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Project for Pollution Abatement of River Volume – 2- Employer’s Requirements
Construction of 75 MLD Bhairoba STP on DBO Basis, Including Rehabilitation of Kalyaninagar Intermediate
Pumping Stations (IPS)
Table of Content
13 Standard Specifications - Civil & Structural Works ....................................................... 1

13.1 General ................................................................................................................... 1
13.2 Demolition............................................................................................................... 5
13.3 Earthworks and Excavation..................................................................................... 7
13.4 Back-Filling and Filling .......................................................................................... 12
13.5 Concrete and Allied Works ................................................................................... 13
13.6 Piling Works .......................................................................................................... 62
13.7 Reinforcement ...................................................................................................... 77
13.8 Formwork.............................................................................................................. 85
13.9 Construction Tolerances ....................................................................................... 92
13.10 Structural Steel Work ............................................................................................ 99
13.11 General Architectural Specifications ................................................................... 104
13.12 Antitermite Treatment and Pesticides ................................................................. 142
13.13 Roads and Pavements........................................................................................ 146
13.14 Landscaping ....................................................................................................... 165
13.15 Piping Works ...................................................................................................... 167
14 Standard Specification – Mechanical.......................................................................... 195
14.1 General ............................................................................................................... 195
14.2 Pumps ................................................................................................................ 206
14.3 Screens .............................................................................................................. 227
14.4 Grit Removal System (Cyclonic / Vortex Type) ................................................... 238
14.5 Primary and Secondary Clarifiers........................................................................ 242
14.6 Air Blowers ......................................................................................................... 248
14.7 Diffuser ............................................................................................................... 256
14.8 Travelling Bridge Filters ...................................................................................... 262
14.9 Cloth Media Filters .............................................................................................. 262
14.10 Membrane Filtration System ............................................................................... 263
14.11 UV Disinfection System ...................................................................................... 263
14.12 Chlorination System ............................................................................................ 269
14.13 Sludge Thickener ................................................................................................ 283
14.14 Sludge Dewatering Units .................................................................................... 286
14.15 Gas Mixing System for Digesters ........................................................................ 293
14.16 Gas Blower ......................................................................................................... 296
14.17 Bio Gas Holder ................................................................................................... 297
Section VI-B: Employer’s Requirement ii Bid Document

14.18 Bio Gas Scrubbers (For H2S Gas Removal)........................................................ 299

14.19 Clean Gas Holder ............................................................................................... 300
14.20 Power Generation System and Heat Recovery System ...................................... 300
14.21 Digesters Sludge Heating System....................................................................... 311
14.22 Digestion Sludge Heat Exchange ....................................................................... 311
14.23 Digesters Mixing Equipment ............................................................................... 313
14.24 Hot Water Boiler for Digesters heating system .................................................... 314
14.25 Flare ................................................................................................................... 317
14.26 Ventilation and Odour Control ............................................................................. 318
14.27 Chemical Waste Tanks and Special Drainage System........................................ 322
14.28 Emergency Equipment (General) ........................................................................ 323
14.29 Standard Specification ........................................................................................ 327
14.30 Pipes, Specials and Fittings ................................................................................ 331
14.31 Valves, Penstocks and Sluice Gates................................................................... 334
14.32 Hoists and Lifting Equipment .............................................................................. 351
15 Standard Specifications – Electrical ........................................................................... 357
15.1 Codes and Standards ......................................................................................... 357
15.2 Regulations......................................................................................................... 357
15.3 Abbreviations ...................................................................................................... 357
15.4 Specification of Electrical Equipments ................................................................ 359
15.5 Solar Power Generation System ......................................................................... 412
15.6 Lighting System .................................................................................................. 413
15.7 Cabling System................................................................................................... 418
15.8 Cable Sealing System......................................................................................... 422
15.9 Earthing and Lightning Protection System .......................................................... 423
15.10 Public Address System ....................................................................................... 427
15.11 Automatic clean agent fire detection, alarm and suppression system ................. 429
15.12 Safety Equipment’s ............................................................................................. 431
15.13 Installation .......................................................................................................... 432
15.14 Substation........................................................................................................... 433
16 Standard Specification – Instrumentations & Control ............................................... 436
16.1 Introduction ......................................................................................................... 436
16.2 General ............................................................................................................... 436
16.3 System Completeness ........................................................................................ 437
16.4 Field Instrumentation and Control ....................................................................... 437
16.5 Instrumentation Design Criteria ........................................................................... 438
Section VI-B: Employer’s Requirement iii Bid Document

16.6 Electromagnetic Flow Meter................................................................................ 439

16.7 Thermal mass flow meter for gas (air) for continuous measurement of flow ........ 441
16.8 Rotameter ........................................................................................................... 443
16.9 Level Measurement and Control ......................................................................... 443
16.10 Pressure Instrumentation .................................................................................... 446
16.11 Temperature Instrumentation .............................................................................. 448
16.12 Temperature Switches ........................................................................................ 449
16.13 Strain-gauge Load Cell Weight Indicator and Transmitters ................................. 449
16.14 Analytical Instrumentation ................................................................................... 450
16.15 Laboratory Instruments ....................................................................................... 460
16.16 Associated Lab Equipment: ................................................................................ 466
16.17 Online Real Time Multi Parameters Continuous Monitoring System for Influent and
Treated Sewage Parameters for the STP’s ......................................................... 468
16.18 Particular Instrumentation, Control & Automation Requirements......................... 472
16.19 Approved Vendor/Manufacturer/Make List-Instrumentation ................................ 480
16.20 Approved Vendor/Manufacturer/Make List-Automation ....................................... 482
16.21 Supervisory Control and Data Acquisition System (SCADA) ............................... 483
Section VI-B: Employer’s Requirement iv Bid Document

13 Standard Specifications - Civil & Structural Works
13.1 General
13.1.1 Notes to the Standard General Technical Specification
This General Technical Specification shall apply for all works associated with the provision
of new, refurbished or updated parts of the Facilities.
The General Technical Specification forms an integral part of the Contract Documents and
should be used in conjunction with all the Volumes which form the Contract Documents
especially the detailed project requirements included within the Engineers Requirements,
which take precedence over the General Technical Specification. Samples of various
materials, fittings etc. proposed to be incorporated in the work shall be submitted by the
Contractor for approval of the Engineer before order for bulk supply is placed.
All works shall be carried out strictly as per detailed specifications whether actually
specified or not. If not specified the works shall be carried out as per directions of Engineer.
13.1.2 Specification Drawings
The site plan, drawings of the proposed work/plant are incorporated in tender documents.
These drawings are made for Tenderer’s guidance only.
The Contractor will have to submit detailed design as well as General Arrangement
drawings as well as structural drawings to the Engineer and obtain prior approval to start
the construction, erection and commissioning of civil, electrical and mechanical
components of the treatment plant.
Work shall be carried out by Contractor exactly in accordance with the Drawings marked
as Released for construction and approved by Engineer and as per the instructions of the
Engineer in writing.
13.1.3 Geo-Technical Studies
The bidders are free to visit and inspect the sites till the submission date for the purpose
of quoting and estimation with prior permission of Engineer. The Contractor shall carry out
geo-technical studies at their cost at the site and with prior permission of Engineer, from
approved soil consultant and the report should be furnished to the Engineer and should
approved by Engineer prior to start of structural design & drawings. Engineer accepts no
responsibility, whatsoever for inferences drawn from this data and the Contractor is to
satisfy Engineer on his own responsibility as to the extent to which this information
represents the conditions to be encountered.
13.1.4 Materials
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.
Section VI-B: Employer’s Requirement 13-1 Bid Document

Part 13: Standard Specifications - Civil & Structural Works
All materials shall be new and of the kinds and qualities described in the Contract and shall
be approved by the Engineer.
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.
13.1.5 Samples and Tests of Materials
The Contractor should submit test certificates of the materials before unloading on the site.
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 and at a laboratory approved by the Engineer.
The Contractor should give Engineer seven days’ notice in writing about the date on which
any of the materials will be ready for testing or inspection at the supplier's premises or at
a laboratory as approved by the Engineer. The Engineer shall attend the test at the
appointed place within 7 days of the said date on which the materials are expected to be
ready for testing or inspection according to Contractor, failing to which the test may
proceed in his absence unless instructed by Engineer to carry out such a test on a mutually
agreed upon date in his presence. The Contractor shall in any case submit to the Engineer
within seven days of every test such number of certified copies (not exceeding six) of the
test readings 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 particularly as to the
provisions under the conditions of contract.
The provisions of this clause shall also apply to materials supplied under any nominated
subcontract.
In any case the Contractor shall not use any material without prior testing and clearance
by the Engineer. In case such material is used, this will be liable for rejection either partly
or fully.
If required rejected material shall be marked and stockpiled separately; and such rejected
material shall be taken out within a week from construction site.
The cost of the material testing at the supplier premises and as on the site shall be borne
by the Contractor and without prior testing and clearance of the Engineer, the materials
should not be used for the work.
13.1.6 List of important Indian Standards
The following list includes various Indian Standards which are important and are referred
to in the general specifications and used in construction works. These standards are to be
strictly adhered to unless otherwise is applicable in the relevant context. These standards
are to be followed both in respect of materials and construction of civil engineering works
included in the tenders.
Though the list of Indian Standards includes the year of Publication of the standard, it may
not in all cases be the latest. It is obligatory that only the latest edition of the standard is
referred to and followed, along with all amendments and revisions issued with respect to

the standard under consideration. This list is not exhaustive but contains only the
standards that are very frequently used on the construction works. If a standard exists for
a particular item of material or equipment or code of practice the same shall be followed
whether the same is included in this list, specifications, other parts of the tender documents
or not. Some Indian Standards are referred to in the specifications/ drawings/ other parts
of the tender documents and they are supplementing this list if they do not find a place in
the list.
Table 13-1 List of IS
Sr. IS Code No.

Title
No. /Year
1 153-1950 Ready mixed paint, spraying, stoving, lead free, for general
purposes
2 171-1985 Cotton and cotton regenerated cellulosic fibre blended grey
yarn
3 2062-1984 Specification for Structural Steel (Fusion Welding Quality)
4 269-1976 Ordinary and low heat Portland cement
5 383-1970 Coarse and fine aggregates from natural sources for
concrete
6 432(part1)-1982 Mild steel and medium tensile steel bars
7 455-1976 Portland slag cement
8 456 Code of practice for plain and reinforced cement concrete
9 458-1971 Concrete pipes
10 516-1959 Methods of test for strength of concrete
11 651-1981 Salt-glazed stoneware pipes and fittings
12 783-1985 Code of practice for laying of concrete pipes
13 784-1978 Pre-stressed concrete pipes
14 800-1984 Code of practice for general construction in steel
15 816-1969 Code of practice for use of metal arc welding for general
construction in mild steel
16 1038-1983 Steel-doors, windows and ventilators
17 1077-1986 Common burnt clay building bricks
18 1199-1959 Methods of sampling and analysis of concrete
19 1200 (part1-26) Method of measurement of building and civil engineering
works
20 1363 (part 1-3) Hexagon head bolts, screws and nuts of product grade C
21 1367 Technical supply conditions for threaded steel fasteners
22 1477 (part 1-2) Code of practice for painting of ferrous metals in buildings
23 1542-1977 Sand of plaster
24 1726 Cast iron manhole covers and frames
(part 1, 2 & 4)
25 1786-1985 High strength deformed steel bars and wires for concrete
reinforcement

Sr. IS Code No.

Title
No. /Year
26 2074-1979 Ready mixed paint, air drying red oxide zinc chrome priming
27 2116-1980 Sand for masonry mortars
28 2212-1962 Code of practice for brickwork
29 2250-1981 Code of practice for preparation and use of masonry mortars
30 2339-1963 Aluminium paint for general purpose in dual container
31 2386 (part I-VIII) Methods of tests for aggregate for concrete
32 2502-1963 Code of practice for bending and fixing of bars for reinforced
concrete
33 2720(part IV, VIII) Methods of test for soil
34 3006-1979 Chemically resistant glazed stoneware pipes and fittings
35 3370 (part I-IV) Code of practice for concrete structures for the storage of
liquids
36 3696 Safety code for scaffolds and ladders
37 3764-1966 Safety code for excavation work
(part 1-2)
38 4082-1977 Recommendations on stacking and storage of construction
materials at site
39 4111 (part 1-4) Code of practice for ancillary structures in sewerage systems
40 4127-1983 Code of practice for laying of glazed stone ware pipes
41 6248-1979 Metal rolling shutters and rolling grills
42 6909-1973 Super sulphated cement
43 7293-1974 Safety code for working with construction machinery
44 7969-1975 Safety code for handling and storage of building materials
45 Code National Building Code of India
46 4014 Code of practice for steel tubular scaffolding.
47 5121 Code of practice for deep foundation
48 2911-1980 Code of practice for design and construction of pile
Part III & IV foundation
49 3764 Safety code for excavation work
50 4082 Recommendations on stocking & storage material at site.
51 7293 Safety code of working with construction machinery.
52 3114 Code of practice for laying CI pipes
53 5822 Code of practice for laying of welded steel for pipes
54 7364 Plastic pipe work for potable water supply (part I-III)

13.1.7 Abbreviations
mm Millimetre CI Cast Iron

cm Centimetre GI Galvanized Iron
m Metre GSW Glazed Stone Ware
km Kilometre BBCC Burnt Brick Cement Concrete
sq.m Square Metre RCC Reinforced Cement Concrete
cum. Cubic Metre PCC Plain Cement Concrete
M.T. Metric Ton Wt Weight
SWG Standard Wire Gauge kg Kilogram
R.M. Running Metre I.D. Internal Diameter
Nos. Numbers C.M. Cement Mortar
MS Mild Steel IS Indian Standards
M.D Metre Depth of Manhole SS Stainless Steel
13.1.8 Design Standards
All designs shall be based on the latest International or Indian Standard (IS) Specifications
or Codes of Practice. The design standards adopted shall follow the best modern
engineering practice in the field based on any other international standard or specialist
literature subject to such standard reference or extract of such literature in the English
language being supplied to and approved by the Engineer. In case of any variation or
contradiction between the provision of the IS Standards or Code and the specifications
given with the submitted tender document, the provision given in the Specification shall be
followed.
13.1.9 Foundation
The minimum depth of foundations for all structures, equipment’s buildings and frame
foundations and load bearing walls shall be as per IS: 1094.
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 Engineer.
13.2 Demolition
13.2.1 General
Demolition work includes, but is not necessarily limited to, the following tasks:
1 Demolition, removal and disposal of existing structures, mechanical and electrical
installations, pipelines and other buried structures and services described in the
Employer’s Requirements at the project sites or included within the project working
areas.
2 Demolition, removal and disposal of those structures, mechanical and electrical
installations, pipelines and other buried services encountered during excavation which
are not required to be retained for future use.
3 Temporary and/or permanent relocation of existing utilities and other buried services
to be retained for future use which are either encountered or affected by demolition
works.

4 Temporary and permanent support and protection of existing utilities and other buried
services affected by or encountered during demolition works which are to be retained
for future use.
5 Temporary and permanent support for existing above ground and buried structures
affected by or encountered during demolition works.
6 Filling, backfilling and compaction to grade level further to demolition and removal. The
Contractor shall complete, at a minimum, the tasks included in the following
paragraphs in the execution of dismantling, demolition and removal of the required
items and shall submit a detailed execution and safety plan to the Engineer for
inspection prior to commencing his activities.
13.2.2 Existing Services, Utilities and Structures
Work shall be carried out in such a way that no damage is caused to the adjoining utilities,
work or property and precautions shall be taken to minimize dust-nuisance.
13.2.3 Temporary Fencing and Hoarding
The Contractor shall barricade around the perimeter of the safe working area required for
demolition and shall demonstrate to the Engineer that the extent of this area fulfils safety
requirements.
The Contractor shall provide hoarding as required and to the satisfaction of the Engineer,
to protect all those who may be affected by those works.
13.2.4 Demolition and Reinstatement
The Contractor shall demolish the required structures in accordance with the detailed
execution plan submitted to the Engineer.
Dismantling shall be commenced in a systematic manner. All materials which are to be

dismantled at height, such as during the demolishing of roofs, shall be carefully lowered
to the ground and not dropped.
The Contractor shall remove and dispose of demolition waste off-site, in accordance with
the regulatory requirements.
The Contractor shall backfill excavated areas and voids due to demolition or the removal
of materials, immediately. Backfilling and compaction shall be suitable for the final
requirements at that location. As a minimum, backfilling shall include compacted hardcore
to 300 mm below grade level and granular fill or topsoil to grade as appropriate.
13.2.5 Removal of Debris
Any serviceable material obtained during dismantling or demolition shall be separated out
and stacked properly. All unserviceable materials shall be disposed of from the site and
the site left in a neat and orderly condition, to the satisfaction of the Engineer and in
accordance with prevailing regulations.
13.2.6 Safety
Following precautions should be taken by the Contractor before any demolition work is
commenced:

i. All roads and open areas adjacent to the work site shall either be closed or suitably
protected;
ii. No electric cable or apparatus which is liable to be a source of danger other than a
cable or apparatus being used by an operator shall remain electrically charged;
iii. The Contractor shall take all practical steps to prevent danger to persons employed
from risk of fire or explosion, and the Contractor shall ensure that no part of a building
shall be so overloaded with debris or materials as to render it unsafe.
iv. The Contractor shall barricade around the perimeter of the safe working area required
for demolition and shall demonstrate to the Engineer that the extent of this area fulfils
safety requirements.
v. The Contractor shall provide hoarding as required and to the satisfaction of the
Engineer, to protect all those who may be affected by those works.
13.2.7 Treatment
All the demolition areas shall be rendered clean of all debris. After the removal of any
doors, windows chowkhats etc. and unless otherwise required, the sides of jambs, sills,
soffits etc. shall be plastered in 1:3 cement mortar with neeru finish to render sides,
corners, edges etc. true and square.
13.2.8 Asbestos Based Materials
Asbestos based materials may be present in buildings to be demolished under this

contract.
If any suspected asbestos based materials are discovered during demolition work this shall
be reported immediately to the Engineer.
Removal of asbestos based materials shall be carried out by a specialist, licensed sub-
contractor prior to any other works starting in the location
13.3 Earthworks and Excavation
13.3.1 Relevant IS Codes
IS: 1200 : Method of Measurement for Building Works

IS: 3764 : Safety code for Excavation Work
IS: 3385 : Code of practice for measurement of civil engineering works
IS: 2720 : Part II - Determination of Moisture Content
: Part VII - Determination of Moisture content dry density relation using light
compaction
: Part VIII - Determination of Moisture Content Dry Density using heavy
compaction
: Part XXVIII - Determination of Dry Density of soils, in place, by the sand
replacement method
: Part XXIX - Determination of Dry Density of soils, in place, by the core
cutter method.

13.3.2 Site Clearance
Before the earthwork is started, the areas coming under cutting and filling shall be cleared
of all obstructions, loose stones, shrubs, vegetation, grass, brush-wood, trees and saplings
of a girth up to 30 cm. measured at a height of one metre above ground and rubbish
removed from the area under clearance. The roots of trees shall be removed to a minimum
depth of 60 cm below ground level, or a minimum of 30cm below formation level whichever
is lower and the hollows filled up with compacted earth.
The trees with a girth above 30 cm at a height of one metre above ground shall only be
cut after permission from tree authority is obtained in writing.
Any useful materials obtained from the site will remain the property of the Employer and
shall be properly protected and stored. The Contractor shall dispose of other materials off
site.
13.3.3 General Excavation
Excavations shall be prepared with shallow side slopes to minimise the risk of slope failure.
Where this is not possible and the depth exceeds 0.6m then the trench slopes must be
stabilised. Prior to man entry into the excavation the Contractor must ensure the
excavation is stable. Further checks should be made following periods of rainfall or when
excessive loadings occur within close proximity to the excavation.
No excavated material shall be placed, even temporarily, nearer than three metres to the
outer edge of an excavation.
The removal of obstructions that would interfere with the proper execution and completion
of the work shall conform to the correct lines and grades or be limited generally to 60 cm
beyond the outer limit of the structure. It shall be the Contractor’s responsibility to provide
all required pumping, ditching or other approved measures for the removal or exclusion of
water from excavations.
The Contractor shall notify the Engineer before any ground is disturbed and shall conduct
a ground level survey. The ground levels shall be taken at 5 to 15 metres intervals in
uniformly sloping ground and at closer distances where local mounds, pits or undulations
occur. The ground levels shall be recorded in field books and plotted on plans, which shall
be signed by the Contractor and the Engineer, before the earth work commences.
The excavations shall be carried out systematically. No under-pining or undercutting will

be allowed. The bottom and sides of excavation shall be dressed to proper levels, slopes,
steps, cambers etc. by removing high spots and filling and thoroughly as necessary.
The width of excavations shall generally be of the width of the mud mat concrete and depth
as required by the design and according to availability of the desired bearing capacity of
soil below. The minimum depth of foundations for all structures, equipment, buildings and
frame foundations and load bearing walls shall murum. be 1.50 m below average ground
level, whether the foundation is in soil or in For any excavation, if taken below the required
depth and level, the Contractor shall fill such over-cut to the specified level with 1:4:8
cement concrete in the case of all types of soils and with 1:2:4 cement concrete in the
case of soft or hard rock.
The Contractor shall provide adequate ventilation and efficient apparatus to keep all
excavation trenches, tunnels and heading structures, sewers and manholes free from all

noxious gases and he shall take precautions to ascertain that they are in a safe condition
before allowing workmen to proceed.
After the excavation is completed, the Contractor shall notify the Engineer to that effect
and no further work shall be taken up until the Engineer has approved the depth and
dimensions and also the nature of the foundation material. Levels and measurements of
the excavation shall also be recorded prior to taking up any further work.
13.3.4 Lead
Lead for deposition of the excavated materials should be as per the instructions by
Engineer. For the purpose of measurement of lead, the area to be excavated or filled or
area in which excavated material is to be deposited /disposed of shall be divided into
suitable blocks and for each of the blocks, the distance between centrelines shall be taken
as the lead which shall be measured by the shortest straight line route on plan and not the
actual route taken by Contractor. No extra compensation is admissible on the grounds that
the lead including that for borrowed material had to be transported over marshy or kaccha
land route.
13.3.5 Classification of Earth Works
The earthwork shall be classified under the following main categories:

1) All types of soils, murum, boulders.
2) Soft rock.
3) Hard rock.
13.3.5.1 All types of soils, murum, boulders
This includes earth, murum, top deposits of agricultural soil, reclaimed soil, clay, sand or
any combination thereof and soft and hard murum, shingle etc. which is loose enough to
be removed with spades, shovels and pick axes. Boulders of not more than 0.03 Cum in
volume found during the course of excavation shall also fall under this classification.
13.3.5.2 Soft rock
This shall include all materials which are rock or hard conglomerate, all decomposed
weathered rock, highly fissured rock, old masonry, boulders bigger than 0.03 m3 in volume
but not bigger than 0.5 m3 and other varieties of soft rock which can be removed only with
pick axes, crow bars, wedges and hammers with some difficulty.
13.3.5.3 Hard Rock
This includes all rock occurring in masses, boulders having approximate volume of more
than 0.5 m3 plain or reinforced cement concrete, which can best be removed by chiselling
and wedging.
The excavation of hard rock shall be done by chiselling and wedging or any other agreed
method. Blasting shall not be allowed on this project.
All the excavated hard rock obtained shall be stacked properly and neatly by the Contractor
as approved by the Engineer.

13.3.6 Excavation Side Slopes
Loose soil or boulders shall be removed from the sides of the trenches before workmen
shall be allowed into the excavation and the trench sides shall be stabilized with screening
or other methods approved by the Engineer.
13.3.7 Undercutting of Adjacent Works
In no case shall the Contractor undercut the foundations of adjacent facilities. Should such
a situation be envisaged or develop the Contractor shall provide protection measures as
necessary to ensure the safety of the adjacent facility.
The Engineer shall be given every opportunity to review the methods adopted by the
Contractor and where he requires, Contractor shall satisfy the Engineer of the adequacy
of the methods employed.
13.3.8 Storage and Transport
Materials suitable for re-use obtained from the excavation shall be properly stored, as
approved by the Engineer, and shall remain the property of the Employer.
Materials shall be stored in a convenient place that will not obstruct the free movement of
materials, workers and vehicles or encroach on the area required for constructional
purposes. Materials shall be used to the extent required to completely backfill excavations
to the finished ground level. Surplus and unsuitable materials shall be disposed of off-site.
13.3.9 Excess excavation to be made good
The Contractor, at his own expense, shall, if directed, remove from the Site all excess
material resulting from excess excavation and shall make good the same with such kind
of fill material or in such class of concrete as may be reasonably required by the Engineer
having regard to the circumstances.
Where ordered by the Engineer, top soil shall be stripped to such depths and over such
areas as he may direct, as a separate operation prior to any further excavation, which may
be required.
13.3.10 Shoring
The Contractor shall be responsible for the design of shoring for the proper retaining of the
sides of trenches, pits etc. with due consideration to any traffic or other superimposed
loads. Shoring shall be of sufficient strength to resist the pressure and ensure safety from
slips and to prevent damage to work and property and injury to persons. Any shoring shall
be removed after the items for which it is required are completed. The slipped material
shall be removed and dressed to a modified stable slope.
Where the Contractor proposes and is permitted by the Engineer to perform excavations
with sloping faces (other than slope excavations shown on the Drawings or required as
permanent features of the Works) and without shoring, the excavated faces shall be to
stable slopes and heights.
13.3.11 Disposing Excavated Material
Materials suitable for re-use obtained from the excavation shall be properly stored, as
approved by the Engineer, and shall remain the property of the Employer. Materials shall

be stored in a convenient place that will not obstruct the free movement of materials,
workers and vehicles or encroach on the area required for constructional purposes.
Materials shall be used to the extent required to completely backfill excavations to the
finished ground level. Surplus and unsuitable materials shall be disposed of off-site. The
cost of royalties and other charges shall be borne entirely by the Contractor.
13.3.12 Dewatering
All excavations shall be kept free of water. Grading in the vicinity of excavations shall be
controlled to prevent surface water running into excavated areas. The Contractor shall
remove by pumping or other means approved by Engineer any water inclusive of rain water
and sub-soil water accumulated in excavation and keep all excavations de-watered until
the foundation work is completed and back filled. Sumps made for dewatering must be
kept clear of the excavations/trenches required for further work. Method of pumping shall
be approved by Engineer; but in any case, the pumping arrangement shall be such that
there shall be no movement of sub-soil or blowing in due to differential head of water during
pumping.
Pumping arrangements shall be adequate to ensure no delays in construction.
When there is a continuous inflow of water and quantum of water to be handled is

considered in the opinion of Engineer, as large, well point system: Single-stage or Multi-
stage shall be adopted. Contractor shall submit to the Engineer his scheme of well pointing
system including stages, the spacing, number and diameter of well points, headers etc.
and the number, capacity and location of pumps for approval.
The rates for excavation are inclusive of dewatering by any means and no extra payment
is allowed for excavation in wet condition.
13.3.13 Safety
All the Earthwork and Excavation work shall be carried out in accordance with the safety
codes and instructions of the Engineer.
13.3.14 Local Rules and Regulations
The Contractor shall familiarize himself with the local rules and regulations governing the
excavation, quarrying operations, etc. and the work shall be carried out strictly in
accordance with rules and regulations, if any. Whenever a quarry is required to be opened
in connection with the execution of work covered under this Contract, the Contractor shall
investigate that it shall yield stones and other materials such as sand, murum; soil etc. of
approved quality and shall satisfy him as to the availability in desired quantity. He shall
supply necessary quantity of sand, stone, metal aggregate etc. to the Engineer for carrying
out tests as desired by the Engineer and well in advance of its use so as to carry out tests
and to get approval. The cost of opening and operating the quarry & royalties and ant other
charges shall be borne entirely by the Contractor.
The Contractor shall obtain necessary permission from the concerned authorities before
opening the quarry. In case of quarries in private land on payment of whatever charges as
may be due to the owner.

13.4 Back-Filling and Filling
13.4.1 Material
Fill material shall be free of rubbish, roots or debris of any sort. Boulders, rock or concrete
fragments over 100 mm in size shall not be present in backfill material. The fill material
shall be subject to the approval of the Engineer.
After carrying out required tests Engineer reserve the right to reject such material which
does not meet the specifications requirements or unsuitable for the purpose for which it is
intended.
Approved fill shall consist of suitable earth or granular material that has been retained from
excavations, taken from designated borrow areas or been hauled from an approved off-
site source. This material will be acceptably dry, free from roots, large stones, boulders or
large broken rocks, refuse, vegetable matter, topsoil, silt or debris.
All other materials not specifically described but required for proper completion of
the work of this section, will be subject to the approval of the Engineer.
The Contractor shall reserve, separate and stockpile suitable excavated materials for use
in backfilling later. If the Engineer deems the native material to be unsound for the purpose
of backfill and an adequate amount of suitable material cannot be so collected, or if the
Contractor fails to collect and preserve the requisite quantity, the Contractor shall furnish
the additional quantity required. The additional material shall be natural sand, gravel or
crushed murum and shall be readily incorporated in a 100 mm lift and containing not more
than 25% by weight of material passing a No. 200 sieve. If a portion of the excavated
materials is found to be unsuitable for use as backfill, the Contractor shall provide suitable
material from another source.
13.4.2 Execution
The use of stones, rocks or concrete fragments of more than 100 mm in their greatest
dimension shall not be permitted in any trench backfill and stones, rock or concrete
fragments larger than 60 mm shall not be permitted in the backfill within 300 mm of the
pavement sub grade or within 300 mm of any utilities.
Some backfilling may have to be carried with sand, as approved by the Engineer. The
sand used shall be medium grain, clean, sharp, angular, hard and durable, free from clay,
mica and soft flaky pieces and free from other impurities. Sea sand shall not be used
except under special circumstances. All sands must be well washed and cleaned before
use.
Sand fill shall be kept flooded with water for 24 hours to ensure maximum consolidation.
The surface of the consolidated sand shall be dressed to the required level or slope.
Construction of floors or other structures on sand fill shall not be started until the Engineer
has approved the fill.
Backfilling work shall be suspended at any time when satisfactory compaction results
cannot be obtained due to rain, or other adverse conditions in the field. The surfaces of
any fill shall be maintained with a slope at all times to provide proper surface drainage.
Materials shall be compacted in maximum 300 mm layers and shall be of the proper
moisture content before compacting to facilitate obtaining the required compaction.

Temporary planking and formwork etc, shall be removed as backfilling progresses to avoid
the formation of voids.
Excavated foundations shall be inspected and approved by the Engineer before

proceeding with further work, including placing of any mud mat, reinforcing steel etc.
Complete final grading at grassed or seeded areas shall be to within 50 mm.
The Contractor shall repair damage and correct deficiencies that may result from the
settlement of backfilled areas.
13.4.3 Site Grading
Generally, site grading shall include the grading of un-surfaced areas to the final landscape
profile with due allowance for topsoil as approved by the Engineer. The grading shall
ensure that the ground profile slopes away from the structures and does not create
ponding. The site grading shall be subject to the approved by the Engineer before any
landscaping is commenced.
Fill for site grading shall be placed in 300 mm layers and compacted to 90% SPD.
Imported fill material shall be used if there is insufficient excavated material on the site.
Ditches and swales shall include trim, grade and slope ditches and swales, to the
satisfaction of the Engineer.
13.4.4 Roads and Parking Areas
The backfill in areas under roads and parking areas shall be filled to the underside of the
sub-base using approved granular fill and compacted in layers of 150 mm to 98% SPD. In
areas adjacent to structures thinner layers may be required to suit lighter compaction
equipment.
In road cut sections, unsuitable material (silt, humus, topsoil etc) shall be excavated and
replaced to the level of the sub-base with approved granular fill, ensuring that the minimum
excavation in cut sections extends to the depth of the road base.
13.4.5 Rain Water Discharge
Grading in the vicinity of excavation shall be such as to exclude rain/surface water draining
into excavated areas. Excavation shall be kept clean of rain and such water as the
Contractor may be using for his work by suitably pumping out the same at no extra cost to
the Owner. The scheme for pumping and discharge of such water shall be approved by
the Engineer.
13.5 Concrete and Allied Works
13.5.1 General
The quality of materials and method and control of manufacture and transportation of all
concrete work irrespective of mix, whether reinforced or otherwise shall conform to the
applicable portions of this specification.
The Engineer-in-Charge shall have the right to inspect the source/s of material/s, the layout
and operation of procurement and storage of materials, the concrete batching and mixing
equipment, and the quality control system. Such an inspection shall be arranged and
Engineer approval obtained, prior to starting of concrete work. However, this shall not

relieve the Contractor with any of his responsibilities and all the materials, which do not
conform to the specifications, will be rejected.
The liquid retaining structures unless otherwise mentioned will be in minimum M 30

grade.
The Contractor will maintain all registers and formats for quantity qualitative and
quantitative measures of all concrete works on daily basis of steel consumed and
concreting done updated on daily basis.
Liquid Retaining structures shall be construed to mean any structure of which any part
contains water or other process liquids, or which are designed or intended to protect
spaces from ground water.
13.5.2 Materials
13.5.2.1 General
The quality of material and method and control of manufacture and transportation of all
concrete work irrespective of mix; whether reinforced or otherwise shall conform to the
applicable portions of this specification.
The Engineer shall have the right to inspect the sources of materials, the layout and
operation of procurement and storage of materials, the concrete batching and mixing
equipment and the quality control system. Such an inspection shall be arranged and the
approval of the Engineer obtained, prior to starting any concrete work.
The ingredients to be used in the manufacture of standard concrete shall consist solely of
a standard type Portland/Portland pozzolana cement, clean sand, natural coarse
aggregate, clean water, ice and admixtures if specially called for.
Where walkways or platforms are to be made of concrete, the walkways/platforms shall

be designed and sized to suit with not less than 1m clear space between the handrails.
13.5.2.2 Storage
All materials shall be stored in the required manner immediately upon delivery to the site.
It will be the responsibility of the Contractor to provide and maintain requisite stocks,
handle the materials with care and store them in such a manner that the materials will
remain fresh for use at the appropriate time.
Cement shall be stored in silos or in dry weather proof and well ventilated structures the
floors of which shall be at least 450 mm above ground level with adequate precautions to
prevent moisture absorption. The storage arrangements shall be subject to the approval
of the Engineer and shall provide easy access for inspection. The different consignments
shall be identifiable and shall be utilized in the order in which they are received at site or
as instructed by the Engineer.
Aggregates shall be so stored that different specified sizes are kept separate and protected
against contamination by soil or other impurities. Adequate storage facilities shall be
provided to prevent the possibility of intermixing of the different sizes of aggregates.

The use of wet fine aggregates shall be permitted if the moisture content is uniform and
after such content is accurately determined to adjust the batching and the water content
of the proposed mix. Wherever possible, the fine aggregate shall be kept dry.
All coarse and fine aggregates shall be stacked separately in stock piles in the material
yard near the work site in bins properly constructed to avoid inter mixing of different
aggregates. Contamination with foreign materials and earth during storage and while
heaping the materials shall be avoided. The aggregate shall be of specified quality, not
only at the time of receiving at site but also at the time of loading into mixer. Rakers shall
be used for lifting the coarse aggregate from bins or stock piles. Coarse aggregate shall
be piled in layers not exceeding 1.00 metre in height to prevent coning or segregation.
Each layer shall cover the entire area of the stock pile before succeeding layers are
started. Aggregates that have become segregated shall be rejected. Rejected material
after remixing may be accepted, if subsequent tests demonstrate conformity with the
required gradation.
13.5.2.3 Cement
Cement shall be as per the latest version of IS 269. Cement for use in concrete for sewage
treatment works and pumping stations shall be Sulphate Resistant Cement. Tests shall
be carried out as and when approved by the Engineer. The cement shall be tagged for
identification at location for sampling. Unless otherwise specified or called for in the
contract, the cement to be used shall be selected from the following and the type selected
shall be appropriate for the intended use and as per the Contract.
1) Sulphate resisting Portland cement conforming to IS 12330.
2) 53 Grade ordinary Portland Cement conforming to IS 12269
3) Portland Slag Cement (with GGBS content of 30%) confirming to IS 455.
4) Portland pozzolana cement (fly ash based) conforming to IS 1489 (Part I)
5) Portland pozzolana cement (calcined clay based conforming to IS 1489 (Part 2)
Should the project require specific use of any of the following cements the same shall be
used with the prior consent of the Engineer and necessary precautions with regard to their
setting and hardening time, time required for removal of shuttering and curing etc. shall be
taken after carefully complying with specific literature with regard to those types.
1) High alumina cement - conforming to IS 6452

2) Low heat cement - conforming to IS 12600
3) Super sulphate cement - conforming to IS 6909
4) Rapid hardening cement - conforming to IS 8041
5) Blended cement for finishing work as below
Other combinations of Portland cement with mineral admixtures of quality conforming to

relevant Indian Standards laid down may also be used in the manufacture of concrete
provided that there are satisfactory data on their suitability, such as performance test on
concrete containing them and only in such case where it is specifically called for in the
contract.
No pre-hardened cement shall be used on any permanent works.
• Mineral Admixtures for Cement
Pozzolana: Pozzolanic materials conforming to relevant Indian Standards may be used

with the permission of Engineer, provided uniform blending with cement is ensured.

