bus of match
open protocol to facilitate future integration if required. Proprietary protocol will not be
accepted.
1 Nos. of PC with 19” TFT monitor with SCADA software shall be provided which shall
communicate on the Ethernet..
The control system shall have following operation options;
MANUAL AUTO
From MCC SCADA
Remote (with PLC) HMI on Local Panel
From Mimic Panel (with PLC) Mimic Panel
Operator shall select the mode of operation from MCC i.e. local or PLC.
In local mode, the individual equipment shall be operated from MCC. In PLC mode, the
operator can select to operate from PLC panel, SCADA. In PLC mode also plant shall be
able to start with single start command or individual drive (semi auto mode).

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However in PLC mode of operation status of all the drives and instrumentation system shall
be available in PLC and SCADA.
SCADA shall be capable of generating the shift report for Production, Inputs, and Power
Consumed etc. in each of those feeders provided with KWH meters. The system shall
include required tools for routine maintenance.
The instrumentation system proposed shall be state of the art type and shall give full
information on;
1. The level switches with back up switch and both these switch status shall be compared
and faulty switch indication shall be provided for maintenance purpose.
2. All the flow transmitter indications shall be made available on MIMIC panel as well as
on PLC.
3. All the pumping station sumps shall have level measurement instruments to monitor
the level of water. All pumps shall be controlled based on liquid levels in the sumps.
The hardwired protection shall be provided for all pumps against dry run based on Low
Level switch.
4. Monitoring systems shall be provided at critical locations to detect flow stoppages etc.
The stoppages if any shall raise alarms indicating the same.

The entire field I/O from field instruments shall be interfaced with PLC for control / monitoring
functions. Typical I/O per device as a minimum shall be 6 inputs and 4 outputs or as required
if it is more than the minimum specified above.
7.6 PLC Data Sheet
The configuration and specifications for PLC shall be as detailed in Table - 2 below.
TABLE – 2

DATA SHEET FOR PLC


Sl. Description Required
No.
A) CPU
1. Processor 32 bit
2. Memory Maximum 60% utilization
including spare I / O
3. Bit execution time
Boolean instruction 0.6 μ sec.
Numerical instruction 0.7 μ sec
Floating point 0.5 μ sec.
4. Typical programmed execution time for 1K
instruction
100% Boolean < 0.66 m sec.
65% Boolean 35% Numerical < 0.10 m sec.
5. Communication Ethernet (MODBUS)
6. Communication speed of I / O with CPU 12 MBPS
B) Digital Input Module
1. Number of Channels / Module 16 / 32 / 64
2. Interrogation voltage 19 - 30 V DC
3. Input impedance 6.3 K Ohms
4. Response Time – Typical 4 m sec.
- Maximum 7 m sec.
5. Confirmation to IEC1131 - 2 Typ1 / 2

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Sl. Description Required
No.
6. Isolation Optical
7. Isolation voltage 1500 V AC for 1 minute
C) Digital Output Module
1. No. of Channels / Module 16 /32 / 64
2. Interrogation voltage 24 V DC
3. Output rating for each channel 2 Amps. (if not
interphasing relays to be
4. Response Time 1.2 m sec.
5. Built in protection
Against over voltage
Against overload and short circuits Yes
Against Polarity Reversal
6. Isolation Optical
7. Isolation Voltage 1500 V – AC for 1 sec.
D) Analog Input
1. Number of channels / Module 8 / 16
2. Operating range 4 - 20 m Amp.
3. Isolation Optical
4. Analog / Digital conversion 12 bits
5. Real time Fast scan 3 x (No. of channels + 1)
6. Isolation voltage 1000 V rms
7. Maximum over voltage / over current 30 V Voltage
30 m Amps

8. Standard IE C 1131
E) Analog Output
1. No. of channels / Module 8
2. Operating range Multi-usage 4 - 20 m Amp
3. Conversion time 5 m sec.
4. Isolation voltage 1000 V rms
5. Type of protection Short circuit and overload
6. Standard IE C 1131

7.7 Particular Requirements for Instrumentation System


This section outlines the particular requirements for the instrumentation systems. Unless
specified in this section to the contrary instrumentation system provided by the Contractor
and workmanship shall comply with the technical specifications for instrumentation system
as specified elsewhere in the document.
7.7.1 Design Criteria
The design criteria to be applied to instrumentation systems shall be as follows;
7.7.1.1 all instruments shall be suitable for continuous operation
7.7.1.2 all transmitting instruments shall have a 4 - 20 mA linear output
7.7.1.3 all digital outputs shall be volt free
7.7.1.4 all instruments shall be designed for the ambient conditions of temperature and
humidity
7.7.1.5 all wetted parts of instrument sensors shall be non-corrosive and suitable for use with
foul water as the case maybe
7.7.1.6 all instrumentation systems for use in outdoors shall be protected to IP:65

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7.7.1.7 all analogue displays shall be of the digital type with no moving parts utilizing back lit
liquid crystal diode LCD / LED technology
7.7.1.8 Instrumentation shall utilize solid state electronic technology and avoid the use where
practical of any moving parts;
7.7.1.9 Instruments shall have minimum maintenance requirements
7.7.1.10 Instrumentation shall resume operation automatically on the application of power
following a power failure
7.7.1.11 Air conditioned room shall be provided for all PLC panels.

Analogue instrumentation systems shall be provided to monitor the parameters and digital
systems shall be provided as necessary for the efficient and safe operation of WTP
Instrumentation sensors shall be suitable for the environment in which they are expected to
work. Sensor located in hazardous (flammable) or potentially hazardous atmospheres shall
be certified for use in these areas.
Instrumentation converter units shall where practical be located in the associated MCC
common control panel well away from any injurious effects of the process.

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PART C - PLANT MATERIALS AND WORKMANSHIP

1.MECHANICAL& ELECTRICAL DESIGNREQUIREMENTS

1.1 Introduction

This part of the Specification sets out the minimum standards of materials, workmanship and
design to be used by the Contractor and reference to any specific material or equipment
does not necessarily imply that such material or equipment is included in the Works. All
component parts of the Works shall, unless otherwise specified, comply with the provisions
of this Chapter or be subject to the approval of the Engineer.

1.2 Standard specifications

Except where otherwise specified all materials and workmanship shall comply with the
current national standards of the country of manufacture provided that these standards are
not less stringent than the equivalent specified Bureau of Indian Standards IS), British
Standards or Codes of Practice or that they comply with the requirements of the International
Standards Organization (ISO) or the International Electro technical Commission (IEC) as
appropriate. The Contractor may be asked to make copies of relevant standards available to
the Engineer or the Engineer‘s Representative, together with, if necessary, English
translations. He shall provide these as requested for prior assessment and for use during
inspection and testing. Reference is made in this section to the Standards listed below.

1.3 Plant design and life

The Works as a whole shall be new, of sound workmanship and robustly designed for a
long, reliable operating life and shall be capable of continuous operation for prolonged
periods in the climatic and working conditions prevailing at the Site, with the minimum of
maintenance. The design shall take account of temperature changes, the stability of paint
finish for high temperatures, the rating of engines, electrical machinery, thermal-overload
services, cooling systems and the choice of lubricants for possible high and prolonged
operating temperatures. The Contractor shall be called upon to demonstrate this for any
component part, either by service records or evidence of similar equipment already installed
elsewhere or relevant type tests.

The Plant shall be designed to provide protection against damage by the entry of vermin and
dust, and to minimise fire risk and consequent fire damage. It shall be protected against
damage due to dampness and condensation. Plant shall operate without undue vibration,
and parts shall be designed to withstand the maximum stresses under the most severe
conditions of service. Materials shall have a high resistance to change in their properties due
to the passage of time or any cause which may have a detrimental effect upon the
performance or life of the Works.

All manually-controlled Plant located outside a building shall be tamperproof. This is in


addition to any requirements of the Specification for securing Plant under operational
conditions. All component parts of the Plant shall be manufactured to be interchangeable
with the component parts of similar Plant.

The Plant shall be designed to have a high resistance to change in its operating
characteristics due to passage of time or any other which may affect the performance or life
of the Works. The Contractor may be called upon to demonstrate this for any component
part either by service records of similar equipment, or by the records of extensive type tests.
Materialsshallbeselectedtakingintoconsiderationtheirlocationandduty.ForPlantin

203
Contact with water, the risk of electrolytic reaction between differing materials of construction
and to the effects of corrosion and erosion shall be taken into account.

The plant shall be designed to provide easy access for replacement of component parts
which are subject to wear, without the need to replace whole units. Except for consumable
items requiring frequent replacement, no part subject to wear shall have a life from new to
replacement or repair of less than five years. Where major dismantling is unavoidable to
replace a part, the life shall not be less than ten years.

1.4 Substances and products

Substances and products used in the Works which may be in contact with water which is to
be supplied for drinking, washing or cooking shall not contain any matter which could impart
taste, odour, colour or toxicity to the water or otherwise be objectionable on health grounds.
All substances and products so used shall meet the requirements of Regulation 25 of the
Water Supply (Water Quality) Regulations 1989 or the Water Supply (Water Quality)
(Scotland) Regulations 1990 or other equivalent body as applicable / relevant IS standards.

1.5 Workmanship

Workmanship and the general finish of plant installations shall be of first-class commercial
quality and in accordance with the best workshop practice, and shall be performed by
persons skilled in their respective trades.

Pipe work, fittings, cables, cable trays and the like shall be fitted in a neat, straight and
symmetrical manner so as to present a pleasing appearance. Indicating gauges fitted to
machine assemblies or control panels shall generally be of similar style and grouped
together.

External welds and flame cuts shall be finished smoothly by grinding. Chequer plate
coverings shall be fixed squarely in their frames with their patterns properly aligned. Hand
railings shall be free from burrs.

1.6 Welding

Where welds may be highly stressed, the Contractor shall supply to the Engineer before
welding starts detailed drawings of all weld preparations and procedures proposed. No
welding shall be carried out before the Engineer has approved the procedures. No alteration
shall be made to any previously-approved procedures without prior approval of the Engineer.

1.7 Non-metallic materials

The use of organic materials shall be avoided as far as possible but where these have to be
used they shall be treated to make them fire resistant and non-flame propagating.

Fabrics, cork, paper and similar materials which are not subsequently to be protected by
impregnation shall be treated with a fungicide. Sleeving and fabrics treated with linseed oil
varnish are not acceptable.

The use of wood shall be avoided as far as possible. If used, woodwork shall be thoroughly
seasoned teak or similar hardwood which is resistant to fungal decay and other blemishes.
All woodwork shall be treated to protect it against damage by any cause. All joints in
woodwork shall be dovetailed or tongued and pinned. Metal fittings on wood shall be non-
ferrous Adhesives shall be impervious to moisture and fungus growth. Only synthetic resin
cement shall be used for joining wood.

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1.8 Gaskets and joint rings

Joint rings shall be manufactured to conform to BS EN 681-1:1996 and BS EN 6812: 2000 /


relevant IS codes. They shall be of chloroprene rubber or other approved synthetic material
suitable for temperatures up to 80°C or greater, to suit the application.

Joints shall be made in accordance with manufacturer‘s instructions or as specified herein.


Each rubber ring or gasket shall be stored in the dark, free from the deleterious effects of
heat or cold, and kept flat so as to prevent any part of the rubber being in tension. Only
lubricants recommended by the manufacturer shall be used for rubber rings and these
lubricants shall not contain any constituent soluble in the fluid conveyed. They shall be
suitable for the climatic conditions at the Site and shall contain an approved bactericide.
Graphite grease or similar shall be applied to the threads of bolts before joints are made.

1.9 Vibration

All rotating elements shall be dynamically balanced so that the level of vibration at any point
on any Plant item when operating at Site, either singly or with other Plant, and at any speed
throughout the operating range, shall be within the limits of Class IV, grade B, as defined in
ISO 10816-1:1995 / relevant IS codes.

Pipe work, valves and other connected equipment, or forming part of the operating system,
shall be provided with adequate supports, brackets and fixtures, as necessary, to restrict any
induced vibration to a minimum, under any operating condition.

Vibration measurements shall be taken on site by the Contractor at various points on each
complete machine as defined above.

Measurements shall also be taken on connecting plant. If any item is found to be vibrating
beyond the level considered by the Engineer to be a reasonable minimum, the Contractor
shall reduce the vibrations to the required level.

1.10 Access steelwork

The Contractor shall provide adequate access to all Plant items to which access is
necessary for routine maintenance and operation. The principal ladders, platforms, covers
and handrails to be supplied and fixed shall be as per approved drawings.

Any small areas of chequer plating or other covering needed to cover gaps between items of
Plant and the surrounding structure, and any access ladders, platforms and handrails that
must be attached to items of Plant to facilitate operation, inspection or maintenance, shall be
supplied and erected by the Contractor.

Handrails shall consist of double ball forged steel standards with tubular rails, hot-dip
galvanized in accordance with BS EN 729-1:1995 / relevant IS codes. Chequer plating shall
be of ‘Durbar‘ or other non-lip pattern, not less than 4.5mm thick (exclusive of pattern) and
hot-dip galvanized after fabrication in accordance with BS EN 729-1:1995 / relevant IS
codes.

Diamond type pattern chequer plate shall not be used. Open-type or solid-type chequer plate
flooring shall be used as appropriate for the location, taking into account ease of cleaning,
precautions against slipping and areas below walkways.

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1.11 Machinery, lifting and dismantling

Machinery bedplate design, packing and fixing shall minimise distortion and vibration.
Aligned machinery shall be mounted on bed or sole plates, permitting removal and
reinstatement without a requirement to re-grout. Bedplates shall incorporate fine adjustment
of the vertical and horizontal alignment between driver and driven Plant. All machinery shall
be fitted with lifting facilities. Large structures shall be provided with jacking points. For Plant
subject to frequent dismantling, tapped holes or other provision shall be made in all main
castings, for the insertion of jacking screws or the fixing of drawing gear. Bolts or studs shall
be used in preference to setscrews.

1.12 Bearings

The Contractor shall select the most appropriate type of bearing for the Plant being supplied.
Single journal plain bearings shall be phosphor bronze or synthetic lubrication impregnated
bushes with carbon or stainless steel journals respectively. Synthetic bearings shall be used
only where bearing condition can be inspected readily.

Plain-type bearings shall be self-lubricating either by grease, forced oil or impregnation. Ball
and roller type bearings shall be adequately lubricated by oil or grease and sealed to prevent
leakage of lubricant along the shaft. The dismantling of bearings shall be simple and free
from risk of damage. Bearings fitted to gearboxes shall have a minimum design life of 100
000 hours at maximum loading.

1.13 Gearboxes

Gearboxes shall have a life of 100 000 hours, be selected in accordance with American
Gearbox Manufacturers ‘Association recommendation / relevant IS codes for horsepower
and service factor application. They shall employ a standard reduction ratio. Gearboxes
which have to be angle-mounted shall have a rating, choice of bearings, seals and
lubrication system designed for such mounting. Dependence on splash lubrication alone is
not acceptable but it may be used in conjunction with a forced-feed method to reach all
bearings and gears.

2 PAINTING ANDPROTECTION

2.1 Scope

Protective coatings shall comply with BS 5493:1977 ‘Code of practice for the protective
coating of iron and steel against corrosion’ / relevant IS codes except as otherwise specified.
For coatings designed to BS 5493:1977 exterior conditions shall be assumed to be ‘polluted
inland‘ conditions and the interiors of buildings shall be assumed to be ‘frequently damp or
wet‘ except for control rooms. The thickness of coatings stated in this section of the
specification is the minimum allowable thickness as defined in Clause 19 of BS 5493:1977 /
relevant IS codes. Where the paints that are available do not provide dry-film thickness as
specified, additional coatings shall be applied. Protective coatings for surfaces of tanks and
other plant in contact with chemicals or otherwise in conditions not foreseen in this section of
the specification or in BS 5493:1977 / relevant ARE codes shall be suitable for those
conditions. They shall be the subject of design submissions supported by evidence proving
satisfactory experience of the proposals elsewhere. Where dissimilar metals are in contact,
the Contractor shall provide insulation to prevent electrochemical corrosion.

2.2 General

The protective coating system shall have a minimum 10-year life to first maintenance.

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A five year minimum performance warranty shall be given in respect of the paint as applied.
All coatings applied to any part of the plant in contact with water to be used for drinking,
washing or cooking shall be non-toxic, non-carcinogenic, shall not impart taste, odour, colour
or turbidity to the water or foster microbial growth and shall be approved in the same manner
as substances and products in relevant Clause 1.4. No manufacturer‘s name-plate
identification, vented filler plugs in gearboxes or grease nipples shall be painted over.

To avoid the possibility of the presence of carcinogenic poly-aromatic hydrocarbons all


bituminous paints and coatings shall be manufactured from petroleum or asphaltic bitumen
and not from coal tar bitumen.