Fly ash (pulverized fuel ash): Fly ash conforming to IS 3812 may be used as part
replacement of ordinary Portland cement provided uniform blending with cement is
ensured.
Silica fume: Silica fume can be used as part replacement of cement provided it is of
sufficient quality approved by the Engineer and uniform blending with the cement is
ensured.
Rice husk ash: Rice husk ash giving required performance and uniformity characteristics
may be used with the approval of the Engineer.
Metakaoline: Metakaoline having fineness between 700 to 900 m2/kg may be used as a
pozzolanic material in concrete.
Ground Granulated Blast Furnace Slag: Ground granulated blast furnace slag obtained by
grinding granulated blast furnace slag conforming to IS 12089 may be used as part
replacement of ordinary Portland cement provided uniform blending with cement is
assured.
• Quality Assurance of Cement:
A certified report attesting to the conformity of the cement to IS specifications by the

cement manufacturer’s chemist shall be furnished to the Engineer, if demanded. The
Contractor shall make his own arrangements for the storage of adequate quantities of
cement at the site of work.
• Storage of Cement
Cement in bags shall be stored and stacked in a shed, which is dry, leak-proof and
moisture proof as far as possible. Storage under tarpaulins will not be permitted. Flooring
of the shed shall consist of the two layers of dry bricks laid on well consolidated earth to
avoid contact of cement bags with the floor. Stacking shall be about 150 to 200 mm clear
above the floor using wooden planks. Cement bags shall be stacked at least 450 mm clear
of the walls and in rows of two bags leaving a space of at least 600 mm between two
consecutive rows. In each row the cement bags shall be kept closed together to reduce
air circulation. Stacking shall not be more than ten bags high to avoid lumping under
pressure. In stacks more than eight bags high, the cement bags shall be arranged in
header and stretcher fashion i.e. alternately lengthwise and crosswise to tie the stacks
together and minimize the danger of toppling over.
Damaged or reclaimed or partly set cement will not be used and shall be removed from
the site. The storage arrangements shall be such that there is no dead storage
consignments so cement shall be stored as received and shall be consumed in the order
of their delivery.
Cement held in store for a period of ninety days or longer shall be retested before used in
work. Should the Engineer have reasons to consider that any cement is defective, then
irrespective of its origin and/or manufacturers test certificate, such cement shall be tested
immediately at a National Test Laboratory or other approved laboratory and until the
results of such tests are found satisfactory, it shall not be used in any work.

13.5.2.4 Aggregates
Aggregate in general designates both fine and coarse inert materials used in the
manufacture of concrete.
Fine aggregate is aggregate most of which passes through 4.75 mm IS sieve.
Coarse aggregate is aggregate most of which is retained on 4.75 mm IS sieve. Aggregate

shall comply with requirement of IS 383. As far as possible preference shall be given to
machine broken and graded aggregate.
All fine and coarse aggregates proposed for use in the work shall be subject to the
Engineer’s approval and after specific materials have been accepted, the source of supply
of such materials shall not be changed without prior approval of the Engineer.
Aggregate shall, except as noted above, consist of natural sand, crushed stone and gravel
from a source known to produce satisfactory aggregate for concrete and shall be
chemically inert, strong, hard, and durable against weathering, of limited porosity and free
from deleterious materials that may cause corrosion to the reinforcement or may impair
the strength and/or durability of the concrete. The grading of aggregates shall be such as
to produce a dense concrete of specified strength and consistency that will work readily
into position without segregation and shall be based on the mix design and preliminary
test on concrete specified.
The maximum percentages of permissible deleterious materials shall be as follows,

subject to total combined impurities, limit of 5 percent by weight.
Coarse Aggregate Fine Aggregate

Impurity
Crushed Uncrushed Crushed Uncrushed
Clay lumps 1 1 1 1
Soft fragments 3 - - -
Fine material passing through 75 3 1 3 3
micron sieve
Shale - - 1 -
Coal, lignite 1 1 1 1
i. Specific Gravity
Aggregates having a specific gravity below 2.6 (saturated surface dry basis) shall not
be used without special permission of the Engineer.
ii. Fine Aggregate
Fine aggregate except as noted above and for other than light weight concrete shall
consist of natural or crushed sand conforming to IS 383. The sand shall be clean,
sharp, hard, strong and durable and shall be free from dust, vegetable substances,
adherent coating, clay, loam, alkali, organic matter, mica, salt or other deleterious
substances which can be injurious to the setting qualities, strength or durability of the
concrete.

Machine Made Sand: Machine made sand will be acceptable, provided the constituent
rock composition is sound, hard, dense, non-organic, uncoated and durable against
weathering. Machine made sand shall be accepted provided grading and fine particle limits
conform to IS 383.
Screening and Washing: Sand shall be prepared for use by such screening or washing
or both, as necessary, to remove all objectionable foreign matter while separating the sand
grains to the required size fractions. Sand with a silt content of more than 3 percent will
not be used unless the same is washed and silt content is brought within 3% by weight.
Foreign Material Limitations: The percentages of deleterious substances in sand,

delivered to the mixer shall not exceed the following:
Percent by weight
Foreign Material
Uncrushed Crushed
i. Material finer than 75 micron IS sieve 3 15
ii. Shale 1 ---
iii. Coal and lignite 1 1
iv. Clay lumps 1 1
v. Total of all above substances including items (i) to 5 2
(iv) for uncrushed sand and items (iii) and (iv) for
crushed sand
Gradation: Unless otherwise approved, the grading of sand shall be within the limits
indicated. Where the grading falls outside the limits of any particular grading zone of
sieves, other than the 600 micron (IS) sieve by not more than 5%, the grading shall be
regarded as falling within that grading zone. This tolerance shall not be applied to
percentage passing the 600 micron (IS) sieve or to percentage passing any other sieve
size on the coarser limit of grading zone I or the finer limit of grading zone IV. Fine
aggregates conforming to Grading Zone IV shall not be used unless mix designs and
preliminary tests have shown its suitability for producing concrete of specified strength and
workability.
Percentage passing for

IS Sieve
Grading Grading Grading Grading
Designation
Zone I Zone II Zone III Zone IV
10 mm 100 100 100 100
4.75 mm 90-100 90-100 90-100 95-100
2.36 mm 60-95 75-100 85-100 95-100
1.18 mm 30-70 55-90 75-100 90-100
600 micron 15 – 34 35 - 59 60 – 79 80 – 100
300 micron 5 – 20 8 - 30 12 - 40 15 - 50
150 micron 0 - 10 0 - 10 0 - 10 0 - 15

Fineness Modulus: The sand shall have a fineness modulus of not less than 2.2 or more
than 3.2. The fineness modulus is determined by adding the cumulative percentages
retained on the following IS sieve sizes (4.75 mm, 2.36 mm, 1.18 mm, 600 micron, 300
micron and 150 micron) and dividing the sum by 100.
i. Coarse Aggregate
Coarse aggregate for concrete, except as noted above and for other than light weight
concrete, shall conform to IS 383. This shall consist of natural or crushed stone and
gravel and shall be clean and free from elongated, flaky or laminated pieces, adhering
coatings, clay lumps, coal residue, clinkers, sag, alkali, mica, organic matter or other
deleterious matter.
Screening and Washing: Crushed rock shall be screened and/or washed for the
removal of dirt or dust coating, if so required by the Engineer.
Grading: Coarse aggregates shall be either single size or graded. The grading shall be
within the limits on the table below. The aggregate pieces shall be angular in shape and
shall have granular or crystalline surfaces.
Friable, flaky and laminated pieces, mica and shale, if present, shall be only in such
quantities that will not, in the opinion of Engineer, affect adversely the strength and/or
durability of concrete.
The maximum size of coarse aggregate shall be the maximum size specified, but in no
case greater than 1/4 of the minimum thickness of the member, provided that the concrete
can be placed without difficulty to surround all reinforcement thoroughly and fill the corners
of form.
Cobbles above 160 mm and up to any reasonable size can be used in plain mass concrete
work of large dimensions up to a maximum limit of 20% by volume of concrete when
specifically approved by the Engineer.
For heavily reinforced concrete members, the nominal maximum size of the aggregate
shall be 5 mm less than the minimum clear distance between the reinforcing main bars or
5 mm less than the minimum cover to the reinforcement whichever is smaller. The amount
of fine particles occurring shall not exceed 1% when determined by laboratory
sedimentation tests as per IS 2386. After 24 hours immersion in water, a previously dried
sample shall not have gained more than 10% of its oven dry weight in air, as determined
by IS2386.
Percentage passing for single sized Percentage passing for Graded

IS Sieve aggregate of nominal size aggregate of nominal size
Design 40 20 16 12.5 40 20 16 12.5
10 mm
mm mm mm mm mm mm mm mm
63 mm 100 -- -- -- -- 100 -- -- --
40 mm 85- 100 -- -- -- 95-100 100 -- --
100
20 mm 0-20 85- 100 -- -- 30-70 95- 100 --
100 100
16 mm -- -- 85- 100 -- -- -- 90- --
100 100

Percentage passing for single sized Percentage passing for Graded

IS Sieve aggregate of nominal size aggregate of nominal size
Design 40 20 16 12.5 40 20 16 12.5
10 mm
mm mm mm mm mm mm mm mm
12.5mm -- -- -- 85-100 100 -- -- -- 90-
100
10 mm 0-5 0-20 0-30 0-45 85-100 10-35 25-55 30-70 40-85
4.75mm -- 0-5 0-5 0-10 0-20 0-5 0-10 0-10 0-10
2.36mm -- -- -- -- 0-5 -- -- -- --
Foreign Material Limitations: The percentages of deleterious substances in the coarse

aggregate delivered to the mixer shall not exceed the following:
Percent by weight
Foreign Material
Uncrushed Crushed
i. Material finer than 75 micron IS sieve 3 3
ii. Coal and lignite 1 1
iii. Clay lumps 1 1
iv. Soft fragments 3 --
v. Total of all the above substances 5 5
13.5.2.5 Water
Water for mixing concrete shall be clean and free from harmful impurities, such as silt,
organic materials, acids, alkalis, salts and oils. In general the water used shall be of potable
quality. In case of doubt, the suitability of water for making concrete shall be ascertained
by the compressive strength and initial setting time test specified in IS 456 - 2000. The
sample of water taken for testing shall be typical of the water proposed to be used for
concreting with due account being paid to seasonal variations. The samples shall not
receive any treatment before testing other than that envisaged in the regular supply of
water proposed for use in concrete. The sample shall be stored in a clean container
previously rinsed out with similar water.
Average 28 days compressive strength of at least three 150 mm concrete cubes prepared
with water proposed to be used shall not be less than 90% of the average strength of three
similar concrete cubes prepared with distilled water as per IS - 516.
The initial setting time of test blocks made with the cement and the water proposed to be
used shall not be less than 30 minutes and shall not differ by more than (+/-) 30 minutes
from the initial setting time of control test blocks prepared with the same cement and
distilled water. The test blocks shall be prepared and tested in accordance with the
requirements of IS 4031(Part 5).
Where water contains an excess of acid, alkali, sugar or salt, the Engineer may refuse to
permit its use. The following concentrations represent the maximum permissible values:

1) Limits of acidity: To neutralize 100 ml sample of water, using phenolphthalein as an

indicator, it should not require more than 5 ml. of 0.02 normal NaOH. The details of
test shall be as per IS 3025 (Part 22)
2) Limits of alkalinity: To neutralize 100 ml sample of water, using mixed indicator, it
should not require more than 25 ml. of 0.02 normal H2SO4. The details of test shall be
as per IS 3025 (Part 23).
3) Limits for Solids: Permissible limits for solids in the water shall be as below:
Solids Percent Method of Test (ref IS : 3025)

Organics 0.02 10 and 11 (organic solids = total solids minus ignited
residue)
Inorganics 0.30 11 (ignited residue)
Sulphates (as SO4) 0.05 20
Alkali chloride (as CI) 0.20 24
Suspended matter 0.20 12
pH: The pH value of water shall be not less than 6.
13.5.2.6 Admixtures
Admixtures may be used in concrete only with the approval of Engineer based upon
evidence that, with the passage of time, neither the compressive strength nor the durability
will be reduced. When admixtures are used, the concrete mix design shall be amended
accordingly. Admixtures shall be used as per manufacturers’ instructions and in the
manner and with the control as necessary or as specified by Engineer.
The addition of admixtures during mixing to alter the properties of the concrete mix shall
only be with the approval of the Engineer in regard to quality, quantity and redesign of the
mix and accompanied by separate preliminary tests.
Admixtures, if used, shall comply with IS 9103. Previous experience with and data on such
materials should be considered in relation to the likely standards of supervision and
workmanship to the work being specified. Admixtures should not impair durability of the
concrete or combine with the constituent to form harmful compounds or increase the risk
of corrosion of reinforcement.
The workability, compressive strength and the slump loss of concrete with and without the
use of admixtures shall be established during the trial mixes before use of admixtures.
The relative density of liquid admixtures shall be checked for each drum containing
admixtures and compared with the specified value before acceptance.
The chloride content of the admixtures shall be independently tested for each batch before
acceptance. If two or more admixtures are used simultaneously in the same concrete, mix
data should be obtained to assess their interaction and to ensure their compatibility.
i. Calcium Chloride
Calcium chloride shall not be used for accelerating the setting of the cement for any
concrete containing reinforcement or embedded steel parts.
ii. Air Entraining Agents

Neutralized vinsol resin or any other approved air entraining agent may be used to
produce the specified amount of air in the concrete mix and these agents shall conform
to the requirements of ASTM standard 6.260, Air Entraining Admixtures for Concrete
if approved by the Engineer. The recommended total air content of air entrained
concrete is 4% (+/-) 1%. The method of measuring air content shall be as per IS1199.
iii. Retarding Admixtures
Where prior approval has been given by the Engineer, retarding agents may be added
to the concrete mix in quantities in accordance with the manufacturer’s
recommendations.
iv. Water Reducing Admixtures
Where prior approval has been given by the Engineer, water reducing lignosulfonate
mixture shall be added in quantities in accordance with the manufacturer’s
recommendations. The admixtures shall be added in the form of a solution.
v. Waterproofing Agents
Where prior approval has been given by the Engineer, chloride and sulphate free
waterproofing agents shall be added in quantities in accordance with the
manufacturer’s recommendations.
vi. Other Admixtures
The Engineer may, at his discretion, approve the Contractor to use any other admixture
in the concrete.
13.5.2.7 Fly Ash
The fly ash should have consistent quality satisfying the requirements of IS 3812 Parts I
and II. The source of fly ash should be so selected that test results of fly ash samples
collected from these sources during last one year at a frequency of maximum one month
intervals should satisfy the requirements of above codes.
The characteristics of fly ash to be used shall be as per the above two codes for each
batch of fly ash. If more than 15% fly ash is used, IS 3812 shall apply and specific care
shall be taken in terms of curing, protecting, repairing, finishing, de-shuttering etc.
13.5.3 Materials Testing
The Engineer shall have the right to inspect the sources of materials, the layout and
operation of procurement and storage of materials, the concrete batching and mixing
equipment and the quality control system. The Contractor shall arrange such an inspection
and the Engineer approval shall be obtained prior to starting any concrete work.
The Engineer, if he so requires, may order tests to be carried out, at the Contractor’s
expense, on cement, sand, coarse aggregate, water etc in accordance with the relevant
Indian Standards.

13.5.3.1 Tests on Cement
Tests on cement shall include (i) fineness tests, (ii) tests for normal consistency, (iii) tests
for setting time, (iv) tests for soundness, (v) tests for compressive strength, (vi) tests for
heat of hydration (by experiment and by calculations) in accordance with IS269.
13.5.3.2 Tests on Sand
Tests on sand shall include (i) sieve tests, (ii) tests for organic impurities, (iii) decantation
tests for determining clay and silt content, (iv) specific gravity tests, (v) tests for unit weight
and bulk age factor, (vi) tests for sieve analysis and fineness modulus.
13.5.3.3 Tests on Aggregate
Aggregates shall be tested before and after the concrete mix is established and whenever
there is a change of the source or character of the materials.
Sampling of the aggregates for mix design and determination of suitability shall be taken
under the supervision of the Engineer rand delivered to the laboratory, well in advance of
the schedule for placing of concrete. Records of tests which have been made on proposed
aggregates and on concrete made from this source of aggregates shall be furnished to the
Engineer in advance of the work for which it is to be used, in determining suitability of the
proposed aggregate.
Tests on coarse aggregate shall include (i) sieve analyses, (ii) specific gravity and unit
weight of dry, loose and rodded aggregate, (iii) soundness and alkali aggregate reactivity,
(iv) petrographic examination, (v) deleterious materials and organic impurities, (vi) tests
for aggregate crushing value.
Additional tests on aggregates would normally only be carried out if the Engineer feels the
materials are not in accordance with the specifications or if the specified concrete strengths
are not obtained and shall be performed by the Contractor, at the Contractor’s expense,
at an approved test laboratory.
13.5.3.4 Tests on Water Stops
The water stops shall be tested in accordance with the Central Water Commission (India)
standards and shall have the following properties:
Characteristics Properties
Tensile strength 116 kg/cm2 minimum (162 kg/cm2 min. for rubber)
Ultimate elongation 300% minimum (500% minimum for rubber)
Tear resistance 49 kg/cm2 minimum
Stiffness in flexure 25 kg/cm2 minimum
Accelerated extractions 105 kg/cm2 minimum (150 kg/cm2 Minimum for rubber)
Ultimate elongation 250% minimum (350% minimum for rubber)
Effect of alkali (7 days):
Weight increase 0.25% maximum
Weight decrease 0.10% maximum

Characteristics Properties
Hardness change + 5 point
Effect of alkali (28 days):
Weight increase 0.40% maximum
Weight decrease 0.30% maximum
Dimension change + 1%
13.5.4 Concrete Grades
The concrete used on the works of this project shall be of one of the following grades:
Minimum Crushing Strength of 150 mm cube at 28 days. In kg/cm2

Grade
Preliminary and Trial Mix Tests Work Tests
M-100 135 100
M-150 200 150
M-200 260 200
M-250 320 250
M-300 380 300
M-350 440 350
1 The characteristic strength is defined as the strength of material below which
2 Not more than 5% of the test results are expected to fall.
3 In the designation of a concrete mix, the letter M refers to the mix and the number
to the specified characteristic compressive strength of 150 mm size cubes at 28
days expressed in N/ mm2.
All concrete used on the work shall be dense, sound, homogeneous and durable and free
from air voids, bleeding, honeycombing and other allied defects. For grade M-100 the
Contractor may be allowed to use an approved nominal mix but for all other grades of
concrete, mix designs are obligatory and preliminary test results shall be submitted to the
Engineer for approval before the commencement of concreting.
Mixes designed with ordinary Portland cement shall be redesigned if Pozzolona or other
cement is to be used. In any event, whether Pozzolona or other cement is used or not,
new mix designs shall be submitted for the Engineer’s approval for each new batch of
cement that is received. To enable this, the cement stocks shall be so stored as to enable
easy identification of different batches. Similarly, new mix designs will be required if the
source of supply of aggregate is changed or a variation exceeding 10 percent in the sieve
analysis is observed from the analysis of the aggregate used in the mix design.
13.5.4.1 Standard Deviation
The standard Deviation for each grade of concrete shall be calculated separately.
Standard Deviation Based on Test Results
Number of test results - The total number of test results required to constitute an
acceptable record for calculation of standard deviation shall be not less than 30. Attempts

should be made to obtain the 30 test results, as early as possible, when a mix is used for
the first time.
Standard deviation to be brought up to date - The calculation of the standard deviation

shall be brought up to date after every change of mix design and at least once a month.
Determination of standard deviation:
1) Concrete of each grade shall be analysed separately to determine its standard
deviation.
2) The standard deviation of concrete of a given grade shall be calculated using the
following formula from the results of individual tests of concrete of that grade obtained
as specified for test strength of sample:
3) Estimated standard deviation S =    /(n-1)}
4) Where = Deviation of the individual test strength from the average strength of a
sample and n = Number of sample test results.
5) When significant changes are made in the production of concrete (for example
changes in the materials used, mix design, equipments or technical control), the
standard deviation value shall be separately calculated for such batches of concrete.
Where sufficient test results for a particular grade of concrete are not available, the value
of standard deviation given in the table below may be assumed for a design of mix in the
first instance. As soon as the results of samples are available, actual calculated standard
deviation shall be used and the mix designed properly. However, when adequate past
records for a similar grade exist and justify to the designer a value of standard deviation
different from that shown in table below, it shall be permissible to use that value.
Grade of Concrete Assumed Standard Deviation N/ mm2

M 10
3.5
M 15
M 20
4.0
M25
M30
M35
M40 5.0
M45
M50
Note: The above values correspond to the site control having proper storage of cement:
weigh batching of all materials: controlled addition of water: regular checking of all
materials: aggregate grading and moisture content: and periodical checking of workability:
and strength. Where there is a deviation from the above, the values given in the above
table shall be increased by 1 N / mm2.
13.5.5 Mix Designs
The quality of materials and method and control of manufacture and transportation of all
concrete work in respect of a mix whether reinforced or otherwise, shall be Design Mix
Concrete as defined in IS 456-2000 and conform to the applicable portions of these
specifications. The provision of IS 456 -2000 with amendment no.3 should be followed
scrupulously for cement concrete and R.C.C. The different concrete mixes shall be
designed by the Contractor for strength, workability and durability of the concrete and shall
be strictly in compliance with the relevant standards. If it is found that an increase in the
proportion of cement is necessary, the requisite adjustment shall be made. Batching shall

be by weight and the combined aggregate shall have a continuous grading. The mixes
should produce an average 28 day cube strength not less than that specified in Section
17.3 for trial mix tests for the relevant grade. In the case of concrete for water retaining
structures, the cement content shall be a minimum of 400kg/m3 of concrete. When
admixtures are used, the mixes shall be redesigned with the test strengths conforming to
those specified in Section 17.3. The workability of the mix shall permit satisfactory
compaction with vibration, with no tendency to aggregate during handling, transporting and
compaction.
In exceptional cases, where the reinforcement is so crowded that the compaction is

difficult, the value of slump may be increased with the explicit approval of the Engineer,
but in no case shall it exceed 15 cm. Any increase in the slump beyond the values given
shall be obtained by the use of additional cement in such quantities as to restrict the water-
cement ratio to the maximum specified values. Special care shall be taken in the case of
M-25 concrete where the water-cement ratio should not exceed 0.45 under any
circumstances.
The minimum cement contents of the different grades shall be as follows, in kg/m 3 of
concrete mixed and ready to be placed:
Grade Cement Content (kg/m3)

M-15 240
M-20 300
M-25 300
M-30 320
M-35 400
1 Cement content prescribed in this table is irrespective of the grades of cement and it
is inclusive of additions stated in mineral admixtures. The additions of such as fly ash
or ground granulated blast furnace slag may be taken into account in the concrete
composition with respect to the cement content and water-cement ratio if the suitability
is established and as long as the maximum amounts taken into account do not exceed
the limit of pozzolona and slag specified in IS 1489 (Part 1) and IS 455 respectively.
2 Minimum grade for plain concrete under mild exposure condition is not specified.
13.5.5.1 Adjustment of Minimum Cement Content
The adjustments to minimum cement contents should be made for aggregates other than
20 mm nominal maximum size as shown in the table below:
Adjustments to minimum cement

No Nominal maximum aggregate size mm
content kg/ m3
i) 10 +40
ii) 20 0
iii) 40 -30
1 For concrete of compressive strength greater than M-55 given design parameters
may not be applicable and the values may be obtained from specialized literature
and experimental results.

2 The mix shall be designed to produce the grade of concrete having the required
workability and characteristic strength not less than the appropriate values given
in the table above.
13.5.5.2 Degree of Control
Selection of Water Cement Ratio: Since different cements and aggregates of different
maximum size, grading, surface texture, shape and other characteristics may produce
concretes of different compressive strength for the same free water cement ratio, the
relationship between strength and free water-cement ratio should be established for the
materials actually to be used. In the absence of such data, the preliminary free water-
cement ratio (by mass) corresponding to the target strength at 28 days may be selected
from the relationship shown in Fig.1 of IS 10262.
Alternatively, the preliminary free water cement ratio (by mass) corresponding to the target
average strength may be selected from the relationship in Fig.2- IS 10262, using the curve
corresponding to the 28 day cement strength to be used for the purpose.
Other relevant items to be used with design of mix should strictly conform to the relevant
clauses and appendices of IS 10262.The calculated mix proportions shall be checked by
means of trial batches as per IS 10262.
The free water cement ratio, selected as above, should be checked against the limiting
water cement ratio for the requirement of durability and the lower of the two values should
be adopted. Whenever there is a change either in required strength of concrete or water
cement ratio or workability or the source of aggregates and/or cement, fresh tests shall be
carried out to determine the revised proportion of the mix to suit the altered conditions.
While designing mix proportions, over-wet mixes shall always be avoided. While fixing the
value for water cement ratio for the design mix, assistance may be derived from the
standard graph showing the relationship between the 28 day compressive strength of
concrete mixes with different water-cement ratios and the 7 day compressive strength of
cement tested in accordance with IS269.
It will be the Contractor’s sole responsibility to establish the concrete mix designs for
different grades of concrete required in the work consistent with the workability required
for the nature of work and also taking into consideration the assumed standard deviation
to be expected at the site or by establishing the standard deviation based on 30 test results
for each grade of concrete to produce concrete of the required strength, durability and
surface finish. The materials and proportions used in making the tests to be carried out
either at site or under laboratory conditions shall be similar in all respects to those to be
actually employed in the works, as the object of these tests is to determine the proportions
of cement, aggregates and water necessary to produce the concrete of the required
consistency to give such specified strength.
13.5.5.3 Proportioning
i. Aggregate
The proportions to be determined by conducting preliminary tests shall be by weight.

These proportions of cement, fine and coarse aggregates shall be maintained during
subsequent concrete batching by means of weigh batchers conforming to IS 2722,
capable of controlling the weights within one percent of the desired value. Except
where it can be shown to the satisfaction of the Engineer, that supply of properly
graded aggregate of uniform quality can be maintained over the period of work, the

grading of aggregate shall be controlled by obtaining the coarse aggregate in different

sizes and blending them in the right proportions. The different sizes shall be stacked
in separate stockpiles. The grading of coarse and fine aggregates shall be checked as
frequently as practicable, as determined by the Engineer, to ensure maintaining of
grading in accordance with samples used in the preliminary mix design. The materials
shall be stockpiled well in advance of use.
ii. Cement
The cement shall be measured by weight. Every facility should be provided to the
Engineer for sampling and inspection of stored cement at the site.
iii. Water
Only such quantity of water shall be added to the cement and aggregate in the concrete
mix as to ensure dense concrete, specified surface finish, and satisfactory workability
consistent with the strength stipulated for each class of concrete. The water added to
the mix shall be such as not to cause segregation of materials or the collection of
excessive free water on the surface of the concrete.
• Definition of water cement ratio
The water cement (W/C) ratio is defined as the weight of water in a mix (including the
surface moisture of the aggregates) divided by the weight of the cement in the mix.
• Water cement ratio
The actual water cement ratio to be adopted shall be determined in each instance by
the Contractor and approved by the Engineer.
• Proportioning by Water-Cement Ratio
The W/C ratios as approved by the Engineer shall be maintained. Contractor shall
determine the water content of the aggregate as frequently as approved by the
Engineer as the work progresses and as specified in IS 2386 part III and the amount
of mixing water added at the mixer shall be adjusted as approved by the Engineer to
maintain the specified W/C ratio. To allow for the variation in their moisture content,
suitable adjustments in the weights of aggregates shall also be made.
iv. Concrete in Alkali Soils, Water & Aggregates
Some aggregates containing particular varieties of silica may be susceptible to attack

by alkalis (Na2O and K2O) originating from cement and other sources, producing an
expansive reaction which can cause cracking and disruption of concrete. Damage to
concrete from this reaction will normally only occur when all the following are present
together.
1) A high moisture level, within the concrete;
2) A cement with high alkali content, or another source of alkali;
3) Aggregate containing an alkali reactive constituent.
Where the service records of particular cement / aggregate combination are well
established and do not include any instances of cracking due to alkali-aggregate
reaction, no further precautions should be necessary. When the materials are
unfamiliar, precautions should take one or more of the following forms:

4) Use of non-reactive aggregate from alternate sources

5) Use of low alkali ordinary Portland cement having total alkali content not more than
0.6 per cent (as Na2O equivalent).
Further advantages can be obtained by the use of fly ash (Grade I) conforming to IS
3812 or granulated blast furnace slag conforming to IS 12089 as part replacement of
ordinary Portland cement (having total alkali content as Na2O equivalent not more than
0.6 percent), provided that the fly ash content is at least 20 % or slag content is at least
50%.
1 Measures to reduce the degree of saturation of the concrete during service such
as the use of impermeable membranes
2 Limiting the cement content in the concrete mix and thereby limiting total alkali
content in the concrete mix as approved by the Engineer.
v. Chlorides in the Concrete
Whenever there are chlorides in concrete, there is an increased risk of corrosion to the
embedded metal. The higher the chloride content, and if subsequently exposed to
warm moist conditions, the greater the risk of corrosion. All constituents may contain
chlorides and concrete may be contaminated by chlorides from the external
environment. To minimise the chance of deterioration of concrete from harmful
chemical salts, the levels of such harmful salts in concrete materials, as well as by
diffusion from the environment should be limited. The total amount of chloride content
(as Cl) in the concrete at the time of placing shall be as given below in the table.
Limits of Chloride Content of Concrete
Maximum Total Acid

Sr. soluble Chloride
Type or Use of Concrete
No. Content Expressed as
kg/m3 of Concrete.
i) Concrete containing metal and steam cured at elevated 0.4
temperature and pre-stressed concrete
ii) Reinforced concrete or plain concrete containing 0.6
embedded metal
iii) Concrete not containing embedded metal or any 3.0
material requiring protection from chloride
The total acid soluble chloride content should be calculated from the mix proportions and
the major chloride contents of each of the constituents. The total chloride content of the
concrete should be determined to the approval of the Engineer.
vi. Sulphates in concrete
Sulphates are present in most cements and in some aggregates. Excessive amounts
of water-soluble sulphate from these or other mix constituents can cause expansion
and disruption of concrete. To prevent this, the total water-soluble sulphate content of
the concrete mix, expressed as SO3, should not exceed 4 % by mass of the cement in
the mix. The sulphate content should be calculated as the total from the various
constituents of the mix to the approval of the Engineer.

The 4% limit does not apply to concrete made with super sulphated cement complying
with IS 6909 or as otherwise approved by the Engineer.
13.5.5.4 Consistency and slump
Concrete shall be of a consistency and workability suitable for the conditions of the job.
After the amount of water required is determined, the consistency of mix shall be
maintained throughout the progress of the corresponding parts of the work and approved
tests e.g. slump tests, compacting factor tests etc. in accordance with IS 1199, which shall
be conducted from time to time to ensure the maintenance of such consistency.
The following tabulation gives a range of workability which shall generally be used for
various types of construction unless otherwise instructed by the Engineer.
Workability of concrete:
Degree of Slump
Placing Condition
workability (mm)
Blinding concrete; Shallow sections; Pavement using pavers Very low See note 1
Mass concrete; lightly reinforced sections in slabs, beams, Low 25-75
walls, columns; floors; hand placed pavements; canal
linings; strip footings
Heavily reinforced sections in slabs, beams, walls, columns, Medium 50-100
slip form work; pumped concrete 75-100
Trench fill, in-situ piling High 100-150
Tremix concrete Very high See notes
1 For most of the placing conditions, internal vibrators (needle vibrators) are suitable.
The diameter of the needle shall be determined based on the density and spacing of
reinforcement bars and thickness of sections. For remix concrete, vibrators are not
required to be used.
2 The ’very low’ category of workability where strict control is necessary, for example
pavement quality concrete, measurement of workability by determination of
compacting factor will be more appropriate than slump (see IS 1199) and a value of
compacting factor of 0.75 to 0.80 is suggested.
3 In the ‘Very high’ category of workability, measurement of workability by determination
of flow will be appropriate (see IS 9103).
When tested in accordance with IS 1199, the consistency of the concrete should be such
that the maximum slumps, unless otherwise specified or permitted by the Engineer do not
exceed the following values.
Part of Structure Maximum Slump (mm)

Footings and un-reinforced mass concrete 76
Slab and Floors 76
Columns, walls over 200 mm thick 102
Walls up to 200 mm thick 102

Part of Structure Maximum Slump (mm)

Equipment bases 127
13.5.5.5 Batching
To avoid confusion and error in batching, consideration shall be given to using the smallest
practical number of different concrete mixes on any site or in any one plant. In batching
concrete, the quantity of both cement and aggregate shall be determined by mass;
admixture, if solid, by mass; liquid admixture may however be measured in volume or
mass; water shall be weighed or measured by volume in a calibrated tank (see also
IS4925).
For large and medium project sites, concrete shall be sourced from ready-mixed concrete
plants or from on-site or off-site batching and mixing plants (see IS 4926).
Except where it can be shown to the satisfaction of the Engineer that supply of properly
graded aggregate of uniform quality can be maintained over a period of work, the grading
of aggregate should be controlled by obtaining the coarse aggregate in different sizes and
blending it in the right proportions when required, the different sizes being stocked in
separate stockpiles.
The accuracy of the measuring equipment shall be within +/- 2 % of the quantity of cement
being measured and within +/- 3 percent of the quantity of aggregate, admixtures and
water being measured.
Volume batching shall be allowed only where weigh-batching is not practical and provided
accurate bulk densities of materials to be used in concrete have already been established.
Allowance for bulking shall be made in accordance with IS 2386 (Part 3). The mass volume
relationship shall be checked as frequently as necessary, the given frequency being
subject to the approval of the Engineer to ensure that the specified grading is maintained.
The water-cement ratio shall be maintained at its correct value. To this end, determination
of the moisture content in both the fine and coarse aggregates shall be made as frequently
as possible, the given frequency being subject to the approval of the Engineer according
to weather conditions. The amount of the added water shall be adjusted to compensate
for any observed variations in the moisture content. For the determination of moisture
content in the aggregates IS2386 (Part 3) shall be followed. To allow for the variation in
the mass of aggregate due to variation in its moisture content, suitable adjustments in the
masses of aggregates shall also be made. In the absence of exact data, and in the case
of nominal mixes the amount of surface water may be estimated from the values given in
table below.
Surface water carried by aggregate
Approximate quantity of surface water

Aggregate
Percent by mass l/m3
Very wet sand 7.5 120
Moderately wet sand 5.0 80
Moist sand 2.5 40

Approximate quantity of surface water

Aggregate
Percent by mass l/m3
Moist gravel or crushed rock 1.25-2.5 20-40

The coarser aggregate the less water it will carry
No substitutions in materials used on the work or alterations in the established proportions

except as permitted as above shall be made without additional tests to show that the
quality and strength of concrete are satisfactory.
13.5.5.6 Mixing
Concrete shall be mixed in a mechanical mixer. The mixers shall comply with IS 1791 and
IS 12119. The mixers shall be fitted with water measuring devices. The mixing shall be
continued until there is a uniform distribution of the materials and the mass is uniform in
colour and consistency. If there is segregation after unloading from the mixer, the concrete
shall be remixed. The mixing time shall be at least two minutes. For more efficient mixers,
manufacturers recommendations shall be followed.
The dosage of retardants, plasticisers and super-plasticisers shall be restricted to 0.5, 1.0
and 2.0 % respectively by weight of cementitious materials unless a higher value is agreed
between the manufacturer and the Contractor based on performance tests.
Each time the work stops, the mixer shall be cleaned out and when next commencing the
mixing, the first batch shall have 10% additional cement to allow for sticking in the drum.
13.5.6 Cast-in-Place (In-Situ) Concrete
13.5.6.1 Execution
i. Preparation for Placing
All excess water shall be removed from the forms before concrete is placed. No flow
of water shall be admitted to the section being concreted. The interior faces of forms
shall be cleaned and any hard concrete, debris or foreign material shall be removed.
The inner faces of the mixing and conveying equipment shall be similarly cleaned.
Reinforcement shall be secured, inspected and approved in compliance with the

relevant specifications and shall be inspected and approved. Embedded metal shall
be clean and free of old mortar, oil, mill scale and other encrustations and coatings.
Wheeled concrete handling equipment shall pass over reinforcement nor shall
walkways be supported on reinforcement.
Any earth sub-grade on which concrete is to be deposited shall be wetted lightly 24

hours in advance of concreting but not muddied. Re-rolling shall be carried out, where
necessary, to create a smooth surface and all loose materials removed.
Where placement of concrete is directly onto a rock base, the rock surface shall be
cleaned and washed and loose material removed with air blower or hosed before
concreting. All stagnant water collected on the rock surface shall be removed before
concreting. Where a bond between old and new concrete surfaces is required, the
steps and precautions stipulated for construction joints shall be adopted. Where no

bond is necessary, the existing surface shall be cleaned, removing any dirt or
deleterious material which might interfere with the concreting.
Before concrete is poured, the inside of the formwork shall be inspected to ensure that
it has been cleaned and oiled. Temporary openings shall be provided where necessary
to facilitate inspection, especially at the bottom of columns and wall forms, to permit
removal of sawdust, wood shavings, binding wire, rubbish, dirt etc. Openings shall be
placed or holes drilled so that these materials and water can be removed easily. Such
openings / holes shall be later suitably plugged.
The Contractor shall install drainage and plumbing lines, floor and trench drains,
conduits, hangers, anchors, inserts, sleeves, bolts, frames and other miscellaneous
embedment to be cast in the concrete as necessary for the proper execution of the
work. All such embedment shall be correctly positioned and securely held in the forms
to prevent displacement during the depositing and vibrating of concrete.
Slots, openings, holes, pockets etc shall be provided in the concrete work in the
positions as necessary.
Prior to concrete placement, all works shall be inspected and approved by Engineer
and if found unsatisfactory, concrete shall not be poured until all defects have been
corrected.
Approval by the Engineer of any and all materials and work as required herein shall
not relieve contractor from his obligations to produce finished concrete in accordance
with the Contract.
ii. Foundation Bedding and Jointing
All surfaces upon or against which concrete will be placed shall be suitably prepared
by thoroughly cleaning, washing and dewatering to meet the various situations
encountered in the work.
Soft or spongy areas shall be dug out and back-filled with either a soil cement mixture,
lean concrete or clean sand fill compacted to a minimum density of 90% modified
Proctor.
iii. Preparation of Rock Strata of Foundations
To provide a tight bond with rock foundations, the rock surface shall be prepared and
the following general requirements shall be observed:
Concrete shall not be deposited on large sloping rock surfaces. Where required, the
rock shall be cut to form rough steps or benches to provide roughness or a more
suitable bearing surface.
Rock foundation stratum shall be prepared by picking, barring, wedging or similar

methods which will leave the rock in an entirely sound and un-shattered condition.
Shortly before concrete is placed, the rock surface shall be cleaned with high pressure
water and air jet even though it may have been previously cleaned in that manner.
Prior to placing concrete, the rock surface shall be kept wet for a period of at least two
hours unless otherwise approved by the Engineer.