Lead based paints shall not be used.

All machined, polished or bright surfaces shall be given suitable protection against corrosion,
damage and deterioration.

The Contractor shall ensure that, before dispatch from the manufacturer‘s works and after
completion of erection, all plant has received suitable preparation followed by the protection
system listed in tables A and B attached.

The Contractor shall liaise closely with the plant manufacturer who shall provide full facilities
for him to inspect and check the preparation and painting during all stages. The Contractor
shall report on his inspections to the Engineer.

All paint materials shall be stored and applied strictly in accordance with manufacturers
‘instructions.

Paint shall not be applied under adverse conditions. Air temperatures shall be above 5°C
and relative humidity less than 55% or as otherwise specified by the paint manufacturer.

The Contractor shall ensure that, for the materials specified, application conditions are in
accordance with the specification and manufacturer‘s instructions. Paint shall be applied only
to surfaces that have been cleaned and prepared in accordance with these instructions.
Where local climatic conditions make the specified requirements difficult to achieve, the
Contractor shall provide temporary protection during painting.

The dry paint-film thickness shall be measured by Elcometer or other approved method. All
manufacturing processes shall be complete prior to galvanizing with all erection markings
clearly legible afterwards. Surfaces shall be adequately degreased before the application of
any coating, pre-treated with a brush application of etches primer or T wash.

Steel subject to hydrogen embrittlement through galvanizing shall not be used. All iron and
steelwork to be painted shall be blast cleaned to all parts of BS 7079 Second Quality /
relevant IS codes to achieve a surface profile with a minimum amplitude of 0.025 mm and a
maximum of 0.100 mm.

Following blast cleaning, steel surfaces shall be zinc metal sprayed where specified.
Aluminium structures and fittings shall need not be painted.

2.3 Fusion-bonded epoxy powder coatings

All fabricated steel pipe work and other Plant where specified, shall have a lining and
coating, not less than 250 microns thick, of 100% solids, thermosetting fusion-bonded, dry
power epoxy coating.

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All grit and dust shall be removed and coating shall be started before formation of visible
oxidation of the surface. The metal shall be pre-heated to a temperature recommended by
the manufacturer and the epoxy powder applied by immersion in a fluidized bed, after which
excess powder shall be removed. The powder shall be allowed to flow out completely before
curing. The thickness of the coating, including any repaired areas, shall be checked with a
calibrated tester. Spark testing, for pinholes, voids, contamination, cracks and damaged
areas, shall use a high-voltage spark generator.

Repairs due to coating imperfections or damage shall be done using a brush-applied


compatible two-pack liquid epoxy compound. The area to be repaired shall be cleaned to
remove dirt, grease, scale and damaged coating, which shall be feathered. Pinhole surface
preparation is not required other than removal of detrimental contaminants which could
impair the adhesion of the repair material. The surface coating shall be applied by an
approved applicator. GRP covers and guards shall be pigmented to give the finished colour
without painting.

2.4 Coating system for electrical enclosures

Enclosures shall be given protective coating at the place of manufacture and before
installation of any electrical fittings. Electrical panels, including switchboards, control panels
and instrument panels, installed within buildings shall be prepared as follows:

(i) Thoroughly clean surfaces to remove rust, scale, dirt, loose paint and the like and
degrease by the use of solvents which are compatible with the paint finish to be applied. If
rust-proof steel has not been used in the construction, the surfaces shall be treated with a
passivating agent such as phosphoric acid.

(ii) Internal surfaces shall have a minimum of three coats of paint of which the first shall be
an approved priming coat. The final coat shall be opaque gloss white enamel.

(iii) External surfaces shall have a minimum of five coats of paint of which the first shall be
an approved priming coat, the second and third a suitable undercoat, all of which shall be
rubbed smooth when dry before application of the next coat. The colour of undercoat paints
shall be different from priming and finishing coats.
(iv) The final coats shall be of stove enamel paint to a finish and colour as specified in Table
C. The dry-film thickness shall be not less than 100 microns. Electrical panels which are to
be installed in exposed positions or in damp conditions shall receive a surface preparation
containing zinc prior to application of the primer undercoat and finishing coats. A 500 ml tin
of matching touch-up paint shall be supplied with each panel.

2.5 Defects

Defects are defined in BS EN 971-1:1996 ‘Glossary of paint terms’.

The Contractor shall ensure that all coatings are free from defects and adequate in all
respects for the purpose intended.

The painting system shall be deemed to have failed if:

(a) after painting, damage has been caused by handling, impact, abrasion or welding;
(b) any portion of the paint film separates from any other or the parent metal;
(c) After painting the total dry-film thickness is less than that specified.

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Failure shall not include:

(a) loss of gloss;


(b) Variation of shade, not affecting the anti-corrosive properties of the system.

2.6 Colour coding

Unless otherwise specified, colour coding for plant, equipment and pipe work shall be as
given in tables C to G. Steel pipes shall be painted and hoses and thermoplastic pipes shall
be colour banded in accordance with BS1710 / relevant IS codes. When using colour bands
on thermoplastic pipes the Contractor shall ensure that the adhesives used on colour bands
do not contain agents which will cause deterioration of the pipes. Colour bands shall be
applied on straight lengths of pipes at no more than 3 m spacing. Bands shall be applied, at
all junctions, both sides of valves, Plant, fittings and wall penetrations.

Finishing coats shall be applied as specified in the colour schedule in accordance with the
requirements of BS 1710:1984, BS 4800:1989, BS 5252:1976 and BS 5499-5:2002 /
Relevant IS codes. Pipeline contents shall be identified by name and the direction of flow by
arrows. Where two or more pipes in a duct or gallery convey the same fluids, each pipe shall
display a separate number, with contents named at each point of entry or outlet.

TABLE A
REQUIRED COATING SYSTEMS AND MINIMUM COATING THICKNESSES FOR PLANT AND EQUIPMENT
Applied prior to delivery and erection Applied
following
Pre treat Second installation
Substrate First coat Third coat
ment coat
ABOVE
WATER Etch
Steel Zinc
LEVEL: prime High-build High-build
(galvanized) phosphate
Machinery & or T wash chlorinated chlorinated
CR
steelwork not in rubber rubber
alkyd primer
contact with paint paint
Steel zinc undercoat
sewage, sludge Etch (0.075mm) (0.075mm)
sprayed (0.050mm)
or water to be used prime
for drinking, (0.070mm)
washing or Zinc Zinc
cooking Blast phosphate phosphate High-build
Steel,
clean CR CR chlorinated
cast iron,
BS7079 alkyd blast alkyd blast rubber
ductile iron nd
2 quality primer primer (0.075mm)
(0.050mm) (0.050mm)
BELOW
WATER Etch
Steel
LEVEL: prime
(galvanized)
Machinery and or T wash
Epoxy Epoxy Epoxy
steelwork in primer primer primer
contact with Steel,
cast iron, high-build high-build high-build
water to be used (0.125mm) (0.050mm) (0.075mm)
ductile iron Etch
for drinking,
zinc prime
washing or
cooking sprayed
(0.070mm)
Pipe work Steel As specified elsewhere
Switchboard
shells, frames Steel As specified elsewhere
and back

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TABLE B
REQUIRED HEAT – RESISTANT COATING SYSTEMS FOR STEELWORK
Working A1: Surface
First coat Second coat Third coat
temperature treatment
Polyvinyl Butyral Aluminium heat Aluminium heat
Blast clean BS (0.025mm) resistant resistant
50°C to 175°C 7079 Zinc chromate @ 200°C @ 200°C
second quality Primer (0.012mm – (0.025mm) (0.025mm)
15mm)
175°C to 500°C Aluminium
Aluminium
Blast clean BS pigmented
pigmented silicone
7079 silicone
heat-resistant
second quality heat-
(0.025mm)
resistant
NB A minimum temperature of 350°C within a short time after application is required

TABLE C
COLOUR CODING FOR PLANT AND EQUIPMENT
BS 4800 shade
Equipment Colour finish
number
Above water Green --- 12–D–45
Pumps and
level: Machinery
machinery --- Saxe blue 18–C–39
and steelwork
not in contact with Dry-well motors Tangerine Tangerine 06–E–51
sewage, Gearboxes Saxe Blue Saxe blue 18–C–39
sludge or potable Compressors &
Blue Blue 24–E–51
water or specified blowers
as Lifting gantries Gorse Gorse 08–E–51
requiring Valves & pipe work Green --- 12–D–45
identification above FFL --- Pale grey 00–A–05
as table D Pipe work below
below Black Black 00–E–53
FFL
Below water level: Machinery and
steelwork (including pumps, penstocks, Black Black 00–E–53
pipe work and the like)
Switchboard shells Light semi grey Light semi grey
18–B–17
gloss gloss
Switchboard supporting frames 00–E–53
Black semi gloss Black semi gloss
Switchboard internal equipment mounting 00–E–55
White semi gloss White semi gloss
plates
Control and instrument panels -external Light semi grey Light semi grey
18–B–17
gloss gloss
Control and instrument panels -internal White gloss White gloss 00–E–55
GRP covers (pigmented) Spruce Spruce 14–C–39

TABLE D
IDENTIFICATION COLOURS FOR PIPES
All pipes are to be identified in accordance with BS 1710
Basic identification Colour BS 4800 shade no.
Drinking water Green
Steam Silver grey
Mineral, vegetable and animal oils combustible liquids Brown
Diesel fuel Brown
Gases in either gaseous or liquid defined condition (except air) Yellow ochre
Acid and alkalis Violet
Air Blue
Other liquids Black
Electrical services such as conduits & trunkings Tangerine

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TABLE E
IDENTIFICATION COLOURS FOR PIPES – HYDRATED LIME

Steel pipe work carrying hydrated lime slurry shall be painted black, colour code 00E53 with
banding. Pipe work conveying hydrated lime slurry shall be banded with vinyl laminated
identification tape to enable individual lines to be identified throughout their length. The
banding shall conform to BS 1710 to indicate the fluid conveyed and shall have flow direction
arrows, lettering and codings as described below.

(a) Lettering
Duty Lettering Colour
Slurry "LIME" White
Service Water Not applicable -
Waste Water "DRAIN" White

(b) Banding
Duty Coded
Slurry violet -da
Service water green Waste
water black

Individual bands shall be 50mm wide. Bands for slurry lines shall incorporate danger warning
markers (black/yellow diagonal stripes) 50mm wide giving a composite width of 150mm.

Colours stated above refer to BS 4800 shades as follows:


Colour Code
Violet 22C37
Green 12D45
Blue (auxiliary) 18E53
Yellow 08E51
White 00E55
Black 00E53

TABLE F
IDENTIFICATION COLOURS FOR PIPES – ALUMINUM SULPHATE

Pipeline shall be banded with vinyl laminated identification tape to enable individual lines to
be identified throughout their length. The banding shall conform to BS1710 to indicate the
fluid conveyed and shall have flow direction arrows, lettering and codings as described
below:

(a) Lettering

Duty Lettering
Aluminium sulphate "ALUM"
Dilution water not applicable
Wastewater "DRAIN"

(b) Banding

Duty C
Aluminium sulphate V
Dilution water G
Wastewater B

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Danger markers shall consist of black/yellow diagonal stripes overall width of individual or
composite bands shall be 150mm.

Colours stated above refer to BS4800 shades as follows:

Colour Code
Violet 22C37
Green 12D45
Blue (auxiliary) 18E53
Yellow 08E51
Black 00E53
White 00E55

TABLE G
IDENTIFICATION COLOURS FOR PIPES – MISCELLANEOUS

Sample lines:

Pipe work conveying sample water shall be banded with vinyl laminated identification tape to
enable individual lines to be identified throughout their length. The banding shall conform to
BS 1710 to indicate the fluid conveyed and shall have flow direction arrows, lettering and
codings as described below.

(a) Lettering

Duty Lettering
Sample "SAMPLE
Wastewater "DRAIN

Note that the approved sample designation for each line is to be substituted for
"XXX".

(b) Banding

Duty C
Sample G
Wastewater B

Colours stated above refer to BS 4800 shades as follows:

Colour C
Green 12
White 00
Black 00

Air pipe work:

Pipe work conveying air shall be identified throughout its length in accordance with BS1710 /
relevant IS codes. For steel pipe work, the finish colour of the protective coating system
generally shall be the basic identification colour, blue 2O-E-51 to BS4800. Where this is
precluded by use of high temperature paint finishes and/or the application of thermal
insulation and cladding, then banding shall be applied in appropriate materials. The banding
shall be 150 mm wide and in the same basic identification colour. For non-steel pipe work
such as instrument air supply branches, identification shall be by means of banding
generally as above except that the width of banding shall be limited to 50mm.

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PART D - PIPELINE WORKS STANDARD SPECIFICATION

MS PIPELINES, APPURTENANCES SPECIALSETC.

SCOPE

This specification covers the general requirements for supply, fabrication, delivery at site
laying, jointing, testing and commissioning of all welded M.S pipeline, appurtenances,
specials etc. above/below ground, including Civil works required for the same.

APPLICABLE CODES &SPECIFICATIONS

The following specifications, standards and codes are made a part of the specification. All
standards, tentative specifications, specifications, codes of practice referred to herein shall
be the latest editions including all applicable official amendments and revisions. In case of
discrepancy between this specification and those referred to herein, this specification shall
govern.

1. IS: 2062 Steel for general structural purposes.


2. IS: 808 Dimensions for hot rolled steel beam, column, channel and angle sections.
3. IS: 814 Covered Electrodes for manual Metal Arc Welding of carbon and C-Mn steel.
4. BS EN 499 Welding Consumables. Covered Electrodes for Manual Metal Arc
Welding of Non Alloy and Fine Grain Steel. Classification
5. AWS: A-5.1 Specification for Mild Steel Covered Arc Welding Electrodes.
6. IS: 3613 Acceptance Tests for Wire Flux combinations for Submerged - Arc Welding.
7. AWS: A-5.17 Specification for Bare Mild Steel Electrodes and Fluxes for Submerged
Arc Welding. IS : 1367 - Technical Supply Conditions for Threaded Fasteners
8. IS: 1367 Technical Supply Conditions for Threaded Fasteners (Parts 1 to3).
9. IS: 2016 Plain Washers.
10. IS: 2074 Ready Mixed Paint, Red Oxide Zinc Chrome and Priming.
11. IS: 102 Ready Mixed Paint, Brushing, Red Lead, no setting, Priming.
12. IS : 1786 High Strength Deformed Steel Bars and Wires for Concrete Reinforcement
13. IS: 432 Specification for Mild Steel & (Part-I) Medium Tensile bars and hard drawn
steel wire for concrete reinforcement: mild Steel & Medium tensile steel bars.
14. IS.432 Specification for mild steel & (Part-II) Medium Tensile steel bars and hard
drawn steel wires for concrete reinforcement : Hard drawn steel wire
15. IS : 269 Specification for Ordinary and Low heat Portland cement
16. IS : 8041Specification for Rapid hardening Portland Cement
IS: 269 Specification for Ordinary and Low heat Portland cement
IS: 8041 Specification for Rapid hardening Portland cement
IS: 383 Specification for coarse and fine aggregate from natural source for concrete
IS: 12330 Specification for Sulphate Resisting Portland Cement
IS: 456 Code of practice for plain and reinforced concrete
IS: 800 Code of practice for General Construction in Steel.
IS: 816 Code of practice for use of Metal Arc Welding for General
17. IS : 383 Specification for coarse and fine aggregate from natural source for concrete
18. IS :12330 Specification for Sulphate Resisting Portland Cement
19. IS : 456 Code of practice for plain and reinforced concrete
20. IS: 800 Code of practice for General Construction in Steel.
21. IS: 816 Code of practice for use of Metal Arc Welding for General Construction in
mild steel.
22. IS: 4353 Submerged Arc Welding of Mild Steel & Low Alloy Steels –
Recommendations.
23. IS: 817 Code of practice for Training and Testing of Metal Arc Welders.