Before placing concrete on rock surfaces, all water shall be removed from depressions
to permit thorough inspection and proper bonding of the concrete to the rock.
iv. Preparation of Earth Strata of Foundations
All earth surfaces upon which or against which concrete is to be placed, shall be well
compacted and free from standing water, mud or debris. Soft, yielding soils shall be
removed and replaced with suitable earth and well compacted and as approved by the
Engineer. Where specified, lean concrete shall be placed on the earth stratum for
receiving concrete. The surface of absorptive soil against which concrete is to be
placed shall be moistened thoroughly.
v. Preparation of Concrete Surfaces
Preparation of concrete surfaces upon which additional concrete is to be placed, shall

be scarified and cleaned while the concrete is between its initial and final set. This
method shall be used wherever practicable and shall consist of cutting the surface with
picks and stiff brooms and by use of an approved combination of air and water jet and
as approved by Engineer. Great care shall be taken in performing this work to avoid
removal of too much mortar and the weakening of the surface by loosening of
aggregate. When it is not practicable to follow the above method, air tools shall be
employed to remove laitance and roughen the surface.
The required final result shall be a pitted surface from which all dirt, unsound concrete,
laitance and glazed mortar have been removed.
vi. Cleaning and Bonding of Formed Construction Joints
Vertical construction joints shall be cleaned as specified above or by other methods

and as approved by Engineer. In placing concrete against formed construction joints,
the surfaces of the joints, where accessible, shall be coated thoroughly with the
specified bed-joint bonding mortar immediately before being covered with concrete or
by scrubbing with wire brushes, dipped into the fresh concrete. Where it is
impracticable to apply such a mortar coating, special precautions shall be taken to
ensure that the new concrete is brought into intimate contact with the surface of the
joint with the aid of vibrators and other suitable tools.
vii. Positioning of Water Stops
Water stops shall be provided in the available maximum lengths and as far as possible,
jointing shall be avoided. All joints, when unavoidable, shall be field jointed for water
tightness as per manufacturer’s specifications.
The water stops shall be positioned with suitable temporary supports to render
adequate rigidity to the water stops while concreting. The exposed surfaces of water
stops revealed after first concreting shall be cleaned thoroughly of all the droppings,
mortar splashing etc. before the next pour of concrete.
viii. Bonding Treatment (Mortar)
All rock or concrete surfaces upon which new concrete is to be placed shall be
scarified, cleaned and wetted as specified herein.
Immediately prior to placing new concrete, the scarified surface of the existing concrete
shall be thoroughly wetted.

ix. Cleaning of Equipment
All equipments used for mixing, transporting and placing of concrete shall be
maintained in clean condition. All pans, buckets, hoppers, chutes, pipe lines and other
equipments shall be thoroughly cleaned after each period of placement.
x. Conveying and Placing Concrete
Concrete shall be poured or placed only after the forms and reinforcement have been
inspected and approved, for which purpose the Contractor shall give the Engineer at
least two days’ notice. Generally, the use of aluminium equipment shall not be
permitted in any operation where the equipment and concrete are likely to come in
contact with each other, unless the aluminium surfaces have to be adequately treated
to prevent reaction with and having a harmful effect on the concrete.
All buckets, containers or conveyers used for transporting concrete shall be mortar-
tight. All means of conveyance shall be adopted to deliver concrete of the required
consistency and plasticity without segregation or loss of slump whatever method of
transportation is employed. Chutes shall not be used to transport the concrete without
the approval of the Engineer and concrete shall not be re-handled before placing.
Conveying - Concrete shall not be released from a mixer, hopper, frame or other
conveyance or device through a height exceeding two metres or through
reinforcement, in a manner likely to cause segregation. Tremmies discharging close to
the point of concreting shall be provided as required. The use of chutes will be
restricted to specific locations approved by the Engineer. Concrete shall be deposited
directly into the conveyance and from the conveyance directly into the locations in the
structure. Deposition of concrete shall be so done to maintain, as far as possible, a
level surface throughout. Manual labour may be used for conveying and placing mixed
concrete provided the above requirements are not contravened.
Placing Concrete - Concrete shall be placed in position and compacted within 30

minutes after the first addition of water to the mix and no concrete showing signs of
initial set shall be used. Re- tampering of set concrete is prohibited.
1 Lifts: Concrete shall be poured into forms after mixing in a manner that will prevent
segregation of the ingredients and in horizontal layers not exceeding 2,000 mm
thick.
a. Walls: Concrete for walls of water retaining structures, including tank exterior
walls, shall be poured, where practicable, as one continuous operation from
footing to top of the wall. Each section shall be left in place at least seven days
before the adjoining section in similarly concreted.
b. Slabs: Concrete between approved joints shall be poured in one continuous
operation in checker-board fashion and shall be allowed to stand at least seven
days before adjoining sections are concreted.
c. Concreting of beams and slabs shall be continuous and monolithic with the
floor.
2 Pumping Concrete: No increase in the water-cement ratios or specified slumps

will be permitted to pumped concrete. The minimum conveyance tube shall be
minimum diameter of 100 mm and capable of maintaining the specified pour rates.
3 Pour Rules:

a. Vertical Elements: concrete shall be placed in lifts as specified at a rate that

does not cause excessive stresses in the formwork or a hardening of the top
layer before next lift is poured.
b. Slabs: Concrete shall be poured at an appropriate time that ensures that all
new concrete poured is adjoined to concrete that is still plastic and before the
initial set of the previous placing.
c. Construction Joints: Concreting adjoining a construction joint shall not be
until the existing surface has been cured for at least seven days, unless
otherwise approved by the Engineer.
Before any concrete is placed, the entire placing programme, consisting of equipment,
layout, proposed procedures and methods shall be submitted to Engineer for approval
and no concrete shall be of such size and design as to ensure a practically continuous
flow of concrete during depositing without segregation of materials, considering the
size of the job and placement location.
xi. Time Interval between Mixing and Placing
Concrete shall be placed in its final position before the cement reaches its initial set
and concrete shall normally be compacted in its final position within thirty minutes of
leaving the mixer and once compacted, it shall not be disturbed. On no account shall
water be added after the initial mixing. Concrete which has become stiff or has been
contaminated with foreign materials shall be rejected.
xii. Avoiding Segregation
Concrete shall, in all the cases, be deposited as nearly as practicable directly in its
final position and shall not be re-handled or caused to flow in a manner which will
cause segregation, loss of material, displacement of reinforcement, shuttering or
embedded inserts or impair its strength. For locations where direct placement is not
possible and in narrow forms, the Contractor shall provide suitable props and
discharge pipes to confine the movement of concrete. Special care shall be taken when
concrete is dropped from a height, especially if reinforcement is in the way, particularly
in columns and thin walls.
xiii. Placing by Manual Labour
Except as otherwise approved by Engineer, concrete shall be placed using approved

implements and shall not be dropped from a height of more than 2.0 m or handled in
a manner which will cause segregation.
xiv. Placing by Mechanical Equipment
The following specifications shall apply when placing of concrete by use of mechanical
equipment is specially called for or is warranted, considering the nature of work
involved.
The control of placing shall begin at the mixer discharge. Concrete shall be discharged
by a vertical drop into the middle of the bucket or hopper and this principle of a vertical
discharge of concrete shall be adhered-to throughout all stages of delivery until the
concrete comes to rest in its final position.

All concrete shall be conveyed from the mixer to the place of final deposit in suitable
buckets, dumpers or containers which shall be leak-tight. All means of conveyance
shall be adopted for delivering concrete to the required consistency/ workability and
plasticity without segregation.
Central bottom-opening buckets of a type that provides for positive regulation of the
amount and rate deposition of concrete shall be employed.
In placing concrete in large open areas, the buckets shall be located directly over the
position designated and then lowered for dumping. The open bucket shall remain clear
of any concrete already in place and the height of drop shall not exceed 2.0 m. The
bucket shall be opened slowly to avoid high vertical bounce. The placing of concrete
in any manner which results in separation of ingredients or disturbance of previously
placed concrete will not be permitted.
xv. Placement in Restricted Forms
Concrete placed in restricted forms shall be subject to the requirements for vertical
delivery of limited height to avoid segregation and shall be deposited as nearly as
practicable in its final position.
xvi. Chuting
Where it is necessary to use transfer chutes, specific approval of the Engineer must
be obtained with regards to the type, length, slopes, baffles, vertical terminal and timing
of operations. These shall be arranged so that almost continuous flow of concrete is
obtained at the discharge and without segregation. To allow for the loss of mortar
against the sides of the chutes, the first mixes shall have less coarse aggregate. During
cleaning of chutes, the waste water shall be kept clear of the forms. The concrete shall
not be permitted to fall from the end of the chutes by more than 1.0 m. Chutes, when
approved for use, shall have slopes not flatter than 1 vertical to 3 horizontal and not
steeper than 1 vertical to 2 horizontal. Chutes shall be metal and of rounded cross
section. The slopes of all chute sections shall be approximately the same. The
discharge end of the chutes shall be maintained above the surfaces of the concrete in
the forms.
xvii. Placing by Pumping/ Pneumatic Placers
Concrete may be conveyed and placed by mechanically operated equipment e.g.

pumps or pneumatic placers, with the approval of Engineer. The slump shall be held
to the minimum, necessary for conveying concrete by this method.
When pumping is adopted, before pumping of concrete is started, the pipelines shall
be lubricated with one or two batches of mortar composed of one part cement and two
parts sand. The concrete mix shall be specially designed to suit pumping. Care shall
be taken to avoid stoppages in work once pumping has started.
When pneumatic placing is used, the manufacturer’s advice on the layout of pipelines
shall be followed to avoid blockages and excessive wear. Restraint shall be provided
at the discharge box to cater for the reaction at the end.
The manufacturer’s advice shall be followed regarding concrete quality and all other
related matters when pumping or pneumatic placing equipment is used.

xviii. Concrete in Layers
Concreting, once started, shall be continuous until the pour is completed. Concrete
shall be placed in successive horizontal layers of uniform thickness ranging between
150 and 900 mm as approved by Engineer. These shall be placed as rapidly as
practicable to prevent the formation of cold joints or planes of weakness between each
succeeding layer within the pour. The thickness of each layer shall be such that it can
be deposited before the previous layer has stiffened. The bucket loads or other units
of deposit shall be located progressively along the face of the layer with such overlap
to facilitate spreading the layer of uniform depth and texture with a minimum of
shovelling.
The top surface of each pour and bedding planes shall be approximately horizontal
unless otherwise instructed.
xix. Compaction
Effective compaction of newly placed concrete shall be obtained by vibration, agitation,

spading and rodding the concrete within the forms. At least two vibrators in dependable
working condition shall be available before commencement of concreting and kept in
working condition during the scheduled concreting period, each under the charge of
an experience workman.
All concrete, excepting slabs of thickness 10 cm or less, shall be compacted with high
frequency, mechanical vibrating equipment supplemented by hand spading and
tamping. Concrete slabs 10 cm or less in thickness shall be compacted by wood or
metal tampers, spading and settling with a heavy levelling straight edged beam.
Vibrators shall be designed to operate with the vibrating element having a frequency
of not less than 7000 impulses per minute. The equipment shall, at all times, be
adequate, in terms of units and power, to consolidate the poured concrete. The depth
of immersion shall be appropriate for the structure being concreted and the location of
concreting.
The vibrators shall not touch the reinforcement. When vibrating a freshly placed layer,
the vibrator shall be pushed down vertically into the preceding plastic layers and
withdrawn gradually, producing a dense concrete free of set concrete. The intervals at
which the vibrator should be immersed shall not exceed 2/3 of the apparent effective
area of vibration of the unit used. Excessive vibration and segregation of aggregates
shall be avoided.
For concrete containing an approved retarding admixture for structural walls, each
layer of concrete shall be in place and compacted for at least 30 minutes before the
next layer is placed. Bleed water on the surface of the concrete shall be removed
before additional concrete is placed and the concrete in place shall be re-vibrated
before the next lift is placed. At the top of walls and columns, concrete containing
excess water or fine aggregates cause by vibration shall be removed while still plastic
and the space filled with compacted concrete of the correct proportion and vibrated in
place.
xx. Slabs

For slabs, screeds shall be set at maximum of 2.5 metres. Centres and the correctness
of elevations shall be checked with an instrument level. The concrete shall be
compacted and tamped to bring ten mm of mortar to the surface and wood floated to
straight edges and screeds. The finished surfaces shall be level or sloped as required
and the maximum deviation permissible being 6 mm from 3m straight edge for the
exposed finishes. No steel or plastic floats shall be used for initial floating. Unless
otherwise specified, special finishes shall be applied only after the surface has
sufficiently hardened. All laitance and bleed water shall be removed as it appears.
Concrete shall be compacted during placing with approved vibrating equipment until
the concrete has been consolidated to the maximum practicable density, is free of
pockets of coarse aggregate and fits tightly against all form surfaces, reinforcement
and embedded fixtures. Particular care shall be taken to ensure that all concrete placed
against the form faces and into corners of forms or against hardened concrete at joints
is free from voids or cavities. The use of vibrators shall be consistent with the concrete
mix and caution is to be exercised to not over vibrate the concrete to the point of
segregation.
xxi. Vibrators
Vibrators shall conform to IS specifications. The type of vibrators to be used shall

depend upon the structure where concrete is to be placed. Shutter vibrators, to be
effective, shall be firmly secured to the formwork which must be sufficiently rigid to
transmit the vibrations and strong enough not to be damaged by it. Immersion vibrators
shall have load frequency amplitude and acceleration as per IS 2505 depending on
the size of the vibrator. Immersion vibrators, in sufficient numbers and each of
adequate size shall be used to properly consolidate all concrete. Tapping or external
vibrating of forms by hand tools or immersion vibrators will not be permitted.
The exact manner of application and the most suitable machines for the purpose shall
be selected and be operated by experienced operatives. Immersion vibrators shall be
inserted vertically at points not more than 450 mm apart and withdrawn when air
bubbles cease to come to the surface. Immersion vibrators shall be withdrawn very
slowly. In no case shall immersion vibrators be used to transport concrete inside the
forms. Particular attention shall be paid to vibration at the top of lift in a column or wall.
When placing concrete in layers which are advancing horizontally as the work
progress, great care shall be exercised to ensure adequate vibration, blending and
melding of the concrete between the successive layers.
Immersion vibrators shall penetrate the layer being placed and also penetrate the layer
below while the under layer is still plastic to ensure good bond and homogeneity
between the two layers and prevent the formation of cold joints.
Care shall be taken to prevent contact of immersion vibrators against reinforcement

steel. Immersion vibrators shall not come in contact with reinforcement steel after start
of initial set. They shall also not be allowed to come in contact with forms or finished
surfaces.
Form attached vibrators shall be used only with specific authorisation of Engineer.
The use of surface vibrators will not be permitted under normal conditions. However,
for thin slabs, surface vibration by specifically designed vibrators may be permitted,
upon approval of Engineer.

Formation of stone pockets or mortar ponding in corners and against faces of forms
shall not be permitted. Should these occur, they shall be dug out, reformed and refilled
to a sufficient depth and shape for thorough bonding as approved by Engineer.
xxii. Placement Intervals
Each placement of concrete shall be allowed to set for a period of 48 hours or longer
when required, before the start of subsequent placement. A time gap between the two
adjoining pours in the horizontal plane and the two adjacent pours in the vertical plane
shall be seven days and three days respectively.
Except when placing with slip forms, each placement of concrete in multiple lift work
shall be allowed to set for at least 24 hours after the final set of concrete and before
the start of a subsequent placement.
xxiii. Special Provision in Placing
When placing concrete in walls with openings, in floors of integral slab and beam
construction and other similar conditions, the placing shall stop when the concrete
reaches the top of the opening in walls or bottom horizontal surface of the slabs as the
case may be. Placing shall be resumed before the concrete in place takes initial set,
but not until it has had time to settle as determined by Engineer.
xxiv. Placing Concrete through Reinforcing Steel
When placing concrete through reinforcing steel, care shall be taken to prevent
segregation of the coarse aggregate. Where the congregation of steel makes placing
difficult, it may be necessary to temporarily move the top steel aside to get proper
placement and then restore the reinforcing steel to design position.
xxv. Bleeding
Bleeding or free water on top of concrete being deposited into the forms shall require
stopping the concrete pour and the conditions causing this shall be corrected before
any further concreting is resumed.
xxvi. Rain or Wash Water
No concrete shall be placed in wet weather or on a water covered surface. Any

concrete that has been washed by heavy rain shall be entirely removed, if there is any
sign of cement and sand having been washed away from the concrete mixture. To
guard against damage which may be caused by rain, the works shall be covered with
tarpaulins immediately after the concrete has been placed and compacted before
leaving the work unattended. Any water accumulating on the surface of the newly
placed concrete shall be removed by approved means and no further concrete shall
be placed thereon until such water is removed. To avoid water flowing over or around
freshly placed concrete, suitable drains and sumps shall be provided.
xxvii. Concreting in Hot Weather
The Contractor’s methods shall comply with the recommendations ACI 305, Hot
Weather Concreting, as modified and supplemented below.

The Contractor shall take great care during hot weather to prevent the cracking or
crazing of concrete. The Contractor shall arrange for concrete to be placed in the early
morning or late evening as directed by the Engineer.
The Contractor shall have particular regard to the requirements specified herein for
curing.
Formwork shall be shaded from direct exposure to the sun both prior to placing of the
concrete and during its setting. The Contractor shall take appropriate measures to
ensure that reinforcement in and projecting from the section to be concreted is
maintained at the lowest temperature practicable.
Concrete at placing shall have a temperature of not more than 32 OC. If necessary, the
Contractor shall cool the aggregates and mixing water by methods approved by the
Engineer.
Where necessary, the Contractor shall design, install and operate a cooling system by
which cooling water is pumped through a piping system in order to decrease the heat
of hydration during concreting. The proposal for such a cooling system shall be
submitted to the Engineer for his approval two weeks prior to the concreting
operations.
The temperatures of ambient air, concrete at various levels and at intervals not
exceeding 5 metres and cooling water where applicable shall be measured by means
of thermocouples and recorded with a Philips type PR 3210 A/00 recorder or similar
approved.
xxviii. Placing of Concrete Under Water
Under all ordinary conditions all foundations shall be completely dewatered and
concrete placed in the dry. However, when concrete placement under water is
necessary, all work shall conform to IS 456 and procedure shall be as follows:
Concrete shall be deposited under water by means of tremies or bottom-drop buckets

of approved type.
All work requiring placement of concrete underwater shall be designed, approved and
inspected with regard to the local circumstances and purposes. All under water
concrete shall be placed according to the specifications and as approved by the
Engineer.
xxix. Protection
All concrete shall be protected against damage.
xxx. Corrosion Resistant Lining
Where required, corrosion resistant linings shall be applied strictly according to the
manufacturer’s instructions. The work shall be performed by experienced personnel
under the supervision of a qualified representative of the manufacturer. The completed
lining shall be securely bonded to the substrate and provide the required corrosion
resistant protection.
xxxi. Installation of Pipes, Electrical Conduits etc Through Concrete Structures

Wherever required, the Contractor shall install in place, before concreting, any pipe,
electrical conduit or other special item that passes through or terminates at any
concrete wall. Alternatively the Contractor shall obtain the prior approval of the
Engineer of shop drawings of the methods he proposes to adopt, particularly if he
intends to leave an opening and install the special item later after approval that a
special item may be concreted in later, the opening shall be accurately fashioned to
receive it. Pipes passing through walls or floors of water retaining or earth supporting
structures shall be provided with welded puddle flanges and the opening provided shall
take this into account.
1) The opening provided shall be of sufficient size to permit accurate final alignment
of the embedded fitting without deflecting any part and allowing adequate space
for satisfactory spacing where the pipe passes through openings so formed.
2) The box-outs shall be provided with continuous keyways to hold the concrete filling
in place and ensure water-tightness.
3) The space left within the box-outs and around the special item positioned in place,
shall be filled with non-shrink grout or non-shrink concrete as approved by the
Engineer.
xxxii. Mass Foundations
Mass foundations shall be poured in lifts not exceeding 1.5 m. in height unless
otherwise approved by Engineer.
xxxiii. Treatment of Construction Joints on Resuming Concreting
All laitance and loose stones shall be thoroughly and carefully removed by wire
brushing/ hacking and surface washed.
Just before concreting is resumed, the roughened joint surface shall be thoroughly
cleaned and loose matter removed and then thoroughly wetted. The new concrete shall
be well worked specially against the prepared face. Special care shall be taken to
obtain thorough compaction and to avoid segregation of the concrete along the joint
plane.
xxxiv. Water
Clean water in pipes under pressure shall be provided by the contractor with all
necessary equipment for giving a nozzle pressure of not less than 2.0 kg/cm2 for the
convenient and effective jetting of rock foundations and concrete surfaces, for cooling
aggregate required for concrete, for curing concrete and other requirements.
xxxv. Protecting Fresh Concrete
Fresh concrete shall be protected from the elements, from defacement and damage due
to construction operations by leaving forms in place for ample periods. Newly placed
concrete shall be protected by approved means, such as tarpaulins, from rain, sun and
winds. Steps, as approved by the Engineer, shall also be taken to protect immature
concrete from damage by debris, excessive loading, vibration, abrasion or contact with
other materials or otherwise disturbed. If it is necessary that workmen enter the area of
freshly placed concrete, bridges shall be placed over the area.

13.5.6.2 Concrete for Large Pours
This clause applies to large concrete pours where measures need to be taken to deal with
the generation of heat and attendant volume change to minimise cracking.
If available, coarse aggregate shall be of limestone or other aggregate with a low

coefficient of thermal expansion and of angular shape. Measures shall be taken to limit the
effects of thermal movement in the concrete. The maximum temperature during hydration
shall not exceed 65 ºC. The concrete mix may include an approved type of water reducing
/workability admixture. Form-work for the sides shall be of minimum 19 mm thick plywood
or equivalent thermal resistant to ensure that the maximum specified thermal gradient is
not exceeded during curing. All formwork for pits, ducts, rebates and holding down bolts
shall be constructed so that it can be easily collapsed to facilitate removal after the initial
set of the concrete. The top of formwork for holes shall be covered to prevent entry of
excess grout or other substances.
Standby plant shall be available for all plant used for the construction of the foundations.
For compressors, vibrators, cranes, concrete pumps, lighting equipment and the like,
standby plant shall be on site before concreting commences.
Concrete shall be placed in single pours lasting no more than 16 hours. The sequence of
placing shall be such, that exposed concrete shall be covered with fresh concrete within
one hour of first mixing of the exposed concrete. Re-compaction of the original with the
fresh concrete shall be undertaken to ensure a homogenous mass without a cold joint.
The concrete shall be placed and compacted in such a manner as to ensure that cracking
due to plastic settlement does not occur. On completion of a pour, the top surface shall be
steel trowel finished and the exposed concrete shall be sprayed with an approved curing
compound. Space shall be arranged around the pour to allow the free flow of air during
curing. The poured concrete shall be protected if necessary with insulation to limit the
thermal gradient between the core and the surface to below 20 °C. The pour shall contain
thermocouples distributed within the concrete in accordance with the Contractors design.
The Contractor shall measure and record the internal and surface concrete temperatures
daily until the formwork is stripped.
The formwork and insulation shall be left in place until the surface temperature is at the
average ambient daily temperature. The method statement for the construction of each
large pour shall include the following information:
1) Details of the mix design and source of supply.
2) Full details of the formwork with particular reference to the installation of holding down
bolt formers.
3) Details of the placing procedure including method of placing, standby arrangements,
number of vibrators and number of supervisors and operatives.
4) Details of insulation for the pours and how the pours are to be cured.
5) Details of how the concrete is to be placed and compacted without cold joints and
without cracking resulting from plastic settlement.
Within six weeks after construction of large pours, the Contractor shall issue a construction
report containing full details of the construction, materials testing results and as-built
drawings.

13.5.6.3 Concrete for Machine Foundations
Design and construction of machine foundations shall be carried out in accordance with
IS 2974. After commissioning rotating machines, the Contractor shall carry out a full
vibration survey to record the vibrations of the foundations. The results of the survey shall
be submitted to the Engineer.
13.5.6.4 Joints in Concrete
i. General
Provision shall be made for expansion and contraction in concrete by the use of special
joints located as necessary. Construction joint surfaces shall be as specified or as
approved by Engineer.
Concrete shall be placed without interruption until completion of the part of the work
between predetermined construction joints. The time lapse between the pouring of
adjoining units shall be as specified or as approved by Engineer.
Construction joints shall be avoided if possible or their number minimised. Concreting

shall be carried out continuously up to construction joints the position and arrangement
of which shall be indicated by the Contractor’s designer. Construction joints shall
comply with IS 11817.
Construction joints shall be placed at accessible locations to permit cleaning out of

laitance, cement slurry and unsound concrete in order to create rough/uneven surface.
Laitance and cement slurry shall be cleaned out by using wire brushes on the surface
of the joint immediately after initial setting of the concrete. The prepared surface should
be in a clean saturated surface dry condition when fresh concrete is placed against it.
In the case of construction joints at locations where the previous pour has been cast
against shuttering, the aggregate of the previously poured concrete shall be exposed
using a high pressure water jet or by another appropriate means.
At least 3 weeks prior to commencement of concreting, the Contractor shall supply

drawings to the Engineer indicating all expansion or other movement joints both
vertical and horizontal including details of the type of joint to be provided, the method
of concreting, the concreting lifts to be achieved in a single continuous operation and
any other relevant details. One copy of the drawing, approved or modified, shall be
returned to the Contractor.
Expansion joints shall be indicated on the Contractor’s drawings. The width of the joint
shall generally be 13 mm. except where synthetic rubber (sealant) sealed joints are
specified, joint filler and joint sealer shall be provided, with the filler to between 13 mm
and 19 mm from the concrete face and then the sealer finished flush with surface. At
synthetic rubber sealed joints, the filler shall be to 13 mm from the concrete face to
receive sealant, unless otherwise specified.
All Construction joints shall be provided with suitable keyways or other keying
methods. The old surface shall be roughened until the clean aggregate embedded in
the mortar matrix is exposed, by chipping, sand-blasting or application of a surface
mortar retardant followed by washing and scrubbing with a stiff brush. Reinforcement
and water-stops shall be effectively protected. The prepared surface shall be kept wet
for at least 24 hours before placing new concrete. Immediately prior to commencement
of the new concreting, water shall be deposited on the prepared horizontal surface of

the old concrete. If water-stops are not used, the coarseness amplitude of the prepared
surface shall be at least 6 mm.
Roof and floor slabs shall be poured in alternating checker-board fashion between
approved construction joints. Concreted sections shall be fully cured before adjoining
sections are concreted. All construction joints in floor slabs and rafts shall be painted
with a 230 mm wide strip of bitumen paint to be applied in two thick layers.
Fresh concrete should be thoroughly vibrated near construction joints so that mortar
from the new concrete flows between large aggregates and develops a proper bond
with old concrete.
Where high shear resistance is required at the construction joints, shear keys shall be
provided.
Sprayed curing membranes and release agents should be thoroughly removed from
joint surfaces.
If the stopping of concreting becomes unavoidable, a properly formed construction joint

shall be made where the work is stopped. Joints shall be either vertical or horizontal.
In the case of an inclined or curved member, the joints shall be at right angles to the
axis of the member. Vertical joints in walls shall be kept to a minimum. Vertical joints
shall be formed against a stop board, horizontal joints shall be level and wherever
possible, arranged so that the joint lines coincide with the architectural features of the
finished work. Battens shall be nailed to the formwork to ensure a horizontal line and
if approved, shall also be used to form a grooved joint. For tank walls, similar work
joints shall be formed as per IS 3370. Concrete that is in the process of setting shall
not be disturbed or shaken by traffic either on the concrete itself or upon the shuttering.
Horizontal and vertical construction joints and shear keys shall be located and shall
conform in detail to the Contractor’s approved drawings unless otherwise approved by
Engineer. The joints shall generally be in accordance with the following:
ii. Column Joints
In a column, the joint shall be formed 75 mm below the lowest soffit of the beams,
including haunches if any. In flat slab construction, the joint shall be 75 mm below the
soffit of column capital. At least two hours shall elapse after depositing concrete in
column, piers or walls, before depositing in beams, girders or slabs supported thereon.
iii. Beam and Slab Joints
Concrete in a beam shall be placed throughout without a joint but if the provision of a
joint is unavoidable, the joint shall be vertical and at the centre or within the middle
third of the span unless otherwise approved. Where a beam intersects a girder, the
joints in the girder shall be offset a distance equal to twice the width of the beam and
additional reinforcement provided for shear. The joints shall be vertical throughout the
full thickness of the concrete member. A joint in a slab shall be vertical and parallel to
the principal reinforcement. Where it is unavoidable at right angles to the principle
reinforcement, the joint shall be vertical and at the middle of span.
iv. Joints in Liquid Retaining Structures

Vertical construction joints in watertight construction will not be permitted. Where a

horizontal construction joint is required to resist water pressure, special care shall be
taken in all phases of its construction to ensure maximum water-tightness.
v. Expansion and Movement Joints
Joint filler shall consist of a proven bituminous compound approved by the Engineer.
Application of the filler shall be strictly in accordance with the manufacturer’s
instructions.
The Contractor shall supply, for the Engineer’s approval, details of the proposed
materials including the mechanical properties. The manufacturer shall design the width
and thickness of the elastomeric compound to accommodate the maximum designed
thermal shrinkage movement at the joint. Joint Sealers shall be of impermeable ductile
material providing a water-tight seal through the full joint movement range. Details of
joint sealing are given in Section 22.16.
vi. Water-Stops
Water bars or water stops shall be extruded from a polyvinyl chloride compound
containing the plasticizers, resins, stabilizers and other ingredients needed to import
the required characteristics or from synthetic rubber. The Contractor shall supply to the
Engineer, details of the thickness of the water- stop offered by him to indicate its
adequacy to withstand the design pressures. All water-stop interactions such as ells,
tees, crosses etc shall be fabricated by the manufacturer and shall have sufficiently
long legs to permit field butt splicing. Water-stops shall be provided in all expansion
and movement joints. Water-stops shall be continuous in joints, following offsets and
angles in joints until spliced to water-stops at intersections and thereby completely
sealing the structure. The flanges of water-stops shall be secured to the reinforcement
with 18 gauge wire ties at a maximum spacing of 45 centimetres or with a PVC binding
where that is specifically recommended by the water-stop manufacturer. PVC water-
stops shall be neatly fused and synthetic rubber water-stops vulcanized at joints and
connections unless explicitly otherwise specified by the manufacturer.
Water stops shall be provided at all vertical construction joints in walls of water
retaining structures and all expansion joints in water retaining structures and wherever
specified or directed by the Engineer.
Water stops shall not be exposed to direct sunlight for long periods. Before being
concreted, water stops shall be cleaned of all foreign materials. Wherever provided,
water stops shall be placed in such a manner that they are embedded in the adjacent
sections of the panels for equal width.
The storage, fixing in position, splicing of water stops shall be as per manufacturer’s
instructions. Water stops shall be fully supported in the formwork, be free of nails and
clear of reinforcement and other fixtures. Damaged water stops shall be replaced and
during concreting care shall be taken to place concrete so that water stops do not bend
or distort.
The different type of water stops to be used in liquid retaining structures shall be as
follows:

Type of Joint Type of Water Stops

1 Partial/ complete construction joint in 150 mm wide, ribbed with hollow centre
walls and slabs bulb and 5 mm minimum thickness
2 Expansion joints in walls and slabs 225 mm wide, ribbed with hollow centre
bulb and 9 mm minimum thickness
3 Construction joint in raft 225 mm wide, ribbed with hollow centre
4 Construction joint in wall 150 mm wide, ribbed with hollow centre
5 Partial/ complete construction joint in 225 mm wide, ribbed with hollow centre
raft bulb and 5 mm minimum thickness
6 Expansion joint in raft 225 mm wide, ribbed with hollow centre
vii. Dowels
Dowels for concrete work, not likely to be taken up in the near future, shall be wrapped
in tar paper and burlap.
13.5.6.5 Curing
i. Curing Formed Concrete
All concrete shall be cured by keeping it continuously damp for the period of time
required for complete hydration and hardening to take place. Curing shall be by use of
the water curing method, specified liquid membrane forming compound or concrete
curing paper, the specified use of any method being subject to the approval of the
Engineer.
Preference shall be given to the use of continuous sprays or ponded water,

continuously saturated covering of sacking, canvas, hessian or other absorbent
materials, or approved effective curing compounds applied with spraying equipment
capable of producing a smooth, even textured coat. Extra precautions shall be
exercised in curing concrete during hot weather. The quality of curing water shall be
the same as that used for mixing the concrete.
Certain types of finish or preparation for overlaying concrete must be made at certain
stages of the curing process and special treatment may be required for specific
concrete surface finishes.
Curing of concrete made of high alumina cement and super-sulphated cement shall be
carried out as approved by the Engineer.
The structural elements with concrete having water binder ratio less than or equal to
0.4 or partial replacement of cement by pozzolanic materials (5% or above
replacement by silica fume or high reactivity metakaoline, or 15% or above by fly ash)
shall be cured in two stages, initial curing and final curing.
The initial curing should be started not later than three hours or after the initial setting
time, whichever is lower, after placement of concrete. The concrete surfaces exposed
to the environment shall be covered by plastic sheet or other type of impermeable

covers. The initial curing should be continued up to a minimum period of 12 hours or 2

hours plus final setting time of concrete, whichever is higher.
Final curing shall be with water and commence immediately after initial curing and
continue for a minimum period of 14 days.
ii. Continuous Spraying
Curing shall be assured by the use of an ample water supply under pressure in pipes,
with all necessary appliances of hose sprinklers and spraying devices. Continuous fine
mist spraying or sprinkling shall be used, unless otherwise specified or approved by
Engineer.
iii. Alternative Curing Methods
Whenever, in the judgment of the Contractor’s designer and with the approval of the
Engineer, it may be necessary to omit the continuous spray method, covering of clean
sand or other approved means such as wet gunny bags, which will prevent loss of
moisture from the concrete, may be used. Any type of covering which would stain or
damage the concrete during or after the curing period shall not be used. The covering
shall be kept continuously wet during the curing period.
For curing of concrete in pavements, side-walks, floors, flat roofs or other level
surfaces, the ponding method of curing is preferred. The method of containing the
ponded water shall be approved by Engineer. Special attention shall be given to edges
and corners of slabs to ensure proper protection to these areas. The ponded areas
shall be kept continuously filled with water during the curing period.
iv. Curing Equipment
All equipments and materials required for curing shall be on hand and ready for use
before the concrete is placed.
v. Membrane Curing
Approved curing compounds may be used in lieu of moist curing with the permission
of Engineer. Such compounds shall be applied to all exposed surfaces of the concrete
as soon as possible after the concrete has set. Impermeable membranes such as
polyethylene sheeting covering, the concrete surface closely may also be used to
provide an effective barrier against evaporation.
For concrete containing Portland pozzolona cement, Portland slag cement or mineral
admixtures, an increased period of curing may be required.
13.5.6.6 Repair and Replacement of Unsatisfactory Concrete
Immediately after shuttering is removed, the surfaces of concrete shall be very carefully
inspected and all defective areas called to the attention of Engineer who may permit
patching of the defective areas or else reject the concrete either partially or entirely.
Rejected concrete shall be removed and replaced by the Contractor. Holes left by form
bolts etc. shall be filled and made good with mortar composed of one part of cement to
one and half parts of sand, that passes through a 2.36 mm IS sieve, after removing any
loose stones adhering to the concrete. Mortar filling shall be struck off flush at the face of

the concrete. The concrete surface shall be finished as described under the particular item
of work.
Superficial honey combed surfaces and rough patches shall be similarly made good
immediately after removal of shuttering, in the presence of Engineer and superficial water
and air holes shall be filled in. The mortar shall be well worked into the surface with a
wooden float. Excess water shall be avoided. Unless instructed otherwise by Engineer,
the surface of exposed concrete placed against shuttering shall be rubbed down
immediately on removal of shuttering to remove fine or other irregularities. Care shall be
taken to avoid damaging the surfaces. Surface irregularities shall be removed by grinding.
If reinforcement is exposed or the honey combing occurs at vulnerable positions. Such as

at the ends of beams or columns, it may be necessary to cut out the member completely
or in part and reconstruct. The decision of Engineer shall be final. If in the opinion of the
Engineer only patching is necessary, the defective concrete shall be cut out until solid
concrete is reached (or to a minimum depth of 25 mm), the edges being cut perpendicular
to the affected surface or with a small undercut if possible, anchors, tees or dowels shall
be provided in slots whenever necessary to attach the new concrete securely in place. An
area extending several centimetres beyond the edges and the surfaces of the prepared
voids shall be saturated with water for 24 hours immediately before the patching material
is placed.
i. Use of Epoxy Mortar
The use of epoxy mortar for bonding fresh concrete used for repairs will be permitted
upon written approval of Engineer. Epoxy mortar shall be applied in strict accordance
with the instruction of the manufacturer.
ii. Method of Repair
Small size holes having surface dimensions about equal to the depth of the hole, holes
left after removal of form bolts, grout insert holes and slots cut for repair of cracks shall
be repaired as follows:
The hole to be patched shall be roughened and thoroughly soaked with clean water
until absorption stops.
A 5 mm thick layer of grout of equal parts of cement and sand shall be well brushed
into the surface to be patched followed immediately by the patching concrete which
shall be well consolidated with a wooden float and left slightly proud of the surrounding
surface. The concrete patch shall be built up in 10 mm thick layers. After an hour or
more, depending upon weather conditions, it shall be worked off flush with a wooden
float and a smooth finish obtained by wiping with hessian. Steel trowels shall not be
used for this purpose. The mix for patching shall be of the same materials and in the
same proportions as that used in the concrete being repaired, although some reduction
in the maximum size of the coarse aggregates may be necessary and the mix shall be
kept as dry as possible.
Mortar filling by air pressure (guniting) shall be used for repair of areas too large and/
or too shallow for patching with mortar. Patched surfaces shall be given a final
treatment to match the colour and texture of the surrounding concrete. White cement
shall be substituted for ordinary cement, if so approved by Engineer, to match the
shade of the patch with the original concrete.

iii. Curing of Patched Work
The patched area shall be covered immediately with an approved non-staining water-
saturated material such as gunny bags, which shall be kept continuously wet and
protected against the sun and wind for a period of 24 hours. Thereafter, the patched
area shall be kept wet continuously by a fine spray of water for not less than 10 days.
iv. Approval by Engineer
All materials, procedures and operations used in the repair of concrete and also the
finished repair work shall be subject to the approval of Engineer. All fillings shall be
tightly bonded to the concrete and shall be sound and free from shrinkage cracks after
the fillings have been cured and dried.
13.5.6.7 Finishing
This specification is intended to cover the treatment of concrete surfaces of all structures.
i. Finishes for Formed Surfaces
The type of finish for formed concrete surfaces shall be as follows, unless otherwise
approved by the Engineer:
For surfaces against which backfill or concrete is to be placed, no treatment is required

except repair of defective areas.
For surfaces below grade, which will receive waterproofing treatment, the concrete
shall be free of surface irregularities which would interfere with proper application of
the waterproofing materials which is specified for use.
Surfaces which will be exposed to the weather and which would normally be level shall
be sloped for drainage. Unless a horizontal surface is specially specified or a particular
slope required, the tops of narrow surfaces such as staircase treads, walls, curbs and
parapets shall be sloped across the width at 1 in 30. Broader surfaces such as
walkways, roads, parking areas and platforms shall be sloped at 1 in 50. Surfaces that
will be covered by backfill or concrete, sub floors to be covered with concrete topping,
terrazzo or quarry tile and similar surfaces shall be smooth, screeded and levelled to
produce even surfaces. Surface irregularities shall not exceed 6 mm. Surfaces which
will not be covered by backfill, concrete or tile topping such as external decks, floors
of galleries and sumps, parapets, gutters, sidewalks, floors and slabs shall be
consolidated, screeded and floated.
Excess water and laitance shall be removed before final finishing. Floating may be
done by hand or power tools and started as soon as the screeded surface has attained
a stiffness to permit finishing operations and these shall be the minimum required to
produce a surface uniform in texture and free from screed marks or other
imperfections. Joints and edges shall be tooled as required or as approved by the
Engineer.
ii. Standard Finish for Exposed Concrete
Exposed concrete shall mean any concrete other than floors or slabs exposed to view
upon completion of the job. Unless otherwise specified on the drawings, the standard
finish for exposed concrete shall be of smooth finish.

A smooth finish shall be obtained with the use of lined or plywood forms having
smoothed and even surfaces and edges. Panels and form linings shall be of uniform
size and be as large as practicable and installed with closed joints. Upon removal of
forms, the joint marks shall be smoothed off and all blemishes, projections etc
removed, leaving the surfaces smooth and unmarred.
iii. Integral Cement Concrete Finish
When required, an integral cement concrete finish of specified thickness for floors and
slabs shall be applied either monolithically or bonded, as specified in IS2571. The
surface shall be compacted and then floated with a wooden float or power floating
machine. The surface shall be tested with a straight edge and any high and low spots
eliminated. Floating or trowelling of the finish shall be permitted only after all surface
water has evaporated. Dry cement or a mixture of dry cement and sand shall not be
sprinkled directly on the surface of the cement finish to absorb moisture or to stiffen
the mix.
iv. Rubbed Finish
A rubbed finish shall be provided only on exposed concrete surfaces as required. Upon
removal of forms, all fins and other projections on the surfaces shall be carefully
removed, offsets levelled and voids and/ or damaged sections repaired. The surfaces
shall then be thoroughly wetted and rubbed with carborundum or other abrasive.
Cement mortar may be used in the rubbing, but the finished surfaces shall not be brush
coated with either cement or grout after rubbing. The finished surfaces shall present a
uniform and smooth appearance.
13.5.6.8 Field Quality Control
All concreting shall be supervised by the Engineer and in order to enable the Engineer to
make the requisite arrangements, the Contractor shall give him adequate notice of the
proposed concreting operations which, except under special circumstances, shall not be
less than 24 hours after checking reinforcement and formwork. Any concreting done in the
absence of, or without the express permission of the Engineer is liable to rejection.
13.5.6.9 Tests
All tests specified in the Indian Standards shall be regularly carried out together with any
additional tests the Engineer may require to satisfy him regarding the quality of the work
done. If the results of any tests indicate the concrete in question is unsatisfactory in any
respect, the Contractor shall take any steps indicated by the Engineer to rectify the same
and if such rectification is not found to be satisfactory or adequate, the section in question
shall be removed and re-concreted.
While all the tests stipulated in the Indian Standards are necessary, the carrying out of the
field slump- tests and the making of the specified works test cubes from every batch of
concrete, or as otherwise specified by the Engineer, shall be carried out as an invariable
general rule. The following requirements in respect of concrete testing will be rigidly
applied throughout the duration of the Contract to all permanent works.
i. Sampling Procedure

Sampling and testing shall be in accordance with IS 1199 and IS 516. Evaluation of
the results and acceptance or rejection of the concrete will be done as described
below.
Two cubes pre 150 Cum. Or part there of or minimum six cubes per days work
whichever is more shall be taken at work site. Half the number in each sample shall be
tested at 7 days and the balance at 28 days. Where the tests are carried out in the site
laboratories, companion cubes shall be tested on the dates on which the
representative samples are tested at site at an independent laboratory approved by
the Engineer. If a significant difference is noticed between the two sets of results all
further testing shall be done at the approved laboratory until the site equipment is
rectified satisfactorily. No reduction in the frequency or number of samples taken shall
be made without the explicit approval of the Engineer who, if agreeing to any reduction,
shall have such a decision mainly on the consistency of good results achieved over an
acceptable period. Any deterioration in quality will result in the more rigorous schedule
being re-implemented.
The values given in table below may be taken for general guidance in the case of
concrete made with ordinary cement. In all cases, the 28 day compressive strength
specified shall alone be the criterion for acceptance or rejection of the concrete. If
however, from tests carried out for a particular job over a reasonably long period, it has
been established to the satisfaction of the Engineer that a suitable ratio between 28
days compressive strength and the modulus of rupture at 72 (+/-) 2 hours or 7 days or
compressive strength at 7 days may be accepted, the Engineer may suitably relax the
frequency of 28 day compressive strength tests, provided the expected strength values
at the specified early age are consistently met.
Optional Tests Requirements of Concrete:
Compressive strength on 15 Modulus of rupture by beam test min.

Grade of cm cubes min. at 7 days
Concrete At 72 (+/-) 2 hours At 7 days
N / mm2 N / mm2 N / mm2
M 10 7.0 1.2 1.7
M 15 10.0 1.5 2.1
M 20 13.5 1.7 2.4
M 25 17.0 1.9 2.7
M 30 20.0 2.1 3.0
M 35 23.5 2.3 3.2
M 40 27 2.5 3.4
ii. Test Specimen
Three test specimens shall be made from each sample for testing at 28 days.
Additional cubes may be required for various purposes such as to determine the
strength of concrete at 7days or at the time of striking the form work or to determine
the duration of curing or to check the testing error. Additional cubes may also be
required for testing cubes cured by accelerated methods as described in IS 9013 -
1978. The specimen shall be tested as described in IS 516 - 1959.

iii. Frequency
The minimum frequency of sampling of concrete of each grade shall be in accordance

with following table:
Quantity of Concrete m3 Number of Samples

1–5 1
6 – 15 2
16 – 30 3
31 – 50 4
51 & above 4 + one per additional 50m3
At least six samples (Cubes) shall be taken from each shift. Where concrete is in
continuous production, such as at a ready-mixed concrete plant, the frequency of
sampling may be agreed upon mutually by suppliers and purchasers.
iv. Test Strength of Samples
The test strength of the samples shall be the average of the strength of three
specimens. The individual variation should not be more than (+/-) 15 percent of the
average.
v. Standard Deviation
This section should be read in conjunction with Section 17.3 17.4.1 of this specification.
The standard deviation and coefficient of variation shall be computed for a set of any
10 consecutive tests. The probable minimum strength of the batch, as calculated from
the results of the 10 tests, based on failure probability of 1 in 10, shall then be
compared with the specified minimum strength for the relevant grade of concrete.
1) If the calculated minimum strength exceeds the specified minimum strength by 10

percent or more, the Contractor will be permitted to redesign the mix with a lower
cement content, if feasible.
2) If the calculated strength exceeds the specified minimum strength by not more than
10 percent, the mix design shall be used for subsequent batches of concrete.
3) If the calculated strength falls short of the minimum specified strength but by not
more than 10 percent, the decision to accept or reject the representative batch of
concrete will be at the sole discretion of the Engineer. The location of the batch in
the structure, the maximum stresses likely to occur therein, the calculated strength
of the cubes and other relevant factors will be taken into consideration, but his
decision, once given shall not be subject to question or dispute nor shall it be
subsequently quoted as a precedent.
4) If the calculated minimum strength falls short of the specified minimum strength by
more than 10 percent, the representative batch of concrete shall be rejected.
5) All water retaining structures shall be tested for water-tightness in conformance
with the requirements of IS 3370 (Part I) – 1965, section 10 to the satisfaction of
the Engineer.

13.5.6.10 Acceptance Criteria
The concrete shall be deemed to comply with the strength requirements when both the
following conditions are met:
a) The mean strength determined from any group of four consecutive test results
complies with the appropriate limits in column 2 of the table below
b) Any individual test result complies with the appropriate limits in column of Table below.
Characteristic Compressive Strength Compliance Requirement:
Non-overlapping
Mean of the group of 4 non-
Specified consecutive test results
overlapping consecutive test results
grade in N / mm2 Individual test
in N / mm2
results in N/ mm2
M 15 = / >fck + 0.825 x established standard = / >fck –3 N/ mm2
deviation (rounded off to nearest
0.5 N/ mm2
Or
= / >fck + 3 N / mm2
whichever is greater
M 20 or above = / >>fck + 0.825 x established standard = / >fck – 4 N / mm2
deviation (rounded off to nearest
0.5 N/ mm2
Or
= / >fck + 4 N / mm2
Note – In the absence of an established value of standard deviation, the values given in
(assumed standard deviation) may be assumed and an attempt should be made to obtain
the results of 30 samples as early as possible to establish the value of standard deviation.
i. Flexural Strength
When both the following conditions are met, the concrete complies with the specified
flexural strength.
1) The mean strength determined from any group of four consecutive test results
exceeds the specified characteristic strength by at least 0.3 N/mm2.
2) The strength determined from any test result is not less than the specified
characteristic strength less 0.3 N/mm2.
ii. Quantity of Concrete Represented by Strength Test Results
The quantity of concrete represented by a group of four consecutive test results shall
include the batches from which the first and last samples were taken together with all
intervening batches.
For the individual test result requirements given in column 2 of above table or in item
(b) of flexural strength, only the particular batch from which the sample was taken shall
be at risk.
Where the mean rate of sampling is not specified the maximum quantity of concrete
that four consecutive test results represent shall be limited to 60m3.

If the concrete is deemed not to comply pursuant to the above, the structural adequacy
of the parts affected shall be investigated and any consequential action as needed
shall be taken.
Concrete of each grade shall be assessed separately.
iii. Alterations and Concreting against Surfaces
Existing concrete surfaces which are to receive new concrete shall be heavily sand-
blasted to expose the coarse aggregate and produce a clean, coarse textured surface.
Such prepared surfaces shall be coated with an epoxy bonding or other approved
coating immediately prior to concreting. The compound shall be equal or superior to
“Sikastix Adhesive” manufactured by the Sika chemical company and shall be mixed
and applied strictly in accordance with the manufacturer’s recommendations under
different conditions.
13.5.7 Ready Mixed Concrete
13.5.7.1 General
Ready mixed concrete (RMC) shall comply with the requirements of IS 4926 or the latest
Indian Standard. Concrete delivered at site shall be in a plastic condition and requiring no
further treatment before being placed in the position in which it is to set and harden. The
continuing mixing of concrete during transport shall be at a reduced speed to prevent
segregation. Concrete shall be produced by completely mixing cement, aggregates,
admixtures (if any) and water at a stationary central mixing plant and delivered in transit
mixers. Concrete may be produced in a transit mixer at the batching plant, with the mixing
being carried out entirely in the transit mixer either during the journey or on arrival at the
site of delivery. No water shall be added to the aggregate and cement until the mixing of
concrete commences.
13.5.7.2 Manufacturing
The ready-mixed concrete shall be manufactured and supplied on either of the following
bases:
1) Specified strength based on 28-day compressive strength of 15 cm cubes tested in
accordance with IS: 456-2000.
2) Specified mix proportion.
Where the contract requires using ready mix concrete of designated strength, the
Contractor shall procure the same from approved suppliers only and Section 17.6 shall
also apply to concreting done with ready mix concrete.
When the concrete is manufactured and supplied on the basis of specified strength, the
responsibility for the design of mix shall be that of the manufacturer and the concrete shall
conform to the requirements specified.
When the concrete is manufactured and supplied on the basis of specified mix proportions,
the responsibility for the design of the mix shall be that of the mix designer and the concrete
shall conform to the requirements specified.

13.5.7.3 Supply
Ready mix concrete prepared and transported will be as per IS 4926 of 1976 or the latest
IS. Code.
Water is not to be added to ready mixed concrete on site.
Ready mix concrete will be brought to the site from the RMC plant only by transit mixers
(agitators).
Every transit mixer will carry a delivery ticket, stating the minimum following details:
a) Name of manufacturer and depot
b) Serial number of the ticket.
c) Date
d) Truck number
e) Name of Contractor to whom the RMC is being supplied
f) Location of contract
g) Grade of concrete.
h) Specified workability
i) Cement content and grade of cement
j) Time of loading
k) Quality of concrete.
l) Batch Mix
When the truck arrives on site, the drum, should always be rotating at about 10 to 15
rev/min, for at least three minutes, to ensure that the concrete is thoroughly mixed and
uniform before discharge.
When a truck mixer or agitator is used for the mixing or transportation concrete, no water
from the truck-water system or from elsewhere shall be added after the initial introduction
of the mixing water for the batch,
Unless otherwise specified, when a truck or agitator is used for transporting concrete, the
concrete shall be delivered to the site of the work and the discharge shall be complete
within 1½ hour when the prevailing atmospheric temperature is above 20ºC and within 2
hours when the prevailing atmosphere temperature is at or below 20ºC of adding the
mixing water to the mix of cement and aggregate or adding the cement to the aggregate
whichever is earlier.
13.5.8 Plain Cement Concrete
For plain cement concrete work, the specification for cement, sand, fine and coarse
aggregates and water shall be the same as that specified in reinforced concrete but the
proportion of mix will be nominal and the ratio of fine and coarse aggregate may be slightly
adjusted within limits, keeping the total value of aggregates to a given volumes of cement
constant to suit the sieve analysis of both the aggregates. Cement shall not be measured
by volume and shall always be used directly from the bags (i.e. 50 kg/bag). The nominal
maximum size of coarse aggregate for 1:2:4 mix shall be as specified for reinforced
concrete and for 1:3:6 and 1:4:8 mix shall be 40 mm for concrete 300 mm and more thick
and 25 mm for concrete less than 300 mm thick.
The quantity of water used shall be such as to produce concrete of the consistency
required by the particular class of work and shall be decided by the use of a slump cone.
Sufficient care should be taken to ensure that no excess quantity of water is used.

Cement Sand
Mix proportion Coarse Aggregate m3 Water
in bags m3
Ordinary mix in volume 40 mm 20 mm 12mm
1:5:10 2.60 0.475 0.6623 0.2583 - 156
1:4:8 3.40 0.500 0.6883 0.6883 - 153
1:3:6 (with 40 mm aggr.) 4.4 0.485 0.672 0.672 0.262 176
1:3:6 (with 20 mm aggr.) 4.4 0.485 - 0.727 0.242 162.5
1:2:4 (with 20 mm aggr.) 6.4 0.47 - 0.705 0.235 205
1:2:4 (with 40 mm aggr.) 6.4 0.47 0.544 0.241 0.126 235
1:1.5:3 8.0 0.441 - 0.6615 0.2205 240
1:1:2 12.20 0.45 - 0.675 0.225 330
The slump shall be specified for each class of work and shall in general be as follows:
Type of Concrete Max. slump (in mm)

Mass concrete 50
Concrete below water proofing treatment 50
Coping 25
Floor paving 50
All plain concrete shall be mixed in a drum type powder driven machine with a loading
hopper which will permit the accurate measure of various ingredients. If hand mixing is
authorised, it should be done on a watertight platform.
The mixing of each batch in the concrete mixer shall continue for not less than 1.5 minutes
after the materials and water are in the mixer. The volume of mixed materials per batch
shall not exceed the manufacturers rated capacity of the mixer. The mixer shall rotate at a
speed of about 10 to 18 rev. per minute.
13.5.9 Pre-Cast Concrete
13.5.9.1 General
Pre-cast concrete and pre-cast reinforced concrete shall comply with IS 456 and with the
following requirements. Pre-cast concrete units shall incorporate sufficient lifting points
and reinforcement to ensure the safe handling, transport and erection.
Where necessary, the Contractor’s shop drawings shall include details of the lifting inserts,
methods to be adopted to join the pre-cast units to other structures or parts thereof and
the allowances made to receive work of other engineering specialties employed on the
works. Pre-cast concrete cladding panels shall be cast in formwork capable of producing
a uniform fair faced finish.

Where appropriate, indelible identification and orientation marks shall be put on pre-cast
concrete components in such a position that the marks shall not show or be exposed in
the finished work.
13.5.9.2 Execution
Casting
The pre-cast units shall be cast to the size and configuration required or otherwise
specified.
The units shall be reinforced as necessary for the stresses likely to be caused by the
methods of handling, transport and installation envisaged by the Contractor.
The longitudinal reinforcement shall have a minimum cover of 12 mm or twice the diameter
of the main bar, whichever is more, unless otherwise approved, except for fencing or
electric posts where the minimum cover shall be 25 mm.
The units shall be equipped with approved lifting devices for safe handling and easy
installation.
Concrete used for pre-casting the units shall be thoroughly compacted by vibration or
tamping to give a dense concrete free from voids and honeycombing.
The exposed surfaces shall be finished as specified or with dense, smooth trowel led finish
free from flaws and irregularities and true to the required configuration.
All angles of the pre-cast units, with the exception of any angles resulting from the splayed
or chamfered faces, shall be true right angles. The arises shall be clean and sharp except
those specified or shown to be rounded. The wearing surface shall be true to the required
lines. On being fractured, the interior of the units should present a clean homogenous
appearance.
Pre-cast units shall be cured to the maximum compressive strength for the specified class
of concrete before the units are handled or lifted for transport or installation.
Curing
After having been cast in the mould or form, the concrete shall be adequately protected
during setting in the first stages of hardening from shocks and from harmful effects of
sunshine and wind. The concrete shall be cured at least for 10 days from the date of
casting.
All pre-cast work shall be protected from the direct rays of the sun for at least 7 days after
casting and during that period each units shall be kept constantly watered or completely
immersed in water if the size of unit so permits. Otherwise curing practices as given in
clauses stated earlier shall be followed.
The pre-cast articles shall be matured for 28 days before being incorporated into the Works
so that the concrete shall have sufficient strength to prevent damage when handled. Side
shutters shall not be struck in less than 24 hours after depositing the concrete and no pre-
cast unit shall be lifted until the concrete reaches a strength of at least twice the stress to
which the concrete may be subjected at the time of lifting.

Pre-cast units shall be clearly marked to indicate the top of member and its location and
orientation in the structure. The reinforced side of the units shall be distinctly marked.
Pre-cast units shall be stored, transported and placed in position in such a manner that
they will not be overstressed or damaged. The lifting and removal of pre-cast units shall
be undertaken without causing shocks, vibration or being put under bending stresses.
Before lifting and removal takes place, the Contractor shall satisfy Engineer that the
methods he proposes to adopt for these operations will not overstress or otherwise affect
the strength of the pre-cast units.
Installation
The installation shall be fully coordinated with the works of the other engineering
specialities comprising the Works and the units shall be installed and secured at such
times as to prevent any delay in the progress of the works.
Pre-cast units shall be aligned and secured in accordance with the approved shop and
working drawings.
The installation shall be in a neat, workmanlike manner. On completion, all surplus

materials or debris arising out of the work shall be removed from the site.
13.5.10 Damp Proof Courses
The surface to receive a damp proof course shall be cleaned and carefully swept to remove
all dust, laitance etc. and shall be approved by the Engineer. Damp proof courses shall be
concrete. An approved waterproofing compound at 3%by weight of cement or as otherwise
approved by the manufacturer shall be mixed into the cement mortar for this concrete. The
damp proof course shall be laid to the full width of the wall and the edges shall be straight,
even and truly vertical. Wooden forms shall be used to obtain good edges. No masonry
work shall be commenced onto a freshly laid damp proof course until it has cured for 48
hours but the curing of cement concrete shall be continued along with the masonry work.
Specifications for cement, sand, aggregate and water shall be as described for concrete
works.
The concrete of ground floors shall be laid in two layers. The top of the lower layer of
concrete shall be painted with two coats of A-90 grade bitumen (conforming to IS: 1580)
applied at the rate of 1.5 kg/m2. The top surface of the lower layer shall be finished smooth
while laying the concrete so that the bitumen can be applied uniformly. The bitumen shall
be applied after the concrete has set and is sufficiently hard. Bitumen felt conforming to
IS: 1322 shall be sandwiched in the sub-floor laid in two layers.
Bunds
Bunds shall be provided around every storage vessel may contain materials potentially
harmful to the environment. The capacity of every bund shall be at least 120% of the
volume of the largest vessel contained in the bund.
Each bund floor shall drain to a sump into which a portable submersible pump could be
lowered. The bund lining shall be resistant to the chemical being stored. The walls of the
bund shall be a maximum of 1200 mm high and designed to support any load induced by
the bund being full. No pipe, cable or duct shall pass through the floor or walls of a bund.

13.5.11 Inspection of Structures
Immediately after stripping formwork, all concrete shall be carefully inspected and any
defective work or small defects, either removed or made good before concrete has
thoroughly hardened, as instructed by Engineer.
In case of doubt regarding the grade of concrete used or results of cube strength are
observed to be lower than the designed strength as per specifications at 28 days,
compressive strength test of concrete based on core test, ultrasonic test and/or load test
shall be carried out by the digital ultrasonic concrete tester as approved by the Engineer.
The Contractor shall also conduct conclusive tests such as ultrasonic pulse test, core test
etc. to prove the suitability of concrete, in case cube tests give unsatisfactory results.
13.5.11.1 Core Test
The points from which cores are to be taken and the number of cores required shall be at
the discretion of the Engineer and shall be representative of the whole of the concrete
concerned. In no case shall fewer than three cores be tested. Cores shall be prepared and
tested as described in IS 516
Concrete in the member represented by a core test shall be considered acceptable if the
average equivalent cube strength of the cores is equal to at least 85% of the cube strength
of the grade of concrete specified for the corresponding age and no individual core has
strength of less than 75%.
In case the core test results do not satisfy the requirements as above, or where such tests
have not been done, load testing may be resorted to.
13.5.11.2 Load Tests
13.5.11.2.1 On Flexural Members
Load tests should be carried out as soon as possible after expiry of 28 days from the time
of placing of concrete. The structure should be subjected to a load equal to the full dead
load of the structure plus 1.25 times the imposed load for a period of 24 hours and then
the imposed load shall be removed.
The deflection due to imposed loads only shall be recorded. If, within 24 hours of removal
of the imposed load, the structure does not recover at least 75% of the deflection under
the imposed load, the test may be repeated after a lapse of 72 hours. If the recovery is
less than 80%, the structure shall be deemed to be unacceptable.
If the maximum deflection in mm during 24 hours under load is less than 40L2/D, where L
is the effective span in metres and D the overall depth of the section in mm, it is not
necessary for recovery to be measured and the recovery provision as above will not apply.
13.5.11.2.2 On Members other than flexural members
Members other than flexural members should be investigated by analysis.

13.5.11.3 Other Non-destructive Test Methods
Other non-destructive test methods may be adopted, in which case the acceptance criteria
shall be agreed upon between the Engineer and the Contractor and the test shall be done
under expert guidance.
Non-destructive tests are used to obtain an estimation of the properties of the concrete in
the structure. The methods adopted include ultrasonic pulse velocity [see IS 13311 (Part
1)] and rebound hammer [IS 13311 (Part 2)], probe penetration, pull out and maturity. Non-
destructive tests provide alternatives to core tests for estimating the strength of concrete
in a structure, or can supplement the data obtained from a limited number of cores. These
methods are based on measuring a concrete property that bears some relationship to
strength. The accuracy of these methods, in part, is determined by the degree of
correlation between strength and the physical quality measured by the non-destructive
tests. Any of these methods may be adopted, in which case the acceptance criteria shall
be agreed upon prior to testing.
13.5.11.4 Hydraulic Testing of Water Retaining Structures
For a test of liquid retention, concrete structures should be cleaned and initially filled to the
normal maximum level with the specified liquid (usually water) at a uniform rate of not
greater than 2 m in 24 hours.
When first filled, the liquid level should be maintained by the addition of further liquid for a
stabilizing period while absorption and autogenous healing take place. The stabilizing
period may be 7 days for a maximum design crack width of 0.1 mm or 21 days for 0.2 mm
or greater. After the stabilizing period, the level of the liquid surface should be recorded at
24 hour intervals for a test period of 7 days. During this 7-day test period the total
permissible drop in level, after allowing for evaporation and rainfall, should not exceed
1/500 of the average water depth of the full tank or 20 mm (IS3370). . Notwithstanding the
satisfactory completion of the test, any evidence of seepage of the liquid to the outside
faces of liquid-retaining walls should be assessed against the requirements of the
specification. In the case of tanks whose external faces are exposed or can be left exposed
prior to testing, all leakages, wet patches and the like, shall be marked out on the outside
of walls during test. The tank shall then be emptied and any necessary remedial treatment
of the concrete, cracks or joints shall be carried out from the liquid face by grouting,
waterproofing, plastering etc as necessary to the entire satisfaction of the Engineer. The
tank shall again be tested for leakage after rectification. The work shall not be accepted
unless the water tightness is established. When a remedial lining is applied to inhibit
leakage at a crack, it shall have adequate flexibility and have no reaction with the stored
liquid.
Should the structure not satisfy the 7-day test, then after the completion of the remedial
work it should be refilled and if necessary, left for a further stabilizing period; a further test
of 7 days’ duration should then be undertaken in accordance with this clause.
The external surfaces of the structure shall then be plastered and cured as per the
specification. The water from the compartments shall then be drained and the inner surface
of the tank in all compartments be checked and any defects rectified. After satisfactory
completion of checks, internal coatings shall be applied as required.

Backfilling, in case of underground sumps, and waterproofing the roof where specified,
shall be carried out after testing and rectification of defects.
13.5.11.5 Unsatisfactory Tests
Should the results of any test prove unsatisfactory, or the structure shows signs of
weakness, undue deflection or faulty construction, the Contractor shall at his own cost (no
extra payment shall be made) remove and rebuild the member or members involved or
carry out such other remedial measures as may be required to the approval of the
Engineer.
The completion certificate shall not be given unless the test for water tightness as
described above is carried out to the entire satisfaction of the Engineer.
13.6 Piling Works
13.6.1 General
Pile foundations may be necessary for supporting structures where the subsoil is
considered to have insufficient bearing capacity. The Contractor shall carry out the detailed
design of these structures in accordance with the Contract Conditions and Employer’s
Requirements and shall determine the type of foundation required, the number of piles and
their working loads and the optimum arrangement of piles required for supporting the
structures.
Piles shall be designed, constructed and tested in accordance with the relevant sections
of IS 2911. Excavation, concrete, steel reinforcement and steel casing, where applicable,
shall conform to the relevant Clauses of the Specification. At least 21 days before the
Contractor intends to commence piling work on the Site, the Contractor shall submit for
the Engineer’s approval full details of his proposed piling system including the type and
dimensions of piles, reinforcement details and full design and driving calculations. The
details to be submitted shall include the Contractor’s proposals for equipment, temporary
works and construction methods.
No work on piling shall commence on the Site until the Engineer’s approval to the
Contractor’s proposal has been received.
Notwithstanding the requirements outlined in this section, the design shall be entirely the
Contractor’s responsibility.
13.6.2 Types of Piles
Bearing piles shall be driven reinforced pre-cast concrete or cast in-situ concrete piles.
All concrete for piles shall be in sulphate resisting cement, unless the Contractor can
document that a lesser quality complies with the actual aggressiveness of soil and ground
water. The use of a lower quality is subject to the approval of the Engineer.
13.6.3 Design of Piles
Piles shall be designed to sustain the required loads with settlements not exceeding those
specified. Allowance shall be made in the design for the incidence of negative skin friction
where appropriate and for resisting the necessary tensile forces due to the swelling and
heave of any soil stratum. Piles shall be designed to have a bearing capacity of at least
2.5 times the working load (working load = design load).

The permissible loading of piles shall be modified where necessary to allow for particular
conditions: piles in close proximity or in groups, soil strength, groundwater level and other
relevant factors. The piles shall be of sufficient cross-section and length, and configured
in a way to sustain the loads designed or specified without settlement (of single piles
combined with additional settlements due to group action) exceeding the following:
Working load allowable settlement 8 mm

1.5 × Working load allowable settlement 10 mm
2 × Working load allowable settlement 12 mm
These settlements shall include both permanent and elastic deflections. Measurement of
the settlement shall be made on first achieving the specified load. Measurement of the
settlement shall be made at the point of application of the load.
Where piles in place are subjected to handling, stacking and pitching or bending moments
and/or shear forces, these shall be combined with the vertical loads (either in compression
or tension) to satisfy the design requirements of BS 8110 Parts 1, 2 and 3.
The average compressive stress in the concrete of bearing piles under working load shall
not exceed 25% of the characteristic cube strength at 28 days, calculated on the total cross
sectional area of the pile shaft.
13.6.4 Preliminary Test Piles
After the Engineer has approved the Contractor’s proposals and calculations for the piling
system, preliminary test piles shall be constructed to the approval of the Engineer.
These shall be loaded to two times the working load to prove the design and system and
to demonstrate that the safe load requirements can be achieved by the piling method
proposed.
The preliminary test piles shall be located in places proposed by the Contractor and
approved by the Engineer. The Engineer shall be given at least 48 hours’ notice of
commencement of construction of the preliminary pile which is to be test-loaded.
The preliminary test piles shall be constructed and installed in a manner similar to that to
be used for the construction of the working piles by the use of similar equipment and
materials. Any variation will only be permitted with the prior approval of the Engineer.
For the preliminary piles that are to be test loaded, a detailed record of the progress during
construction/installation shall be made and submitted to the Engineer daily.
The pile shafts shall be terminated at the normal cut-off level or at some other level as
required by the Engineer.
The pile shafts shall be extended where necessary above the cut-off level of working piles
so that gauges and other apparatus to be used in the testing process will not be damaged
by water or falling debris and to permit exposure of the reinforcement.
Where the pile shaft is extended above the cut-off level of the working piles in soils that
would influence the load bearing capacity of the pile, a sleeve shall be left in place during
testing to eliminate friction that would not arise in working piles.

If the cut-off level is below ground level and the shaft is not extended and there is a risk of
the borehole collapsing, a sleeve shall be left in place or inserted above the pile shaft or
other means satisfactory to the Engineer shall be employed. Adequate clearance shall be
given between the top of the pile shaft and the bottom of the sleeve to permit unrestricted
movement of the pile.
For a pile that is tested in compression, the pile head or cap shall be formed to give a
plane surface, which is normal to the axis of the pile and sufficiently large to accommodate
the loading and settlement measuring equipment. The pile head or cap shall be adequately
reinforced or protected to prevent damage due to the concentrated application of load from
the loading equipment.
The pile cap shall be concentric with the test pile and the joint between the cap and the
pile shall have a structural strength equivalent to that of the pile.
A sufficient clear space shall be made under any part of the cap projecting beyond the
section of the pile so that at the maximum anticipated settlement, load is not transmitted
to the ground except through the pile.
The connection between the pile and the loading equipment shall be constructed in such
a manner as to provide strength equal to the maximum load that is to be applied to the pile
during the test with an appropriate factor of safety on the structural design.
If the preliminary test pile fails to meet the requirements, the piling system proposed will
be considered unsatisfactory. The Contractor shall then submit revised proposals and
calculations for the approval of the Engineer. Unless otherwise agreed by the Engineer,
any test pile that has failed the preliminary test will be rejected and the Engineer and the
Contractor shall provide one or more further test piles and tests to prove his modified
system.
13.6.5 Lengths and Tolerances
The Contractor shall determine the approximate lengths of piles by examination of the
available geotechnical information.
In case the available geotechnical information does not describe the ground conditions to
a sufficient depth to ensure safety, additional soil investigations shall be carried out by the
Contractor to the Engineer’s approval.
Piles shall be constructed within the following tolerances:

• in plan, at the working level of the piling rig 0.15 × B in any direction from the designed
position; B = pile dimension (diameter or side);
• in 75 from the vertical for a vertical pile;
The cross-sectional dimensions of the pile shall not be less than those proposed by the
Contractor nor shall they exceed them by more than 0.015 × B (B = pile dimension,
diameter or side).
No face of a pre-cast pile shall deviate by more than 6 mm from a straight edge 3 m long
joining two points on that face, nor shall the centre of area of the pile at any cross section
deviate more than 1/500 of the pile length from a line joining the centres of area of the
ends of the pile. The deviation / tolerance for piles shall be as per IS 2911 (Part I /
Section I).

13.6.6 Sequence for Constructions
The sequence of construction of piles shall be to the approval of the Engineer and shall
be arranged to minimise the vertical and lateral displacement of piles already installed.
Levels of the tops of adjacent piles or the structures founded upon them or any other
structures shall be measured at intervals while a pile is being installed. Driven piles which
have risen, shall be re-driven or forced down to the original resistance.
13.6.7 Driving Piles
The Contractor shall submit for the Engineer’s approval, details regarding the suitability,
efficiency and energy of his driving equipment.
Pre-cast concrete piles shall not be driven until the concrete has achieved the specified
characteristic strength.
Cast-in-situ piles driven with steel casing shall be bottom driven using a casing that shall
not distort or buckle during driving. Concrete casing shall be driven on the pile shoe using
a mandrel.
Each pile shall be driven continuously until the approved set and/or depth has been
reached except that the Engineer may permit the suspension of driving if he is satisfied
that the rate of penetration prior to cessation of driving will be substantially re-established
on its resumption or if he is satisfied that the suspension of driving was beyond the control
of the Contractor.
A follower (long dolly) shall not be used except with the approval of the Engineer who will
then require the set to be revised to take into account the reduction in the effectiveness of
the hammer blow.
The final set of each pile shall be recorded either as the penetration in millimetres per 10
blows or as the number of blows required to produce a penetration of 25 mm.
When a final set is being measured the following requirements shall be met:
1) The exposed part of the pile shall be in good condition without damage or distortion;
2) The dolly and packing, if any, shall be in sound condition;
3) The hammer blow shall be in line with the pile axis and the impact surfaces shall be
flat and at right angles to the pile and hammer axis;
4) The hammer shall be in good condition, delivering adequate energy per blow and
operating correctly; and
5) The temporary compression of the pile shall be recorded, if required by the Engineer.
The Contractor shall give adequate notice and provide all facilities to enable the Engineer
to check driving resistances. A set for purposes of the Contract shall only be taken in the
presence of the Engineer unless otherwise agreed.
At the start of the work and in new areas or sections, a detailed driving record shall be
obtained over the full length of the first pile and during the last 3 m of driving of subsequent
piles to establish the behaviour of the piles.
The Contractor shall inform the Engineer without delay if an unexpected change in driving
characteristics is noted. A detailed record of driving resistance over the full length of the
nearest available pile shall be taken.

Re-drive checks, if required, shall be carried out by a procedure to be agreed by the

Engineer.
Piles shall be driven in an approved sequence to minimise the detrimental effects of heave
and lateral displacement of the ground.
Measurements shall be taken to determine the movement of ground or any pile resulting
from the driving process when required by the Engineer.
Where piles have risen as a result of driving adjacent piles, the Contractor shall submit to
the Engineer his proposals for correcting detrimentally affected piles and for avoidance or
control of heave effects in subsequent work
Jetting may be carried out only when approved by the Engineer and the Contractor shall
submit detailed proposals and it shall not normally be undertaken over the last 3 m of
penetration.
13.6.8 Repair and Lengthening of Piles
In preparation for repairing the head of a pile, the concrete shall be cut off square at sound
concrete to expose the reinforcement and all loose particles shall be removed by wire
brushing followed by washing with water.
If the pile is to be subjected to further driving the head shall be replaced with concrete of
an approved class.
If the pile has been completely driven but the sound concrete is below cut-off level, the pile
shall be made good to cut-off level with concrete of a class not inferior to that of the
concrete of the pile.
In preparation for lengthening a normal reinforced pile, the concrete shall be cut off square
to expose a sufficient length to ensure that the full strength of the bars will be developed
across the joint.
For lap or splice joints, sufficient link bars shall be provided to resist eccentric forces.
If the pile is to be subjected to further driving the additional length shall be of an approved
grade of concrete.
Other methods of lengthening shall be subject to approval by the Engineer.
Repaired or lengthened piles shall not be driven until the added concrete has reached the
specified characteristic strength of the concrete of the pile.
13.6.9 Reinforcement
Unless otherwise required by the design, cast in situ piles shall be reinforced over the
whole of their length.
The minimum longitudinal reinforcement shall be 1.0% of the gross concrete area in the
top 3 m of the pile and 0.8% of the gross concrete area in the remainder of the pile. Lateral
ties shall be provided to maintain the alignment of the longitudinal reinforcement at centres
not closer than 150 mm.