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24. IS : 1182 Recommended practice for Radiographic examination of Fusion - Welded
Butt Joints in steel plants
25. IS: 2595 Code of Practice for Radiographic Testing.
26. IS : 3658 Code of Practice for Liquid Penetrate Flaw Detection
27. IS: 5334 Code of practice for Magnetic Particle Flaw Detection of welds.
28. ASTM E 94 Guide for Radiographic Testing
29. ASTM E 709 Guide for Magnetic Particle Examination.
30. ASTM E 165 Test Method for Liquid Penetrate Examination.
31. IS : 3600 Methods of Testing Fusion Welded Joints and weld metal in steel(Parts 1 to
9)
32. IS: 4853 Recommended Practice for Radiographic Inspection of Fusion Welded Butt
Joints in Steel Pipes.
33. IS : 3589 Seamless or Electrically welded steel pipes for Water Gas and Sewage
(168.3 to 2032 Outside Diameter)
34. IS : 6631 Steel pipes for Hydraulic Purposes
35. IS : 7343 Code of practice for ultrasonic Testing of Ferrous Welded Pipes and
Tubular Products
36. IS : 2598 Safety Code for Industrial Radiographic Practice
37. IS : 5822 Code of Practice for Laying of Electrically Welded steel pipes for water
supply
38. IS: 1608 Mechanical testing of Metals.
39. IS: 9595 Metal Arc welding of Carbon and Carbon-Manganese Steels.
40. IS : 2825 Code of unfired Pressure Vessels
41. IS:5504& IS:3589 Code for SW PIPES
42. IS: 10748 Requirement for Wieldable Hot Rolled Carbon Steel Strip uncoils.
43. IS 10234: Recommendation for radiography for general pipeline welding.
44. API-1104 Welding of pipeline & related facilities

1.3 MATERIALS

Steel Coils - The steel Coils for pipes, fittings, specials and stiffeners shall be of mild
steel conforming to IS: 10748 grade III and shall bear ISI mark

Welding Consumables - such as electrodes, filler rods and wires shall conform to IS:
814,IS 3613, IS : 6419 and IS :7280

Before fabrication of pipes and specials/fittings is commenced, the copies of the mill sheets
and the manufacturer's test certificates for Coils and other materials required forth
fabrication, shall be submitted by the Contractor to the Engineer for his approval.

When requested by the Engineer, the Contractor shall supply free of charge to the
Employer, for testing suitable samples of the materials to be used/used in the Works.

The cost of such tests shall be borne by the Contractor and shall be included in his quoted
rates.

1.4 INSPECTION

1.4.1 All works and material under specification will be rigidly 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.

1.4.2 The Contractor shall notify the Engineer, in advance of the production of materials
and fabrication thereof, in order that the Employer may arrange for mill and shop
inspection.

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1.4.3 The Engineer may reject any or all materials or works that do not meet with any of the
requirements of this specification. The Contractor shall rectify or replace such
rejected material/performed work at his own cost, to the satisfaction of the Engineer.

1.4.4 The Engineer shall have free access to those parts of all plants or any other premise
sand sites that are concerned with the furnishing of materials or the performance of
work under this specification.

1.4.5 The Contractor shall furnish to the Employer's inspector reasonable 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.

1.4.6 The Contractor shall supply free of cost required specimen of materials for testing by
the Owner at any time during the progress of work and shall bear the cost of all such
tests or retests to the satisfaction of Engineer.

1.4.7 The Contractor shall provide 2 (two) sets of accurate `Go' and `No Go' ring gauges to
measure the diameter of pipes specials and fitting for the use of the Engineer at no
extra cost.

1.5 FABRICATION OFPIPE

1.5.1General

1.5.1.1 All pipes and specials shall be manufactured as per IS: 3589 out of new mild steel
HR Coils (IS: 10748 grade-III) which shall be free from any cracks, surface flaws,
laminations, excessive fittings or any other defects. The pipes shall be truly
cylindrical, and straight in axis. The ends shall be accurately cut and prepared for
field welding.

The external circumference of the pipe pieces which are to be fixed adjacent to flange
adapter with fixed outer diameter shall not deviate from theoretical one by more than
1mm.To obtain this accuracy the pipe shall be rolled several times, if necessary, as pipe
pieces should be truly cylindrical. The external longitudinal welding of this pipe shall be
ground smooth flush with surface to the satisfaction of the Engineer, for a length of 200mm.
No extra cost shall be charged by the Contractor for this grinding work. However, the pipe
shall be manufactured as per tender specification.

1.5.1.2Minor repair by welding or otherwise shall be permitted at the discretion of the


Engineer, but such repairs shall be done only after obtaining the previous
permission of the Engineer. Any pipe or part thereof which develops injurious
defects during shop welding or other operations shall be rejected.

1.5.1.3 Permissible Stress

The permissible stress in the pipe shell shall be related to yield stress (fy) of pipe material
making due allowance for weld efficiency of the joint.

i) Working stress for combined bending and direct tensile stress shall not exceed 60%of
yield stress of the material making due allowance for efficiency of welded joint (as per
IWWAM-1).

ii) Working stress for combined bending and direct compressive stress shall not exceed 50%
of yield stress making due allowance for weld efficiency (as perIWWAM-1).

215
iii) It is also necessary to check the shell thickness for adequate factor of safety against
failure by buckling (as per IWWAM-11).

For field welded joint, efficiency factor of 80% is generally adopted, while for shop welding
joint 90% efficiency is allowed (as per IS 5822 ).
1.5.2 Fabrication

1.5.2.1 The Contractor shall get the fabrication work done in a duly valid licensed factory of
his own or that of an approved nominated sub-contractor. This factory meant for
fabrication of pipes, specials etc. shall also be involved with testing etc., machining
as well as painting. For completing the work under the present contract within the
contract period, the factory shall be equipped with adequate number of various
equipment and plant such as:

i) Plate bending machines for rolling of pipe drums


ii) Automatic welding machines (suitable for circumferential welding)
iii) Hydraulic Testing Machines
iv) Travelling gantry or crane of capacity 10 Tonnes or above.
v) Mobile cranes for loading/unloading of Coils, pipes etc. 15 tonnes capacity each
vi) Lathe for machining of the flanges rings, Coils etc.
vii) Equipment for sand blasting and applying paint by spray gun.
viii) Equipment for cold pressing of Coils up to 25 mm thick to the required curvature
(specials, plug Coils etc.)
ix) Bending machine of adequate capacity for manufacturing ring girders and other
necessary equipments.

1.5.2.2 The factory shall have adequate area, and shall also have stacking yard for the
stacking of Coils, structural, fabricated pipes etc. and the scrap.

1.5.2.3 The Bidder may establish pipe fabrication factory within the project site for
minimizing the transportation of pipes after fabrication to bring the pipes to the
trench where pipes are to be laid. Contractor shall furnish with his bid the details of
the factory where he intends to get the fabrication done, such as its location within
the project site and the equipment, plant and other facilities available in the factory
for the manufacture of M.S.Pipes and special required under this contract.

1.5.3 Cutting Coils or from Coils rolled as coil to the required sizes.

1.5.3.1 The Coils shall be indented in such length as to have minimum wastage and so as
to make the pipe as far as possible.

1.5.3.2 Before cutting, all the edges of the Coils shall be cleaned by brushing/grinding on
both the sides.

1.5.3.3 After the Coils are cut, the edges shall be made smooth and even by polishing with
an electrical or pneumatic grinder to remove all inequalities. Care shall be taken to
see that the cut edges of the plate are perfectly straight. Jigs to be used for this
purpose shall depend upon the types of cutting machine used. The Coils cut to the
required shape shall be checked for correctness before they are rolled into pipe
drums. If any corrections are required, the Contractor shall do the same by re-
cutting, if necessary.

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1.5.3.4 Rolling of Coils

1.5.3.5 The Coils prepared as mentioned above are cut to the exact size shall be put into
rolling machine to form a pipe of the required diameter as under:

 The Contractor shall adjust the rolling machine so as to give a uniform curvature to the
pipe throughout its circumference.
 The curvature obtained shall be checked by the Contractor's foreman during the process
of rolling and if proper curvature is not obtained at any place including the ends, the rolling
operation shall be repeated at this stage
 Heating of Coils to obtain the desired curvature shall not be permitted.

1.5.4Welding

1.5.4.1 All components of a standard shell, either straight or bent etc. shall be welded,
wherever possible by use of automatic arc welding machine by Submerged Arc
welding process with alternating current. Generally hand welding shall not be
permitted except specific cases, where it is absolutely necessary. This should be
done in consent with clients representative. Hand welding shall also not be
permitted except for sealing runs and such other minor works at the discretion of
the Engineer-in-charge. The strength of the joint shall be at least equal to that of
the parent material.

1.5.4.2The Contractor shall use electrodes of client approved make and size, the size
depending on the thickness of coil and the type of joint. It shall also be used with
standard current and arc voltage required for the machine in use with such
modifications as may be found necessary after experimental welding. For this
purpose, samples of welded joints shall be prepared and tested in the presence of
the Engineer. The values once determined shall be maintained throughout the work
and if any modifications are to be made, a written permission of the Engineer shall
be obtained. In the case of thin sheets, electric arc welding may not give
satisfactory results and gas welding shall be resorted to. Gas welding shall be
subject to the same specifications and tests as those for electric welds. Welding
should be carried out inside as well as outside.

1.5.4.3All the shop and field joints shall be welded, all welding shall conform to the
requirements of IS 9595 and IS4353.

1.5.4.4 All circumferential joints shall be double welded butt joints. Field joints shall be from
outside, with a sealing weld from inside. End preparation for such welding shall
conform to IS: 2825.

1.5.4.5 All circumferential welds involving Coils of unequal thickness shall be so kept that
the inside surfaces of Coils match to provide stream lined joints without alteration in
the internal diameter. As far as practicable, welding of dissimilar thickness of shells
shall be carried out in the shops.

1.5.4.6 The welding shall be of the best workmanship free from flaws, burns, etc. and the
Contractor shall provide for his own electrodes and equipments, ovens to keep the
electrodes at the desired temperatures and dry. In order to maintain a good
standard in welding, welders shall be tested by the Contractor with prior intimation
to the client before they are entrusted with the job. Qualification standard for
welding procedures, welders and welding operation shall conform to the
requirements of IS: 7307 and IS: 7310 (latest). Periodical tests as regards their
efficiency shall also be taken at intervals of about 6 months and those found
inefficient shall be removed from the job. Only those who pass the test shall be
posted on the job. If an incompetent welder has already welded some pipes, all
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welding done by him previously shall be fully checked by X-ray in addition to
the regularX-ray inspections. The defects if any shall be set right to the satisfaction
of the Engineer. All such check tests and rectification of defects shall be entirely at
the cost of the Contractor. No pipes or steel sections shall be erected unless the
work of the welder concerned has been proved to be satisfactory. Specially
selected welders shall do site welds.

1.5.4.7 A record shall be maintained showing the names of welders and operators who
have worked on each individual joint. Hand-welding shall preferably be carried out
by a pair of welders (parallel welding putting two welders at a time both will be
working in diametrically opposite side of the curvature. Welding shall be divided
into 4 quadrants shall be welded simultaneously, so that by observing proper
sequence, distortion can be avoided. A joint entrusted to a particular individual or a
pair shall be as far as possible, completed by them in all respects, including sealing
run. No helper or other unauthorized person shall be permitted to do any welding
whatsoever. In case of infringement of above, the persons shall be punished as
directed by the Engineer.

1.5.4.8 The welded joint after welding should not become brittle or sensitive to blows and
there should be no loss of toughness due to welding or heat treatment. The
material after welding and heat treatment is to be tougher than the base metal and
is to retain its original ductility. No allowance will be made for thinning of weld and
the weld should in no point be less than the nominal thickness of plate.

1.5.4.9 Upon receipt of the order and prior to the start of fabrication, the Contractor shall
submit to the Engineer for his approval the ``welding procedure'' he intends to use
in the shopworn. Similarly, prior to the start of the field welding, procedure for the
field welding must be submitted to the Engineer for his approval. Manual welding
shall be adopted only when machine welding is not possible.

1.5.5 Ultrasonic and Radiographic tests of Welded Joints

1.5.5.1 For the mild steel pipes manufactured in site factory/workshop, fabricated from mild
steel Coils, 100 % of the each welded joints shall be subjected to ultrasonic test
and15% of the each welded joints shall be subjected to radiography test.

1.5.5.2In case of field joints 15% of the each welded joints shall be subjected to Ultrasonic
and radiography test. In case of failure of joints the contractor shall be required to
carry out radiography of thrice the number of field joints failing during the Ultrasonic
and radiography test. Even after such radiography testing, if any one of the joint
fails, the contractor shall be required to carry out Ultrasonic and radiography of
joints on all field welded joints i.e. 100 % basis. All these testing’s shall be carried
out by the contractor at his own risk and cost.

1.5.5.3 The weld ripples or weld surface irregularities, on both inside and outside shall be
removed by any suitable mechanical process to a degree such that resulting
radiographic contact due to any remaining irregularities cannot mark or be
confused with that of objectionable defect. The radiograph shall be made in strict
accordance with the latest requirements and as per the latest and most efficient
technique either with X-ray or gamma ray equipment.

1.5.5.4 The photographs are to be marked in such a way that the corresponding portion of
the welded seam can be readily identified. All radiographs will be reviewed by the
Engineer to identify the defect and determine those which must be removed.
Defects that are not acceptable shall be removed by chipping, machining or flame
gouging to sound metal and the resulting cavities shall be welded. After
rectification, the joint is tube radiographed again to prove the quality of the repair.
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The Engineer based on the latest standards prescribed by Indian Standard
specification will judge the radiographs as acceptable or unacceptable.
1.5.5.5All X-ray shall be made with equipment and by personnel furnished by the
Contractor. Films shall be developed within 24 hours of exposure and be readily
accessible at all times for inspection by the Engineer. The Contractor shall provide
for the use of the Engineer suitable X-ray viewing equipment. X-ray films shall be
properly maintained byte Contractor and shall be handed over to the department
on completion of the Contract. All films shall be identified by the No. and chart
prepared indicating location of the joint each X-ray photo represents. In the event
of additional radiographic inspections required of any work associated with the pipe
erection, the Radiographer at the discretion of the Engineer shall perform such
inspection.

1.5.6 Radiographic Inspection

1.5.6.1 General

1.5.6.1.1 The Engineer shall assure himself that the welding procedure employed in the
construction of pipes has been qualified. The Contractor shall submit evidence
to the Engineer that the requirements have been met. The Contractor shall
certify that the welding of pipes has been done only by qualified welders and
welding operators and the Engineer shall ensure himself that only qualified
welders and welding operators have been used.

1.5.6.1.2 The Contractor shall make available to the Engineer a certified copy of the
records of the qualification tests of each welder and welding operator. The
Engineer shall have the right at any time to call for and witness tests of
welding procedure or of the ability of any welder and welding operator.

1.5.6.1.3 Radiographic Inspection of welded joints

All welded joints to be radiographer shall be examined in accordance with


IS: 2595- Code of Practice for Radiographic Testing
IS: 4853 Recommended Practice for Radiographic Inspection of Fusion Welded Butt joints in
Steel Pipes.
IS: 1182 Recommended Practice for Radiographic Examination of Fusion Welded Butt-
Joints in steel Coils.

1.5.6.1.4 The reinforcement on each side of all butt welded joints shall not exceed 1.5
mm complete set of radiographs and records as described in IS: 2595 for each
job shall be retained by the Contractor and kept on file for a period of at least
five years.

1.5.6.1.5 Radiographers performing radiograph shall be qualified in accordance with


SNT- TC1A.Supplements and Appendices ``Recommended Practice for
Nondestructive Testing Personnel Qualification and Certification''
published by the American Society
for Nondestructive Testing as applicable for the technique and methods used.

1.5.6.1.6 Final acceptance of radiographs shall be based on the ability to see the
prescribed penetrometer image and the specified hole.

1.5.6.1.7 The acceptance criteria for radiography of the joint shall be as per IS-10234 or
as per API -1104standard.

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1.5.7Thermal Stress Relieving Not applicable.

1.5.8Tolerance
1.5.8.1 The shell in the completed work shall be substantially rounded. The difference
between maximum and minimum inside diameters at any cross section shall not
exceed 1% of the nominal diameter of the cross section under consideration
subject to a maximum of10mm.

1.5.8.2 Machined parts shall be within the limits specified by IS3589.

1.5.8.3 Straight pipes shall have their faces perpendicular to the axis of the section with a
maximum deviation of 2 mm on either side of the plane. Pipe ends shall be beveled
as per IS: 3589. The pipes shall be supplied in length of 10.5 metres to 12.5metres.

1.5.8.4 For the shell thickness, no negative tolerances are acceptable:

1.5.9 Shop Testing

1.5.9.1After fabrication, but before application of protective coatings all pipes and specials
shall be subjected to a shop hydraulic test (100%). Standard lengths of pipes shall
be directly subjected to test and non-standard pipe and elbows can be tested as
standard pipe before being cut to size.

1.5.9.2 Field Hydraulic Testing

1.5.9.3 The Pipeline after laying at site shall be subjected to 100% Hydro testing. The test
pressure shall be 1.5 times working pressure or 6 kg/cm2 whichever is higher. The
pressure shall be maintained for a period of 24 hours. The length of pipe for hydro
testing shall be generally 5 km as directed by Engineer-In-Charge.

1.5.9.4Each pipe shall be filled with water and the pressure slowly and uniformly increased
until the required test pressure is reached.

1.5.9.5 The pipe to be tested shall be given a serial no. which shall be painted on its inside
together with details such as pipe No. Shell thickness, diameter, length etc. as
directed. It shall be entered in the register to be maintained by the Contractor.

1.5.9.6Prior to testing, the pipe shall be inspected thoroughly and all the apparent defects
in welding such as jumps, porosity etc. shall be repaired by gouge and re-welding.

1.5.9.7 The hydraulic test shall be carried out under cover at the fabrication shop, in the
presence of and to the satisfaction of the Engineer or the inspection agency
appointed by the Employer.

1.5.9.8For indicating the pressure inside the pipe an accurate pressure gauge of approved
make duly tested and calibrated for the accuracy of readings shall be mounted on
one of the closures which close the pipe ends.

1.5.9.9The pressures shall be applied gradually by approved means. and shall be


maintained for period of 24 hours. The pipe shall be hammered throughout its
length with sharp blows, by means of a 1 kg. hand hammer.

1.5.9.10The pipe shall withstand the test without showing any sign of weakness, leakage,
oozing or sweating. If any leak or sweating is observed in the welded joints, the
same shall be repaired by gouging and re-welding after dewatering the pipe. The
repaired pipe shall be re-tested to conform to the specified pressure.

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1.5.9.11 If any leak or sweating is observed in pipe shell the pipe under test shall be
rejected temporarily. The Contractor shall stack such rejected pipes separately in
his yard. The Engineer shall inspect the same and after taking cuts if necessary,
shall determine the nature of repairs to be carried out thereon and shall then
decide as to how and where they shall be used. No payment shall be made for
handling or carrying out repairs, but, payment for the fabrication and hydraulic
testing of the pipe shall be released only after acceptance of the pipe with
necessary repairs and subsequent testing etc. are carried out by the Contractor to
the satisfaction of the Engineer. The Engineer shall be supplied with two copies of
the results of all the tests carried out. The Mechanical Tests for Pipe material at
Manufacturers work shall be carried as per approved Quality Assurance Plan(
QAP) and tests shall be as perIS:3589

1.5.9.12 Testing of Site Welded Joints

(i) The welded joints at site shall be tested for Tensile test, Bend test & Tre-panned plug in
accordance with procedure laid down in as per the latest edition of IS No.3600 “code of
procedure for testing of fusion welded joints and weld metals in steel”.

(ii) Test pieces shall be taken by the contractors from the welded joints at the position on
fabricated pipes pointed out by the Engineer in-charge.

(iii) The sample so taken shall then be cut to the exact shape and dimensions and machined
as described below and handed over to the Engineer-in-charge for testing. All the work up to
and including machining and arranging for test shall be done by the contractors.

1.5.10 Submission of Daily Progress Report

1.5.10.1 The Contractor shall submit to the Engineer a daily progress report in the pro
forma approved by the Engineer, wherein all the details of the work carried out in
the factory shall be fully recorded. Similarly, works done in the various units in the
factory shall be separately mentioned. The Contractor shall maintain a register of
all the finished materials giving dates of carrying out important operations such as
testing, transport, etc. The register shall be presented at least once a week to the
Engineer who shall initial the entries after verification.

1.6A INTERNAL FOOD GRADE EPOXY COATING

MS pipe shall be lined inside with food grade epoxy as per the provisions of IS: 3589
Annexure B.

B: INTERNAL CEMENT MORTAR LINING

1.6.1 General

The inside surface of all pipes shall be provided with 12.5 mm thick cement mortar lining in
proportion of 1 : 1.5 by weight, applied by centrifugal spinning method at factory. The lining
shall be in conformity with AWWA C 205. At each ends minimum 6 Nos. of MS rings of 6 mm
diameter shall be welded before lining.

1.6.2 Material

1.6.2.1 Cement

Portland cement shall confirm to the requirements of IS: 269, IS: 1489, IS: 8112. Cement
containing lumps shall be rejected and shall immediately be removed from the lining site.
1.6.2.2 Sand
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Sand shall consist of inert granular material having hard, strong, durable uncoated grains
confirming to the requirements of IS: 2116. The sand shall be well graded and 100% of the sand
shall pass a US standard sieve number No. 4.

1.6.2.3 Admixtures

A water reducing, set-controlling admixtures confirming to ASTM C 494 may be used to improve
the workability, density, and strength of the mortar. No admixture shall contain injurious amounts
of chlorides. The ratio of admixture to cement shall not exceed that used in the qualification
tests of ASTM C 494. No admixtures shall be used that would have a deleterious effect on
potable water flowing through the pipe line.

1.6.2.4 Water

Water shall be clean, colorless, and free from injurious quantities of organic matter, salt, alkali,
orother impurities that might reduce the strength, durability, or other desirable qualities of the
mortar.

1.6.3 Cement mortar

Cement mortar shall be composed of cement, sand and water, well mixed and of proper
consistency to obtain a dense, homogenous lining that shall adhere firmly to the pipe surfaces.
Mortar proportion shall be with 1.5 parts of sand and 1 part of cement by weight. The soluble
chloride-ion (Cl) content of the cement mortar mix shall not exceed 0.15 percent, expressed
as percentage of cement weight. Maximum water / cement ratio shall not exceed 0.45:1.

1.6.4 Mixing

The mortar shall be mixed in batches. The amount of cement and sand entering into each batch
shall be measured by weight. The quantity of water entering the mixer shall be measured
automatically by an adjustable device, or it shall be otherwise measured to ensure that the
correct quantity of water is being added. The mortar shall be mixed long enough to obtain
maximum plasticity and shall be used before initial set.

1.6.5 Equipment

Straight sections of pipe shall be lined by using a spinning machine specifically designed and
built for the purpose of rotating the pipe section and centrifugally applying cement mortar
lining to the interior of steel pipe or by method known to provide equivalent results.

1.6.6 Lining thickness

Thickness of inside lining shall be uniform throughout except at joints and other
discontinuities in the pipe wall. Ends of lining shall be left squareand uniform with regard to the
longitudinal axis of the pipe. The lining shall be terminated at 10 to 15 cm at the end of pipe for
joint welding. The lining thickness requirements shall be maintained by mechanical end
retaining rings and verified by physical measurements. Positive tolerance of 3 mm in
thickness is permissible; however, no negative tolerance is allowed.

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1.6.7 Surface preparation

Before application of the lining, the internal surface shall be cleaned thoroughly. The pipe
interior surface shall be free of oil and grease etc. Loose mill scale, dirt, rust, shall be removed
from the interior surface, so that the surface is thoroughly clean and dry to receive the lining.

1.6.8 Machine lining

1.6.8.1 Bracing /Struts

When required to prevent distortion or vibration during the spinning, each section of pipe shall be
suitably braced with external or internal supports, appropriate to the equipment to maintain
thecircular shape of pipes. Contractor may provide adjustable steel struts of approved design
for this purpose before application of lining. Minimum two struts at ends shall be provided for
each pipe. The struts shall not be removed till the pipes are laid and jointed. The cost of
providing struts with material and labour required is covered under the item of pipeline and
hence shall not be payable extra.

1.6.8.2 Placement

In application of lining by spinning machine, the entire quantity of mortar required for completion
of the lining of the section of pipe shall be placed without interruption.

1.6.8.3 Lining for specials

The application of lining to MS specials such as bends, reducers, tees, tapers etc, the shape of
which precludes application by the spinning process, shall be done by mechanical / pneumatic
placement or hand application and finished to produce a smooth, dense surface.

1.6.8.4 Hand application

Cement mortar for hand application shall be in 1.5 parts of sand and 1 part of cement by weight
and plaster sand confirming to ASTM C 35 shall be used in place of sand confirming to ASTM
C 33. Areas shall be cleaned to remove loose or other foreign matter that would interfere with
the adherence of cement mortar and, if necessary, shall be moistened with water just before the
placing of the cement mortar.

1.6.9 Field joints

Material and mortar proportion for application of lining at field joints shall be 1 part of cement and
2 parts of sand by weight. The cement and sand shall be dry mixed and moistened with
sufficientwater to permit placing and troweling without crumbling. Inside joints of mortar lined pipe
shall be filled with cement mortar and finished off smooth flush with the inside surface of the
pipe by troweling or by equivalent means. Before placing the cement mortar against the surfaces
of the lining, the surfaces shall be carefully cleaned, have all soap removed, and then be wetted
to ensure a good bond between the lining and the joint cement mortar.

1.6.10Defective lining

All defects in cement mortar lining including, but are not limited to, sand pockets, voids, over
sanded areas, blisters, and cracking as a result of impacts, shall be cutout, and replaced by
hand or pneumatic placement.

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1.6.11Repairs of defective lining

Small defective areas shall be repaired by manual removal of the defective lining and
reapplication of mortar lining by hand. Defective areas encompassing the full diameterof the
pipe shall be replaced by machine application wherever possible.

1.6.12Lining cracks

Temperature and shrinkage cracks in the mortar lining less than 1.5 mm in width need not
be repaired. Cracks wider than 1.5 mm need not be repaired if it can be demonstrated to the
satisfaction of the BIL that the cracks shall heal autogenously under continuous soaking in water.
The autogenously healing process may be demonstrated by any procedure that keeps the lining
of the pipe continuously wet or moist.

1.6.13Sampling and testing

1.6.13.1 Sampling and testing frequency

Compression test cylinders or centrifugal test cylinders shall be prepared for testing. A set of at
least two standard test cylinders, 150 mm in diameter and 300 mm in length, shall be made
each day from the cement mortar lining for each shift. Samples may be prepared by omitting
sufficient water from the production mix to obtain a 25 to 75 mm slump. Test cylinders from this
mix shall be made in conformance with ASTM C 31.

Centrifugal spun test cylinders may be substituted for cement mortar test cylinders, at the option
of the manufacturer. The test cylinders shall be spun about their longitudinal axis in 150
mmdiameter by 300 mm long steel moulds at a speed that shall simulate the compaction of
mortar in the lining to produce a spun cylinder wall thickness of approximately 40 mm. The net
cross sectional area of hollow cylinder shall be used to determine its compressive strength.
Damaged cylinders shall not be used.

1.6.13.2 Curing of samples and testing

All cement mortar test cylinders shall be cured with the pipe at the same temperature and for the
same length of time, and shall be tested in accordance with ASTM C 39 in an approved testing
laboratory unless the manufacturer has approved testing facilities at the work site.

1.6.13.3 Strength requirements

Cement mortar test cylinders shall attain a minimum compressive strength of 31 MPa in 28 days
or at the time of dispatch to work site, if less than 28 days.

The average of any 10 successive strength tests of cylinders representing each cement
mortar mix shall be equal to or greater than the specified strength, and not more than 20% of
the strength tests shall have values less than the specified strength. No cylinder test result
shall be less than 80% of the specified strength.

1.7 CEMENT MORTAR GUNITING TO EXTERNAL SURFACE

1.7.1 General

The outside surface of the MS pipes and specials shall be provided with reinforced cement
mortar (1:3) coating of 25 mm thickness, applied by mechanical / pneumatic placement at shop /
factory.

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1.7.2 Material

1.7.2.1 Reinforcement

The reinforcement shall consist of BRC fabric number 13 of size 50 mm x 50 mm.


Reinforcement shall be free of oil, grease and other contaminants that may reduce the
adherence between the coating and reinforcement. The BRC fabric shall be placed in the
middle third of the coating. Mortar cover blocks shall be provided to place the BRC fabric
properly. Splicing for fabric reinforcement, if required, shall have minimum 100 mm overlap.

1.7.2.2 Cement

Portland cement shall confirm to IS: 269 / IS: 8041 / IS: 1489 and IS: 8112.

1.7.2.3 Sand

Sand shall consist of inert materials having hard, strong, durable uncoated grains confirming to
the requirements of IS: 2116.

1.7.2.4 Water

The water used for guniting shall be clean, colorless, and free from injurious quantities of
organic matter, alkali and salt. The maximum water cement ratio shall not exceed 0.45: 1.

1.7.3 Cement mortar

The mortar applied by mechanical or pneumatic process shall consist 3 parts of sand and 1 part
of cement by weight. The water in the mixture shall be carefully controlled so that the mortar
shall not run, sag or segregate. The soluble chloride-ion (Cl) content of the cement mortar mix
shall not exceed 0.15 percent, expressed as a percentage of cement weight. Rebound not
exceeding one fourth of the total mix weight may be used as replacement material for fine
aggregate only. Rebound not used within 1 hour shall be discarded.

1.7.4 Surface preparation

The outer surface shall be cleaned for oil grease etc. The dust shall be removed by
compressedair or vacuum cleaner before placement of reinforcement. The BRC fabric
reinforcement shall then be placed with required cover on the pipe surface.

1.7.5 Application

The pipe shall be supported on wooden logs at the ends to keep bottom clearance and to
facilitate easy rotation while applying the coating. The mortar coating shall be applied in one or
more continuous applications for achieving required thickness. If applied in more than one
course, the interval between the first and last course shall not be more than 2 hours. The mortar
shall be projected at high velocity against the exterior surfaces of the pipe with a pressure of 2.1
to 2.8 kg / cm2 to produce a hard, tight adhering coating of specified thickness. The coating
shall not be applied on ends of pipes for 100 mm length. Ends of coating shall be uniform and
square to the longitudinal axis of the pipe. The rebound material unused shall be disposed
off within a lead of50m.

1.7.6 Placement temperature

The temperature of the cement mortar mix shall not be less than 4° C, nor shall the surface
temperature of the MS pipe be greater than 35° C at the time of placement.

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1.7.7 Curing

After the initial set of the cement mortar coating has taken place, the mortar coating shall be
cured by the moist curing method. The coating shall be kept continuously moist by intermittent
orcontinuous spraying of water for a period of at least 7days.

1.7.8 Defective coating

If any sand pockets or porous spots occur, they shall be completely cut out and replaced by
mechanical / pneumatic placement or hand application of mortar in proportion of 2 parts of sand
and 1 part of cement, by weight.

1.7.9 Coating cracks

Care shall be taken to minimize the occurrence of cracks in the mortar coating. However,
hairline cracks need not be repaired. The cracks, if developed, shall be repaired by brushing
orwiping of neat cement in to the cracks, or painting of the cracks with epoxy coating or a
combination of these methods shall be adopted.

1.7.10Transportation of pipes foraying

Handling of the mortar coated pipes while transporting those from shop / factory, for laying and
jointing purpose, shall be done very carefully to avoid any damage or development of cracks to
the mortar coating. Any damaged portion shall be cut out and replaced. The pipes shall be laid
in the trenches as early as possible after the curing period is over to avoid hair cracks in the
coating due to temperature variations.

1.7.11Coating for welded joint portion

After the welding and testing of the welded joints of MS pipeline, the BRC fabric reinforcement
shall be provided over the joint. Cement mortar used for the joints shall be composed of one
part of cement to not more than two parts of sand, by weight, thoroughly mixed with water to the
consistency of thick cream. Sand shall be graded confirming to the requirements of ASTM C
33, except that 100% shall pass a US standard sieve number16.

Outside field joints shall be coated with cement mortar, retained by suitable water-
impermeable bands or diapers to bridge the joint and retain the cement mortar without
leakage. Before filling, the cement mortar space shall be flushed with water so that the surface
of the joint shall be in contact with the cement mortar shall be moistened when the cement
mortar is poured. The joint shall be filled with cement mortar by pouring from one side only
until the cement mortar reaches at least the pipe spring line on the opposite side, and shall be
rodded with a wire or other flexible rod, or vibrated so that the cement mortar completely fills the
joint recess by moving down one side of the pipe, around the bottom of the pipe, and up the
opposite side. Pouring and rodding the cement mortar shall be continued to allow completion of
the filling of the entire joint recess in one operation. Care shall be taken to leave no unfilled
space. The exposed portion of the grout at the top of the pipe shall be coated with a sealing
compound or covered with burlap or moist earth for curing.

1.7.12Inspection

The tests performed shall be inspected by the Engineer-in-Charge. If any sample fails to meet
the requirements, the Contractor shall be notified immediately. Material affected by the test results
shall be set aside pending final disposition.

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1.8 EXTERNAL EPOXY PAINTING FOR EXPANSIONJOINTS

1.8.1 General

Unless otherwise specified, the expansion joints shall be epoxy painted externally. The shop
applied painting is to be stopped 150 mm short at each end of pipe to facilitate field welding
and then made up on site following testing of the joint.

Painting shall be generally in accordance with standard painting specifications as given


separately except for the following.

The expansion joints shall be painted externally with zinc rich epoxy primer and epoxy paint.
Both in factory and site application is to be done by airless spray equipment. Paints of
reputed make and approved by Engineer-in-Charge shall be used. Thinning or heating of
paints will not be permitted except with specific approval from Engineer-in-Charge and in
accordance with manufacturer’s instructions.