Unless otherwise required by the design, reinforcement in pre-cast concrete piles shall
comply with the following minimum requirements:
Area of longitudinal reinforcement (12 mm diameter minimum) shall be at least 1% of the

gross concrete area (cast in-situ and pre-cast concrete piles);
Lateral reinforcement shall be in the form of hoops or links not less than 6 mm diameter.
Over a distance of 3 times the width of the pile measured from each end of the pile the
volume of lateral reinforcement shall be not less than 0.6% of the gross volume. In the
body of the pile, the lateral reinforcement shall not be less than 0.4% spaced at not more
than half the width of the pile. The transaction between the close spacing near the ends
and the maximum spacing shall be made gradually over a length equal to 3 times the
width.
Piles of rectangular cross section shall have a minimum of 4 longitudinal reinforcement

bars and piles of circular cross section shall have a minimum of 6 longitudinal
reinforcement bars. Bars shall be 12 mm diameter minimum. The main longitudinal bars
shall be level at the top of the pile and fit tightly into the shoe if one is used.
Hoops and links shall fit tightly against longitudinal bars and be bound to them by welding
or soft iron wire with the free ends turned inwards. The longitudinal bars shall be held apart
by spreader forks not more than 1.5 m apart.
The main longitudinal reinforcing bars in piles not exceeding 12 m in length shall be in one
continuous length unless otherwise required. In piles exceeding 12 m in length, joints will
be permitted in main longitudinal bars at 12 m nominal intervals. Joints in adjacent bars
shall be staggered at least 1 m apart along the length of the pile. Joints shall be such that
the full strength of the bar is effective across the joint.
The cover to the outermost reinforcement, including binding wire shall not be less than 60
mm measured to the inside of the casing. Lap or splice joints shall be provided with
sufficient link bars or other elements to resist eccentric forces. Laps shall have a minimum
length of 40 times the diameter of the main longitudinal reinforcement.
Main longitudinal reinforcement shall project a minimum of 40 times the bar diameter
above the cut- off level of the pile. For pre-cast piles, compliance with this requirement will
necessitate breaking down of the pile head after driving.
13.6.10 Pile Shoes
Driven piles shall be provided with flat or pointed co-axial shoes of cast iron if driving is
liable to damage the concrete at the tip of the pile.
13.6.11 Records
The Contractor shall maintain a complete record of all piling works that shall include the
following where relevant:
• pile type and number
• nominal diameter or dimension, pile length
• date of casting and date driven
• depth from ground level to toe of pile
• depth from ground level to bearing stratum

• set of pile or pile tube in mm per 10 blows or blows per 25 mm of penetration for first
piles in new areas or sections, sets taken at intervals during the last 3 m of driving for
subsequent piles
• final set, weight and drops of hammer
• Details of any obstructions observed.
• ground level at pile position at commencement of pile installation
• pile cut-off level
• length of temporary or permanent casing
• length and details of reinforcement
• concrete mix
• volume of concrete supplied to pile where this can be measured in practice
• All records shall be accurately kept in duplicate as the work proceeds and one copy
shall be handed to the Engineer at the completion of each day’s work.
13.6.12 Pre-cast Reinforced Concrete Piles
Pre-cast reinforced concrete piles shall be designed cast and cured to develop the strength
necessary to withstand the transporting, handling and driving stresses without damage.
Square piles shall have chamfered corners.
13.6.13 Cast-In-Situ Piles
13.6.13.1 Driven or Bored Cast-in-situ Piles
Driven or bored cast-in-situ piles shall comprise a temporary or permanent casing of steel,
or a permanent casing of pre-cast concrete, augured or driven to a set and completely
filled with dense concrete reinforced with steel bars.
All joints in the casing and between the casing and shoes, where applicable, shall be
watertight during driving and completion of driven cast-in-situ piles. Permanent casing
shall be inspected by using a light lowered from the top after installation to ensure that the
casing is neither damaged nor deformed and that all loose soil has been removed from
the bottom of bored piles.
Drilling mud shall not be used unless otherwise approved by the Engineer.
13.6.13.2 Casing for Cast-in-situ Piles
The casing shall be suitable for the method of installation and for the purpose of jointing
piles. The casing may either be permanent or temporary.
Steel casing shall be delivered to Site in as a long length as can be conveniently handled.
Ends shall be prepared for butt-welding and designed to maintain true alignment of the
pile.
Joints between steel casings shall be made by butt-welding so that the full strength of the
original section is developed. Welded joints shall be watertight.
13.6.13.3 Concreting Cast-in-situ Piles
Concrete in cast-in-situ piles shall be in accordance with the requirements. The slump for
the concrete shall be agreed with the Engineer prior to concreting preliminary test piles.
Concrete filling in cast-in-situ piles shall be placed continuously. Removal of temporary
casings must be complete before the placed concrete loses its workability to ensure that

the concrete is not lifted, but placing of concrete shall keep in advance of withdrawal of
casing to prevent necking.
Pile heads shall be stripped down and bonded into the pile caps as specified for pre-cast
concrete piles.
13.6.14 Pile Load Tests
13.6.14.1 General
Pile load tests shall be carried out in the following situations:

• when using a type of pile or installation method that is outside comparable experience
and which has not been tested under comparable soil and loading conditions;
• when using a piling system which is outside the experience of the operatives carrying
out the work;
• when the piles will be subject to loading for which theory and experience do not provide
sufficient in the design. The pile testing procedure should then provide loading similar
to the anticipated loading; and
• when observations during the process of installation indicate pile behaviour that
deviates strongly and unfavourable from the behaviour anticipated on the basis of the
site investigation or experience when additional ground investigations do not clarify the
reasons for this deviation.
Load test can be as a static test or a dynamic test.
If one pile load test is carried out, it shall normally be located where the most adverse
ground conditions are believed to occur. If this is not possible, an allowance shall be made
when deriving the characteristic value of the bearing resistance.
If load tests are carried out on two or more test piles, the test location shall be
representative of the site of the pile foundations, and one of the test piles shall be located
where the most adverse ground conditions are believed to occur.
Between the installation of the test pile and the beginning of the load test, adequate time
shall be allowed to ensure that the required strength of the pile material is achieved and
the pore pressures have regained their initial values.
13.6.14.2 Static Load Tests
i. Loading Procedure
The pile load test procedure, particularly with respect to the number of loading steps,
the duration of the loading steps and the application of load cycles, shall be such that
conclusions can be drawn about the deformation behaviour, creep and rebound of a
pile foundation from the measurements on the pile. For trial piles, the ultimate loading
shall be such that conclusions can also be drawn about the ultimate failure load.
Devices for the determination of forces, stresses or strains and displacements shall be
calibrated prior to the test.
The direction of the applied force to compression or tension pile tests shall coincide
with the longitudinal axis of the pile.

In general, pile load tests for the purpose of designing a tensile pile foundation should
be carried out to failure. Extrapolation of the load-displacement graph for tension tests
should normally not be used, especially in the case of transient loading.
ii. Trial Piles
The number of trial piles required to verify the design shall be selected on the following
aspects:
• the ground conditions and their variability across the site;
• type of structure;
• documented evidence of the performance of the same type of pile in similar ground
conditions; and
• the total number and types of piles in the foundation design.
The ground conditions at the test site shall be investigated thoroughly. The depth
of borings or piles tests shall be sufficient to ascertain the nature of the ground both
around and beneath the pile tip. It shall include all strata likely to contribute
significantly to pile deformation behaviour, at least five times the diameter beneath
the pile tip, unless sound rock or very hard soil is found at a lesser depth.
The method used for installation of the trial piles shall be fully documented.
iii. Working Piles
The number of working pile load tests shall be selected on the basis of the recorded
findings during construction.
The load applied to working test piles shall be at least equal to the design load
governing the design of the foundation.
13.6.14.3 Dynamic Load Tests
i. General
The results of dynamic load tests may be used for design provided an adequate site
investigation has been carried out and the method has been calibrated against static
load tests on the same type of pile of similar length and cross-section, and under
comparable soil conditions.
Dynamic test results shall always be considered in relation to each other.
Dynamic load tests may be used as an indicator of the consistency of the piles and to
detect weak piles (integrity testing).
In a dynamic load test the pile is instrumented with accelerometers and strain gauges
within two pile diameters of the top of the pile.
The gauges are connected to a recording and data processing device. During blows
on the pile signals from the gauges are recorded and processed for assessment of pile
bearing capacity. The data processing will be of two kinds: one simple (CASE or
likewise method) and one more exact method based on signal matching (CAPWAP or
likewise program).
In the CASE method or likewise the following data shall be registered and reported:
• bearing capacity;
• toe resistance and skin friction;

• maximum compression stress, acceleration, velocity and displacement;

• maximum tension stress in pile;
• pile structural integrity; extent and location of damage;
• maximum energy transferred to the pile;
• blows per minutes for hammer check;
• blow number;
• input and reflection of force, velocity, upward and downward force waves; and
• load versus deflection of cushions and of pile toe bearing’
CAPWAP or likewise program determines that set of soil resistance parameters
which produces the best match between measured and computed pile top force
and velocity. After CAPWAP analysis, additional information produced than from
CASE is:
• deformation properties, ultimate capacities and soil damping parameters for each
soil segment of normally 1 m length;
• unit skin friction for each segment and end bearing;
• maximum of tension and compression forces and stresses;
• pile structural damping;
• dynamic pile toe displacement; and
• graph on bearing capacity and pile stresses versus blow count.
An introductory program (WEAP) can be utilised before pile driving to assess

preliminary combinations of sets and bearing capacities for specified pile driving
equipment and soil conditions.
Well-experienced experts shall carry out the data processing.
ii. Dynamic Load Test Procedure
The Contractor shall notify the Engineer at least two weeks prior to dynamic testing.
The Contractor shall submit a qualified testing consultant and his experience to the
Engineer for approval.
The Engineer shall determine if the test is to be performed or if some pile waiting
periods at the proposed site is required before a decision will be made.
The Engineer will establish a date for the tests and will also determine the location of
all piles to be dynamically load tested.
iii. Dynamic Load Test Procedure on Driven Piles
The Contractor shall supply all personnel and equipment needed to strike the test pile
with the hammer.
The Contractor shall provide the hammer (drop, diesel, etc) or the crane to lift a steel
ram weight by a single non-twisting cable and be able to strike the pile top by means
of full-gravity-fall.
The testing consultant personnel will drill holes into the pile to be tested so that
transducers (two accelerometers and two strain gauges) can be attached.
When the transducers have been placed in position and the recording and processing
equipment has been made ready to receive the acceleration and strain measurement,

the Contractor shall strike the driven pile with the hammer as many times as is required
to obtain adequate measurements as determined by the Engineer.
The Engineer may ask the Contractor to provide surveying instrument to monitor the
pile set after each strike.
After the dynamic testing measurements have been obtained and analysed the
Contractor shall prepare and submit a complete report to the Engineer.
iv. Dynamic Load Test Procedure on Bored Piles.
The Contractor shall prepare the pile top and, if necessary, improve the structural
integrity of the pile top to resist a sharp impact force. All loose concrete at the pile top
shall be removed. The top portion of the bored pile shall be extended a length of at
least two times the diameter of the bored pile with the same diameter as the bored pile.
The extended portion of the bored pile shall be cast with concrete having a minimum
compressive strength of 40 MPa.
Additional shear reinforcement such as spiral hoops at the pile top is recommended
for the impact force. The Contractor shall provide the windows for the installation of
instruments by means of burring 0.35 × 0.35 m2 to the steel casing using a cutting
torch.
On top of the bored pile, a timber cushion shall be placed under a steel plate to act as
a hammer cushion. Adhesive material may be applied between the pile top and the
timber.
The Contractor shall provide an additional steel casing inserted into the pile top. This
casing shall act as a guide for the steel ram weight, having a length not less than the
summation of the drop height and the length of the steel ram weight. A vibrating
hammer shall be used to secure and stabilise the steel casing.
The Contractor shall supply all personnel and equipment needed to strike the test pile
with the steel ram weight. The Contractor shall provide a crane which has the capability
to lift the steel ram weight by a single non-twisting cable and be able to strike the pile
top by mean of full-gravity-fall.
The testing consultant personnel will drill holes in the windows of the left-in-place steel
casing into the pile to be tested so that transducers (two accelerometers and two train
gauges) can be attached.
When the transducers have been placed in position and the recording and processing
equipment has been made ready to receive the acceleration and strain measurement,
the Contractor shall strike the driven pile with the hammer as many times as is required
to obtain adequate measurements as determined by the Engineer.
The Engineer may ask the Contractor to provide surveying instrument to monitor the
pile set after each strike.
After the dynamic testing measurements have been obtained and analysed the
Contractor shall prepare and submit a complete report to the Engineer.
v. Load Test Report

The Contractor shall, within 24 hours of the completion of the tests, submit to the
Engineer a complete record of each pile test. Where appropriate, this report shall
include:
• a description of the site;
• the ground conditions with reference to ground investigations;
• the pile type;
• a description of the loading and measuring apparatus and the reaction system;
• calibration documents of the load cells, the jacks and the gauges;
• the installation record of the test piles;
• photographic records of the pile and the test site;
• test results in numerical form;
• time settlement plots for each applied load when a step loading procedure is used;
• the measured load-settlement behaviour; and
• Justification of the reasons for any departures from the recommendations.
13.6.14.4 Piles in Compression
i. Ultimate Bearing Resistance from Static Pile Load Tests
Trial piles to be tested shall be installed in the same manner as the piles that will form
the foundation and shall be founded in similar stratum.
In the case of a very large diameter pile, it is often impractical to carry out a load test
on a full size trial pile. Load tests on smaller diameter trial piles may be considered
provided that:
• the ratio of the trial pile/working pile diameter is not less than 0.5;
• the smaller diameter trial piles are fabricated and installed in the same way as the
piles used for the foundations; and
• the trial pile is instrumented in such a manner that the base and shaft resistance
can be derived separately from the measurements.
In the case of a pile foundation subjected to down drag, the pile resistance at failure or
at a displacement which equals the criterion for the verification of the ultimate limit
state determined from the load test results shall be corrected by subtracting the
measured or the most unfavourable design positive skin friction force in the
compressible stratum from the forces measured at pile head.
When deriving the ultimate characteristic bearing resistance 𝑹𝒄𝒄 from values 𝑹𝒄𝒎𝒔
measured in one or several static pile load tests, an allowance shall be made for the
variability of the ground and the variability of the effect of pile installation. As a
minimum, both conditions of the table below shall be satisfied using the equation:
𝑹𝒄𝒎𝒔
𝑹𝒄𝒄 =
𝜸𝒏𝒔
Factors 𝜸𝒏𝒔 to derive 𝑹𝒄𝒄 :
Number of load tests 1 2 >2

𝛾𝑛𝑠 on average 𝑅𝑐𝑚𝑠 1,5 1,35 1,3
𝛾𝑛𝑠 on lowest 𝑅𝑐𝑚𝑠 1,5 1,25 1,1

In order to derive the ultimate design bearing resistance, the characteristic value,
𝑹𝒄𝒄 , should be divided into components of base resistance, 𝑹𝒄𝒃𝒄, and shaft resistance,
𝑹𝒄𝒔𝒄, such that:
𝑹𝒄𝒄 = 𝑹𝒄𝒃𝒄 + 𝑹𝒄𝒔𝒄
The design bearing resistance, 𝑹𝒅 , shall be derived from

𝑹𝒄𝒃𝒄 𝑹𝒄𝒔𝒄
𝑹𝒄𝒅 = +
𝜸𝒃𝒔 𝜸𝒔𝒔
where 𝜸𝒃𝒔 and 𝜸𝒔𝒔 are taken from the table below.
Values of 𝜸𝒃𝒔 , 𝜸𝒔𝒔 and 𝜸𝒕𝒔 :
Component factors 𝛾𝑏𝑠 𝛾𝑠𝑠 𝛾𝑡𝑠

Driven piles 1,3 1,3 1,3
Bored piles 1,6 1,3 1,5
CFA piles 1,45 1,3 1,4
Normally the load test only provides the pile load test versus settlement and time versus
settlement diagrams without distinction between point and shaft resistance. Therefore, it
is often not possible to distinguish between partial factors for the assessment of the design
value of base resistance and shaft resistance. Instead a partial factor on the ultimate
characteristic pile resistance 𝑹𝒄𝒄 may be taken as the 𝜸𝒕𝒔 values given in the table above.
ii. Ultimate Bearing Resistance from Pile Driving Formulae
If pile-driving formulae are used to assess the ultimate bearing resistance of individual
compression piles in a foundation, the validity of the formulae shall have been
demonstrated by previous experimental evidence of good performance or static load
tests on the same type of pile of similar length and cross-section and in the similar
ground conditions.
Pile driving formulae shall only be used if the stratification of the ground has been
determined.
In the design, the number of piles to be re-driven shall be specified. If re-driving gives
lower results, these shall be used as the basis for ultimate bearing resistance
assessment. If re-driving gives higher results, these may be taken into consideration.
Re-driving should usually be carried out in silt soils, unless local comparable
experience has shown it to be unnecessary.
iii. Ultimate Bearing Resistance from Dynamic Load Tests
Dynamic load tests and their evaluation can be used to assess pile-bearing resistance
of individual compression piles. The validity of the evaluation shall have been
demonstrated by previous evidence of acceptable performance or static load tests on
the same pile type of similar length and cross-section and in similar soil conditions.
The input energy level during the dynamic load testing shall be high enough to allow

for an appropriate interpretation of the pile capacity at a correspondingly high enough

strain level.
When deriving the ultimate characteristic bearing resistance 𝑹𝒄𝒄 from values
𝑹𝒄𝒎𝒅 measured in two or several dynamic pile load tests, an allowance shall be made
for the variability of the ground and the variability of the effect of pile installation. As a
minimum, both conditions of the4 table below shall be satisfied using the equation:
𝑹𝒄𝒎𝒅
𝑹𝒄𝒄 =
𝜸𝒏𝒅
Factors 𝜸𝒏𝒅 to derive 𝑹𝒄𝒄 :

a) 𝛾𝑛𝑑 on average 𝑅𝑐𝑚𝑑 1,5 1,35 1,3
b) 𝛾𝑛𝑑 on lowest 𝑅𝑐𝑚𝑑 1,5 1,25 1,1
In order to derive the ultimate design bearing resistance, the characteristic value, 𝑹𝒄𝒄
should be divided into components of base resistance, 𝑹𝒄𝒃𝒄, and shaft resistance, 𝑹𝒄𝒔𝒄,
such that
𝑹𝒄𝒄 = 𝑹𝒄𝒃𝒄 + 𝑹𝒄𝒔𝒄
The design bearing resistance, 𝑹𝒄𝒅 , shall be derived from

𝑹𝒄𝒃𝒄 𝑹𝒄𝒔𝒄
𝑹𝒄𝒅 = +
𝜸𝒃𝒅 𝜸𝒔𝒅
where 𝜸𝒃𝒅 and 𝜸𝒔𝒅 are taken from the table below. Values of 𝜸𝒃𝒅 , 𝜸𝒔𝒅 and 𝜸𝒕𝒅
Component factors 𝛾𝑏𝑑 𝛾𝑠𝑑 𝛾𝑡𝑑

Driven piles 1,4 1,4 1,4
Bored piles 1,7 1,4 1,6
In case 𝑹𝒄𝒃𝒄 and 𝑹𝒄𝒔𝒄 are not known the design bearing resistance 𝑹𝒄𝒅 is derived from
𝑹𝒄𝒄
𝑹𝒄𝒅 =
𝜸𝒕𝒅
13.6.14.5 Piles in Tension
i. Ultimate tensile resistance from static pile load tests
Pile load tests to determine the ultimate tensile resistance 𝑹𝒕𝒄 of an isolated pile shall
be carried out in accordance with Clause
When deriving the ultimate characteristic resistance 𝑹𝒕𝒄 from values 𝑹𝒕𝒎 measured in
one or several static pile load tests, an allowance shall be made for the variability of
the ground and the variability of the effect of pile installation. As a minimum, both
conditions of the table below shall be satisfied using the equation:
𝑹𝒕𝒎𝒔
𝑹𝒕𝒄 =
𝜸𝒏𝒕

Factors 𝜸𝒏𝒕 to derive 𝑹𝒕𝒄 :

a) 𝛾𝑛𝑡 on average 𝑅𝑡𝑚𝑠 1,5 1,35 1,3
b) 𝛾𝑛𝑡 gnt on lowest 𝑅𝑡𝑚𝑠 1,5 1,25 1,1
Normally when piles are loaded in tension, more than one pile shall be tested. In the case
of a larger number of tension piles, at least 2% shall be tested.
The design tensile resistance, Rtd, shall be derived from

𝑹𝒕𝒄
𝑹𝒕𝒅 =
𝜸𝒎
Where𝜸𝒎 = 𝟏. 𝟔.
13.6.14.6 Supervision of Construction
A pile installation plan shall be the basis for the construction work. The plan should give
the following design information:
• the pile type with designation if standardised or technical approval otherwise;
• the location and inclination of each pile and tolerances on position;
• pile cross-section;
• pile length;
• number of piles;
• required pile load carrying capacity;
• pile toe level or the required penetration resistance;
• installation sequence;
• known obstructions; and
• any other constraints on piling activities.
The installation of all piles shall be monitored and records shall be made at site and as the
piles are installed. A record signed by the supervisor of the work and the pile manufacturer
shall be kept for each pile.
The record for each pile shall include the following, where appropriate:
• pile type and installation equipment;
• pile number;
• pile cross-section, length and reinforcement;
• data and time of installation (including interruptions to the construction process);
• concrete mix, volume of concrete used and method of placing for cast-in-situ piles;
• pumping pressures of the grout or concrete, internal and external diameters, pitch of
screw and penetration per revolution (for continuous flight auger piles or other injection
piles);
• for driven piles, the values of driving resistance measurements such as weight and
drop or power rating of hammer, blow frequency and number of blows for at least the
last 0.25 m penetration;
• the power take-off of vibrators (where used);
• the torque applied to the drilling motor (where used);
• for bored piles, the strata encountered in the borings and the condition of the base, if
the performance of the base is critical;
• obstructions encountered during piling; and

• deviations of positions and directions and as-built elevations.
Records shall be kept for at least a period of five years after completion of the works. As-
built record plans shall be compiled after completion of the piling and be kept with the
construction documents.
If site observations or inspection of records reveal uncertainties with respect to the quality
of installed piles, additional investigations shall be carried out to determine the as-built
conditions of the piles and whether remedial measures are necessary. These
investigations shall include either re-driving or pile integrity tests, in combination with soil
mechanics field tests adjoining the suspected piles or static pile load tests.
Tests shall be used to determine the integrity of piles for which the quality is sensitive to
the installation procedures if the procedures cannot be monitored in an alternative reliable
way.
Dynamic low-strain integrity tests can be used for a global evaluation of piles that might
have severe defects or that may have caused a serious loss of strength in the soil during
construction. Since defects like insufficient quality of concrete and thickness of concrete
cover, affecting the long-term performance of a pile, often cannot be found by dynamic
tests, other tests such as sonic tests, vibration tests or coring may be needed in
supervising the execution.
13.7 Reinforcement
13.7.1 General
All steel shall be FE 500 D CRS procured from ‘Original producers” who manufactures
billets directly from iron ores and roll the billets to produce steel confirming to IS 1786. No
re-rolled material shall be accepted. If instructed by the Engineer, the Contractor shall
submit the manufacturer’s test certificates for the steel. Random tests on steel supplied by
the Contractor may be performed by the Employer as per relevant Indian Standards. Each
steel bar shall be identified by the number duly moulded on the bar itself.
13.7.2 Submittals
Bar bending schedules for reinforced concrete works shall be provided by the Contractor.
The submittals for extra or modified work shall also be made by the Contractor at least two
weeks prior to commencement of bending. Dimensions shown on the submittals furnished
by the Contractor shall be his responsibility and approval of the submittals shall not
constitute approval of the dimensions thereon.
13.7.3 Tie Wire
Tie wire shall be of annealed steel, 16 gauge minimum.
13.7.4 Supports and Accessories
Support blocks shall be of concrete with embedded wire ties or dowels for placement on
grade or on membranes. Reinforcement for footings, grade beams and slabs on sub-grade
shall be supported on pre-cast concrete blocks as approved by the Engineer. The use of
pebbles or stones shall not be permitted. The blocks are to be embedded.

Plastic coated spacers or accurately dimensioned concrete blocks shall be used in all
water retaining surfaces, roofs of water retaining structures and in all interior or exterior
surfaces exposed to weather after completion of the structure. Plastic cover blocks of
approved manufacture will be permitted at the discretion of the Engineer.
13.7.5 Dowels
Where so required, reinforcing bar dowels shall be provided in new work and for anchorage
to existing concrete. Where anchorage to existing concrete is required, a non-shrinking
epoxy type grout or approved equal or deferred bolting devices shall be provided in each
case, conforming to the relevant requirement specified in the section for cast-in-situ
concrete.
The outer diameter of the dowel shall be equal to the diameter of the mounting hole of the
fixtures so that they can be installed directly.
13.7.6 Testing
Testing of materials shall be at the Contractor’s expense and as instructed by the Engineer
and when so tested, shall conform to the relevant standards. Tests may be ordered on
bars as selected by the Engineer from material at the site or from any place of distribution.
Each sampling selection shall include at least two pieces, each 500 millimetre long.
The Contractor shall submit the manufacturer’s test certificates. Regular tests on the steel
supplied shall be performed by the Contractor at an approved laboratory in the presence
of the Engineers as per relevant Indian Standards. The Engineer may require the
Contractor to perform tests of samples at random as per relevant Indian Standard. The
quality, grade, colour coding embossing marks etc shall all be to the entire satisfaction of
the Engineer. Steel not conforming to the above test criteria shall be rejected.
The chemical, physical and mechanical properties of the steel reinforcement bars shall be
as per IS 1786. Unless otherwise specified, the selection and preparation of test samples
shall be as per the requirements of IS 2062.
All test pieces shall be selected either from the cuttings of bars or from any bar after it has
been cut to the required or specified size and the test piece taken from any part of it. In
either case, the test piece shall be detached from the bar in the presence of the Engineer.
The test pieces shall be full sections of the bars and shall be subjected to physical tests
without any further modifications. No reduction in size by machining or otherwise shall be
permissible, except in case of bars of size 28 mm and above. No test piece shall be
annealed or otherwise subjected to heat treatment. Any straightening which a test piece
may require shall be done cold.
For the purpose of carrying out tests for tensile strength, proof stress, percentage
elongation and percentage elongation at maximum force for bars of 28 mm in diameter
and above, deformations of the bars only may be machined. For such bars, the physical
properties shall be calculated using the actual area obtained after machining.
Title IS No. ISO No.

Mechanical testing of metals - Tensile testing 1608 6892
Methods for bend test 1599, 7438 & 1786 15630-1
Method for re-bend test for metallic wires & bars 1786 15630-1

Chemical Composition of the bars shall conform to the following requirement
Maximum permissible percent Permi-

Constituents Fe Fe Fe Fe Fe Fe Fe ssible max.
415 415D 500 500D 550 550D 600 Variation
Carbon 0.300 0.250 0.300 0.250 0.300 0.250 0.300 0.020%
Sulphur 0.060 0.045 0.055 0.040 0.055 0.040 0.040 0.005%
Phosphorus 0.060 0.045 0.055 0.040 0.050 0.040 0.040 0.005%
Sulphur & 0.110 0.085 0.105 0.075 0.100 0.075 0.075 0.010%
Phosphorus
Notes:
1 For welding of deformed bars, the recommendations of IS 9417 shall be followed.
2 In case of deviations from the specified maximum, two additional test samples shall be
taken from the same batch and subjected to the test or tests in which the original
sample failed. Should both additional test samples pass the test, the batch from which
they were taken shall be deemed to comply with this standard. Should either of them
fail, the batch shall be deemed not to comply with this standard.
Mechanical Properties of High Strength Deformed Bars
Tolerance on the nominal mass in percent

Nominal Size in mm Individual sample
Batch Individual sample
for coils only
Up to and including 10 ±7 -8 ±8
Over 10 up to and including 16 ±5 -6 ±6
Over 16 ±3 -4 ±4
Note: To satisfy Clause of IS 456 -2000, no mixing of different types of grades of bars shall
be allowed in the same structural members as main reinforcement, without prior written
approval of the Engineer.
13.7.7 Fabrication and Delivery
Tagged reinforcement bundles which can be easily identified shall be stored at the site in
sufficient quantities to enable uninterrupted progress of the work. These shall be so stored
as to prevent damage or undue exposure to harmful weather conditions.
13.7.8 Stacking and Storage
Steel for reinforcement shall be stored in such a way as to prevent distorting and corrosion.
The steel for reinforcement shall not be kept in direct contact with ground. Fresh /
fabricated reinforcement shall be carefully stored to prevent damage, distortion, corrosion
and deteriorations. Care shall be taken to protect steel from exposure to saline
atmospheres during storage, fabrication and use. This may be achieved by treating the
surface of the reinforcement with a cement wash or by other suitable methods. Bars of
different classification, size and length shall be stored separately to facilitate their issue in
such sizes and lengths to cause minimum wastage in cutting from standard lengths.

13.7.9 Bending and Forming
Bars shall be fabricated accurately to dimensions, forms and shapes indicated by methods
that will not damage the bars. Heating for purposes of bending will not be permitted. Field-
bending of bars that are partially embedded in concrete shall not be done unless such
procedure is specifically approved by the Engineer.
All bars shall be accurately bent according to the sizes and shapes shown on the approved
detailed working drawings and bar bending schedules. Bars shall be bent gradually by
machine or other approved means. Reinforcing bars shall not be straightened and re-bent.
Bars containing cracks or splits shall be rejected. Bars shall be bent cold unless specifically
approved by the Engineer.
Where approved, bars bent hot shall not be heated beyond a cherry red colour (not
exceeding 645oC) and after bending shall be allowed to cool slowly without quenching. No
reinforcement bar shall be bent when in position in the work without approval, whether or
not it is partially embedded in hardened concrete. Bars having kinks or bends other than
those required by design shall not be used.
Where reinforcement bars are necessarily bent aside at construction joints and afterwards
bent back into their original position, care shall be taken to ensure that, at no time, the
radius of the bend is less than 4 bar diameters for plain mild steel or 6 bar diameters for
deformed bars. Care shall also be taken when bending back bars to ensure that the
concrete around the bar is not damaged.
13.7.10 Laps
Laps and splices for reinforcement shall be as shown on the approved Contractor’s
drawings. Splices in adjacent bars shall be staggered and the locations of all splices shall
be subject to the approval of the Engineer. Bars shall not be lapped unless the length
required exceeds the maximum available lengths of bars at site.
13.7.11 Reinforcing Bars for Masonry
Reinforcing bars for masonry shall be shop fabricated.
13.7.12 Exposure conditions
Exposure conditions are defined in the table below:
Environment Exposure Conditions

Mild Concrete surfaces protected against weather or aggressive conditions,
except those situated in coastal areas.
Moderate Concrete surfaces sheltered from severe rain
Concrete exposed to condensation and rain
Concrete continuously under water
Concrete in contact or buried under non-aggressive soil/ground water
Concrete surfaces sheltered from saturated salt air in coastal areas
Severe Concrete surfaces exposed to severe rain, alternate wetting and drying
or severe condensation.
Concrete completely immersed in sea water
Concrete exposed to coastal environments
Very severe Concrete surfaces exposed to seawater spray or corrosive fumes.

Environment Exposure Conditions

Concrete in contact with or buried under aggressive sub- soil/ground
water. Concrete exposed to sewage, sewage effluent, sewage sludge
and digester gases.
Extreme Concrete surfaces in tidal zones
Members in direct contact with aggressive liquid or solid chemicals
13.7.13 Fusion Bonded Epoxy Coating
Where fusion bonded epoxy coating (FBEC) is to be applied to reinforcement bars, it shall
conform to IS 13620.
The coating material shall conform to Annex A1 of IS 13620.
The surface of the steel reinforcing bars to be coated shall be cleaned by abrasive blast
cleaning to near white metal.
The protective coatings shall be applied by the electrostatic spray method.
The film thickness of the coating shall be evaluated by bending production-coated bars
around a mandrel as prescribed in IS 13620.
Tests, retests and permissible coating damage shall be in accordance with IS 13620.
Coating damage shall be repaired with the repair compound supplied by the coating
manufacturer.
13.7.14 Nominal cover to reinforcement
Nominal cover is the design depth of concrete cover to all steel reinforcements, including
links. The dimension shall be used in the design and indicated on the Contractor’s detailing
drawings. Cover shall be not less than the diameter of the bar. Unless otherwise specified,
cover to reinforcement shall be provided generally as per guidelines of IS 456.
Minimum values for the nominal cover of normal weight aggregate concrete which should
be provided to all reinforcement, including links depends on the condition of exposure. The
nominal cover to meet durability requirements is shown in the table below:
Environment Nominal concrete cover in mm not less than

Mild 20
Moderate 30
Severe 45
Very severe 50
Extreme 75
1) For main reinforcement of up to 12 mm diameter subject to mild exposure, the nominal
cover may be reduced by 5 mm
2) Unless specified otherwise, the actual concrete cover should not deviate from the
required nominal cover by +10 mm

3) For exposure conditions severe and very severe, a reduction of 5 mm may be made,
where concrete grade is M 35 and above.
Unless otherwise approved by the Engineer, clear concrete cover for reinforcement
(exclusive of plaster or other decorative finish shall be as follows:
1) At each end of a reinforcing bar not less than 25mm or less than twice the diameter of
the bar.
2) For a longitudinal reinforcing bar in a column, nominal cover shall in any case not be
less than 40 mm or less than the diameter of such bar. In the case of column of
maximum dimensions of 200 mm or less, whose reinforcing bars do not exceed 12
mm, a cover of 25 mm may be used.
3) For longitudinal reinforcing bars in a beam cover shall be not less than 25 mm, or less
than diameter of the bar.
4) For tensile, compressive, shear, or other reinforcement in a slab, cover shall be not
less than 25 mm, or less than the diameter of the bar.
5) For any other reinforcement not less than 15 mm, or less than the diameter of the bar.
6) For footings and other principal structural members in which the concrete is deposited
directly against the ground, the cover to the bottom reinforcement shall be 75 mm. If
concrete is poured on a layer of lean concrete the bottom cover may be reduced to 50
mm.
7) For concrete surfaces exposed to the weather or the ground after removal of forms,
such as retaining walls, grade beams, footing sides and tops etc, not less than 50 mm
for bars larger than 16 mm diameter and not less than 40 mm for bars 16 mm diameter
or smaller.
8) Increased cover thickness may be provided when surfaces of concrete members are
exposed to the action of harmful chemicals (as in the case of concrete in contact with
earth faces contaminated with such chemicals), acid, vapour, saline atmosphere,
sulphurous smoke (as in the case of steam-operated railways) digester gases etc and
such increase of cover may be between 15 mm and 50 mm beyond the figures given
above (1 to 6) as may be specified by the Engineer. The interior of sludge digestion
tanks will fall into this category.
9) For reinforced concrete members, totally immersed in sea water, the cover shall be 40
mm more than specified (1 to 6) above.
10) For reinforced concrete members, periodically immersed in sea water or subject to sea
spray, the cover of concrete shall be 50 mm more than that specified (1 to 6) above.
11) For concrete of grade M 25 and above, the additional thickness of cover specified in
(8), (9) and (10) above may be reduced to half. In all such cases the cover should not
exceed 75 mm
12) Protection to reinforcement in cases where concrete is exposed to harmful
surroundings may also be given by providing dense impermeable concrete with an
approved protective coating. In such cases, the extra cover, as stated in (7) and (8)
above, may be reduced with the approval of the Engineer.
13) The minimum clear distance between reinforcing bars shall be in accordance with IS
456.
The minimum values of nominal cover for normal-weight aggregate concrete to be

provided to all reinforcement including links to meet specified period of fire resistance is
shown in the table below:
Nominal Cover
Fire
Beams Slabs Ribs
resis- Col-
Simply Conti- Simply Conti- Simply Conti-
tance umns
Supported nuous Supported nuous Supported nuous
Hr mm mm mm mm mm mm mm

0.5 20 20 20 20 20 20 40
1 20 20 20 20 20 20 40
1.5 20 20 25 20 35 20 40
2 40 30 35 25 45 35 40
3 60 40 45 35 55 45 40
4 70 50 55 45 65 55 40
The nominal covers given relate specifically to the minimum member.
13.7.15 Placing of Reinforcement
Reinforcement shall be accurately fixed by any approved means and maintained in the
correct position by the use of blocks, spacers and chairs as per IS 2502 to prevent
displacement during placing and compaction of concrete.
Any steel not conforming to the specifications shall be rejected. All reinforcement shall be
clean, free from grease, oil, paint, dirt, loose mill scale, loose rust, dust, bituminous
material or any other substances that will destroy or reduce the bond. All rods shall be
thoroughly cleaned before being fabricated. Pitted and defective rods shall not be used.
Unless otherwise specified, reinforcement shall be placed within the following tolerances:
1) For effective depth, 200 mm or less + /- 10 mm
2) For effective depth, more than 200 mm + /- 15 mm
The correct cover shall be maintained by cement mortar blocks or other means approved
by the Engineer, as described in Section 17.10.4.
i. Cleaning
Before placing reinforcement and again prior to concrete placement, the reinforcement
shall be cleaned of loose mill scale, rust, oil or other coating that would reduce strength
or bond. Steps shall be taken to ensure that the reinforcement shall not contact form
coatings, release agents, bond breaker or curing compounds.
ii. Positioning of Reinforcement
Reinforcement shall be kept in the correct position using the following methods:
For beam and slab construction, pre-cast cover blocks in cement mortar 1:2 (1 cement
: 2 coarse sand) about 4 x 4 cm section and of thickness equal to the specified cover
shall be placed between the bars and shuttering, to secure and maintain the requisite
cover of concrete over reinforcement.
For cantilevered and doubly reinforced beams or slabs, the vertical distance between
the horizontal bars shall be maintained by introducing chairs, spacers or support bars
of steel at 1.0 metre or shorter spacing to avoid sagging.
For columns and walls, the vertical bars shall be kept in position by means of timber
templates with slots accurately cut in them; or with 1:2 cement mortar blocks (1 cement
: 2 coarse sand) of the required size suitably tied to the reinforcement to ensure that
they are in correct position during concreting.