Each lot of primer and paint used by Contractor shall be accompanied by certified copies of
the test results on hardness, impact and heat resistance and resistance to corrosion carried
out by manufacturers in accordance with relevant Indian or International standards.

Surface preparation shall be in accordance with manufacturer’s instructions, but as a


minimum the pipes shall be abrasive blast cleaned to BS: 7079 Grade SA 2.5 or equivalent
to achieve surface roughness profile of 40 - 50 microns. The primer shall be applied within 2
hours of surface preparation, before flash rusting can occur. Two coats of Zinc rich epoxy
primer shall be applied by spray equipment.

The priming coat shall be uniform in thickness and free from floods, runs, sags, drips, and
bare spots. Any bare spots or defects shall be recoated with an additional application of the
primer. All defects shall be rectified as per the instructions of the Engineer-in-Charge.

Though the priming coats become touch dry in 10 to 15 minutes, the finishing coats with
epoxy paints shall be applied after allowing the film to cure at least for 48 hours. The final dry
film thickness shall be a minimum of 300 microns. This may be achieved by applying in 2 to
4coats.

On completion of the work, the contractor shall remove any oil stains or paint spots, leaving
the pipe in a clean and acceptable condition.

1.8.2 Inspection and Testing

The entire procedure of applying the paint as specified will be rigidly inspected right from the
cleaning stage to the application of the final coat by the Engineer-in-Charge. If, at any time, it
is found that the procedure of applying the paint or defects noticed, all such painting work
done shall be rectified or redone by the Contractor at his own cost, as directed by the
Engineer-in-Charge.

Samples of the paint brought by the Contractor shall be sent to the testing laboratory for
testing, as directed by the Engineer-in-Charge. If any sample is found to be not conforming
to the specifications, the entire consignment to which the sample may pertain shall be
rejected. Samples shall be taken at intervals at the option of the Engineer-in-Charge. The
entire cost incidental to such testing shall be deemed to be included in the rates quoted by
the Contractor.

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1.9 TRANSPORTATION AND HANDLING

All pipes and specials manufactured at factory and internally cement mortar lined and
externally gunited in the yard and temporarily stacked in the factory shall be transported
carefully to the work site for laying and jointing.

Any vehicles on which pipes are transported shall have a body of such length that the pipes
do not overhang. Large pipes shall be placed on cradles and the loads properly secured
during transit.

Additional precautions shall be taken to avoid deformation of flexible pipes. To maintain


their circular cross-section internal struts shall be fitted in the pipes. Details of the proposed
strutting system shall be submitted to the Engineer-in-Charge for approval and if required by
the Engineer-in-Charge, the method of strutting shall be demonstrated and tested onsite.

The pipes and specials shall be handled in such a manner as not to distort their circularity or
cause any damage to their coating. Wide non-abrasive or other approved slings shall be
used and hooks and other metal devices shall be well padded. Hooks engaged on the comer
wall surface at pipe ends shall not be used. Steadying ropes shall be employed. The
positions of lifting slings shall ensure that stresses and tendency towards deformation in the
pipes are kept to a minimum.

Pipe handling equipment shall be maintained in good condition and any equipment which in
the opinion of the Engineer-in-Charge may cause damage to the pipes shall be discarded.

Under no circumstances shall pipes be dropped, be allowed to strike one another, be rolled
freely or dragged along the ground. No valves shall be lifted by the spindle.

Fabricated materials such as man-hole covers, appurtenances, bolts, nuts, flanges, saddles,
collars, bypass arrangements etc., shall be transported to the site of laying from the
fabrication yard according to needs of the laying operations only.

3 PIPELINE LAYING ANDJOINTING

3.1 General

Laying / erection of factory made internal lined and external gunited pipes shall be carried
out by the Contractor who shall equip himself, at his cost, with all necessary tools,
machinery, labour etc., required for the purpose. The pipeline shall be constructed in lengths
with a separate full time gang working on each length.

3.2 Laying Programme

The Contractor shall submit a detailed bar chart for manufacturing and laying of the pipeline,
which shall be subject to the Engineer-in-Charge’s approval. In preparing this bar chart, the
Contractor shall plan his activities such that the laying of pipes shall closely follow the
manufacturing schedule and no pipes shall remain stacked in factory or at site for a period
more than 15 days.

Together with the chart he shall submit a methodology describing how he will carry out this
work within the contractual period and the required resources in terms of construction
equipment and other facilities that he shall utilize to complete the works.

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3.3 Buried Pipelines

3.3.1 Trenching

Unless otherwise specified, all buried pipes and fittings, specials shall have minimum
cushion of 1.20 m above the top surface of external pipe guniting.

Trenching includes all excavation which is carried out either by hand or by machine and shall
be carried out in accordance with all general requirements as specified elsewhere. In
addition to those general requirements, the following requirements shall apply to pipelines.

The width of the trench shall be kept to a minimum consistent with the working space
required and having regard to the safety of the trench, the method of laying and jointing the
pipe and the need to avoid damage to pipe coating and so as to provide the minimum
horizon as stated in the table below. The bottom of the trench shall be properly trimmed to
permit even bedding of the pipeline.

The portion of the trench which extends from the formation level to not less than 300 mm
above the crown of the pipe when laid in its correct position, shall, unless otherwise specified
or ordered by the Engineer-in-Charge, be formed with vertical sides. The clearance between
the sides and bottom of the trench and the barrel of the pipe shall be kept minimum.

The clearance at joints may be increased to allow the joints to be made and inspected; any
proposed increase shall be approved by the Engineer-in-Charge.

All trenches deeper shall have the trench walls battered or supported to ensure the safety of
all persons working in the trench if required. The Contractor is to provide details of these
arrangements for approval by the Engineer-in-Charge prior to any work being undertaken in
such a trench.

No excavations with battered sides shall be made in roads, footpaths, private gardens, or
within 10 m of any buildings or other structures.

The Contractor shall erect temporary fencing around all open excavations and post warning
signs in English and the local language. A fencing shall be at least 1.0 m tall, rigid in nature
and strong enough to prevent people falling into the trench. The Contractor shall also take all
other necessary measures to ensure the safety of the public and others.

The maximum length of excavation which may be left open in any length is 500 m. The
opening of two lengths within 500 m of each other shall require the approval of the Engineer-
in-Charge.

The excavation shall be kept free of water to allow placing of bedding, laying of pipes,
welding of pipes, inspection and testing of joints, coating of joints, placing of backfill and
other activities within the pipe trench, to be carried out in a satisfactory manner.

3.3.2 Bedding

The depth and type of bedding shall be as per approved drawing certified by BIL. Based on
the site conditions, the Contractor shall submit detailed drawings with bedding details for
BIL’s approval. Where rock or boulders are encountered, the trench shall be trimmed to a
depth of at least 300 mm below the level at which the bottom of the barrel of the pipe is to be
laid and filled to a like depth with sand as shown in the approved drawings.

The class of bed and surround to be used are indicated below:

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Class of bed and surround Brief description of bedding material
Class A Mass Concrete
Class N Well Graded Sand
Class S Granular material

Class S bed and surround shall be used on all pipes unless otherwise specified or shown on
the drawings.

The concrete to be used for Class A bedding and surround shall be M: 15 type. Class A
bedding shall be used at all road / drain crossings under the road / drain and for a distance
of 5 m back from the back edge of road / drain or footpath.

Class N bed material shall only be used where the pipe trench is founded in hard rock or
otherwise as directed by the Engineer-in-Charge. The sand shall be clean and well graded
and free from topsoil, clay or vegetable matter and to the approval of the Engineer-in-
Charge. 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 as described in IS: 383 shall
apply.

The graded granular bed material for use in Class S bedding and surround shall consist of
durable gravel, crushed stone or disintegrated rock. Selected material excavated from the
pipe trench may be used, provided it contains no topsoil, clay or vegetable matter and is to
the approval of the Engineer-in-Charge. Any imported bed and surround materials shall be to
the approval of the Engineer-in-Charge and shall be supplied with certification which gives
details of its content, source and grading. In all cases the soluble sulphate and chloride
content of the granular material shall not exceed 0.5 % and 0.06 % by weight respectively.

Graded Material

The Contractor's method of grading the excavated material shall be to the approval of the
Engineer-in-Charge. All Class S graded material shall pass though test sieves to IS: A60
(Part 1) in the following proportions by mass:

Aperture Size Percentage Passing


50 mm 100%
37.5 mm 90 - 100 %
20.0 mm 35 - 70 %
14.0 mm 25 - 55 %
10.0 mm 10 - 40 %
5.0 mm 0 -5 %

3.3.3 Construction of Class a bed and Surrounds

Class A bed and surround shall be constructed as indicated in the approved drawings by
BIL.

Before placing concrete the pipes shall be supported near each joint with a padding of
compressive material on a precast concrete block. Concrete shall not be placed until the
pipes have been jointed, inspected and tested. The concrete shall be placed to ensure full
contact with the pipe barrel throughout its length.

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The concrete shall be made discontinuous at flexible pipe joints by a diaphragm of fiber
board or other compressible material of at least 20 mm thickness extending for the full area
of the surround.

No concrete shall be placed around joints of a welded steel pipe until that length of pipe has
passed a sectional hydraulic test.

3.3.4 Construction of Class S bed and Surrounds

Class S pipe bed and surround shall be constructed as indicated in the approved drawings.

The granular material shall be evenly spread over the full width of the formation and lightly
compacted to a level slightly higher than level corresponding to the underside of the pipe
barrel to allow for settlement of the pipe to the correct level.

Following placement and jointing of the pipe further granular material shall be placed in the
trench, special care being taken to fill under the sides of the pipes to ensure full contact with
the barrel of the pipe.

Field joints which have not been tested shall be left exposed for a minimum length of 150
mm each side of the joint. The granular material shall then be placed and compacted evenly
on both sides of the pipe to a depth of 300 mm above crown of the pipe.

Trench supports shall be withdrawn gradually in accordance with the progress of the fill with
the provision that such withdrawal shall not prejudice the safety of the works.

The contractor shall ensure that the material to the sides of the pipe is adequately
compacted in layers having a maximum thickness of 150 mm and that the method of
compaction used shall achieve not less than 95% of the maximum dry density as determined
from IS: 2720: Part - 7.

After each section of the pipeline has passed the hydraulic test, the exposed joints shall be
backfilled and compacted to the above specification. .

The same general requirements shall apply to Class N bedding.

3.3.5 Pipe Laying

The laying of the pipes shall be in accordance with IS: 5822 unless otherwise specified. The
pipeline shall be constructed in lengths with a separate full time gang working on each
length. No metal tools or heavy objects shall be permitted to come into contact with the pipes
or fittings. External gunited pipe shall be handled at all times with wide non-abrasive canvas,
rubber or leather straps or other equipment to prevent damage to the guniting. The use of
chains, wire slings, or any other handling equipment found to be injurious to the guniting
shall not be permitted. The timber or skids used to support the gunited pipe prior to lowering
into the trench shall be properly padded with sufficient bags stuffed with sand or straw for the
purpose of protecting the guniting. Alternatively, the pipe may be supported alongside the
trench on mounds of sand. Any injury to the protective guniting from any cause must be
repaired before the pipes or fittings placed in the trench. During laying operations, no debris,
tools cloth or other material shall be placed in the pipe. Pipes and fittings shall be lowered
into the trench with equipment suitable for the weight of the pipes and fittings, and they shall
be carefully cleaned before jointing.

Pipes shall be laid accurately to the lines and levels shown on the drawings, within a
tolerance of ± 10 mm.

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Pipe alignments shall be straight between bends or curves. Length laid to curves shall only
be allowed where shown on drawings or in accordance with detailed proposals approved by
the Engineer-in-Charge.

Properly painted sight rails shall be supplied and erected, with boning rods of predetermined
measurement for the boning of individual pipes to the correct gradient. The sight-rails shall
be situated vertically above the line of the pipe or immediately adjacent thereto, and there
shall at no time be less than three sight rails in position on each length of pipeline under
construction to anyone gradient.

The Contractor may submit to the Engineer for his approval an alternative method of the
control of pipe laying to the correct levels and alignment.

The joining of pipes shall be made in accordance with the requirements of this specification.
The Contractor shall obtain from manufacturers all special information regarding the
handling of the pipes, joints and other fittings and he will be deemed to have made himself
thoroughly conversant with all phases of pipe laying before commencing the works.

A "badger" or "bung" about 10 mm smaller than the internal diameter of the pipe shall be
kept in the pipe at all times, pulled forward as the work progresses. When pipe laying is not
in progress, including overnight, the open ends of the pipeline shall be blanked off with a
temporary watertight fitting approved by the Engineer-in-Charge. The pipe shall be suitably
held down so that the pipe does not become buoyant in the event of the trench becoming
flooded.

To restrict the flow of rain runoff along the trench, the Contractor shall plug the trench with
backfill material at distances not exceeding 250 m until the pipeline can be filled in. The
plugs shall be removed when trench filling is taking place. In granular bedding areas the
plugs shall be of clay and shall be left in.

3.3.6 Level Control

The criterion for the level to which transmission main shall be laid such that the cover above
the crown of the pipe to ground level shall be as specified in the drawings but in no case
shall be less than 1200 mm unless otherwise directed by Engineer-in-Charge.

3.3.7 Laying to Curves

Where pipes are to be laid to curves, the deflection at each joint shall not exceed one
degree. For sharper curves specifically made bends shall be provided.

3.3.8 Lowering and Jointing

The pipe shall be lowered into the trenches such that no part of any shoring is disturbed or
damaged and, if necessary, additional temporary struts may be fixed during the lowering
operations. Care shall be taken to ensure that the longitudinal joints of two consecutive pipes
at each circumferential joint are staggered by 90°. While assembling the pipes, the ends
shall have to be brought close enough to leave a uniform gap not exceeding 4 mm. There
shall be no lateral displacement between the pipe faces to be joined. If necessary, spiders
from inside and tightening rings from outside or other suitable equipment shall be used to
bring the two ends in perfect contact and alignment. In no case shall hammering or
longitudinal slitting be permitted. Jacking may be permitted for this purpose in particular
circumstances as approval by the Engineer-in-Charge, when the pipe is properly assembled

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firmly supported on wooden beams and wedges or by other approved means it shall be
checked for correct line and level.

On completion of the pipe jointing the external portion of MS pipes shall be coated with M:
15 concrete and the trench and the welding pits shall be cleaned. The pipe jointing pit for all
the pipe materials shall be filled with approved bedding material and compacted in 150mm
layers.

3.3.9 Floatation

The Contractor shall take proper precautions against the risks of floatation and of flooding of
the excavated works and shall make due allowance in his programme for any closure he
considers necessary on account of monsoon.

Should any section of the pipeline be affected by floatation in the course of works the entire
work shall be removed and then reinstalled to the satisfaction of Engineer-in-Charge. The
entire cost of laying it again to the correct line and level shall be to account of the Contractor.

3.3.10 Steel Props

For mild steel pipes in order to effectively provide cement mortar lining to the inside of the
pipes and to avoid difficulties during the work, it is necessary that the roundness of the pipes
is maintained circular till the lining work is taken up. To achieve the same, steel adjustable
screw type props or similar approved type consisting of minimum six legs (three props) shall
be fixed inside the pipe and the diameter correctly set.

The design and drawings of the props that the Contractor intends to use should be approved
by the Engineer-in-Charge before starting the work. These props shall be fixed vertically at
intervals as directed by the Engineer-in-Charge. The props should be kept in position at least
for three days after the encasing of the pipe in that section is completed or until refilling is
done to the full height of fill over the pipe in case the pipes are not encased. The props shall
be removed only after obtaining permission from the Engineer-in-Charge.

3.3.11 Backfilling

On completion of the pipe laying operations in any section, for a length of about 100 m and
while further work is still in progress, refilling of trenches shall be started by the Contractor
with a view of restricting the length of open trenches. Pipe laying shall closely follow the
progress of trench excavation and the Contractor shall not permit unreasonably excessive
lengths of trench excavation to remain open while awaiting testing of the pipeline. If the
Engineer-in-Charge considers that the Contractor is not complying with any of the foregoing
requirements, he may prohibit further trench excavation until he is satisfied with the progress
of laying and testing of pipes and refilling of trenches. Filling to a level of 300 mm above the
crown of the pipe shall be done in accordance with the requirements of the clause on
bedding. Care shall be taken during backfilling, not to injure or disturb the pipes, joints or
guniting. Filling shall be carried out simultaneously on both sides of the pipes so that
unequal pressure does not occur. Walking or working on the completed pipeline shall not be
permitted unless the trench has been filled with the instructed bedding and surround material
up to height of at least 300 mm over the top of the pipe except as may be necessary for
tamping etc., during backfilling work.

The remaining portion of the trench shall be filled in with selected excavated material free
from and topsoil, vegetation or boulders and clods of earth larger than 75 mm in size. Filling
shall be done in layers not exceeding 150 mm in thickness accompanied by adequate
watering, ramming etc., so as to be compacted to 95% of the maximum dry density as per

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Part 7 of IS: 2720. The water contents of the soil shall be kept near to optimum moisture
content as possible. 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. The surface of the
refilled excavations shall be left slightly higher than the adjacent ground and be maintained
by the Contractor to a smooth even slope.

The Engineer-in-Charge shall, at all times, have powers to decide which portion of the
excavated materials shall be used for filling and in which portion of the site and in what
manner it shall be so used.

If suitable material for refilling is not available from already excavated material the Contractor
shall import material of approved quality as directed by the Engineer-in-Charge.

Regular measurement of the field dry density shall be taken by the Contractor at various
levels in the backfilling as required by the Engineer-in-Charge.

No mechanical plant other than approved compacting equipment shall run over or operate
within the trench until backfilling has reached its final level or the approval for the Engineer-
in-Charge has been obtained.

Should any subsidence take place either in the filling of the trenches or near about it during
the works the Contractor shall make good the same at his own cost.

Surplus excavated material shall be used to fill in any low spots above the pipeline which are
identified on the drawings or are instructed by the Engineer-in-Charge. Such material shall
be evenly placed and compacted in layers not exceeding 200 mm thick after compaction.
The method of compaction employed shall achieve not less than 90% maximum dry density
as determined from IS: 2720, Part 7. Unless approved of by the Engineer-in-Charge, the
width of areas to be filled shall not exceed 20m.

3.3.12 Above Ground Pipelines

3.3.12.1 General

The procedure for handling the pipes, lowering and assembling specified in previous clauses
shall be followed for lifting and laying pipes on supports. The pipeline should be laid on
saddle and ring girder supports as specified in approved drawings by BIL and as directed by
Engineer-in-Charge. No material shall be erected unless they have been previously
approved by the Engineer-in-Charge.

Erection of fabricated pipes shall be carried out by the Contractor who shall equip himself, at
his cost, with all necessary tools, machinery, labour etc., required for the purpose. The
pipeline shall be constructed in lengths with a separate full time gang working on each
length.

3.3.12.2 Ring Girders

Unless specified otherwise in the BIL approved drawings, ring girders are to be used to
support pipe work on all pipe bridges. They shall be fabricated from IS: 2062 Grade B steel
and supported by pipe bridge piers. Ring girders are usually installed 1.0 m behind each
welded joint. Pipes are supported on ring girders placed at 13.5 m c/c directly over bridge
piers. Ring girders shall be fabricated as per approved drawings. All pipes and fittings on
pipe bridges shall be epoxy painted as specified. Any damage to the painting shall be made
good.

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3.3.12.3 Expansion Joints

Expansion joints are designed to allow for thermal induced movement of pipelines laid above
ground. Contractor shall submit detailed design and drawings for the expansion joints as per
the standard specifications.

Expansion joints shall be welded on to pipelines at locations indicated on approved


drawings. Expansion joints shall be fabricated true to shape and sizes as shown in the
approved drawings. All contact surfaces shall be properly machined and finished smooth to
ensure smooth working of the joints. The steel bolts and nuts used in the manufacture shall
comply with BS: 1083. The joints shall be assembled without undue hammering or forcing in,
to avoid damage to any part thereof. The packing material to be used in the expansion joint
shall be asbestos synthetic rubber / or any other suitable material and rubber ring as
approved by the Engineer-in-Charge. It shall be capable of withstanding the test pressure
and shall have high compressibility and properties to withstand deterioration by abrasion or
water action. For dispatch to the site, the expansion joint shall be assembled with steel ring
without other packings using bolts and nuts only in a locked position. The machined
surfaces shall be greased before assembly. The remaining bolts, nuts and washers and the
packing material including rubber rings shall be supplied by the vendor at the site of laying
along with expansion joining.

If any defects are noticed after its erection at site, the Contractor shall carry out necessary
repairs either at site or at their works as directed by the Engineer-in-Charge. All expenses in
this connection including its removal, transporting and refixing shall be borne by the
Contractor. The responsibility as regards the defects noticed shall be determined by the
Engineer-in-Charge and his decision shall be final and binding on the Contractor.

Hydrostatic pressure test shall be conducted in accordance with BIS or equivalent


international standards for the water tightness of expansion joints. The expansion joints
shall prove to be sound and water tight at the time of testing. Any leakage shall be stopped
by normal tightening of bolts on the gland.

3.3.12.4 Laying of pipe line above ground levels

Pipes shall be laid in accordance with relevant IS Specifications

The Contractor shall provide suitable pipe supports or pedestals as per detailed working
drawings. Pipe laying shall generally start from the fixity points on either side, the expansion
joints being provided last.

Fixity points are at all anchor blocks and fixed supports.

Anchor blocks shall be constructed in stages. The anchorages shall be made from concrete
and constructed as per designed dimensions.

As per approved drawings the concrete pedestals shall be cast at least 3 weeks before the
pipeline is laid on them. In case of any errors in casting the pedestals, corrections shall be
applied as directed by the Engineer-in-Charge. The method of joining the pipes and erecting
them on the previously cast pedestals shall be determined by the Contractor in consultation
with the Engineer-in-Charge.

The pipe shall be assembled in position on the pedestal by the equipment approved by the
Engineer-in-Charge.

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3.4 Puddle and Thrust Flanges

The puddle flange and weld between the flange and pipe work shall be sufficient to take care
of designed total shear force. Puddle flanges on steel pipe work over 1000 mm Dia. shall be
a minimum thickness of 60 mm. and height of 150 mm.

3.5 Gaskets

All gaskets shall be manufactured from SBR rubber in accordance with IS: 5382. Gaskets for
spigot and socket pipes shall comply with ARE: 12820. The dimensions of flange gaskets
shall comply with BS: 4865.

3.6 Anchor Blocks

Contractor shall provide anchor blocks at horizontal bends, vertical bends at intervals on
pipelines with gradients in excess of 1 in 6. The anchorages shall be made from RCC M: 25
concrete or grade as specified elsewhere only and constructed to the dimensions as per the
approved drawings. Anchor blocks shall also be provided at line valves to counteract
unbalanced forces developed in lines and valves. Anchorage shall also be provided to
counteracting buoyancy forces acting on the pipelines when empty. Anchor blocks designed
as (i) gravity anchors, where pipelines are encased in concrete block for the entire length or
in sections to give adequate counteracting weight and (ii) ground anchor, where pipeline is
passing through areas subjected to high water tables or in marshy land. The buoyancy force
is resisted by buoyant weight of block and soil / rock supported by the anchor. Adequate
factor of safety shall be considered.

Where faces of anchor blocks are bear against undisturbed ground, the Contractor shall take
all necessary measures to ensure that such bearing is given over the full dimensions shown.

3.7 Pipe Work Surrounded by Concrete

When pipe work is in a Class A bed and surround or surrounded in concrete at thrust and
anchor blocks etc, the pipes shall be given the normal external guniting and shall be
wrapped with at least two layers of 0.30 mm thickness waterproof polythene securely fixed in
place with waterproof tape.

3.8 Flexible Joints

Pipelines entering and leaving certain structures shall include two flexible joints, at distances
from the face of structure as per the design and as identified by the Engineer-in-Charge.

3.9 Thrust Blocks

A pipe line laid in the alignment having deviation points, be they underground or above
ground, due to internal pressures unbalanced forces develops, which causes development
of stress in the pipe shell. To counteract these forces RCC thrust blocks shall be provided.
The thrust block size is governed by following criteria:

 The resultants of vertical forces due to weight of block, pipe and water and horizontal
forces due to thrust and component of longitudinal forces wherever acting shall fall
within middle third of base width.

 Frictional forces at the base shall have adequate factory of safety against sliding.

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 Ground pressure developed at the base shall not exceed safe bearing capacity of
foundation strata.

Also following two cases are considered for different conditions of side supports.

First case shall be, design of block neglecting support of soil and soil pressure and second
one is design of block where support of surrounding soil is considered.

Wherever there is a transition between above ground and buried pipelines. Vertical thrust
blocks shall be provided. Vertical thrust blocks shall have flexible joints at either end to allow
for small amounts of settlement to occur. The Contractor shall undertake the construction of
the thrust blocks as early in the programme of work as is practical, in order to reduce the risk
of settlement of imposing additional loads on the pipeline supports.

Where possible the base of the thrust block shall be cast against solid rock in order to
prevent any settlement. Any material overlying the rock shall be excavated and replaced with
class M: 15 grade mass concrete. In the event of no rock being encountered the base of the
thrust block shall be cast against undisturbed ground. Any ground which in the Engineer-in-
Charge’s opinion is unsuitable shall be excavated and replaced with class M: 15 grade mass
concrete.

3.10 Pipelines under Existing Roads

The Contractor shall programme the works to reduce disruption to road traffic to a minimum,
and before any work commences in existing roads shall:

i. Obtain the permission and approval of all authorities concerned serving notices of
intent to start work as may be necessary and observing all the local Laws and
Regulations.

ii. Submit details of his proposals, and obtain approval from the Engineer-in-Charge and
local highway authority.

iii. Constructing of temporary diversion roads.

The pipelines crossing roads shall be provided with RCC ducts in M: 25 concrete as per the
approved design and drawings by BIL.

Pipelines which are laid along a road shall be laid in trench. The bed and surround shall be
previously specified but above this the trench shall be backfilled with crushed rock up to the
underside of the road sub-base. Not more than 20% of the crushed rock shall pass through a
IS test sieve with 4.75 mm apertures and all material shall pass through a IS test sieve
having an aperture of 40 mm. The backfill shall be compacted in layers having a maximum
thickness of 200 mm and the method of compaction used shall achieve not less than 95%
maximum dry density as determined from IS 2720: Part7.

3.11 Reinstatement of Roads

The replacement of road structures shall be carried out as soon as practicable after
backfilling has been completed. Suitable excavated road pavement which complies with the
requirements of the Engineer-in-Charge may be used at the sub-base levels. Compaction
shall be carried out with approved mechanical compacting equipment. The depth and type
of reinstatement shall consist of the following:

i. backfilling the trench with crushed stone

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ii. laying and compacting a 150 mm thick layer of Water Bound Macadam
iii. laying and compacting a 150 mm thick of Built Up Spray Grout
iv. where the carriage way surface adjoining the trench is of rolled asphalt the
Contractor shall lay a wearing course of 40 mm thick rolled asphalt

The edges of the trench shall be cut to form a uniform line consistent with the varying width
of the trench and the agreed trimming allowances. Any part of the structure of the road which
has been damaged beyond the width of trench must be cut out and made good. Prior
approval for such additional work must be obtained from Engineer-in-Charge.

A vertical joint shall be formed between the new work and the existing road surface and shall
be painted with hot bitumen or as approved by the Engineer-in-Charge. The joint between
the base course and wearing course shall be stepped 75mm.

The finished levels of the completed reinstatement shall conform with adjoining carriageway
surface.

Reinstatement of wearing courses shall match as nearly as practicable the colour or other
characteristics of the existing surface.

3.12 Internal Cleaning of Pipeline

Pipelines shall be cleaned of all dirt, debris, dust or other deposits by repeated hosing of
copious quantities of water on the pipe surface and simultaneously rubbing the surface with
gunny cloth to the satisfaction of Engineer-in-Charge. Cleaning with metal cleaning solution,
acid, wire brushes, scrappers or sand paper shall not be permitted.

The section of the pipeline once cleaned shall not be entered into for any purpose later.
Sufficient precaution shall be taken to prevent the ingress of any dirt, debris, or dust inside
the section. Failing this the section shall be cleaned again at the discretion of the Engineer-
in-Charge.

In the case of above ground pipeline, the length of the section to be taken up for cleaning
shall be decided in consultation with the Engineer-in-Charge from the point of view of
ventilation etc.

In case of buried pipeline a section, shall be taken up for cleaning after the work of back
filling around and over the pipeline is completed and the spiders have been removed from
inside with approval of Engineer-in-Charge.

During the pipe laying operation in the adjoining section, the Contractor shall take all
precautions to prevent ingress of water, debris, dirt, etc. in the cleaned section, failing which
the section shall be cleaned again at the discretion of the Engineer-in-Charge. When
deemed necessary by the Engineer-in-Charge suitable closures shall be provided at the
open end or the ends of the cleaned sections.

3.13 Hydraulic Testing of Pipeline.

Pipelines and fittings shall be subjected to hydraulic pressure tests in the presence of the
Engineer-in-Charge which shall comply with relevant IS specifications.

The Contractor shall equip with all plant, equipment, fittings and water necessary for the
hydraulic tests. The Contractor shall submit to the Engineer-in-Charge, well in advance of
the time of tests, details of his proposals.

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Test gauges shall be of approved manufacture having dials at least 200 mm diameter,
graduated such that the test pressure is at least 75% of the full scale reading shall be used.
As directed by the Engineer-in-Charge different gauges shall be supplied for different
pipeline sections. Two gauges shall be provided for the sole use of the Engineer-in-Charge
and shall remain in the Engineer-in-Charge possession for the duration of the Contract. All
gauges shall be dead weight tested and calibrated at the commencement of work and at
regular intervals as required by the Engineer-in-Charge.

The Contractor's arrangements for testing shall include a suitable means of quick installation
and removal of the Engineer-in-Charge’s gauges during testing.

3.14 Field Hydraulic Testing

The Sectional Hydraulic Test shall be carried out, after the pipeline section which has been
laid, joined and backfilled to a depth sufficient, to prevent floatation, but leaving the joints
exposed which have not been tested. The sections to be tested shall be to the approval of
the Engineer-in-Charge and shall be not longer than 20000 in or 500 m when either the
pipeline is laid adjacent to or underneath the carriageway or when section includes an air
valve chamber. The joints between each tested section shall be left until the pipeline has
passed the Test on Completion.

In addition to the above requirements the Contractor shall perform a hydraulic test on the
first 200 m length of pipeline to be laid under the Contract. This test shall be undertaken
within one month of the Contractor commencing the laying of pipes. Should the pipeline fail
the test or the Contractor fail to undertake the test, all laying and welding work shall come to
a halt until that section of pipeline passes a hydraulic test.

Each length of the pipeline to be tested shall be capped or blanked off at each end and
securely strutted or restrained to withstand the forces which will be exerted when the test
pressure is applied. Testing against closed valves will not be permitted. Washout valves
shall be fitted with blank flanges and these together with in-line valves shall be left open. Air
valves already fitted shall be permitted to function during the test.

Proposals for testing where thrusts on structures are involved, even where thrust flanges on
the piping are installed, shall be submitted, with the calculations of the forces to be carried,
to the Engineer-in-Charge for approval.

The method of filling the pipeline with water shall be approved by the Engineer-in-Charge.
The length under test shall be filled making certain that all air is displaced through an air
valve installed at the top of the blank flange situated at the high end of the line. The length
shall then remain under constant moderate pressure, 10 to 20 m head of water, for a period
of several hours until the pressure can be maintained without additional pumping.

The pressure shall then by slowly increased at a maximum rate of 1 bar per minute to the full
test pressure and pumping discontinued for 3 hours or until the pressure has dropped by 10
m, whichever occurs earlier. Thereafter pumping shall be resumed and continued until the
test pressure has been restored. The quantity of water pumped to restore the pressure shall
be the measure of leakage from discontinuation of pumping until its resumption.

The pipe length shall pass the test if the leakage is not more than 0.33 litres per mm
diameter per kilometre per 24 hours for each 100 m head of pressure applied.

Notwithstanding the satisfactory completion of the hydraulic test, if there is any discernible
leakage of water from any pipe or joint the Contractor shall, at his own cost, replace the pipe,
repair the pipe or re-make the joint and repeat the hydraulic test.

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No pipeline shall be accepted until the leakage on any length is not more than the rate of
leakage specified above and all sources of leakage have been rectified.

Pipelines shall be tested as above except where the Engineer-in-Charge issues such
instructions as are necessary for testing parts of the works that have been designed for
stresses limited by considerations other than those applying to the pipeline systems.

3.15 Test Pressures

Test pressures are to be measured in bars or in Kg/ cm 2 at the centre of the blank flange
situated at the lowest end of the pipeline under test. Pipeline test pressure shall be as per
specified below;

The field test pressure to be imposed should not be less than the maximum of the following:

 1.50 times the maximum sustained operating pressure

 1.50 times the maximum pipe line static pressure

 Sum of the maximum sustained operating pressure and the maximum surge
pressure

 Sum of the maximum pipeline static pressure and the maximum surge pressure

However minimum test pressure for all the reaches shall be 6.0Kg/cm2.