For other RCC structures such as arches, domes, shells, storage tanks etc a
combination of cover blocks, spacers and templates shall be used as approved by
Engineer.
iii. Tying in Place
The reinforcement shall be accurately placed and tied securely with tying wire at all
points where bars cross. Stirrups shall be tied to bars at both the top and bottom. The
loose ends of the tying wire shall be bent inwards to prevent them projecting out of the
concrete cover provided, taking special care at surfaces where a form finish has been
specified. Bars and fabric shall be supported as described in Section 17.10.4.
Bars intended to be in contact at crossing points shall be securely bound together at

all such points with 16 gauge annealed soft iron wire. When epoxy coated
reinforcement is used, the wire shall be plastic coated. The vertical distances required
between successive layers of bars in beams or similar members shall be maintained
by the provision of spacer bars at such intervals that the main bars do not perceptibly
sag between adjacent spacer bars.
iv. Splices
Unless otherwise approved, splices shall be wired contact lap splices and conform to
the relevant local standard or to IS 2502.
No splicing of vertical bars will be allowed except at approved horizontal construction

joints.
Splices in horizontal bars shall be lapped with at least one continuous bar between
adjacent splices. The minimum spacing of splices in any one run of bar shall be 6 m
and in slabs which contain two layers of reinforcement, splices in opposite layers shall
be offset by at least 1.5 m.
v. Welding
Welding of reinforcement shall not be permitted unless specifically approved. If welding

is approved, the work shall be carried as per IS 2751, according to best modern
practices and as approved by the Engineer. Where permitted, the bars shall be shop
or field welded by experienced welders by the direct electric arc process, using low
hydrogen electrodes. In all cases of important connections, tests shall be made to
prove that the joints are of the full strength of bars welded. The completed weld shall
develop a minimum strength of 125 percent of the bar yield strength.
All surfaces close to the weld shall be cleaned free of loose mill scale or other foreign
material. The same precautions shall be taken each time an electrode is charged. Chip
burned edges shall be cleaned before welds are deposited.
When wire-brushed, completed welds shall exhibit uniform section, smoothness of

welded metal, feather edges without undercuts or overlays, freedom from porosity and
clinker and good fusion, with penetration into the base metal. Defective welds or parts
of welds shall be cut out and re-done satisfactorily. Defective welds or parts thereof
shall not be removed by using a cutting torch.
vi. Welded Wire Mesh

Welded fabric shall be placed on approved supports to hold it in place during

concreting. The fabric shall be laid flat in one plane and bent as required to fit the work.
Laps shall be a minimum of one mesh. At laps, alternate wires shall be tied with tying
wire.
vii. Additional Reinforcement
Additional reinforcement shall be provided at sleeves and openings as required.
viii. Inspection
Erected and secured reinforcement shall be inspected and approved by the Engineer
prior to placement of concrete.
13.7.16 Field Quality Control
The Contractor shall appoint an experienced officer to make continuous inspections of the
reinforcement during cutting, bending, placing in position, tying and cleaning before the
pouring of concrete. He shall effect any corrections or irregularities noted or requested by
the Engineer.
Welding for all shop and field welded reinforcing steel bars shall be inspected by the
assigned Contractor’s officer and regular inspections may be required by the Engineer
who shall be given the fullest opportunity to witness the welding operations.
13.8 Formwork
13.8.1 General
The Contractor shall submit to the Engineer sufficient details of the proposed shoring and
formwork to enable the Engineer to satisfy him about their general adequacy and
effectiveness. Forms, shoring and false work shall be adequate for imposed live and dead
loads, including equipment, the height of concrete drop, concrete and foundation
pressures, stresses, lateral stability and other safety factors during construction.
The formwork used in the works shall, unless otherwise specified herein, or approved or
permitted by the Engineer, comply with IS 14687.
13.8.2 Materials
All formwork shall be constructed of timber, sheet metal or other approved materials,
capable of providing the required finish. Where a special finish is required, the Contractor
shall provide, before commencement of fabrication, all details of the materials and means
he proposes to adopt to obtain the finish. All materials used shall be dimensionally stable
on exposure to extremes of weather. Sliding forms and slip forms may be used with the
approval of Engineer.
13.8.3 Formwork Requirements
The design of formwork shall take into account all the vertical and lateral loads that the
forms will be carrying including live and vibration loadings.
Forms shall conform to the shapes, lines, grades and dimensions including camber of the
concrete as necessary. Ample studs, waler braces, straps, shores etc. shall be used to
hold the forms in proper position without any distortion whatsoever until the concrete has

set sufficiently to permit removal of the forms. Forms shall be strong enough to permit the
use of immersion vibrators. In special cases, form vibrators may also be used. The
shuttering shall be close boarded. Timber shall be well seasoned, free from sap, loose
knots, worm holes, warps or other surface defects in contact with the concrete. Faces
coming in contact with concrete shall be free from adhering grout, plaster, paint, projecting
nails, splits or other defects. Joints shall be sufficiently tight to prevent loss of water and
fine material from the concrete.
Plywood shall be used for exposed concrete surfaces, where called for. Sawn and wrought
timber may be used for unexposed surfaces. Inside faces of forms for concrete surfaces
which are to be rubbed finished shall be planed to remove irregularities or unevenness in
the face. Form work with lining will be permitted.
All new and used form lumber shall be maintained in a good condition with respect to
shape, strength, rigidity, water tightness, smoothness and cleanness of surfaces. Form
lumber unsatisfactory in any respect shall not be used and if rejected by Engineer shall be
removed from the site.
Shores supporting successive stories shall be placed directly over those below or be so
designed and placed that the load will be transmitted directly to them. Trussed supports
shall be provided for shores that cannot be secured on adequate foundations.
Formwork, during any stage of construction, showing signs of distortion or distorted to such
a degree that the intended concrete work will not conform to the exact contours required,
shall be repositioned and strengthened. Poured concrete affected by faulty formwork shall
be entirely removed and the formwork corrected prior to placing new concrete.
Excessive construction cambers to compensate for shrinkage settlement etc that may
impair the structural strength of members will not be permitted.
Forms for substructure concrete may be omitted when, in the opinion of Engineer, the
open excavation is firm enough to act as the form. Such excavations shall be slightly larger
than required by the drawings to compensate for irregularities in excavation and to ensure
the design requirements are met.
Forms shall be so designed and constructed that they can be stripped in the order required
and their removal does not damage the concrete. Face formwork shall provide true vertical
and horizontal joints conforming to the architectural features of the structure as to location
of joints and be as approved by Engineer.
The formwork shall be so constructed that up and down vertical adjustment can be made
smoothly. Wedges may be used at the top or bottom of timber shores, but not at both ends,
to facilitate vertical adjustment or dismantling of formwork.
Where exposed smooth or rubbed concrete finishes are required, the forms shall be
constructed with special care so that the desired concrete surfaces can be obtained which
require a minimum finish.
13.8.4 Form Coating
Form coating shall be non-grain raising and non-staining resin type coating or other
suitable non-staining mould oil which will not leave residual matter on the surface of the
concrete or adversely affect bonding to concrete of paint, plaster, mortar, protective
coatings, waterproofing’s or other applied materials. The coatings shall not contain any

mineral oils, paraffin, waxes or other non-drying ingredients, nor, in the case of surfaces
in contact with potable water, any toxic ingredients of any type whatsoever.
13.8.5 Metal Forms
Metal forms shall be true to detail in condition, clean, free from dents, bends, rust and oil
or other defects likely to impair the specified finish.
13.8.6 Round Column Forms
Forms for round columns shall be of metal tubes of materials described for metal forms,
fibre glass reinforced plastic or other approved material.
13.8.7 Tie Bolts
Only tie bolts which avoid embedding any metal parts permanently within 50 mm of the
concrete surface shall be permitted. Voids remaining after the removal of all or part of each
tie bolt shall be filled flush with the surrounding concrete using a freshly prepared non-
shrink cement and fine aggregate paste.
In the case of structures designed to retain an aqueous liquid, the Contractor shall ensure
that the measures adopted shall not impair the water tightness of the structure. Tie bolts
which form a continuous hole through a structure designed to retain an aqueous liquid
shall not be used.
13.8.8 Form Joint Sealers
Effective precautions shall be taken to ensure that joints between form panels are
sufficiently water tight to prevent honey combing resulting from the escape of mortar during
the placing and vibration of concrete. The joints shall be sealed with resilient foam rubber
strips, non-hardening plastic type caulking compound free from oil or other such material
or compound as may be approved by the Engineer. Form tie holes shall be plugged with
plastic caulking compound, tight fitting rubber plugs or equal.
13.8.9 Moulds
Moulds for grooves, drips, rebates, profiles, chamfers and other similar items shall be of a
smooth-milled approved timber or standard extruded polymer plaster units of the required
shapes.
13.8.10 Bracing Shuttering and Props
Shuttering shall be braced, strutted, propped and so supported that it shall not deform
underweight and pressure of the concrete and also due to the movement of men and other
materials. Bamboos shall not be used for props or cross bracings.
The shuttering for beams and slabs shall be so erected that the shuttering on the sides of
beams and under the soffits of slabs can be removed without disturbing the beam bottoms.
Re-propping of beams shall not be done except when props have to be reinstated to
support construction loads anticipated to be in excess of the design load. Vertical props
shall be supported on wedges or other measures shall be taken whereby the props can
be gently lowered vertically while striking the shuttering.
If the shuttering for a column is erected for the full height of the column, one side shall be
left open and built upon sections as placing of concrete proceeds, or windows may be left

for pouring concrete from the sides to limit the drop of concrete to 1.0 m. or as otherwise
approved by Engineer.
13.8.11 Chamfers & Fillers
All corners and angles exposed in the finished structure shall be formed with mouldings to
form chamfers or fillers on the finished concrete. The standard dimensions of chamfers
and fillets, unless otherwise specified, shall be 20 x 20 mm. Care shall be exercised to
ensure accurate mouldings. The diagonal face of the moulding shall be planed or surfaced
to the same texture as the forms to which it is attached.
Vertical Construction Chamfers
Vertical construction joints on faces which will be exposed at the completion of the work
shall be chamfered as above except where not permitted by Engineer.
Form Types for Surface Finishes
Concrete surface finishes shall generally be of the following types

1) All interior faces of walls and exposed roofs of structures of above and below grade
and exterior surfaces above finished grade shall have a smooth form finish.
2) All exterior walls below finished grade and other surfaces not included in category (1)
above shall have a rough finish, unless otherwise specified.
3) Metal, plywood or forms of other approved material shall be used to provide a smooth
finish.
4) Plywood or board forms of lesser quality may be used to provide rough finishes.
13.8.12 Shoring and False work
Shoring and false work shall be designed to distribute loads safely over the base area on
which the shoring is erected. Adequate precautions shall be taken against undermining or
settlement particularly against wetting of soils, when cleaning forms or curing concrete or
by any other cause.
i. Alignment and Camber
All forms shall be constructed to produce the required lines, grades and camber as
required, in the finished structure. The tolerance on line and level shall not exceed 3
mm. In the absence of any specific camber, the forms for soffits of beams, other than
pre-stressed beams, shall under normal circumstances be constructed to provide an
upward camber of 6 mm for every 3 metres of clear span.
ii. Means Adopted
S-Jacks, wedges or similar approved means shall be used to induce the required
camber in the forms and to correct any settlement which may occur either before or
during the placing of concrete.
13.8.13 Construction
Form windows shall be provided as necessary to provide access for placement and
vibration of concrete. The windows shall be adequately sized to admit chutes and vibrators
and should generally be spaced at 2 metre intervals. The windows shall be firmly closed
and braced before placing concrete at higher levels.

Temporary openings shall be provided in wall and column forms for inspection and
cleaning. All inner surfaces of forms shall be cleaned before any concrete is poured.
Reglets and rebates to receive flashing, frames and other equipment shall be properly
formed. Dimensions, details and precise positions of all such reglets and rebates shall be
ascertained from the suppliers of the flashings, frames or equipment, if supplied under a
separate contract.
If form materials are found to be fit for reuse, they shall be cleaned and re-conditioned
before re-erection.
13.8.14 Embedded Piping and Other Hardware
Before the commencement of fabrication of the formwork, all trades requiring openings for
the passage of pipes, electrical conduits and other inserts shall be consulted and the
necessary pipe sleeves, anchors or other inserts shall be properly and accurately installed
by the representative trades or adequate details obtained which would enable the requisite
openings to be correctly positioned. Pipes and conduits, when embedded shall not weaken
the construction and no pipes, other than electric conduits, shall be permitted to be
embedded within a slab not exceeding 12 cm thick. Conduits placed in a concrete slab
shall not have an outside diameter exceeding 1/3 the thickness of the slab and shall be
placed between the upper and lower layers of reinforcement. Conduits may be embedded
in walls if the outside diameter is less than 1/3 the wall thickness and they are not spaced
closer than at three diameters centre to centre and do not otherwise weaken the wall.
13.8.15 Field Quality Control
Tell-tale devices or other methods shall be adopted, where approved, to detect

movements and deflection of forms during concrete placement. The required slab and
beam cambers and verticality and the specified batter of column sides shall be regularly
checked, corrected and maintained as concrete loads are applied on the forms. Workmen
shall be assigned to check forms and seal all mortar leaks discovered during concreting.
13.8.16 Inspection of Formwork
Any member which is to remain in position after the general dismantling is completed
should be clearly marked.
Material used should be checked to ensure that, wrong items / rejects are not used.
If there are any excavations nearby which may influence the safety of the formwork,
corrective and strengthening action shall be taken.
The bearing soil must be sound and well prepared and sole plates shall bear well on the
ground and;
1) Sole plates shall be properly seated on their bearing pads or sleepers.
2) The bearing plates of steel props shall not be distorted.
3) The steel parts on the bearing members shall have adequate bearing areas.
Safety measures to prevent the impact of traffic, scour due to water etc should be taken.
Adequate precautionary measures shall be taken to prevent accidental impacts etc.

Bracing, struts and ties shall be installed along with the progress of formwork to ensure
the strength and stability of the formwork at intermediate stages. Steel sections (especially
deep sections) shall be adequately restrained against tilting, over turning.
When adjustable steel props are used, they shall:

1) Be undamaged and not visibly bent;
2) Be complete with the steel pins provided by the manufacturers;
3) Be restrained laterally near each end; and
4) Have means for centralising beams placed in the fork-heads.
Screw adjustment of adjustable props shall not be over extended.
Double wedges shall be provided for adjustment of the form to the required position
wherever any settlement / elastic shortening of the props may occur. Wedges should be
used only at the bottom end of single props. Wedges should not be too steep and one of
the pair should be tightened / clamped down after adjustment to prevent shifting.
The number of nuts and bolts shall be adequate. All provisions of the design shall be
complied with. Cantilever supports shall be adequate. Props shall be directly under one
another in multistage constructions as far as possible. Guy ropes or stays shall be properly
tensioned. There shall be adequate provision for the movement and operation of vibrators
and other construction plant and equipment. The required camber shall be provided over
long spans. Supports shall be adequate and in plumb within the specified tolerances.
13.8.17 Removal of Forms and Shoring and Striking
Contractors shall record on the drawings or a special register, the date upon which the
concrete is placed in each part of the work and the date on which the shuttering is removed
there from.
In no circumstances shall forms be struck until the concrete reaches a strength of at least
twice the stress due to self weight and any construction erection loading to which the
concrete may be subjected at the time of striking the formwork.
The striking of formwork shall be as approved by the Engineer. Generally, however, the
following table gives the minimum periods that must elapse before the formwork is
removed, reckoned from the time the pouring of concrete was completed.
Position of Formwork and Props Minimum days for Removal

Walls 1
Sides of beams and columns 1
Slabs (props left under) 3
Props to slabs (spans not exceeding 4 ½ metres) 7
Props to slabs (spans exceeding 4 ½ metres) 14
Beam soffits (props left under) 7
Props to beams (spans not exceeding 6 metres) 14
Props to beams, Cantilever beams, Cantilever slabs 21
(spans exceeding 6 metres)
The stripping time recommended above may be modified subject to the approval of the
Engineer.

The number of props left under beams and slabs and their sizes and the position shall be
such as to safely carry the full dead load of the slab, beam or arch together with any live
load likely to occur during curing or further construction.
Where the shape of an element is such that the formwork has re-entrant angles, the form
work shall be removed as soon as possible after the concrete has set, to avoid shrinkage
cracking occurring due to the restraint imposed.
Striking shall be done slowly with utmost care to avoid damage to arises and projections
and without shock or vibration, by gently easing with wedges. If, after removing the
formwork, it is found that timber has been embedded in the concrete, it shall be removed
and made good.
Reinforced temporary openings shall be provided, as approved by Engineer, to facilitate

removal of formwork which otherwise may be in-accessible.
Tie rods, clamps, form bolts etc which shall be entirely removed from walls or similar
structures shall be loosened not sooner than 24 hours nor later than 40 hours after
concrete has been deposited. Ties, except those required to hold forms in place, may be
removed at the same time. Ties withdrawn from walls and grade beams shall be pulled
towards the inside face. Cutting ties back from the faces of walls and grade beams will not
be permitted.
13.8.18 Restrictions
No permanent load or loads from construction equipment shall be imposed on columns,

supported beams or supported slabs until the concrete has attained at least twice the
compressive strength necessary to sustain the imposed loads.
13.8.19 Surface Finishes
13.8.19.1 Surface Finishes Produced Without Formwork
1. Screeded Finish
The concrete shall be levelled and screeded to produce a uniform plain or ridged
surface as required. No further work shall be applied to the surface unless it is a first
stage for a wood float or steel trowel finish.
2. Wood Float Finish
The screeded finish shall be wood floated under light pressure to eliminate surface
irregularities.
3. Steel Trowel Finish
When the moisture film has disappeared and the concrete has hardened sufficiently to
prevent laitance from being worked to the surface, the surface to the wood float finish
shall be steel-trowelled under firm pressure to produce a dense, smooth, uniform
surface free from trowel marks.

4. Power Float Finish
Power floating shall be undertaken by steel floating the concrete to an even finish with
no ridges or steps. When the concrete has taken a primary set it shall be power
trowelled to a uniform smooth polished surface free from trowel marks or other
blemishes. Once power floating is complete the surface finish must be adequately
protected from construction traffic.
5. Where the type of finish is not specified it shall be wood float finish.
13.8.19.2 Surface Finishes produced with Formwork
1. Rough Finish
This finish shall be obtained by the use of moulds or properly designed forms of closely
jointed sawn boards. The surface shall be free from substantial voids, honeycombing
or other large blemishes.
2. Fair Finish
This finish shall be obtained from forms designed to produce a hard smooth surface
with true, clean arises. Only very minor surface blemishes shall be permitted and there
shall be no staining or discolouration. Any projections shall be removed and the surface
made good.
3. Fair Worked Finish
This finish shall be obtained by first producing a fair finish and then filling all surface
blemishes with a fresh, specially prepared cement and fine aggregate paste whilst the
concrete is still green, where possible. After the concrete has been properly cured the
faces shall be rubbed down, if required to produce a smooth and even surface. If the
surface is to be exposed in the final work, every effort shall be made to match the
colour of the concrete.
Liquid retaining surface and other surfaces exposed in the completed Works shall
receive a fair worked finish. All other structural concrete surfaces shall receive a fair
finish.
13.9 Construction Tolerances
13.9.1 General
Tolerances are a specified permissible variation from the designed lines, grade or
dimensions as approved by the Engineer. No tolerances specified for horizontal or vertical
building lines or footings shall be constructed beyond the legal boundaries. Unless
otherwise approved by the Engineer, the following tolerances shall be permitted:
13.9.2 Tolerances for Reinforced Concrete Buildings
i. Variation from Plumb
In the line and surfaces of columns, piers, walls and in buttresses: 5 mm per 2.5 m,
but not more than 25 mm.

For exposed corner columns and other conspicuous lines.

In any bay or 5 m maximum : (+/-) 5 mm
In 10 m or more : (+/-) 10 mm
ii. Variation from the design levels or grades
In slab soffits, ceilings, beam soffits and in arises.

1. In 2.5 m. : (+/-) 5 mm
2. In any bay or 5 m maximum : (+/-) 8 mm
3. In 10 m. or more : (+/-) 15 mm
For exposed lintels, sills, parapets, horizontal grooves and other conspicuous lines.
4. In any bay or 5 m. maximum : (+/-) 15 mm
5. In 10 m or more : (+/-) 10 mm
iii. Variation in linear building lines
In any bay or 5 m. maximum : (+/-) 10 mm
In 10 m. or more : (+/-) 20 mm
iv. Sizes and locations of sleeves, openings in walls and floors
Allowable tolerance : (+/-) 5 mm (excludes anchor bolts)
v. Variation in cross-sectional dimensions of columns, beams slabs and walls
Allowable tolerance : +10 mm/5 mm
vi. Footings
Variation in dimensions in plan : +50 mm/-5 mm

Misplacement or eccentricity : 2% of footing within the direction of
misplacement but not more than 50 mm
Reduction in thickness : (-) 5% of specified thickness subject to maximum
of 50 mm
vii. Variation in Steps
Rise in a flight of stairs : (+/-) 3.0 mm

Tread in a flight of stairs : (+/-) 5.0 mm`````````````
Rise in consecutive steps : (+/-) 1.5 mm
Tread in consecutive steps : (+/-) 3 mm
13.9.3 Tolerances in other Concrete Structures
i. All structures:
Variation of the constructed linear outline from established position in plan.

In 5 m. : (+/-) 10 mm
In 10 m. or more : (+/-) 15 mm

Variation of dimensions to individual structure features from established positions in

plan.
In 20 m. or more : (+/-) 25 mm
In buried constructions : (+/-)150 mm
Variation from plumb, from specified batter or from curved surfaces of all structures.
In 2.5 m. : (+/-) 10 mm
In 5.0 m. : (+/-) 15 mm
In 10.0 m. or more : (+/-) 25 mm
In buried constructions : (+/-) Twice the above limits.
Variation from level or grade indicated on drawings in slabs, beams, soffits, horizontal
grooves and visible arises.
In 2.5 m. : (+/-) 5 mm
In 7.5 m. or more : (+/-) 10 mm
In buried constructions : (+/-) Twice the above limits.
Variation in cross-sectional dimensions of columns, beams, buttresses, piers and

similar members.
Allowable tolerance : (+)12 mm/(-) 6 mm
Variation in the thickness of slabs, walls, arch sections and similar members.
Allowable tolerance : (+)12 mm/(-) 6 mm
ii. Footings for columns, piers, walls, buttresses and similar members:
Variation of dimensions in plan : (+)50 mm/(-)12 mm

Misplacement or eccentricity : 2% of footing within the direction of
misplacement but not more than 50 mm
Reduction in thickness : 5% of specified thickness subject to a
maximum of 50 mm
iii. Other Tolerances
Tolerances in other types of structures shall generally conform to those given in Clause
of Recommended Practice for concrete form work IS 14687.
13.9.4 Cement Grouting
13.9.4.1 General
These specification clauses refer to grouting where required in excavated rocky strata.
13.9.4.2 Requirements
The Contractor shall furnish all tools, equipment, materials and labour for furnishing and
placing grout to stop leaks and permanently control the inflow of water through rock faces
when necessary for the proper construction of the Works or if instructed to do so by the
Engineer.
The Contractor shall carry out the works in accordance with the requirements of IS 6066
– 1971.

13.9.4.3 Construction Plant and Products
i. Equipment
The equipment used shall be of type, capacity and mechanical condition suitable for
satisfactorily completing the work. The power and equipment and their layouts shall
conform to all relevant regulations and safety codes applicable to the Mumbai Sewage
Disposal Project- Stage II. All motors shall be equipped with suitable mufflers and
scrubbers.
Standard drilling equipment of the rotary type shall be used to perform the drilling.
Rotary percussion drills of any type will not be permitted to be used. The drilling
equipment utilized within subsurface structures shall be capable of drilling at any
orientation to a maximum depth of 7.5 metres.
Holes shall be grouted using the shortest practicable length of line. Fouling of the
equipment shall be prevented by maintaining a continuous flow of grout and by
periodically flushing with water. A water supply shall be directly connected into the
grout supply line. Pressure gauges and adequate valves required for by-pass and shut-
off shall be attended constantly by qualified operators at the collar of the hole being
grouted.
Additional grout headers, to a maximum of six, shall be available to interconnect holes.

Such interconnected holes shall be grouted simultaneously as long as the capacity of
the mixing and pumping system permits the design grouting pressure to be maintained.
The Contractor shall be equipped to continuously flush with fresh water, as approved
by the Engineer, those interconnected holes he is not able to grout, if the grout take in
a series of interconnected holes exceeds the pump capacity.
The general requirements for the cement grout plant shall include two independent,
operational grout pumps connected to allow switching from one to the other in the
event of mechanical failure without interrupting the grout flow, operational stand-by
equipment for each element of the operation shall be available at the job site.
ii. Materials
Mixes consist of cement, water, sand and an approved fluidifier in the proportions as
designated by the Contractor’s designer and approved by Engineer. The mix may, from
time to time, be amended to suit the conditions encountered in particular locations. The
water cement ratio by volume shall be varied to meet the characteristics of each holes
as revealed by the grouting operation and may range between 10.0 and 0.6. If after
mixing, the grout cannot be placed for any reason whatsoever, it shall be wasted.
The proportions of grout shall produce a flowable mixture consistent with a minimum
water content and shrinkage. The grout proportions shall be limited as follows:
W/C. Ratio in
Use Grout thickness Mix. proportions
(Max.)
a) Fluid mix Under 25 mm One part Portland cement to 0.44
one part sand.
b) General more than 25 mm One part Portland cement to 2 0.53
but less than 50 parts of sand.
mm

W/C. Ratio in
Use Grout thickness Mix. proportions
(Max.)
c) Stiff mix. 50 mm and over One part Portland cement to 3 0.53
parts of sand.
Variations in grout mixes and procedures shall be permitted if approved by the

Engineer.
Special grout shall be provided in strict accordance with the manufacturer’s

instructions.
1) Cement Water and Sand
All cement, water and sand shall be as that used in concrete.
2) Fluidifier
Fluidifiers shall be compounds possessing characteristics which will improve the

fluidity of the mixture and assist in dispersing shrinkage of the grout. Bentonite or other
clay like materials are not acceptable as fluidifiers. Fluidifiers shall be furnished in
moisture resistant sacks, shipped in dated sealed containers and shall be handled and
stored to avoid absorption of moisture, damage or waste. Material which has become
caked due to moisture absorption shall not be used in the work. No fluidifier shall be
used that has exceeded the manufacturer’s recommended shelf life.
3) Pipes
All metal pipes and fittings required for grouting operations shall be furnished, cut,
threaded, fabricated and embedded by the Contractor. The pipes shall conform to
IS 6631 – 1972.
13.9.4.4 Execution
i. General
All holes for cement grouting shall be drilled at the locations, in the directions and to
the depths approved by the Engineer, as the grouting operations proceed. Grouting
shall be performed in the presence of the Engineer. The actual number, depth
sequence and spacing of holes and the pressures, pumping rates and grout mixes to
be used for grout injections will depend upon the nature of the rock, the results of the
water pressure tests or observations and the results of previous grouting operations.
They will be determined by the Contractor and subject to the approval of the Engineer.
ii. Supervision
The Contractor shall have an experienced supervisor directing his grouting operations.
The supervisor shall be experienced in cement grouting in rock.
iii. Grout Hole Drilling and Preparation
The holes at the maximum required spacing are referred to as primary holes, hereafter.
The number of grout holes shall be increased progressively by split spacing between
the primary holes as approved by the Engineer. The type of bit used for drilling shall

be at the discretion of the Contractor. The minimum diameter of the hole shall be 38
mm at the point of maximum penetration. Only clean water may be used as a
circulating medium when drilling grout holes. Recirculated water shall not be used.
Grout hole drilling ahead of the grouting operation shall be limited to the extent that
can be grouted within two calendar weeks.
Grout pipes shall be installed in a workman like manner and shall be thoroughly
cleaned of all dirt, grease, oil grout and mortar immediately before embedment. All
grout pipes shall be sealed to the rock. On completion of grouting, grout pipes shall be
cut off flush with the rock line and the holes shall be thoroughly washed before grouting,
to the approval of the Engineer. Drill cuttings, fragments and slurry shall be removed
from the hole by an air/water jet applied at the bottom of the hole and returned through
the hole to the surface. Washing shall continue until all debris is removed from the hole
and the return water is clear.
Surfaces to be grouted shall be thoroughly roughened and cleaned of all foreign matter
and laitance. Prior to grouting, hardened concrete surfaces to be grouted shall be
saturated with water.
The cleaning of bedding planes, joints and fractures shall be accomplished by pumping
water through the grout connection at the anticipated grouting pressure. Such pressure
washing shall continue at the desired pressure as long as there is an increase in the
rate of water intake.
Holes in which the optimum pressure cannot be reached shall be washed for as long
as the fracture filling is being removed, as will be revealed by the escape of muddy
water through nearby openings and for not less than five minutes unless otherwise
approved. Open holes in which no pressure can be built up shall be washed for a
minimum of five minutes or for such a period as fractures or joint filling, as determined
by the Engineer.
Each grout hole shall be water pressure tested immediately prior to grouting. Water
shall be injected through the test apparatus and through the grout connection. All holes
shall be tested at pressures to be determined by the Engineer, but not to exceed 7
kgf/cm2. Water tests shall consist of water absorption under designated grouting
pressures for a maximum of 10 minutes. This procedure is designated as the water
pressure check. Expandable rubber packers shall be provided to seal off the portion of
the hole to be tested as instructed. Atmospheric or open hole testing may be required
in addition to the pressure testing. A selected number of holes will be utilized for water
pressure check holes to determine the grouting effectiveness after the primary holes
are grouted.
iv. Grouting under equipment and base plates
Anchor bolts, anchor bolt holes and the bottom of equipment and column base plates
shall be cleaned of all oil, grease, dirt and loose material. The use of hot, strong, caustic
solution for this purpose shall be permitted.
Water in anchor bolt holes shall be removed before grouting is started.
Forms around base plates shall be tight to prevent leakage of the grout.
Adequate clearance shall be provided between forms and base plates to permit grout
to be worked properly into place.

v. Grouting
Unless specifically approved by the Engineer, each grout hole shall be grouted
individually. Approval may be given to grout adjacent holes penetrating the same
geologic stratum up to a maximum of six, if communication is established between the
holes during grouting and if the water pressure test results in each hole have revealed
similar requirements for grout mix and pressure.
Grouting, once started, shall be done quickly and continuously to prevent segregation,
bleeding and breakdown of initial set. Grout shall be worked from one side of one end
to the other to prevent entrapment of air. To distribute the grout and to ensure more
release from entrapped air, link chains shall be used to work the grout into place.
Grouting through holes in base plates shall be by pressure grouting.
Grouting pressure to be used in the work will vary with conditions encountered in
different holes and the pressures used for each holes will be as approved by the
Engineer. It is anticipated that pressures will range from 0.7 to 7 kgf/cm 2, but in no
event will pressures exceeding 10.5 kgf/ cm2 be required.
vi. Grout Inspection
Once started, the grouting of a hole shall not be interrupted without approval of the
Engineer. If necessary to prevent premature stoppage, periodic applications of water
under pressure shall be made. Under no conditions shall the pressure or rate of
pumping be increased or decreased suddenly. The grouting of any hole shall not be
considered complete until refusal. Refusal is defined as a grout injection rate of zero
litres per minute measured over a five-minute interval at 100 percent grouting pressure,
although in no case will the Contractor be required to pump into a hole in which the
grout takes below 30 litres per hour for more than four hours.
The Contractor shall caulk all grout leaks as they develop, as approved by the
Engineer. Caulking shall begin on the leaks with the highest volume and progress to
those of lesser volume until all leaks are caulked. Prior to grouting, the Engineer may
require caulking of leaks which have shown high volume during water pressure testing.
If due to the size and continuity of fractures, it is found impossible to reach the required
pressure after pumping a reasonable volume of grout at the minimum workable water-
cement ratio, or a mortar grout with the maximum volume of sand at the minimum
workable water-cement ratio, the speed of pumping shall be reduced or pumping shall
be stopped temporarily and intermittent grouting shall be performed, allowing sufficient
time between grout injections for the grout to stiffen. If the desire result is still not
obtained, grouting the hole shall be discontinued when approved. In such an event,
the hole shall be cleaned, the grout allowed to set and additional drilling and grouting
shall then be continued to the this hole or in the adjacent area as approved until the
desired resistance is developed.
After grouting refusal is reached, the pressure on the hole shall be maintained by
means of a stop-cock or other suitable device until the grout has set.
Grout check holes shall be drilled after the primary hole has been grouted to assess
the grouting effectiveness. Additional grouting and drill holes shall be placed between
the primary holes as approved by the Engineer.

vii. Clean-up
During grouting operation, the Contractor shall take such precautions as may be
necessary to prevent drill cuttings, equipment oil, wash water and grout from defacing
or damaging the permanent structure. The Contractor shall furnish such pumps as
necessary to care for waste water and materials from his operations and clean up
waster water and materials from his operations. The clean-up procedure shall be to
the satisfaction of the Engineer.
viii. Records
The Contractor shall keep records of all grouting operations including:

1) logs of grout holes;
2) hole locations and depths;
3) results of washing and pressure testing operations;
4) time of each change of grouting operation;
5) pressure;
6) rate of pumping;
7) amount of cement for each change of water cement ratio; and
8) Any other data which he considers pertinent and important.
All records shall be in a form approved by the Engineer and shall contain all data as
required by the Engineer.
13.10 Structural Steel Work
13.10.1 Materials
All structural steel shall be of standard sections and shall be free of scale, blisters,
laminations, cracked edges and defects of any sort. The Contractor shall furnish duplicate
copies of all mill orders and/ or the test report received from the mills, to the satisfaction of
the Engineer.
All structural steel and electrodes shall comply in all respects with IS for structural steel.
Any other quality may be used only if approved by the Engineer. Such permission shall be
preceded by yield point stress, ultimate tensile stress, ductility, weld-ability tests or any
other characteristics as required by the Engineer.
Steel castings shall conform to Grade III of IS 1030 - Specifications for steel casting for
general engineering purposes.
13.10.1.1 Dimensions and Tolerances
i. General
The dimensional and weight tolerance for rolled shapes shall be in accordance with
IS: 1852 for indigenous steel and equivalent applicable codes for imported steel.
An acceptable deviation from flatness in girder webs in the length between the
stiffeners or in a length equal to the girder depth shall be 1/150th of the total web depth.

A reasonable limit for combined warping and tilt on the flange ends of a built up
member is 1/200th of the total width of flange or 3 mm whichever is smaller measured
with respect to centreline of flange.
Lateral deviation between centreline of web plates and centreline of flange plates at
the contact surface, in the case of built up sections, shall not exceed 3mm
Columns bearing on each other or resting on base plates and compression joints
designed for bearing shall be milled true and square to ensure proper bearing and
alignment. Base plates shall also have their surfaces milled true and square.
ii. Rolled Shapes
The dimensions, form, weight and tolerances of all hot rolled shapes (and other
members) shall comply with the relevant Indian Standards.
iii. Cold Formed Sections
The dimensions and tolerances of all cold formed light gauge structural steel sections
shall conform to clauses of I.S 811- Specification for cold formed light gauge structural
steel sections.
iv. Castings
All steel castings shall conform to IS 4899 and grey iron castings shall comply with IS
210 and malleable castings with IS 2108 or latest version.
13.10.2 Execution
13.10.2.1 General
In general, fabrication shall conform to the requirements of IS 800.
The Contractor shall deliver the component parts of the steelwork in an undamaged state
at the site of the works and the Engineer shall be entitled to refuse acceptance of any
portion which has been bent or otherwise damaged before actual delivery.
13.10.2.2 Workmanship
All workmanship shall be of first class quality in every respect to the greatest accuracy
being observed to ensure that all parts fit together properly on erection.
All ends shall be cut true to planes and shall fit the abutting surfaces closely. All stiffeners
shall fit tightly at both ends.
All butt ends of compression members shall be in close contact through the area of the
joints.
All holes in plates and section between 12 mm and 20 mm thick shall be punched to such
diameter that 3 mm of metal is left all around the hole to be cleaned out to correct size by
reaming.
Base connections shall be provided as required and the greatest accuracy of workmanship
shall be ensured to provide the best connections.