With above criteria’s and as per approved design Contractor shall calculate the required field
hydraulic test pressure. On the approval of the same field hydraulic tests shall be carried out.

3.16 Pipeline Disinfection

Upon completion of a newly laid pipeline, the pipeline shall be cleaned, disinfected and
dewatered as directed by the Engineer.

The internal surfaces of pipeline, specials and appurtenances shall be disinfected using
chlorine solution in accordance with procedure specified in IS: 5822. Alternative methods
may be adopted with the approval of the Engineer-in-Charge. The chlorinated water shall
stand in pipeline for a minimum period of 24 hours and all valves in the system shall be
operated twice during this period.

The chlorinated water shall be neutralized and disposed off as directed by Engineer-in-
Charge.

After final flushing and before the pipeline is placed into service, water samples shall be
collected and tested for bacteriological quality and shall not indicate the presence of Coli
forms. If the initial disinfection fails to produce satisfactory results, disinfection shall be
repeated until satisfactory samples are obtained.

3.17 Markings

Details like valve type, size, and number shall be painted on all valve chambers as directed
by the Engineer.

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In case of the pipeline laid above ground, details such as chain age, invert levels of pipe,
pedestal / saddle number, culvert number, anchor / thrust block number etc., shall be
suitably painted either on pipeline or the supporting structure in distinct colour.

4 DUCTILE IRON PIPES ANDSPECIALS:

4.1 General

In particular, the following standards, specified herein shall be referred. In all cases, the
latest revision of the codes shall be referred to. If requirements of specifications conflict with
the requirements of the codes and standards, this specification shall govern.

IS: 8329 Specification for Centrifugally Cast (spun) Ductile Iron pressure pipes for water, gas
and sewage specification.

IS: 1387 General requirements for supply of metallurgical

materials.IS: 1500 Methods for Brinell hardness test for metallic

materials.

IS: 9523 Ductile Iron fittings for pressure pipes for water, gas and sewage.

IS: 12820 Dimensional requirements. of rubber gaskets for mechanical Joints and push on
joints for use with cast Iron pipes and fittings for carrying water, gas and sewage.

ISO: 4179 Ductile iron pipes for pressure and no pressure- Centrifugal cement mortar lining -
General requirements.

ISO: 2531 Ductile iron pipes, fitting and accessories for pressure pipe lines.

IS: 12288 - Code of practice for use & laying of Ductile iron pipes.

4.2 Manufacturing:

4.2.1 General

a) DI pipes shall be systematically checked for any manufacturing defects by


experienced supervisors and a very high standard quality shall be maintained.

b) Owner / Engineer shall at all reasonable times have free access to the place where
the pipes are manufactured for the purpose of examining and testing the pipes and
for witnessing the test and manufacturing.

c) All tests specified either in this specification or in the relevant Indian Standards shall
be performed by the supplier/contractor at his own cost and in presence of
Owner/Engineer if desired. For this, sufficient notice before testing of the pipes shall
be given to Owner/Engineer.

d) If the test is found unsatisfactory, Owner/Engineer may reject any or all pipes of that
lot. The decision of Owner/Engineer in this matter shall be final and binding of the
contractor and not subject to any arbitration or appeal.

4.2.2 Materials

The general requirements relating to the supply of material shall be as per IS: 1387.

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4.2.3 Dimensions:

The internal diameter, thickness and length of barrel, dimensions of pipes shall be as per the
relevant tables of IS.8329/IS: 9523 for different class of pipes. The tolerances for pipes
regarding dimensions and deviations from straight line shall be as per relevant IS codes. The
standard weight of uncoated pipes and the permissible tolerances shall be per relevant IS
codes.

3.2.4 Testing

Mechanical Tests

Mechanical tests shall be carried out during manufacture of pipes as specified in relevant IS
codes. The results so obtained shall be considered to represent all the pipes and fittings of
different sizes manufactured during that period and the same shall be submitted to
Owner/Engineer. The method for tensile tests and the minimum tensile strength requirement
for pipes shall be as per relevant IS codes.

3.2.5 Coating

All DI pipes shall be delivered with internal lining and external coating. Coating shall not be
applied to any pipe unless its surface is clean dry and free from rust. All DI pipes shall be
mortar lined on internal surface as specified in ISO: 4179 and externally coated with
bituminous paint as specified in IS: 8329.

3.2.6 Marking

Marking shall be done as per IS: 8329.

3.2.7 Transporting of Pipes

All pipes manufactured in the factory and temporarily stacked in the Contractor's yard shall
be transported to the site of laying after cleaning them internally etc. The item of transport
covers the cost of loading in the factory, transporting to the site of laying or to stacking yard
selected byte Engineer in its vicinity and unloading and stacking them carefully in such a
manner that the material so kept is not easily disturbed or rolled away from the place of
stacking.

The loading in the factory shall be carried out by means of either a crane, gantry or shear
legs, so as not to cause any damage to the finished material. Similarly, while unloading and
stacking, great care shall be taken to ensure that the material is not damaged or dented. The
contrivances to be used for unloading will be different in different situations and in each case
the one approved byte Engineer shall be adopted.

The material stacked at site shall be jointly inspected by the Engineer and the Contractor
and defect or damage noticed shall be repaired to the satisfaction of the Engineer before
payment is admitted. The stacking ground, both in the Contractor's yard and at the site of
laying shall be selected in such a way as not to get waterlogged during monsoon. If this
cannot be done, the pipes shall be supported on sleepers to avoid contact with wet earth. As
explained in earlier paragraphs, materials such as pipes, tapers, etc. may be transported to
the site of laying as soon as the material is finished in all respects with the permission of the
Engineer.

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3.3 Laying of Ductile Iron Pipes and Fittings /Specials

3.3.1 Scope

The specification covers laying of DI pipes and DI fittings/specials for over


ground/underground works.

3.3.2 Carting &handling

Pipes and fittings/specials shall be transported from the factory to the work sites at places
along the alignment of pipeline as directed by Owner/Engineer and as specified by
manufacturer. Contractor shall be responsible for the safety of pipes and fittings/specials in
transit, loading/unloading. Every care shall be exercised in handling pipes and
fittings/specials to avoid damage. While unloading, the pipes and fittings/specials shall not
be thrown down from the truck on to hard surfaces. They should be unloaded on timber
skids with steadying ropes for by any other approved means. Padding shall be provided
between coated pipes, fittings/specials and timber skids to avoid damage to the coating.
Suitable gaps between pipes should be left at intervals in order to permit access from one
side to the other. In case of spigot socket pipes, care should be taken regarding orientation
of pipes while unloading. As far as possible pipes shall be unloaded on one side of the
trench only. All pipes shall be checked for any visible damage (such as broken edges,
cracking or spilling of pipe) while unloading and shall be sorted out for recantation. Any pipe
which shows sufficient damage to preclude it from being used shall be discarded. Dragging
of pipes and fitting/specials along concrete and similar pavement with hard surfaces shall be
prohibited.

3.3.3 Storage

Each stack of pipes shall contain only pipes of same class and size, with consignment or
batch number marked on it with particulars of suppliers wherever possible. Storage shall be
done on firm level and clean ground and wedges shall be provided at the bottom layer to
keep the stack stable. The stack shall be in pyramid shape or the pipes laid lengthwise and
crosswise in alternate layers. The pyramid stack shall be made for smaller diameter pipes for
conserving space in storing them. The height of the stock shall not exceed 1.5 m.
fittings/specials, shall be stacked under cover and separated from pipes. Rubber rings shall
be stored in a clean, cool store away from windows, boiler, electrical equipment and petrol,
oils or other chemicals. Particularly in the field where the rubber rings are being used it is
desirable that they are not left out on the ground in the sun or overnight under heavy frost or
snow conditions.

3.3.4 Laying

Excavation

Before excavating trench the alignment of pipeline shall be approved by Engineer. The
excavation shall be carried out in accordance with the relevant Standards. To protect
persons from injury and to avoid damage to property, adequate barricades, construction
signs, red lanterns and guards as required shall be placed and maintained during the
progress of the construction work and until it is safe for the traffic to use the roadways.

The relevant Indian standards and the rules and regulations of local authorities in regards to
safety provisions shall be observed. Suitable fencing shall be provided along the sides of
trenches and pits. The posts of fencing shall be of timber securely fixed in the ground not
more than 3 in apart and they shall not be less than 75 mm in diameter or less than 1.2 m
above surface of the ground. There shall be two rails, one near the top of the post and the

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Other about 450 mm above the ground and each shall be from 50 mm to 70 mm in diameter
and sufficiently long to run from post to post to which they shall be bound with strong rope.

The method of projecting rails beyond the post and tying them together where they meet will
not be allowed on any account. All along the edges of the excavation trenches a bank of
earth about 1.2m high shall be formed where required by Owner/Engineer for further
protection. The road metal and also the rubble packing shall first be stripped off for the whole
width of the trench/pit and separately deposited in such place or places as may be
determined by Owner/Engineer. During excavation, large stones and rubble shall be
separated and removed from the excavated soil and stacked separately.

The material from excavation shall be deposited on either side of the trench leaving
adequate clear distance from the edges of the trench and pit, or as may be necessary to
prevent the sides of the trench pit to slip or fall, or at such a distance and in such manner as
to avoid covering fire hydrants, sluice valves, manholes covers etc. and so as to avoid
abutting the wall or structure or causing inconvenience to the public and other service
organizations or otherwise as Owner/Engineer may direct.

Contractor shall take into account additional excavation if any as Owner/Engineer may
require in order locating the position of water pipes, drains, sewers etc. or any other works
which may be met with, in or about the excavation of trenches/pits while quoting the rates for
excavation of trenches/pits while quoting the rates for excavation. Such service lines if met
with during excavation shall be properly maintained by Contractor, by means of shoring,
strutting, planking over, padding or otherwise as Owner/Engineer may direct, and shall be
protected by the Contractor from damage during the progress of the work.

All precautions shall be taken during excavation and laying operations to guard against
possible damage to any existing structure/pipe line of water, gas, sewage etc. If the work for
which the excavation has been made is not completed by the expected date of the setting of
monsoon or the setting in of rain whichever is earlier, or before the day fixed by
Owner/Engineer for filling in any excavation on account of any festival or special occasion,
Contractor shall backfill such excavation and consolidate the filling. Utmost care shall be
taken to see that the width of the trench up to ground level is not more than as per required
standards.

If any extra width is provided in the pipe zone, the Contractor shall have to provide remedial
measures in the form of lime concrete or rubble masonry otherwise at the discretion and to
the satisfaction of Owner/Engineer. If rock is met with, it shall be removed to 15 cm below
the bottom of pipes and fittings/specials and the space resulting shall be refilled with
granular materials and properly consolidated. Bottom of trenches/pits shall be saturated with
water well rammed wherever Owner/Engineer may consider if necessary to do so.

Wherever a socket or collar of pipe or fitting/special occurs, a grip is to be cut in the bottom
of the trench or concrete bed to a depth of at least 75 mm below the bed of the pipe so that
the pipe may have a fair bearing on its shaft and does not rest upon its socket. Such grip
shall be of sufficient size in every respect to admit the hand all around the socket in order to
make the joint and the grip shall be maintained clear until the joint has been approved by
Owner/Engineer.

When welding is to be carried out with the pipes and specials in the trench, additional
excavation of not more than 60 cm in depth and 90 cm in length shall be made at joints in
order to facilitate welding.

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The excess excavated material shall be carried away from site of works to a place up to a
distance as directed by Owner/Engineer. This shall be done immediately so as not to cause
any inconvenience to the public or traffic. If the instructions from Engineer are not
implemented within seven days from the date of instructions to cart the materials and to
clear the site, the same shall be carried out by Owner/Engineer and any claim or dispute
shall not be entertained in this respect. The contractor shall make proper provision for
protecting the work by fencing, watch and ward lighting at right on in another manner as may
be directed by Engineer.

De-watering

During the excavation, if subsoil water is met with Contractor shall have to provide
necessary equipment and laborers for dewatering the trenches/pits by bailing out water or
water mixed with clay if pumping out subsoil water is found to be necessary; Contractor shall
provide sufficient number of pumps for the same. In both the above cases the excavation
shall be done to the required level and the pipes shall be laid to proper alignment and
gradient.

Contractor shall also make necessary arrangement for the disposal of drained water to
nearby storm water drain or in a pit if allowed by Owner/Engineer. In no case the water shall
be allowed to spread over the adjoining area. Before discharging this water into public
sewer/drain, Contractor shall take necessary permission from the local authorities.

Special foundation in poor soil

Where the bottom of the trench and sub grade is found to consist of material which is
unstable touch a degree that in the opinion of Owner/Engineer, it cannot be removed and
replaced with an approved material thoroughly compacted in place to support the pipe
properly, a suitable foundation for the pipes, consisting of piling, limbers or other materials, in
accordance with Relevant drawings and as instructed by Owner/Engineer shall be
constructed.

3.3.5 Repairs of Damaged Cement Mortar Linings

The mortar lining is strongly bonded with the pipe wall at all places. However, near the spigot
end due to rough handling of pipes or on account of incidental shock loads the mortar lining
may get damaged over a small area. Such damages if taken place shall be immediately
identified and repaired before installation. When repairing damaged cement-mortar-lining,
the following shall be adhered to:

I. Materials required

(a) Standard Cement (of the same quality as in the lining)


(b) Argillaceous Sand (size of coarse grains max. 1.6mm)
(c) Acrylic Emulsion for cement mortar
(d) Potable water

II. Preparation of the areas to be repaired

The damaged lining shall be removed with hammer and chisel, with due care without
disturbing the surrounding lining. Contractor shall supply protective spectacles for workmen
to prevent penetration of cement fragments into their eyes.

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III. Composition of repair mortar

The proportion of the materials will be as follows:

IV. Dry mixture of mortar:

One part of cement


One part of sand

V. Emulsions:

One part of acrylic emulsion, four parts of potable water Firstly the dry sand and the dry
cement shall be mixed separately. The acrylic emulsion shall be added to the water stirring
constantly(The container for acrylic emulsion should be resealed at once after use and
stored in a cool place) Small quantities of the treated water shall be gradually added to the
cement and sand mixture mixed thoroughly. Care shall be taken not to prepare too large
quantity of cement to avoid premature hardening.

Any loose sand from the areas to be repaired shall be brushed off. Moisten the areas under
repair and surrounding areas with water but avoid water accumulations. Mortar is to be
applied to cleaned areas and the lining surface is to be smoothened.

VI. After - Treatment of repaired areas

In order to ensure faultless hardening of cement it is recommended that the repaired area to
be covered temporarily with plastic sheet. In the case of diameters exceeding DN 300 it is
possible that after cutting off a piece the new spigot end has become out of round. On
account of the elastic and plastic properties of ductile iron, it is possible to re-round these
pipe ends. This shall be done on site by means of a hydraulic or mechanical jack, acting
from inside and pressing outwards or by using press acting from outside the pipe and
pressing inwards by the contractor.

In order to avoid damage to the cement mortar lining it is recommended that hardwood ads
of shape to match the pipes internal diameter be used. The re-rounding device should
remain in place during assembly. If necessary the manufacture may consulted for
resounding.

3.3.6 Thrust Blocks

Thrust blocks shall be provided, to counteract hydraulic thrust, at places wherever directed
by Engineer in charge

3.3.7 Jointing

Jointing for pipes and fittings/specials shall be done in accordance with the relevant
specifications for DI pipes and DI fittings and as recommended by manufacturer. The
recommended bolting torque to be followed for assembling flanges as specified in
manufacturer instructions.

3.3.8 Testing and Commissioning

Testing and commissioning of pipes shall be done in accordance with the relevant
specification.

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3.3.9 Backfilling

Trenches shall be backfilled with approved selected excavated material only after the
successful testing of the pipeline as directed by engineer. The tamping around the pipe shall
be done by hand or other hand-operated mechanical means. The water content of the soil
shall be as near the optimum moisture content as possible. Filling of the trench shall be
carried out simultaneously on both side of the pipe in such a manner that unequal pressure
does not occur.

Backfilling shall be done in layers not exceeding 30 cm. Each layer shall be consolidated by
watering, ramming, care being taken to avoid damage to the pipeline. Where timbers are
placed under the pipeline to aid alignment, these timbers shall be removed before backfilling.

3.3.10 Reinstatement of Road/Footpath

Reinstatement of road/footpath shall be done as per the requirements of local Authorities


and the relevant specifications after completion of work.

4.0 HDPE PIPES AND SPECIALS:

This specification covers the requirements for successfully designing, manufacturing,


supplying, laying, jointing and testing at works and site of High Density Polyethylene Pipes
used for water supply. Distribution network comprising of PE100, HDPE pipelines.

Applicable Codes

The manufacturing, testing, supplying, laying, jointing and testing at worksites of HDPE
pipes shall comply with IS: 4984-1995 all currently applicable statutes, regulations,
standards and amendments and others as follows;

Code No. Title / Specification

IS 4984 High Density Polyethylene Pipes for Water Supply


IS 2530 Methods of test for polyethylene molding materials and Polyethylene
compounds GRP Pipes, Joints and Fittings for use for Potable Water
Supply
IS 5382 Rubber sealing rings for gas mains, water main sand sewers.
IS 4905 Methods for random sampling
IS 7328 High density polyethylene materials for molding and extrusion
IS 7634 Laying & Jointing of Polyethylene (PE) Pipes

Colour

The color of the pipe shall be black.

Materials

The material used for the manufacture of pipes should not constitute toxicity hazard, should
not support microbial growth, should not give rise to unpleasant taste or odour, cloudiness or
discoloration of water. Pipe manufacturers shall obtain a certificate to this effect from the
manufacturers of raw material by any internationally reputed organization as per the
satisfaction of the Engineer-in-Charge in charge.

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Raw Material

(a) Resin used to manufacture the HDPE pipes shall be 100% virgin PE Black pre
compounded confirming to IS: 4984, IS: 7328 and ISO: 4427-2007 (latest
version).The resin proposed to be used for manufacturing of the pipes should also
comply with the following norms as per ISO 9080-2003 (latest version).

(b) The resin should also have been certified by an independent laboratory of
international repute like Bodycote / Slevan / Advantica for having passed 10,000
hour-long term hydrostatic strength (LTHS) test extrapolated to 50 years to show that
the resin has a minimum MRS of over 10MPa. There should not be any brittle knee
at80OC before 5000 hours. Internal certificate of any resin manufacturer will not be
acceptable.

(c) Certificate from reputed organization or Raw material supplier for having passed the
full scale rapid crack propagation test as per ISO 13478. High IS 9845 Method of
analysis for the determination of specific and/or overall migration of constituents of
plastics material and articles intended to come into contact with foodstuffs IS
10141Positive list of constituents of polyethylene in contact with food stuffs,
pharmaceuticals and drinking water. IS 10146 Polyethylene for its safe use in contact
with foodstuff, Pharmaceuticals and drinking water. Density Polyethylene (HDPE)
used for the manufacture of pipes shall conform to designation PEEWA-50-T- 003 of
IS 7328. HDPE conforming to designation PEEWA-50- T-003 of IS: 7328 may also
be used with the exception that melt flow rate (MFR) shall not exceed 1.10 g/10
min.In addition the material shall also conform to clause 5.6.2 ofIS:7328.

(d) The specified base density shall be between 940 kg/ m³ and 958 kg/ m³ (both
inclusive) when determined at 27°C according to procedure prescribed in IS 7328
The value of the density shall also not differ from the nominal value by more
than3kg/m³asper5.2.1.1ofIS7328.TheMFRofthematerialshallbebetween
0.20 and 1.10(both inclusive) when tested at 190°C with nominal load of 5 kgf as
determined by method prescribed in IS 2530. The MFR of the material shall also be
within ± 20percent of the value declared by the manufacturer.

(e) The resin shall be compounded with carbon black. The carbon black content in the
material shall be within 2.5 ±0.5% and the dispersion of carbon black shall be
satisfactory when tested as per IS: 2530.

Anti-oxidant

The percentage of anti-oxidant used shall not be more than 0.3 percent by mass of finished
resin. The anti-oxidant used shall be physiologically harming less and shall be selected from
the list given in IS: 10141

Reworked Material

No addition of Reworked/ Recycled Material from the manufacturer’s own rework material
resulting from the manufacture of pipes is permissible and the vendor is required to use only
100% virgin resin compound.

Maximum Ovality of Pipe

The outside diameter of pipes, tolerance on the same and ovality of pipe shall be as given in
table 2 of IS 4984. Ovality shall be measured as the difference between maximum outside
diameter and minimum outside diameter measured at the same cross section of the pipe,
at

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300 mm away from the cut end. For pipes to be coiled the ovality shall be measured prior to
coiling. For coiled pipes, however, re-rounding of pipes shall be carried out prior to the
measurement of ovality.

Detectability

HDPE Pipes shall be detectable when buried underground, by providing an insulated copper
wire having minimum diameter of 1.20 mm, firmly attached along the entire length of pipe.
To avoid theft or dislocation during handling / laying or earth refilling in trench, the insulated
Copper wire shall be firmly fixed on the outer surface of HDPE pipe at Pipe manufacturer’s
works through external adhesion or co-extrusion or any other appropriate method.

Length of Straight Pipe

The length of straight pipe used shall be more than 6 m or as agreed by Engineer-in-Charge
in charge. Short lengths of 3 meter (minimum) up to a maximum of 10% of the total supply
may be permitted.

Coiling

The pipes supplied in coils shall be coiled on drums of minimum diameter of 25 times the
nominal diameter of the pipe ensuring that kinking of pipe is prevented. Pipe beyond 110mm
dia shall be supplied in straight length not less than 6m.

Workmanship / Appearance

Pipes shall be free from all defect including indentations, delaminating, bubbles, pinholes,
cracks, pits, blisters, foreign inclusions that due to their nature degree or extent detrimentally
affect the strength and serviceability of the pipe. The pipe shall be as uniform as
commercially practicable in colour opacity, density and other physical properties as per
relevant IS Code or equivalent International Code. The inside surface of each pipe shall be
free of scouring, cavities, bulges, dents, ridges and other defects that result in a variation of
inside diameter from that obtained on adjacent unaffected portions of the surface. The pipe
ends shall be cut clearly and square to the axis of the pipe. IS 4984:1995 will be followed for
visual appearance.

Handling, Transportation Storage and Lowering of pipes

During handling, transportation, storage and lowering, all sections shall be handled by such
means and in such a manner that no distortion or damage is done to the section or to the
pipes as a whole. The following procedures should be followed so as to eliminate potential
damage to pipes and fittings and to maintain maximum safety during unloading, lifting and
lowering.

• Pipes must not be stored or transported where they are exposed to heat sources
likely to exceed60oC.

• Pipes shall be stored such that they are not in contact with direct sunlight, lubricating
or hydraulic oils, petrol, solvents and other aggressive materials.• Scores or
scratches to a depth of greater than 10% or more of wall thickness are not
permissible; any pipes having such defects should be strictly rejected.

• PE pipes should not be subjected to rough handling during loading and unloading
operations. Rollers shall be used to move, drag the pipes across any surface.

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• Only polyester webbing slings should be used to lift heavy PE (>315mm) pipes by
crane. Under no circumstances, chains, wire ropes and hooks are used on PE pipes.

• Pipes shall not be dropped to avoid impact or bump. If any time during handling or
during installation, any damage, such as gouge, crack or fracture occurs, the pipe
shall be repaired if so permitted by the competent authority before installation.

• During coiling care should be taken to maintain the coil diameter at or above the
specified minimum to prevent kinks. Coiling shall be done when the pipe attains the
ambient temperature from the extruder. In uncoiling or recoiling care should be taken
that sharp objects do not scour the pipe.

• When releasing coils, it must be remembered that the coil is under tension and must
be released in a controlled manner. The end of the coil should be retained at all
times, then the straps released steadily, one at a time. If the coil has bands at
different layers of the coil, then they should be released sequentially starting from the
outer layers. The amount of the energy locked up in the coil will depend on the size
of the pipe, the SDR of the pipe, and the size of the coil.

• Straight lengths should be stored on horizontal racks giving continuous support to


prevent the pipe taking on a permanent set• Bare coils shall be wrapped with hessian
cloth for long distance (> 300Kms) transportation. The truck used for transportation of
the PE pipes shall be exclusively used of PE pipes only with no other material loaded
– especially no metallic, glass and wooden items. The truck shall not have sharp
edges that can damage the Pipe.

• Pipes manufactured at factory are to be carried to the site of work directly or stacked
suitably and neatly along the alignment/road side/elsewhere near by the work site or
as directed by the Engineer-in-Charge.

• Damages during transit, handling, storage will be to the Contractor’s account and
replacement for such pipes has to be made by the Contractor without any extra cost
as directed by the Engineer-in-Charge.

Lowering, Laying of Pipes

• Each pipe shall be thoroughly checked for any damages before laying and only the
pipes which are approved by the Engineer-in-Charge shall be laid.

• While installing the pipes in trenches, the bed of the trench should be level and free
from sharp edged stones. In most cases, the bedding is not required, as long as the
sharp and protruding stones are removed, by sieving the dug earth, before using the
same a backfill material. While laying in rocky areas suitable bed of sand or gravel
should be provided. The fill to about 10 to 15 cm above the pipe should be fine sand
or screened excavated material. Where hard rock is met with, bed concrete M15,
15cm or 20cm thick sand bed as approved by the Engineer-in-Charge may be
provided

• As PE pipes are flexible, long lengths of fusion-jointed pipes having joints made
above ground can be rolled or snaked into narrow trenches. Such trenches can be
excavated by narrow buckets.

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• During the pipe laying of continuous fusion jointed systems, due care and allowance
should be made for the movements likely to occur due to the thermal
expansion/contraction of the material. This effect is most pronounced at end
connections to fixed positions (such as valves etc) and at branch connections. Care
should be taken in fixing by finishing the connections at a time the length of the pipe
is minimal (lower temperature times of the day.)

• For summer time installations with two fixed connection points, a slightly longer
length of PE pipe may be required to compensate for contraction of the pipe in the
cooler trench bottom.

• The final tie-in connections should be deferred until the thermal stability of the
pipeline is achieved.

• The flexibility of polyethylene pipes allows the pipe to be cold bend. The fusion
jointed PE pipe is also flexible as the plain Pipe. Thus the total system enables
directional changes within the trench without recourse to the provision of special
bends or anchor blocks. However, the pipe should not be cold bend to a radius less
than 25 times the OD of the pipe.

• The Installation of flanged fittings such as connections to sluice/air/gate valves and


hydrant tees etc. requires the use of stub ends (collars/flange adaptors complete with
backing rings and gaskets. Care should be taken when tightening these flanges to
provide even and balance torque.

• Provision should be made at all heavy fittings installation points for supports (such as
anchoring of the flange in the soil) for the flange joint to avoid the transfer of valve
wheel turning torque on to the PE flange joint.

• PE pipe is lighter than water. Hence care should be taken for normal installations
where there could be a possibility of flooding of the trench thus the trench shall be
kept free of water till the jointing has been properly done

• When flooded, some soils may lose cohesiveness, which may allow the PE pipe to
float out of the ground. Several design checks are necessary to see if groundwater
flotation may be a concern. Obviously, if the pipeline typically runs full or nearly full of
liquid, or if groundwater is always below the pipe, flotation may not be a significant
concern.

• However, weights by way of concrete blocks (anchors) are to be provided so that the
PE pipe does not float when suddenly the trench is flooded and the soil surrounding
the pipe is washed away. Thus site conditions study is necessary to ensure the
avoidance of flotation.

• Pipe embedment backfill shall be stone-free excavated material placed and


compacted to the 95% maximum dry density.

Jointing of Pipes

The pipe shall have Electro-fusion jointing system that shall provide for fluid tightness for the
intended service conditions.

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Bedding, Backfilling and Compaction

Bedding

In case of sandy strata no separate bedding is required. However the bottom face /trench
bed where pipe shall be placed shall be compacted to provide a minimum compaction
corresponding to 95% of maximum dry density. The pipe bedding should be placed so as to
give complete contact between the bottom of the trench and the pipe. The minimum cover
over buried pipe should be 1 m.

Back Filling

Backfilling should be placed in layers not exceeding 15cm thickness per layer, and should be
compacted to a minimum of 95% maximum dry density. The refilling should be done on both
sides of pipe together & height difference in earth fill on each side should not be more to
cause lateral movement of pipe. Most coarse grained soil are acceptable. This may
comprise of gravel or sand. However silty sand, clayey sand, silty and clayey gravel shall not
be used unless proposed to be used in conjunction with gravel or cleans and.

It is very important that the pipe zone backfill material does not wash away or migrate in to
the native soil. Likewise, potential migration of the native soil in to the pipe zone backfill must
also be prevented.

Heavy earth moving equipment used for backfilling should not be brought until the minimum
cover over the pipe is 90 cm in the case of wide tracked bulldozers or 120cm in the case of
wheeled roaders or roller compactors.

Compaction

Vibratory methods should be used for compaction. Compaction within distances of 15cm to
45 cm from the pipe should be usually done with hand tempers. The backfill material should
be compacted not less than 95% of maximum dry density.

Restoration

All excavated roads/streets are to be restored to its original condition by making the same as
previous.

Thrust Block

RCC thrust block should be suitably designed & provided at bends and at places of
reduction in cross section to take care of thrust

Fittings & Specials

All HDPE fittings/ specials shall be of minimum PN 6.0 or above Pressure Class unless
specified otherwise, fabricated in accordance with IS: 8360 (Part I& III). PE Injection molded
fittings shall be as per IS: 8008 (Part I to IX). All fittings/specials shall be fabricated or
molded at factory only. No fabrication or molding will be allowed at site, unless specifically
permitted by the Engineer-in-Charge. Fittings will be welded on to the pipes or other fittings
by use of Electrofusion process.

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Bends

HDPE bends shall be plain square ended conforming to IS: 8360 Part I & III Specifications.
Bends shall be molded.

Tees

HDPE Tees shall be plain square ended conforming to IS: 8360 Part I & II Specifications.
Tees may be equal tees or reduced take off tees. Tees shall be molded.

Reducers

HDPE Reducers shall be plain square ended conforming to IS: 8008 Part I & VII
Specifications. Reducer must be molded.

Flanged HDPE Pipe Ends

HDPE Stub ends shall be square ended conforming to IS: 8008 Part I & VI Specifications.
Stub ends will be welded on the pipe. Flange will be of slip on flange type as described
below.

Slip-On Flanges

Slip-on flanges shall be metallic flanges covered by epoxy coating or plastic powder coating.
Slip-on-flanges shall be conforming to standard mating relevant flange of valves, pipes etc.
Nominal pressure rating of flanges will be PN10.

Electro Fusion Tapping Saddle, Branch Saddle & Electro Fusion fittings:

a. All the Electro fusion fittings should be manufactured with top quality virgin
precompounded PE 100 resin which should be compatible with the distribution
mains.

b. The products shall comply with the requirements of EN 12201-3, EN 1555-3 or ISO
8085-3.

c. All the fittings shall be of SDR 11rating.

d. The fittings shall have the approval from any three Agencies like KIWA, DVGW, and
WRC-NSF, U.K. CIPET etc.

e. All the products shall be manufactured by injection molding using virgin compounded
PE 100 polymer having a melt flow rate between 0.2- 1.4 grams/10minutes and shall
be compatible for fusing on PE 100 distribution mains manufactured according to the
relevant national or international standards. The polymer used should comply with
the requirements of EN 12201-1.

f. Process voltage of all saddles must not exceed a maximum of 40volts.

g. The heating elements should be designed for fusion at any ambient


temperatures between -5 to +40 degree centigrade.

h. The heating coils contained in each individual saddle should be so designed that only
one complete process cycle is necessary to fully electro fuse the fitting to the
adjoining pipe or pipeline component as applicable. The heating coils shall be
terminated at terminal pins of4.0 or 4.7 millimeter diameter.

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i. No heating element shall be exposed and all coils are to be integral part of the body
of the fitting.

j. The EF tapping / branch saddles should be fixed by fixation device and shall be
achieved by external or integral clamping device.

k. The cutter should be designed in such a way that the cut coupon is not allowed to fall
into the pipeline and is retained inside the body of the cutter.

l. A limited path style fusion indicator acting for each fusion zone as visual recognition
of completed fusion cycle should be incorporated into the body of each fitting near
the terminals. The fusion indicators should not allow the escape of the molten
polymer through them during or after the fusion process.

m. All the sockets in the electro fusion fittings should include a method of tapping
controlling the pipe penetration (pipe positioner/stopper).

n. All the electro fusion products should be individually packed in transparent protective
bags to allow easy identification without opening the bag and must clearly indicate its
contents

o. The brand name, size, raw material grade, SDR rating and batch identification arête
be embedded as part of the injection molding process. Each fitting should also be
supplied with a Data Card or stickers with appropriate barcode as well as manual
setting information for data transfer purpose.

p. Installation and Fusion Jointing

The fusion jointing process is to be carried out is as per the procedure outlined in
theDVS2202 standard, if not available equivalent standards acceptable to employer.
A protocol for each fusion joint to be printed to ensure the joint process carried out is
error free. The electro fusion machine shall have the facility to record & make print for
each joint.

The precautions & measures as mentioned by electro fusion fittings/machine


manufacturer should be taken up rigorously while