13.10.2.3 Erection and Marking
Erection and fabrication shall be according to IS 800-1984 section-11. During erection, the
work shall be securely braced and fastened temporarily to provide safety for all erection
stresses etc. No permanent welding shall be done until proper alignment has been
obtained.
Any parts which do not fit accurately or which are not in accordance with the approved
fabrication drawings and specifications shall be liable to rejection and if rejected.
13.10.2.4 Straightening
All materials shall be straight and free from twists. If rectification is necessary, this shall be
affected by cold working and applying pressure, but not by hammering or any other method
that will affect or damage the metal. Material with sharp kinks or bends shall be rejected.
13.10.2.5 Cutting
Cutting shall be effected by shearing, sawing, cropping or gas cutting and shall be
reasonably square and free from distortion with all burrs removed. If approved by the
Engineer the edges shall be ground afterwards. For gas cutting of high tensile steel,
sufficient steel shall be left over beyond the required profile to enable all metal hardened
by heat to be removed by machining. Except where material is subsequently Plates in
built-up members shall be end edge planed, except where flats with square edges are
used. Plates specified to be planed milled or chipped, shall be cut in the first instance to
such a size as to allow 3 mm to be planed, milled or chipped from the sides or ends.
Edges or gussets not exceeding 8 mm thickness may be sheared in a machine which can
take the full side in one cut. Edges of thicker gussets shall be prepared by planning milling
or grinding. Edge preparation for welding of surfaces shall be carried out by grinding,
planing or milling but not by shearing or cropping.
13.10.2.6 Holing
Holes for rivets or bolts shall not be formed by gas cutting. Drilled or reamed holes shall
be cylindrical and perpendicular to the surface. Finished holes shall not be more than
1.5mm larger than the specified diameter of bolts and rivets up to 25 mm diameter. For
larger sizes the finished holes shall not be more than 2 mm larger than the specified
diameter of the bolts and rivets. Holes for turned and fitted bolts shall be drilled to a slightly
smaller diameter and reamed to a diameter equal to the nominal diameter of the shank or
barrel subject to H8 tolerances specified in IS 919.Holes through more than one thickness
of material shall, where possible, be drilled after the members are assembled and tightly
clamped or bolted together. Punching may be permitted before assembly provided the
holes are punched 3 mm less than the required size and reamed after assembly to the full
diameter. The thickness of material punched shall not be more than 16 mm When holes
are drilled in one operation through two or more separable parts, these parts shall be
separated after drilling and all burrs removed. Matching holes for rivets or black bolts shall
register with each other so that a gauge 1.5 mm or 2 mm, depending of bolt size, less in
diameter than the diameter of the hole shall pass freely through the assembled members
in a direction perpendicular to the member surface.
For parts connected with turned and fitted bolts or close tolerance barrel bolts, the
matching holes shall be drilled through all the thickness in one operation after securing the
parts firmly together and subsequently reamed to size. Where this is not practicable, the

parts shall be drilled and reamed separately through hard bushes steel jigs. All holes not
drilled through all thicknesses at one operation shall be drilled to a smaller size and reamed
out after assembly. All holes, whether for shop or field connections, shall be accurately
centred and matched to render reaming or drifting unnecessary during erection. Members
with poorly matching holes shall be rejected.
13.10.2.7 Bolting
Installation of high strength friction grip bolts in joints shall comply with IS: 4000. The
diameter of the bolt holes must not be more than 1.5 mm larger than the nominal diameter
of the bolt. All contact surfaces in a connection including those associated with the nut
heads, nuts and washers shall be free of scale, burrs, dirt and other foreign matter tending
to inhibit uniform sealing of the joint components.
13.10.2.8 Riveting
Rivets shall be heated uniformly throughout their lengths and shall, when driven,
completely fill the holes. Riveted members shall have all parts firmly drawn and held
together before and during riveting, for multiple riveted connections, a service bolt shall be
provided in every third or fourth hole. All loose, burred or otherwise defective rivets shall
be cut out and replaced before loading the structure.
13.10.2.9 Testing and Inspection
All structural steel and other materials supplied by the Contractor shall be supported by a
manufacturer’s test certificate conforming compliance with the relevant specifications. The
Engineer may order further sampling and testing on any item brought to site.
The Engineer shall have free access at all reasonable times to the Contractor’s
manufacturer’s fabrication shop or yard and shall be provided with all co-operation and
facilities for inspection and no work shall be taken down, painted or despatched until it has
been inspected and passed. All gangs, templates, tool etc required shall be supplied by
the Contractor. Inspection by the Engineer and testing by approved authorities will not
relieve the Contractor of his liability to fulfil his contractual obligations.
13.10.2.10 Tolerances for Steel Structures
Tolerances stated below shall be achieved after the entire structure, or part thereof, is in
line, level and plumb.
Deviation of column axes at foundation top level with respect to true axes
a) In longitudinal direction ± 5 mm
b) In lateral direction ± 5 mm
Deviation in the level of bearing surface of columns at
foundation top with respect to true level ± 5 mm
Out of plumbness (verticality) of column from true vertical axis, as measured at column top
a) For columns up to and including 15 m in height height 1/1000 of column

height in mm or 15 mm
whichever is less
b) For columns exceeding 15 m in height 1/1000 of column

height in mm or 20 mm
whichever is less
Deviation in straightness in longitudinal and 1/1000 of column height
transverse planes of column at any point along the or 10 mm whichever is less
height
Difference in erected position of adjacent pairs of 10 mm
columns along length or across width of building,
prior to connecting trusses/beams with respect to
true /distance
Deviation in any bearing or seating level with 5 mm
respect to true level
Deviation in differences bearing levels of a member 10 mm
on adjacent pair of columns both across and along
the building
Beams:
Deviation in difference of bearing levels of Depth <1800 mm i 6 mm

beams from the true difference Depth >1800 mm i 10 mm
Deviation in sweep of beams in the 1/1000 of span in mm subject to a maximum
horizontal plane of 10 mm
Crane Girders and Rails:
Shift in the centreline of crane rail with respect to 5 mm

centreline of web of crane girder
Shift in plan of alignment of crane rail with respect to 5 mm
true axis of crane rail at any point
Differences in alignment of crane rail in plan 1 mm
measured between any two points 2 metres apart
along rail
Deviation in crane track with respect to true gauge: 5 mm
For track gauges up to and including15 metres
For track gauges more than 15 metres [5 + 0.25 (S – 15)) where S
in metres is true gauge
Deviation in the crane rail level at any point from true 1/1200 of the gauge distance or
level +10 mm whichever is less
Difference in the crane rail actual levels between any 2 mm
two points 2 metres apart along the rail length
Difference in levels between crane tracks rails at:
Supports of crane girders 15 mm

Mid span of crane girders 20 mm
Relative shift of crane rail surfaces at a joint in plan and 2 mm subject to grinding of
elevation surfaces for smooth transition
Relative shift in the location of crane stops (end 1/1000 of track gauge S
buffers) along the crane tracks with track gauge S in m subject to maximum of 20 mm

13.11 General Architectural Specifications
13.11.1 Materials
Hydrated lime shall be obtained by burning “Kankars” in the manner approved by the
Engineer. It shall be properly burnt or calcined. It shall be free from unburnt pieces, ashes
and other impurities. It shall be brought in an unslaked condition on site and shall be slaked
in fresh clean water on site. Fat or un-hydrated lime shall be from Katni or Satna or any
other approved place.
Lime that has been in any way spoiled by rain, moisture, dirt or by any other cause will be
rejected and all material that has been rejected shall be removed within 24 hours from the
site of the work.
Recommendations of IS: 712 Building limes shall be followed.
13.11.1.1 Lime Cream Putty
Lime cream putty shall be made from best description of fat lime slaked with excess of
water and stored in a pit.
13.11.1.2 Lime Mortar
Lime mortar shall consist of

1) One part of fat lime, one part of surkhi and one part of sand or:
2) One part of hydrated lime and one part of sand
The mortar shall be ground in a mechanical mill or in bullock mill fitted with Beal’s tell-tale.
It shall be ground for 200 revolutions. The mortar shall be used as soon as possible after
grinding. All mortar prepared and not used for four days shall be rejected and shall be
removed from the works within 24 hours of its rejection.
13.11.1.3 Stone for Masonry
Stone shall be selected from quarries selected by the Engineer. It shall be hard, durable
and tough. Each stone must be laid in the work, in its quarry natural bed. Dumb-bell shaped
bond stones or headers shall not be used in the work.
13.11.1.4 Timber
Timber shall be of the best description, well-seasoned and free from sapwood. Timber
shall be sound, straight, free from unsightly or loose knots, cracks, shakes, rot and other
defects.
13.11.1.5 Wrought Iron
Wrought iron shall be of good tough metal with an even, silky fibrous grain which will be
apparent if broken gradually. It shall be neither cold-short (i.e. brittle when cold) nor hot-
short (i.e. tendency to cracking at surface edges when worked at red heat.)
Plates, bars and angles shall be well and clearly rolled, sound and free from flaws, cracks,
crop ends and defects of any description.

13.11.1.6 Concrete Tiles
All concrete tiles shall be subject to the approval of the Engineer and shall be of the best
quality. Floor tiles shall be 250 mm x 250 mm with a thickness of 20 mm to 25 mm. Tiles
for wall linings and skirting shall be 250 mm x125 mm with 12 mm to 16 mm thickness and
shall be provided with a protective cover. All tiles shall be perfectly plain with sharp and
plain arises and sharp edges. Any tile which is warped or in which the edges are not square
or arises are broken or the angles are not perpendicular shall be rejected.
Plain cement concrete tiles shall be manufactured with a mix of cement and hard-wearing
aggregate for grey tiles and white cement and pigment mixed with hard-wearing aggregate
for coloured tiles. Tiles shall be cast in steel moulds, vibrated for compaction and
thereafter, subjected to hydraulic pressure. The tiles shall be properly cured. The tiles shall
be provided with keyed backs.
Marble mosaic tiles shall be formed with a mix of white cement mixed with pigments and
thoroughly washed and cleaned, chips of marble of 10 mm to 20 mm size, set on a normal
concrete backing of cement and aggregate. Tiles shall be manufactured in the same
manner as the plain cement tiles. The tiles shall conform to IS: 1237 cement concrete
flooring tiles.
13.11.1.7 Glazed Tiles
White glazed tiles shall conform in every respect to the requirements of IS: 777 glazed
earthenware tiles. Tiles shall be 6 mm thick and subject to the approval of the Engineer.
Any tile which is warped or in which the edges are not straight shall be rejected.
Unless otherwise specified, glazing shall be flattened sheet glass of the best quality, plain
or ground as necessary and free from flaws, specks or bubbles. Glass shall weigh 24 oz.
per square foot up to a size of 600 mm x 600 mm and above that size 26 oz per square
foot.
13.11.2 Stone Masonry
13.11.2.1 Materials
Stone shall be selected from quarries selected by the Engineer. It shall be hard, durable
and tough. Each stone must be laid in the work, in its quarry natural bed. Dumb-bell shaped
bond stones or headers shall not be used in the work.
All stones shall be wetted before laying in masonry. Concrete surfaces of columns, beams,
lintels; chajjas etc. coming in contact with masonry shall be properly chipped, wash and
wetted before start of masonry work. The concrete surface coming in contact with masonry
shall be given a thick coat of cement slurry as the masonry work progresses in height.
Clean chips and spalls carefully selected to fit in the space shall be wedged into the mortar
joints and beds wherever necessary to avoid thick beds or joints of mortar. However,
proper shaping and dressing of stones shall be done prior to their laying and there shall
be no hammering after the stones are laid in position.
The bond stones shall be used in every square metre area of masonry wall and shall
extend from front to back in walls having width of up to 600 mm and shall overlap by at
least 150 mm in walls having a thickness of more than 600 mm when laid from both sides.

The Engineer may permit cement concrete 1:2:4 to act as bond stone, as required. When
work starts on an old or long completed section, care shall be taken to roughen and clean
the old surface satisfactorily without disturbing the masonry before laying the new. The old
masonry shall be wetted before laying the bedding mortar.
Care shall be taken to ensure that no dry work or hollow space is left in the masonry. The
joints at the face shall be finished off neatly, being struck and smoothed with a trowel,
while the mortar is fresh. The upper surface of the work shall be brought to a uniform level
at the height of each course. The faces of masonry walls shall be kept plumb and, where
batter has to be given, it shall be uniform. The stones at all corners and junctions of wall
shall be of large sizes and hammer dressed to the correct angle.
Completed masonry shall be kept wet for a minimum period of 14 days. In wet weather,
newly laid masonry shall be protected from the effects of heavy rainfall.
Joints in exposed masonry faces shall be formed while the mortar is still green and shall
be finished as flush joints, weathered joints, round-recessed joints or square-recessed
joints as directed by the Engineer. Masonry which is to be rendered or plastered shall have
the joints raked out to a depth of 15 mm to form a key.
13.11.3 Pre-Cast Cement Concrete Block Masonry
Pre-cast cement concrete blocks shall be of best quality locally available or manufactured
at site and should be approved by the Engineer before incorporation in the work. The
ingredient and the cement concrete used shall conform to the relevant IS as stipulated in
specification for cement concrete works.
Minimum crushing strength of the solid blocks shall be 40 Kg/ cm2 28 days after curing.
The type of the bond to be adopted will be decided by the Engineer but vertical joints shall
be staggered. The size of the blocks shall be 390 x 190 x 140 mm and 390 x 190 x 100
mm.
Concrete blocks, whether made on or off site shall be manufactured to the shapes, sizes
and finishes as approved by the Engineer and shall comply with the requirements of IS:
2185. Concrete for blocks shall be made generally in accordance with Section 17 except
that the combined aggregate shall have a fineness modulus lying between 3.6 and 4 and
shall conform with the following grading:
IS Sieve Percentage passing by weight

12.5 mm 100
10 mm >85
4.75 microns >60
300 microns >10
Concrete for blocks shall be minimum Class M-20. Hand mixing shall not be permitted.
When ordered by the Engineer, sample blocks from any batch shall be tested as specified
in IS: 2185.
The Contractor shall submit full details of his proposed manufacturing arrangements to the
Engineer for his approval before making any blocks for use in the works and shall submit

such samples as may be needed to demonstrate the quality of the finished product.
Production of blocks shall be of equal standard to the approved sample blocks.
The blocks shall be cured for at least for 14 days before incorporation in the work. The
cement mortar for concrete blocks masonry shall be 1:4 and joints shall not be more than
10 mm thick.
Finished blocks shall be neatly stacked for storage on a firm dry support and shall be
covered to protect them from dirt, sun and rain. Damaged blocks shall not be used in the
works.
Concrete block work shall be laid generally as specified or as directed by the Engineer.
The construction of hollow block masonry shall be generally in accordance with IS: 2572.
Block work for partition walls shall be laid in stretcher bond. Fair face block work which is
not to be plastered shall be neatly pointed.
13.11.4 Brickwork
Bricks provided for common brickwork shall be whole, sound, well burnt clay bricks free
from cracks and shall comply with the requirements of IS: 1077. Clay engineering bricks
shall comply with the requirements of IS: 2180. Samples of the proposed bricks to be used
shall be submitted to the Engineer for his approval.
Bricks shall be class designation 35 of size 22.5 x 11.1 x 7 cm. Permissible tolerance on
dimensions shall not be more than (+/-) 8%.
The minimum crushing strength shall not be less than 35 kg/cm2 and water absorption
shall not be more than 25% by weight.
Brickwork shall be built in accordance with the requirements of IS: 2212.
Bricks shall be carefully stacked by hand in separate stacks. Broken or damaged bricks
shall not be used. Every brick shall be thoroughly soaked in water before use until the
bubbles cease to come up. No broken bricks shall be used except as closures.
All the courses shall be laid truly horizontal and where required all vertical joints shall be
truly vertical. Joints shall be broken vertically and they shall not exceed 12 mm in
thickness. Bricks shall be thoroughly bedded and flushed with mortar. Specified mortar of
good and approved quality shall be used. Lime shall not be used where reinforcement is
provided in brick work. The mortar shall completely cover the bed and sides of the bricks.
Proper care shall be taken to obtain a uniform mortar joint throughout the construction.
The brickwork shall not be raised by more than 12 single courses per day.
The walls shall be raised uniformly in a proper approved bond. The walls shall be uniformly
raised in all cases not leaving any part one metre lower than another. When circumstances
render it necessary to carry on the same section of a building in uneven courses, the bricks
shall be raked back to maintain a uniform and effectual bond.

In construction of a wall, firstly the two end corners shall be carefully laid to line and level
and then the interim portion shall be built using a cord stretching along the headers or
stretchers held in position at the ends to keep the correct alignment and level of the
courses. Care shall be taken to keep the perpendiculars properly aligned within following
maximum permissible tolerances:
1) Deviation from vertical within a storey shall not exceed 6 mm per 3 m height.
2) Deviation in verticality in total height of any wall of building more than one storey in
height shall not exceed 12.5 mm
3) Deviation from position shown on plan of any brick work shall not exceed 12.5 mm
4) Relative displacement between load bearing wall in adjacent storeys intended to be
vertical alignments shall not exceed 6 mm
5) A set of tools comprising of a wooden straight edge, a masons spirit level, square, a 1
metre rule, line and plumb shall be kept on the site of work for every three masons for
proper checking during the progress of work.
String courses, cornices and mouldings shall be straight and true by projecting brick work
with properly cut and shaped bricks wherever necessary with as fine joints as possible.
In all brick arches and other curved work, the bricks shall be shaped to the slope, joints
radiating correctly to the centre, from front to back of walls and not smaller than 10cm
thick. The adhesion between brick masonry and the concrete surfaces of columns, beams,
chajjas, lintels etc shall be ensured by the concrete being hacked/ chipped/keyed, cleaned
and with a cement slurry applied so that a proper bond is achieved.
The joints of all surfaces which are to be finished in plaster shall be raked out to depth of
20 mm as the work progresses and before the cement mortar has set. All joints shall be
thoroughly flushed with mortar at every course. Care shall be taken to ensure that the
bricks are bedded effectively and all joints completely filled to the full depth.
Newly laid brickwork shall be protected from the harmful effects of sunshine, surface water
and impacts. The work shall be watered three times a day for 14 days and afterwards twice
a day for a month.
In the event that cracks in the brickwork appear, they shall be made good by cement
grouting or epoxy putty grouting/ polysulphide compound grouting or as otherwise
13.11.4.3 Half Brick Work
Materials and workmanship for a half brick or brick on edge partition wall shall be as
specified above. The wall shall be stiffened by RCC stiffeners 115 mm wide x 80 mm thick
to the full length of the wall and shall be provided with two 6 mm diameter mild steel bars
or as otherwise approved by the Engineer. These bars shall be securely anchored at their
end where the partition ends. The free ends of the reinforcement shall be keyed into the
mortar of the main brick work to which the half brick work is joined. Overlaps in
reinforcement, if any, shall not be less than 30 cm.
13.11.5 Carpentry Work
All timber shall be uniform in texture, straight in fibre and shall be well and properly
seasoned. Timber shall be free from all defects or damage of a nature which will affect the
strength, durability, appearance and fitness for the purpose for which it is required.

Samples of the timber to be used shall be submitted by the Contractor to the Engineer for
approval before commencement work. The Contractor shall produce cash vouchers and
certificates from the kiln seasoning plant to show the timber sections to be used on the
work as having been kiln seasoned. Seasoning of timber shall be judged from its moisture
content as laid down in IS 287. The seasoning of timber shall conform to IS1141-1993.
Scantling of all types of timber shall be straight. Warped scantling shall not be used. Before
use in the works, the scantling shall be kept in a covered and well ventilated store.
13.11.5.1 Teak
Best quality well-seasoned C.P. Teak shall be used for all carpentry work. The timber shall
be properly planed and wrought in a workmanlike manner. Joints shall be true and fit
properly and be subject to the approval of the Engineer.
i. First Class Teak Wood
Individual hard and sound knots shall not be more than 25 mm in diameter and the
aggregate area of all knots shall not exceed one percent of the area of the piece.
ii. Second Class Teak Wood
Individual hard and sound knots shall not be more than 40 mm in diameter and the
aggregate area of all knots shall not exceed one and half percent of the area of the
piece. Wood shall be generally free from sapwood, but traces of sapwood may be
allowed.
The workmanship shall be of best quality. All wrought timber is to be sawn, planed, drilled
or otherwise machine worked to the correct sizes. All joinery work shall fit truly and without
wedging or filling. Woodwork in frames shall be wrought. All frame joints shall be put
together with white lead and pinned with hard wood pins securing with corrosion resistant
star shaped metal pins as approved by the Engineer. If after fixing in position, any shrinking
or substandard materials or bad workmanship is detected, the Contractor shall remove
them and replace the same, as approved by the Engineer.
Individual members shall be of continuous length. The heads and posts of frames shall be
through tennoned into the mortices to the full widths. All necessary mortising, grooving,
matching, tonguing, housing rebate and other necessary works for correct jointing shall be
carried out in the best workmanship like manner. Joints shall be of a recognised form of
approved joints for each position.
All parts of woodwork resting on or set in masonry or concrete shall be well painted with
two coats of bituminous paint or as otherwise approved by the Engineer, prior to
installations. All nails, screws, hold fasts, plates, plugs, pins required for woodwork joinery
and fixing work, shall be provided by the Contractor. All materials shall be approved by
Engineer before use in works.
13.11.6 Plastering Works
The joints of all masonry work shall be raked out to 20 mm. The surface of all concrete
and reinforced concrete work shall be roughened in the manner specified for reinforced

concrete work before plaster is applied. All the surfaces shall be thoroughly washed and
well watered before plaster is applied.
A long straight edge shall be freely used to ensure an even surface. All corners and angles
shall be plumb and true and soffits of arches shall be true arcs of circles. All exposed
angles with door and window frames shall be carefully finished. Internal angles shall be
rounded and arises shall be rounded, splayed or beaded as required and as approved by
the Engineer.
A sample of plaster shall be approved by the Engineer as regards the texture etc. before
proceeding with the work. All subsequent work shall generally conform to the approved
sample panel. The finished work shall be cured for a minimum period of seven days.
13.11.6.1 Sand Faced Plaster
Cement mortar shall consist of 1 part of cement to 3 parts of screened and washed sand
and shall be placed in 2 coats. The undercoat shall be similar to the undercoats for cement
plaster.
The surface of the undercoat shall be scratched by special wire tools for forming the key
for the finishing coat before the mortar has set and hardened.
The second or finishing coat shall be 1 part of white cement, 3 parts of properly graded
washed sand to give a grained texture. The finishing coat shall be 6 mm thick, uniformly
applied and surface finished with special cork thapies and tools recommended for coloured
cement plaster work. When finished the surface shall be even and shall have a grained
texture.
Adequate time interval shall be allowed between the applications of successive coats for
hardening. The coats shall be kept moist by watering for 7 days and shall not be allowed
to dry out.
Three coats of approved cement paint shall be applied on the finished surface of sand
faced plaster. Cement paint application shall be in accordance with the manufacturer’s
specifications.
13.11.6.2 Cornices & Enrichment
All plaster cornices, string courses, label courses, beading and mouldings around door
and window openings, consoles, key stones, base mouldings, imports, moulded panels,
foliated caps and enrichments etc. to the exterior and interior walls (if of greater projection
than 20 mm be laid with projecting masonry and/or concrete work) shall be rough cast in
mortar, clear cut, rubbed perfectly smooth until a high polish is obtained and finished with
clean sharp arises in strict accordance with the details supplied. All lines of mouldings shall
truly parallel.
All plaster cornices shall be laid with projection masonry and /or concrete work as the case
may be. Nailed cornices shall not be allowed.
13.11.6.3 Ceiling Fibrous Plaster of Paris
Fibrous plaster of Paris boards shall be made from the best quality plaster of Paris
reinforced with jute fibres. The boards shall be 12 mm thick and shall be cast on plate
glass to obtain a perfectly smooth surface on one side.

The board shall be fixed to ceiling joists and battens with brass screws. The joints in the
boards shall be flushed and filled in with a paste of plaster of Paris and the whole surface
shall be smooth, uniform and even on completion.
Cornices and other enrichments shall be provided wherever required. They shall be cast
to the precise profile with clean and sharp edges, arises, moulds and shall be made of
plaster of Paris reinforced with jute fibres.
13.11.6.4 Cement Plaster
Blended cement, sand and water required for the work shall conform to Section 17.2,
except that sand for the finishing coat shall be fine sand conforming to IS 1542. The
plastering works shall generally conform to IS 1661 (Pt. III) (Code of practice for cement
and cement plaster finish on walls and ceilings). All general precautions as specified in IS
1661 (Pt. III) shall be taken and preparation of the background shall be as laid down in IS
1661 and IS 2402 shall be followed for rough cast and sand faced plaster work.
13.11.6.5 Preparation of Surface
The surface to be plastered shall first be thoroughly cleaned. All joints shall be raked out
in case of brick work / stone masonry and closely hacked in case of concrete, under the
relevant masonry / concrete items. The surface to be plastered shall be well wetted for a
minimum period of 6 hours before commencing the work.
The surface to be plastered shall first be dubbed out with cement mortar to cover all
irregularities and faces up to the proudest part. The dubbing coat which shall be 12 mm
thick and be applied/scored and keys shall be formed on the surface by thoroughly
combing it with heavy horizontal lines about 12 mm apart and about 3 mm deep when
mortar has just set.
The cement mortar for sand faced plaster shall have washed and approved sand with
slightly larger proportions of coarse materials, but not exceeding 3 mm. The water shall be
gradually added to make the mixture homogenous. The thickness of the finishing coat
excluding the key shall be 8 mm. After application, the surface shall be finished with a
wooden float lined with cork closely pricked on with a wet sponge tapped gently to bring
sand particles into prominence.
Any other horizontal portions shall be cleaned of any mortar splashes. Junctions between
walls and chajjas shall be rounded off simultaneously as approved by the Engineer.
The Contractor shall ensure that all service pipes, electrical conduits, boxes, switch boxes
etc. have been installed in position and the plastering surface is duly approved by the
Engineer.
In order to avoid the formation of cracks and for the dispersion of cracks at the junctions
between concrete surfaces and brick masonry work and between junction of windows/door
frames and brick masonry works, cautionary measures such as fastening and lapping of
chicken mesh over the junction areas shall be carried out over which the plastering work
shall be taken up as required by the Engineer.
Gaps between window/door frames with cills and jambs shall be filled up/caulked by
plaster of Paris/epoxy putty/silicon sealants, rubber based sealants by caulking guns or by
approved methods as approved by Engineer.

Before plastering work is taken up, all the ceilings and walls etc. shall be marked indicating
the thickness of plaster required and which shall be in true line, level and plumb and shall
be approved by the Engineer.
13.11.6.6 Grooves
The grooves shall be of required dimensions. The same shall be made to turn wherever
necessary. The finish, inside, shall be of the same finish as that of the plaster. The lines
of the grooves shall be well defined and rounded. The grooves shall be provided in
plastering in internal and external surfaces.
13.11.6.7 Mixing
Cement and fine aggregates shall be mixed dry in the required proportions to obtain a
uniform colour. Water shall then be added to get the required consistency for the plaster.
Mixing shall be done mechanically. Manual mixing may be allowed only in exceptional
circumstances at the discretion of the Engineer. Manual mixing, where adopted, shall be
carried out on a clean watertight platform. After water is added during mixing, the mix shall
be mixed for 10 to 15 minutes.
In machine mixing, the mixer shall run at least five minutes after placing all the ingredients
in the drum. Only so much quantity of mortar which can be used within half an hour after
the addition of water shall be prepared at a time. Any mortar for plaster which is set or
partially set shall be rejected and shall be removed forthwith from the site.
13.11.6.8 Application
The plaster on walls shall consist of two coats. The undercoat shall be 20 mm thick and
be of one part cement and 4 parts coarse sand and shall be dashed against wall. It shall
be uniformly applied and shall be floated and the surface shall be made even. The surface
of the undercoat shall be scratched by wire brush to form a key for the finishing coat, before
cement has set or hardened. The second coat or finishing coat shall be a thin coat to
produce a smooth and even surface.
Plaster to concrete ceilings may be finished in two coats, the first coat of 1 part cement
and 4 parts of sand dashed and floated to make the surface uniform and even. The ceiling
plaster shall be completed before commencement of wall plaster. The surface shall be
scratched as above to form a key for the finishing coat. The second or finishing coat shall
be a thin coat of cream of lime putty evenly applied and trowelled smooth to produce a
smooth and even surface.
Rough cast plaster shall be carried out in two coats. The first coat shall consist of 1 part of
cement to 3 parts of clean sand or as specified otherwise. The finished thickness of the
first coat shall be 12 mm and shall be laid by throwing the mortar (by using strong whipping
motion) on the prepared surface with a trowel in a uniform layer but shall not be smooth.
The second coat shall consist of 1 part of cement and 3 parts of 6 mm to 10 mm gravel all
as approved by the Engineer. The gravel shall be thoroughly cleaned with water removing
all dirt and organic materials. All these ingredients shall be mixed into a paste which shall
be flung upon the first coat with large trowels to form an even protective coat. The
thickness of this coat shall be 10 mm. Due care shall be taken to avoid concentration of
either large size or small size of gravel in one place.
Plaster to other concrete surfaces shall be as for walling.

An adequate time interval shall be allowed between the applications of successive coats
for hardening. The coats shall be kept moist by watering and shall not be allowed to dry
out for seven days.
The finished plastered surface shall be free from cracks, fissures, crevices, hair cracks,
blisters, local swellings and flakes. The finished surface shall be true to line, level, and
plumb and be plain and durable.
13.11.6.9 Finishes
i. Neeru Finish
Wherever required, the surface render shall be finished smooth with good quality lime
neeru class ‘C’ conforming to revise IS 712-1984. The lime shall be tested in an
approved testing laboratory for the chemical analysis of the lime and test certificate
submitted regarding suitability of lime for plaster work. Neeru shall be prepared at site
out of best quality pure fat lime slaked at site with fresh water and slaked in accordance
with the relevant IS code. The slaked and sifted lime shall be reduced to a fine paste
by grinding 150 turns in a mortar mill. Sufficient quantity, which can be used within 10
days only, shall be prepared at a time. Chopped hessian or jute fibre in the required
quantity may also be added to neeru and properly ground to pure paste.
An entire unobstructed area shall be plastered in one operation. Neeru shall be applied
to the prepared and partially set but somewhat plastic surface with a steel trowel to a
thickness slightly exceeding 1.5 mm and rubbed down to 1.5 mm. It shall be polished
to a smooth and even finish working from top to bottom for at least 3 days. All corners
shall be truly brought to the desired lines and levels in the base plaster and the
thickness of neeru shall not exceed 1.5 mm at these locations.
Moistening shall be commenced as soon as the plaster has hardened sufficiently and
is not susceptible to damage. The surfaces shall be kept sprinkled with water for 7
days to prevent excessive evaporation. On the sunny or wind-ward sides of buildings
in hot dry weather, matting or gunny bags shall be hung over on the outside of the
plaster and kept wet. If blow holes are observed in neeru plaster at any time during the
contract period and during the defect liability period, the Contractor shall rectify the
defective plaster work including the redoing of the whitewashing/colour washing/
distempering work etc. as the case may be.
ii. Terol Finish of Terraco
Wherever required, the surface render shall be finished smooth with a 0.5 to 3 mm
thick coat of Terol of Terraco as per manufacturer’s specification. It shall be ensured
that the surface to be covered is free of loose particles, dust, dirt, grease, oil and paint.
Terol shall be applied on top of finished coat of plaster which should be levelled without
any scratch/key marks. Adequate care should be taken that the first coat is levelled
well to enable the thin layer Terol plaster to give a smooth finish; substrata/sub base
should be moistened with water prior to the application of the Terol.
13.11.6.10 Mixing
Put water into a clean empty drum. Add Terol start stirring with paddle. Gradually add
water and Terol alternatively in the required proportion to get desired creamy consistency,
convenient for application and stir continuously and ensure that no lumps remain. Terol

should not be allowed to stand without stirring for longer than 60 minutes. In normal
condition Terol shall stand for 5 minutes then stirred and used. Where rapid drying
conditions are prevalent, Terol shall be mixed 20 minutes before using.
Terol shall be sprayed or hand applied and smoothened with a steel float. Smooth finishing
shall be achieved with wooden float or trowel when Terol has set. The float should be
moistened during the smoothening operation.
Curing the surface shall be carried out after 24 hours of application for at least 4 days
using light water spray.
Wherever required, the surfaces shall be finished smooth with approved quality plaster of
Paris (POP). POP shall be mixed in water for hydration at site. A quantity which can be
used within half an hour only shall be prepared at a time.
POP shall be applied immediately after the under coat of cement plaster has set. An entire
unobstructed area shall be finished in one operation. POP shall be applied on top of the
finished coat of plaster which shall be flat and smooth without any scratch/key marks to
the prepared and partially set. It shall be ensured that the surface to be covered is free of
loose particles, dust, dirt, grease, oil and paint. POP shall be applied with steel trowel to a
thickness slightly exceeding 2 mm and rubbed down to 2 mm. POP shall be polished to a
silk smooth and even finish working from top to bottom. All corners shall be truly brought
to the desired lines and levels in the base plaster along and the thickness of POP shall not
exceed 2 mm, at these locations.
13.11.7 Cement Pointing
13.11.7.1 Surface Preparation
The joints shall be raked out properly with dust and loose mortar brushed out.
Efflorescence, if any, shall also be removed by brushing and scraping. The surface shall
be thoroughly washed with water, cleaned and kept wet before pointing is commenced.
13.11.7.2 Application of Mortar Finishing
The mortar shall be pressed into the raked out joints with a pointing trowel, either flush,
sunk, ruled or raised according to type of pointing required. The mortar shall not spread
over the face of brick work or stone work, corners, edges of the masonry but restricted to
the width of joints only.
Superfluous mortar shall be the struck off and the surface of the masonry shall be cleaned
completely. The finish shall be such that the pointing is to the exact size and shape
required and the edges shall be straight, neat and clean. The pointing lines shall be
straight, regular and uniform. No false joints shall be allowed.
13.11.7.3 Curing
The pointing shall be kept wet for at least seven days and be suitably protected from all
damage.
13.11.7.4 Types
i. Raised and Cut Pointing

Raised and cut pointing shall project from the wall facing with its edges cut parallel to
have a uniformly raised band about 6 mm raised and width 10 mm or as otherwise
approved.
ii. Flush Pointing
The mortar pressed into the joints shall be finished off flush and level with the edges
of bricks, tiles or stones to give a smooth appearance. The edges shall be neatly
trimmed with a trowel and straight edges.
iii. Ruled Pointing
The joints shall be initially formed as for flush pointing and then while the mortar is still
green, a groove of shape and size as approved shall be formed by running a forming
tool straight along the centre line of the joints. This operation shall be continued until a
smooth and hard surface is obtained. The vertical joints shall also be finished in a
similar way. All vertical lines shall make true right angles at their junctions with
horizontal lines and shall not project beyond the same.
13.11.8 Wall Care Putty
13.11.8.1 General
Wall care putty shall consist of white cement, high quality polymers and special chemicals
and mineral fillers and shall be formulated to make it suitable to apply even on damp
surfaces. Wall care putty shall be suitable for application to both interior and exterior
plastered surfaces and have a water resistant base coating to provide a fine flat and
protective base for the surfaces to be painted.
Wall care putty shall have superior water resisting properties to prevent paint from flaking
even if the walls are damp and it shall fill-up fine pores in walls and ceilings to get the
smooth and dry surface. Wall care putty shall have better properties in terms of water-
resistance, adhesive strength and durability compared to the ordinary putties. The putty
shall provide a breathable surface and allow any trapped moisture to move out keeping
the wall dry and clean.
13.11.8.2 Material
Wall care putty shall be in dry free flowing powder form. The putty shall conform to the
International standards (viz. HDB-Singapore Standards with Water-resistant properties).
The putty shall be procured in the form of fine or coarse (matt) finish.
13.11.8.3 Preparation of Surfaces
Surfaces should be clean of loose particles, dirt, grease and traces of foreign material.
Sand papering or chipping shall be done if so required.
Loose plastered areas/defective materials shall be removed and the surface re-plastered
and cracks filled.
Uneven ceiling/wall surfaces shall be made even by re-plastering.
Surfaces should be pre-wetted prior to application to provide a strong bond with substrate.

13.11.8.4 Mixing
12 to 16 litres of clean water shall be required for a bag of 40 kg of wall care putty. Required
quantity of putty (which is required to be used at a time) shall be added to the water in right
proportion. (Considering pot life of the mix is 60 minutes).
The mix shall be stirred continuously by using an electric mixer or by hand to obtain a
homogeneous lump-free paste.
The paste shall be allowed to stand for about 10 minutes for the additives to dissolve.
The paste shall be re-mixed again for about 2 minutes.
This mix should be used within 60 minutes.
The plastered surface shall be dampened with clean water and excess water shall be
allowed to be drained off.
Using a steel trowel/blade, the above mix shall be applied to a thickness of about 1 – 2
mm then the surface shall be levelled and smoothed. This first coat shall be cured lightly
after it dries.
The second coat shall be applied after the first coat is fully dried and set. The second coat
shall be cured lightly for two days.
Over plastered / coarse putty substrate, fine wall care putty of about 1 to 1.5 mm thickness
shall be applied and a steel trowel used to smooth the surface. The finished surface of wall
care putty shall not require any further dressing.
The thickness of each coat should not exceed 1.5 mm and total wall putty thickness should
not exceed 3 mm
If necessary, coarse wall care putty of about 6 to 10 mm thickness shall be applied to

remove the undulations and level the surface. More coats of coarse putty shall be applied
to cover up undulations, only after approval of the Engineer.
Coverage of wall care putty depends upon surface quality, however, approximate
coverage for fine wall care putty shall be 20-22 ft2/kg and for coarse wall care putty, it shall
be 9-10 ft2/kg.
Application of primer before painting is not necessary over the surfaces finished with wall
care putty.
13.11.9 Glazing
13.11.9.1 Materials
This shall be the same as described for aluminium curtain wall system.
Aluminium extruded sections shall be from an approved and reputed / renowned

manufacturer. In absence of specific extruded section, sections available conforming to

BIS specification, manufactured by approved reputed companies, shall be used in the

works.
13.11.9.2 Tolerances for Aluminium Extrusions
i. Circumscribing Circle Diameter (CCD)
The product range shall be broadly as categorized below;

1. For solids up-to 190 mm
2. For hollows up-to 135 mm
Sections with higher CCD, if required, shall be produced from reputed / renowned
manufacturer as approved by the Engineer.
ii. Manufacturing Tolerance
Dimensional extrusions shall be normally as per IS / BSS. Special tolerances shall be

mutually agreed upon.
iii. Tolerance on cut length:
The standard cut length is 3.66m the tolerance on cut length shall be as follows:
Length Up to 6 metres Over 6 metres

Tolerance + 5 mm + 7 mm
Sections shall also be acceptable in random lengths between 1500 to 5000 mm

depending upon actual requirements.
iv. Tolerance in Weights
A tolerance of ± 10% shall be acceptable on sectional weight per metre.
13.11.9.3 Fabrication
There is a slight difference in the actual fabrication of the aluminium curtain wall system
and structural glazing though quantity of materials required for execution in both the cases
is the same except the quantity of sealant.
13.11.10Waterproofing
13.11.10.1 Brick Bat Coba Waterproofing
i. Materials
The aggregate for brick bat coba shall be broken from good and thoroughly well burnt
bricks. These shall be strong, durable, clean and free from impurities and not contain
any soft or powdery materials. The aggregate shall be 20 mm to 10 mm size and shall
be approved by the Engineer before use.
Lime to be used for preparing brick bat coba shall be of lime class B, conforming to IS
712-1959. Lime burnt from lime stone shall be used. All impurities, ashes or pieces
improperly burnt shall be screened or picked out before slaking. Lime shall be in the

form of lumps when brought to site and not in powder form. The lime shall not be slaked
with water less than one week or more than two weeks before use.
ii. Storage
The slaked lime, if stored shall be kept in a weather proof and damp proof closed shed
with impervious floor and sides to protect against rain, moisture, weather and
extraneous materials mixing with it and shall be approved by the Engineer.
iii. Proportion
The proportion for brick bat coba shall be 0.906 m3 of brick bat to 0.34 m3 of slaked
lime.
iv. Laying
The concrete surface shall be thoroughly rubbed, cleaned of all set mortar, all dirt and
dust and slightly wetted. The brick aggregate shall be soaked in water before mixing
with lime. The brick bat coba shall be laid in an even layer and to the required thickness
and slope to form ridge, hip or valley line as may be necessary and as approved by
the Engineer. The compaction shall be started immediately with wooden beaters and
during the above process; the surface shall be constantly kept wet by sprinkling water
observing the following precautions:
1. Brick bat coba shall not be rammed with heavy iron rammers as brick aggregates
are likely to be crushed into powder thereby, but shall be beaten lightly and rapidly
with wooden beaters to get the required compaction and to obtain complete
integration of brick bats and lime.
2. While beating, fresh fracture may take place which may cause absorption of water
from the mortar. Additional water may be sprinkled with beating in such cases as
considered necessary by the Engineer. The beating work shall continue for at least
7 days.
3. The top of the coba shall be given a slope or made level and edges taken into the
brick masonry parapet or rounded off at junctions as approved by the Engineer.
13.11.10.2 China Mosaic Waterproofing
i. General
This type of waterproofing shall consist of setting in thick cement slurry selected
colour/white broken glazed tile pieces of approved make and size over 20 mm thick
bedding of 1:4 cement mortar with approved waterproofing agent, to the required slope
and level, over brick bat coba and finishing with neat cement and cleaning to the
required degree of fineness and evenness.
The surface of brick bat coba shall be thoroughly cleaned of dust, dirt and loose
particles removed and adequately watered. A thick coat of cement slurry of honey like
consistency shall be sprayed on the base before the lime mortar screening of specified
thickness is laid.
ii. Laying
Over the prepared surface of brick bat coba, a layer of cement mortar, 20 mm thick or
as specified, shall be laid and cement slurry of consistency of honey, shall be spread
over it using cement at a rate of not less than 0.01 m3 per 10 m2. While the bed is fresh,

broken pieces of 6 mm thick selected white/colour glazed tiles not less than 25 mm
and not more than 50 mm in any direction shall be set closely by hand at random. The
glazed tile pieces shall be soaked in water before setting in position. The glazed
surfaces shall be kept exposed and pressed with a wooden mallet.
Over the glazed tile pieces, a neat cement slurry, using cement not less than 0.01 m3
per 10 m2 shall be spread and the surface brushed in and lightly rolled with wooden
roller, taking care that no air pocket is left between brick bat coba and china mosaic
flooring.
The top surfaces shall be cleaned with saw dust and cotton waste. Finally the surface
shall be cleaned with weak acid solution to remove cement marks over the glazed tile
pieces.
The finished work shall be cured for at least 7 days. Care shall be taken to ensure that
cement in joints does not get dissolved due to acid washing. At corners and junctions
with parapets, the waterproofing course shall be rounded off with cement mortar.
13.11.10.3 Cement Based Waterproofing of Roof Terraces
i. General
The waterproofing treatment shall be essentially a cement based waterproofing

treatment.
The waterproofing treatment shall consist of providing cement slurry mixed with
waterproofing compound, at desired proportions including grouting the cracks and
crevices with cement slurry mixed with waterproofing compound, laying brick bats over
cement mortar bedding to the required slopes for roof drainage, filling and grouting the
joints with cement mortar, finishing the surface smooth/chequered with cement plaster
mixed with waterproofing compound etc as approved.
ii. Preparation of Surfaces
After removal of this rubbish, debris etc, the surface to receive the waterproofing
treatments shall be thoroughly cleaned with wire brushes including removing of scales
and laitance, set mortar etc by the waterproofing Contractors. If any honeycombing
including cracks and crevices are observed at column junctions/and elsewhere, the
same shall be grouted with cement slurry mixed with approved waterproofing
compound.
iii. Treatment
The waterproofing treatment shall be generally as per manufacturers own

specifications, method and procedure. A typical cross section of the waterproofing
treatment shall generally consist of the following:
1) Applying cement slurry mixed with waterproofing compound for the entire surface
to be treated.
2) Laying of broken brick bat of required thickness over cement mortar bedding to
give proper roof drainage, grouted with cement mortar with waterproofing
compound.

3) Laying of jointless cement based waterproofing cement mortar layer of uniform

thickness.
4) Final rendering to give a smooth finish of cement colour with false lines at 300 x
300 mm or nearer convenient dimensions.
The Contractor shall ensure that sufficient slope for effective roof drainage is provided
within the average thickness of waterproofing treatment proposed by the Contractor.
The rain water down take pipes if any, shall be fixed by the Contractor prior to
commencement of waterproofing operation. Curing of the finished surface by ponding
shall be done for 7 days at least.
iv. Testing
The Contractor shall test the surface for the bone dry condition by ponding water over
roof for a minimum seven days period to the entire satisfaction of the Engineer.
Alternately, the curing of the finished surface done by ponding of water on the entire
surface for seven days can also be used for testing water tightness.
After a period of two months, once again the roof shall be ponded with water to check
its efficiency of waterproofing treatment against leakage.
13.11.10.4 Waterproofing Treatment of Expansion Joints at Roof Level
i. Treatment
The expansion joint treatment at roof level shall be provided with approved cement
based waterproofing treatment. This treatment shall be 20 mm thick waterproof plaster
on top sides and ends of RCC covering hood over expansion joint.
ii. Testing
The Contractor shall carry out the test for waterproof joint provided for expansion joint
at roof level by any approved method.
13.11.10.5 Internal Waterproofing Treatment of Concrete Structures
i. General
The waterproofing treatment of concrete structure shall be essentially a cement based

waterproofing treatment, consisting of providing waterproof cement plaster after
preparing the surface, filling the cracks and crevices by means of injection and surface
method, using proprietary waterproofing compound as per their own specifications and
as per recommended proportions etc and testing of water-tightness of the
waterproofing treatment.
ii. Preparation of Surfaces
The surface to receive the waterproofing treatment shall be thoroughly cleaned of

scales, laitance, set mortar etc. The surface shall be roughened with close hacking to
provide adequate key for the waterproofing treatment. All honeycombs in concrete
surface shall be carefully hacked and loose materials removed and all pockets plugged
suitably well before commencing waterproofing treatment.

iii. Treatment
Before any work of waterproofing is taken in hand, all the surface preparation stated
above shall be approved by the Engineer. All plumbing work will be completed before
commencing the treatment.
The treatment shall then be commenced with injection into RCC members wherever
required by cement slurry mixed with waterproofing compound of appropriate
consistency to fill up all cracks and crevices if any. A layer of waterproofing plaster in
the proportion as per manufacturer’s recommendations with admixture of approved
manufacture waterproofing compound shall then be laid over floor from inside and will
be continued along the sides and partition walls to their full height. The thickness of
this treatment on the floor shall not be less than 50 mm and on walls not less than 20
mm. The entire surface shall be finished smooth with steel trowel in cement colour.
The plastered surfaces shall be kept continuously wet immediately after 24 hours to
cure it properly for at least seven days.
13.11.10.6 External Cement Based Waterproofing Treatment of Concrete Structures
i. On Horizontal Surfaces
Preparing the Surface

The waterproofing treatment over the lean concrete/levelling course surface should
adhere to the surface firmly. The surface of the levelling course should be roughened
when the concrete is still green. In case the surface is not made rough in the initial
stages itself i.e. before the concrete is set, the work of waterproofing shall not be
permitted until proper key is provided for the 25 mm thick base layer. If this key cannot
be achieved by hacking the already set concrete surface, instead a spatter- dash key
should be provided.
Blending Cement/Water with Waterproofing Compound
Mixing waterproofing compound in powder or liquid form, to already prepared cement

mortar shall not be allowed. Preparing cement with waterproofing compound shall be
prepared as followed:
1) The required quantity of cement bags to be used for a particular portion of work
shall be sorted out and the contents of each bag should be emptied on a suitable
dry platform. Waterproofing compound in powder form manufactured by a reputed
approved manufacturer, bearing ISI mark and conforming to IS 2645 should be
mixed with the contents of each bag. The quantity of waterproofing compound to
be mixed should be as prescribed by the manufacturer but not exceeding 3% by
weight of cement.
2) The quantity of cement and waterproofing compound in powder form should be
mixed thoroughly, blended by employing skilled labourers and the cement thus
blended should again be packed in gunny bags so that the material can be readily
used for preparing mortar/slurry for the waterproofing works, to achieve best
results.
Unless otherwise specified, all waterproofing works shall be carried out using blended
/ PPC cement.
Blending Water with Liquid Waterproofing Compound

In case the waterproofing compound to be used is in liquid form then instead of

blending cement with waterproofing compound the water to be used in the particular
mix should be blended with waterproofing compound.
This shall be done by taking just required quantity of water to be mixed in the particular
batch of dry cement mortar. The required quantity of water thus collected per batch of
dry cement mortar to be prepared should be mixed with liquid waterproofing compound
from sealed tins with ISI mark and manufactured by reputed approved manufacturer.
The water thus mixed with waterproofing compound shall be stirred so that the water
is blended with waterproofing compound well.
The quantity of blended water thus prepared should only be used per batch of dry
cement mortar/dry cement to make slurry to be used for waterproofing works to
achieve the best results.
Use of cement mixed with waterproofing compound is referred as blended cement in

this chapter which shall mean use of waterproofing compound in powder/liquid form
for use in cement mortar/slurry.
Rough Shahabad Stone
The stone slabs to be used for this item shall be carefully selected for uniform
thickness. Stones with varying thicknesses shall not be permitted to be used. Unless
otherwise specified, the size of rough Shahabad stone shall not be less than 300 x 300
mm and thickness 22 mm (+/-) 3 mm
Preparation of Cement Slurry
Cement slurry shall have a thick honey like consistency. Only the quantity of slurry that
can be used within half an hour shall be prepared at a time. Slurry prepared and
remained un-used for more than half an hour shall be rejected.
Preparation of Cement Mortar
The cement mortar 1:3 (1 blended cement : 3 sand) shall be prepared with cement /
water duly blended. Each time only that much quantity of cement mortar that can be
consumed within half an hour, shall be prepared. Any quantity of cement mortar that
is prepared and remains unused for more than half an hour shall be rejected.
Laying Waterproofing Course
First layer : 25 mm thick base course in cement mortar 1:3
1) Before laying the first course of cement mortar 1:3 base the lean concrete surface
shall be cleaned neatly with water and cement slurry shall be applied only on the
area of the concrete surface that can be covered with the cement mortar (1:3) base
course within half an hour.
2) The cement slurry shall cover every spot of the surface and no place shall remain
uncovered.

3) Just after the application of cement slurry on the surface, the cement mortar should
be used for laying the base course.
4) For laying the base course to a level at least three 25 mm high wooden strips with
three legs shall be placed on the concrete surface at suitable distances and the
cement mortar shall be laid to the level of the strips and tamped gently. The top
surface should be finished neatly and later scratched when green with a suitable
instrument.
5) Before the base course dries and gets hard that is just before the base course
takes up initial set, the 2nd layer of Shahabad stone/slab cladding shall be taken
up immediately.
6) As far as possible work of different layers of this waterproofing treatment shall be
taken up in immediate succession without allowing any time gap in between the
layers, otherwise it would be difficult to achieve homogenous treatment.
Second layer: Shahabad Stone
1) When the 25 mm thick base course is just getting set the cement slurry should be
spread over the base course up to the area that shall be covered with just two to
three stone slabs.
2) The cement slurry shall be spread in such a way that the area of base course to
be covered immediately shall be covered with slurry without any gap, or dry spots.
3) Each time only the area that is required to clad two to three stone slabs shall be
taken up for spreading the slurry and only after fixing the stone slabs over the slurry
shall a further area shall be taken up.
4) Immediately on applying cement slurry on the base course the Shahabad stone
slabs shall be laid over the base course and pressed gently so that the air gap can
be removed.
5) The slurry applied on the surface which gets spread when the stone slab is pressed
shall accumulate in the joints and if any gap still remains between the stone slabs
the same should also be filled with additional quantity of cement slurry.
6) To lay the stone slabs level, two slabs at adjacent corners/ends shall be fixed firmly
to the required level and a string stretched over the two slabs, the intermediate
slabs shall then be set to the level of the string.
Third layer: 25 mm thick course in cement mortar 1:3
1) On filling all the joints of the Shahabad stone slabs with cement slurry and after a
gap of 6 to 8 hours, the area of stone slabs shall be clad with 1:3 cement mortars.
2) The surface of stone slabs shall be cleaned and lightly watered. The cement mortar
(shall be used for laying this course, no cement slurry need be used and the mortar
can be laid on the slab surface directly.
3) For laying this course level, 25 mm high wooden strips with legs used for laying
base course shall be used and the top surface shall be finished smooth without
using additional cement or slurry.
Fourth Layer: Top Finish with Stone Aggregates 10 to 12 mm Size
1) Immediately after laying 3rd course and before the clad mortar takes the initial set,
stone aggregate of 10 mm to 12 mm nominal size shall be pressed into the finished
surface at a rate of 0.008 m3/m2.

2) The aggregates though embedded shall be clearly visible on the surface, i.e. the
stone aggregates shall not be embedded totally inside the mortar.
3) This treatment shall be provided over the surfaces which are at their proper slope
or level the profile shall not be altered by varying the 25 mm thickness of base
course.
4) In case a slope is to be provided for the waterproofing layer on a surface which is
level, grading with additional cement concrete/cement mortar shall be provided and
then the waterproofing layer shall be laid on the graded surface.
13.11.10.7 Curing
Immediately after completing the fourth layer, arrangements shall be made to lay the top
RCC slab as quickly as possible and in the mean time until the top slab is concreted the
waterproofing treatment shall be kept wet continuously. In case the concreting of the slab
gets delayed for more than two weeks the curing can be stopped after 14 days.
The waterproofing treatment done on the offset of the floor slab shall be kept wet
continuously for 14 days minimum.
i. On Vertical Surfaces
The vertical waterproofing treatment either from inside or outside shall be undertaken
only when the entire work is structurally complete.
13.11.10.8 Preparing the Surface and Providing Ancillary Arrangements
The surface of the structure to be treated shall be roughened properly either by raking
joints when the mortar is still green in case of brick/stone masonry structures, or by
preparing the cement concrete surface with a scabbler just after removing the shuttering.
In case the raking joints/hacking concrete surface is not done properly the only alternative
method to make the surface rough by a scabbler.
While doing the waterproofing to vertical faces from inside, particular care shall be taken
to ensure that the waterproofing layer of the floor slab does not get damaged while resting
the vertical props of any scaffolding. Alternatively waterproofing for vertical surface shall
be provided before horizontal floor slab waterproofing. In order to arrest any leakage
through junctions of vertical/horizontal waterproofing, a proper haunch in cement concrete
shall be provided.
For the stone slabs that are used for arresting leakage, while executing this type of
waterproofing treatment, the first and foremost mandatory condition is that the number of
joints in the portion covered by the stone slabs shall be kept to a minimum and this
condition can be achieved only by using the maximum size of stone slabs. Normally the
size of stone slabs used for the purpose is 600 x 600 mm x 90 mm each stone slab
weighing approximately 16 kg to 25 kg.
The rough stone slabs used for such works are usually rough on the surface but such
roughness will not be sufficient for the stone slabs to remain in a vertical position held by
cement slurry. Therefore the grip for the stone slabs shall be increased by planting 12 mm
to 15 mm nominal size stone aggregate fixed with Araldite (or equivalent) on the face of
each stone slab.
A 20 mm thick clear gap shall be formed between the masonry/concrete surface and the
stone slabs erected in a vertical position for pouring the cement slurry. This gap shall be

maintained by fixing with Araldite (or equivalent) the 20 mm x 20 mm cover blocks made
out of rich cement mortar on the four corners and the centre of the stone slabs.
Preparation of Cement Mortar (1:4)
Cement mortar shall be prepared as explained above except that the proportion shall be
1:4 (1 blended cement: 4 coarse sand) instead of 1:3.
Fixing Waterproofing Courses on Vertical Surfaces
Normally the item of work prescribes executing the first layer as base course with cement
slurry, second layer fixing rough Shahabad stone slab, third layer as plastering the surface
and the fourth layer as finishing surface with neat cement punning, but a gap of 20 mm
width shall to be formed for pouring cement slurry. The 20 mm wide gap shall be formed
by erecting the 20 mm thick Shahabad slab at a distance of 20 mm from the
masonry/concrete surface, over which the cement slurry is to be clad.
The sequence of layers shall be considered as per actual construction layers rather than
the chronological sequence in which they were placed. To avoid confusion and to
distinguish between the two different layers laid and the actual work executed, actual
working is termed as Step I, Step II etc.
Step I: Erecting Shahabad Stone Slab forming 20 mm wide gap.
1) The Shahabad stone slab duly fixed with 20 x 20 mm cover blocks and 12 to 15 mm
size stone aggregate on the surface shall be erected against the masonry/concrete
surface to be treated by abutting the 20 mm thick cover block against the surface, thus
forming a clear gap of 20 mm
2) The joints of stone slabs shall be temporarily closed from outside with cement mortar
so that the cement slurry poured in the gap does not escape through the joints. The
bottom portion of the stone slabs shall also be closed with cement mortar.
3) While erecting the stone slabs, proper care shall be taken to ensure that stone slabs
are of uniform size. In case similar width slabs are used, it shall be ensured that these
are not fixed at the corners but the same should be at the middle portion.
4) Interlinking of the Shahabad stones of horizontal layers of waterproofing with this
vertical layer of waterproofing shall be done very carefully, as per standard practice.
5) The Stone slabs shall be erected plumb and fixed in position and it will be considered
as 2nd layer of waterproofing on completion.
6) Further lifts of Shahabad stone slabs up to the full height of the masonry/ concrete wall
shall be erected only after filling the gap of each lift erected, with cement slurry.
Step II: Filling Cement Slurry in the gap formed by erecting Shahabad Stone Slabs:
1) When the first lift of stone slabs are erected and checked to be plumb, cement slurry
shall be poured in the gap until the gap is filled completely.
2) The further filling of slurry in the second lift shall be done when the second lift of stone
slabs are erected in position and thus the work on 2nd and 1st layer of the item shall
be completed sequentially until the cladding over the entire height of the wall is
complete.
3) Thus on completion of filling cement slurry and erecting stone slabs for the entire height
of the wall, it shall be considered that the first layer (i.e the layer of cement slurry) and
the second layer (i.e. the layer of erecting Rough Shahabad Stone Slabs) is complete
as per the item.

Step III: 3rd Layer: Plastering Over 2nd layer with Cement Mortar 1:4 (1 Blended
Cement: 4 Sand)
1) Immediately on completion of the work of cladding the entire masonry/ concrete wall
with Shahabad Stone slabs, the cement mortar applied over the joints shall be
removed and the joints exposed. The entire surface shall be cleaned with water neatly
to start the plastering work.
2) Cement mortar 1:4 (1blended cement: 4 coarse sand) shall be used for the purpose.
Care shall be taken to ensure that the 20 mm thickness of cement plaster over the
entire surface is maintained correctly.
3) The work of plastering shall be taken up immediately on completion of cladding the
wall surface, so the work shall be a continuous process from the day of starting the
erection of stone slabs until the finishing work of plastering is done.
4) The plastering shall be from top to bottom without leaving any joint. As far as possible
the joints in plaster shall be minimised. In case a joint has to be left to continue the
work on the subsequent day, cement slurry shall be applied over the entire joint and
then only the further work of plastering shall be taken up.
Step IV: 4th Layer: Finishing with Neat Cement Punning:
1) When the surface of plastering is still green, the cement slurry shall be applied over
the plastered surface and the surface shall be finished neatly to a smooth surface with
specially made semi-rounded thapis. The surface should show a smooth and neat
finish without any undulations.
13.11.10.9 Curing and Testing
On completion of the waterproofing course from outside, the tank shall be cleaned from
inside, scaffoldings shall be removed and the tank gradually filled with water for testing,
which shall commence within two or three days. The exposed faces of the waterproofing
course shall be kept wet for 14 days. No back filling shall be done before expiry of 14 days
from the date of completing the waterproofing course from outside.
13.11.11Expansion Joint Fillers
13.11.11.1 Materials
Materials for expansion joint filler boards shall be of best quality bitumen impregnated
preformed non-extruding, resilient type of appropriate thickness in the standard sizes
available.
The sealing compound to close the gaps at the edges shall be of best quality rubberized
bituminous hot pour, made from special grades of bitumen and shall not show flowing
tendency in hot weather and is resilient in the cold weather. The liquid primer shall be
made from blown grade bitumen of approved quality.
The aluminium plates for fixing at floor level shall be of appropriate size and made out of
extruded sections, free from any rolling defects.
The aluminium sheet for fixing on the underside of beams or the sides of columns shall be
of appropriate size without any defects.

13.11.12Preparation of Surfaces
All the concrete surfaces already cast and where the expansion joint is to be formed, shall
be properly cleaned of all dirt, mortar/concrete, dust etc. One coat of primer shall be
applied by brush to the entire concrete surface, just prior to the next concreting.
Soon after the primer is applied, the filler board shall be placed at the side and held tight
with the concrete surface, by suitable means. Care shall be taken that the boards do not
get damaged or warped during all the operations. Utmost care shall also be taken to
ensure that the board is held tightly to the concrete surface and no stone chip, concrete
etc shall enter between the board and the existing concrete surface against which the
board is placed.
The aluminium plates shall have round holes at 300 mm c/c. of required diameter on one
side of the joint through which screws shall be fixed into the concrete. On the other side,
slotted holes at 300 mm c/c shall be provided so that when screwed, these shall render
smooth movement of plates during expansion/contraction. The plates shall be fixed
correctly to the required level, line, plumb etc and as approved by the Engineer.
In case of plates fixed on floors, they shall be fixed when the floor mortar screed is laid to
the required level over the expansion joint duly filled up with sealing compound.
In case of roofs, the expansion joints in beams placed vertically, shall be extended
upwards, when RC/brick masonry curbing is laid to the desired height (approximate 450
mm) over which horizontal flat board is laid to the extent of 150 mm, as per procedure laid
down previously.
13.11.13Floor Pavement
13.11.13.1 General
The sub-floor shall be cleaned, brushed, washed and prepared as recommended in the
Codes of Practice.
13.11.13.2 Finishes
i. Floor Screeds
Where specified, dense concrete floor screeds shall be placed over the structural
concrete floor. Before the structural concrete is fully hardened, the surface shall be
roughened by wire brushing in order to expose the aggregate. Immediately before
laying the screed, the concrete shall be cleaned with stiff brushes and then thoroughly
dampened. Before the screed is laid and after the excess water has been removed, a
thin layer of stiff cement grout shall be well brushed into the roughened surface.
Where approved by the Engineer, a waterproofing admixture shall be added to screed

concrete in accordance with the manufacturer’s recommendations.
Heavy duty screeds shall be in M10 grade plain concrete with coarse aggregate of size
20 mm downgraded. Light duty screeds shall also be in M10 grade plain concrete but
with coarse aggregate of size 10 mm downgraded. Water content shall be kept to the
minimum consistent with providing adequate compaction. Unless otherwise specified,
screeding shall be finished to class U2.

Screeds shall be laid to a minimum fall of 1 in 120. The minimum thickness of screed
shall be 80 mm for heavy duty and 50 mm for light duty.
ii. Surface Hardeners on Concrete Surfaces
Application of approved surface hardeners to the finished concrete surface shall be

carried out in accordance with the manufacturer’s recommendations.
13.11.13.3 Cement Concrete Flooring (Indian Patent Stone)
i. Preparation of Base
The base concrete surface shall be thoroughly chipped to remove laitance, caked
mortar, loose sand, dirt etc, cleaned with wire brush and washed clean and watered
until no more water is absorbed. Where the base concrete has hardened so much that
roughening the surface by wire brushes is not possible, the same shall be roughened
by chipping or hacking at close intervals.
Concrete flooring shall be laid in a chess board alternate panel fashion. The edge of
each panel shall be separated by wooden strips duly oiled to prevent sticking.
The panels shall be of uniform size and, unless otherwise specified, no dimension of
panel shall exceed 2 m. and the area of a panel shall not be more than 4 m2. The joints
in the floor finish shall extend through the edges and skirting/dado. The edges shall
have mitred joints at the corners of the room.
The depth of dividing strips shall be the thickness as proposed for the finished floor.
ii. Mixing
The cement concrete shall be mixed in the proportion of 1:2:3 with an admixture of
approved waterproofing compound. The maximum size of coarse aggregate shall be
10 mm. The fine aggregate shall consist of properly graded sand. The least amount of
mixing water that will produce a workable mix and will allow finishing without excessive
trowelling shall be used. Generally, a water cement ratio of 0.5 should suffice. Concrete
shall be mixed preferably by machine and hand mixing shall be avoided as far as
practicable.
iii. Laying
The free water on the surface of the base shall be removed and a coat of cement slurry
to the consistency of thick cream shall be brushed on the surface. On this fresh grouted
base, the prepared cement concrete shall be laid immediately after mixing. The
concrete shall be spread evenly and levelled carefully. The concrete shall be
completed and brought to the required level by means of a heavy straight edge resting
on the side forms and down ahead with a sawing motion in combination with a series
of lifts and drops alternatively with small lateral shifts, either mechanically or manually
as approved by the Engineer.
While concreting the adjacent bays, care shall be taken to ensure that the edges of the
previously laid bays are not broken by carelessness or hand tamping. Immediately
after laying the concrete, the surface shall be inspected for high or low spots and any
needed correction made up by adding or removing the concrete and the whole surface
shall be levelled again. Before the initial set commences, the surface shall be trowelled

to smooth and even surface free from defects and blemishes and tested with straight
edges.
In the case of flush joins, alternate panels only may be cast on the same day. At least
48 hours shall elapse before the concreting of an adjacent bay is commenced.
iv. Finishing the Surface
Finishing operations shall start shortly after the compaction of concrete and shall be
spread over a period of one to six hours depending upon the temperature and
atmospheric conditions. Immediately after laying, only just sufficient trowelling shall be
carried out to give a level surface. The surface shall subsequently be trowelled
intermittently at intervals several times to produce a uniform and hard surface and to
close any pores in the surface and to bring to surface and remove any excess water
or laitance.
The final trowelling shall be carried out before the concrete has become too hard but
at such a time that considerable pressure is required to make any impression on the
surface. Dry cement and fine aggregate shall not be added to the surface. Trowel
marks shall not be seen on the finished surface.
Where a broom finish is required, after the concrete has been thoroughly compacted
and the surface water has been removed, the surface shall be given a broom finish
with an approved type of brass or mild steel fibre broom. The broom shall be pulled
gently over the surface from edge to edge in such a manner that corrugation shall be
uniform in width and depth, the depth shall be not more than 1.5 mm Brooming shall
be done when the concrete is in such a condition that the surface will not be torn or
unduly roughened by the operation. Coarse or long bristles which cause irregularities
or deep corrugation shall be trimmed out. Brooms which are worn or otherwise
unsatisfactory shall be discarded.
After the concrete in the bays has set, the joints of the panels should be filled with
cement cream and neatly floated smooth or jointed. Care should be taken that just the
minimum quantity of cream for the joint is used and excess spilling over the already
finished surface shall be removed when the cream is still green.
In case of wide joints the same shall be filled with pigmented cement concrete (1:2:4)
using approved pigment.
v. Curing
The completed flooring shall be protected from the sun, wind and rain for the first two
days and movement of persons over the floor is prohibited during this period. The
finished surface shall be covered and cured continuously for a minimum period of
seven days. The surface shall then be allowed to dry slowly. All corners, junctions of
floor with plastered wall surface shall be rounded off when required. Bunding with
murrum for curing is prohibited.
13.11.13.4 Ironite (or Hardonate) Flooring
13.11.13.4.1 General
To withstand heavy wear and tear, concrete flooring with metallic concrete hardening
compound such as Ironite or Hardonate shall be laid as wearing layer as detailed below:

i. Metallic Concrete Hardening Compound
The metallic compound shall be Ironite or Hardonate of or similar of approved quality

consisting of uniformly graded iron particles, free from non-ferrous metal particles, oil,
grease and soluble alkaline compound.
ii. Cement Concrete Under Layer
Cement concrete flooring of specified thickness and mix shall be laid as specified and
generally conforming to specifications laid down for cement concrete flooring. The top
surface shall be roughened with brushes while the concrete is still green and the form
shall be kept projecting up 12 mm over the concrete surfaces, to receive the metallic
hardening compound topping.
iii. Metallic Concrete Hardening Topping
This shall consist of a 12 mm thick layer of mix 1:2 (1 part of cement mixed with
hardener: 2 parts of stone aggregate of 6 mm nominal size by volume). The metallic
concrete hardener compound being mixed with cement in the ratio of 1:4 (1 metallic
concrete hardener: 4 cement used by weight) or as specified by the manufacturer. The
concrete hardener shall be dry mixed thoroughly with cement on a clean dry pucca
platform. This dry mixture shall then be well mixed with the 6 mm stone aggregate in
the ratio of 1:2 (1 cement mixed with hardener: 2 stone aggregate) by volume. Just
enough water shall then be added to this dry mix as required for floor concrete, water
cement ratio not exceeding 0.4.
The mixture so obtained shall be laid in to the 12 mm thickness, on cement concrete

floor within 1 to 4 hours of its laying.
The topping shall be laid true to provide a uniform and even surface. It shall be firmly
pressed into the bottom concrete to have a good bond with it. The concrete shall be
compacted well mechanically. Manual compaction will not be permitted unless
approved by the Engineer. After the initial set has started, the surface shall be finished
smooth and true to slope with steel floats.
iv. Curing, Precautions etc.
Specifications for curing, precautions etc shall be same as specified for cement
concrete flooring.
13.11.13.5 Glazed Tiles
Where walls are to be finished with glazed tiles, walls shall be lined with glazed tiles set in
cement and sand (1:3) mortar and pointed in neat cement.
Tiles shall be soaked in water before fixing them.
All external and internal angles shall be of angle bead fitting of radius approved by the
Engineer. Angle bead internal angles shall be provided at all junctions of wall tiling with
floor pavements, whatever be the material of the floor pavement.
The wall tiling shall be finished with a border of approved coloured tile, budded and pointed
as glazed tile, with all necessary internal and external angles and stopped ends.

13.11.13.6 Tiled Flooring
i. Materials
Clay floor tiles shall be heavy duty fully vitrified tiles 25 mm thick at least equal to Class
1 of IS: 1478 or light duty fully vitrified tiles 15 mm thick at least equal to Class 3 of IS:
1478. Coved bull nosed skirting with radius internal and external angles and other
special tiles shall be supplied to match the floor tiles. Water absorption shall be less
than 3 % and hardness as measured by the Moh’s scale shall be greater than 6. The
tiles shall resist acidic action and staining by oil. Jointing material shall be acid resistant
where shown.
Vitrified tiles shall be of approved make like Marbonite / Granamite or equivalent and
shall conform to the approved standards. They shall be flat and true to shape, free
from cracks, crazing spots, chipped edges and corners.
The tiles shall be square or rectangular of nominal sizes such as: 600 x 600 mm; 900
x 900 mm or as otherwise approved by the Engineer. Thickness shall be as per
recommendations of the approved manufacturers.
Technical specifications of the tiles shall be generally conforming to the following

standards: Technical Specifications for Vitrified Tiles
Property Expected standards

Deviation in length (+/-) .6%
Straightness of sides (+/-) .5%
Rectangularity (+/-) .6%
Surface flatness (+/-) .5%
Water absorption <0.50%
Mohs. hardness >6
Flexural strength > 27 N / mm2
Abrasion resistance < 204 mm2
Skid resistance (friction coefficient) > 0.4
Glossiness Min. 85% reflection
The tiles shall conform to the relevant standards in all respects. Samples of tiles shall
be approved from the Engineer before bulk procurement for incorporation in the work.
ii. Mortars
Mortar shall be used as soon as possible after mixing and before it has begun to set
and in any case within 30 minutes after the water is added to the dry mixture. Mortar
unused for more than 30 minutes shall be rejected and removed from the site of work.
For lime mortar, lime from burnt stone shall be used. It shall be free from ash and
impurities and be in the form of lumps and not powder when brought to site. Lime which
is damaged due to rain, soaking, moisture or air slaking will be rejected.
iii. Proportioning

The unit of measurement for cement shall be a bag of cement weighing 50 kg and this
shall be taken as 0.035 m3. Sand in the specified proportion shall be measured in
boxes of suitable size on the basis of its dry volume. In case of damp sand, its quantity
shall be increased to allow for bulking which shall be determined as per IS
specifications.
iv. Mixing
The mixing of mortar shall be done at site of work in mechanical mixer. Hand mixing,
if permitted, shall be done as approved by the Engineer.
v. Mixing in Mechanical Mixer
Cement and sand in the specified proportion shall be mixed dry thoroughly in the mixer.
Water shall then be added gradually and wet mixing continued for at least one minute.
Care shall be taken not to add more water than that shall bring the mortar to the
consistency of a stiff paste.
vi. Hand Mixing
The measured quantity of sand shall be levelled on clean masonry platform and
cement bags emptied on top. In hand mixing the quantity of cement shall be increased
by 5% above that specified. The cement and sand shall be thoroughly mixed dry by
being turned over and over backwards and forwards several times until the mix is of a
uniform colour. The quantity of dry mix which shall be used within 30 minutes shall
then be mixed in thoroughly with just sufficient quantity of water to bring the mortar to
the consistency of a stiff paste. Mortar shall not be mixed on floor slabs or landings of
staircase.
vii. Cleaning of Surface & Laying of Cement Mortar Bedding
Before laying the cement mortar bedding, the concrete floor surface shall be thoroughly
hacked, cleaned of all mortar scales, concrete lumps etc brushed, washed with water
to remove mud, dirt etc from the surface and shall be thoroughly wetted. Until and
unless the surface is approved by the Engineer, the flooring shall not be started.
The mortar shall be evenly spread on the sub-floor, 25 to 30 mm thick. Over this mortar
bed, 5kg.of cement per m2 of floor area shall be spread.
viii. Laying of Tiles
The tiles shall then be laid immediately after laying the mortar.
All tiles shall be truly and evenly set in a thick slurry of cement of honey like consistency
applied to the sides and bottom and over the prepared base at the rate of 4.4 kg/m 2
over such an area that accommodates about 20 tiles. The tiles shall be fixed on this
bed one after another, each tile being gently tapped with a wooden mallet until it is
properly bedded and level with the adjoining tiles. The joints shall be straight and
uniform in thickness and not be greater than 1.5 mm. The tiles shall be laid level unless
otherwise specified or required by the Engineer.

Tiles shall extend up to un-plastered surfaces of walls and columns. All tiles shall be
laid to have continuous lines from various rooms to the passage. Wherever full tiles /
half tiles cannot be fixed, tiles shall be cut from full tiles to the required size and their
edges rubbed smooth to ensure a straight and true joint. Freshly laid tiles shall not be
walked upon.
After laying the tiles the joints shall be finished with white cement or cement of
approved colour.
ix. Curing, Polishing & Finishing
After laying, the flooring shall be allowed to cure undisturbed for seven days.
About a week after laying the tiles, each and every tile shall be lightly tapped with a
small wooden mallet to determine if it gives a hollow sound; if it does, such tiles along
with any other cracked or broken tiles shall be removed and replaced with a new tile
to proper line and level. The same procedure shall be followed again after the tiles are
finally polished. For the purpose of ensuring that such replaced tiles match with those
earlier laid, the Contractor shall order enough extra from the factory to meet this
contingency. The tiles shall be cleaned and polished by using dilute oxalic acid or
another method recommended by the manufacturer and approved by the Engineer.
After the joints have developed sufficient strength the floors shall be machine polished
to the desired finish as approved by the Engineer. Sufficient quantity of water shall
always be used for polishing to prevent scratching.
For dado and skirting work, the vertical surface shall be thoroughly cleaned and wetted.
Thereafter it shall be evenly and uniformly covered with about 12 mm thick 1:2 cement
mortar. For this work the tiles as obtained from the factory shall be of the size required
and practically fully polished. The back of each tile to be fixed shall be covered with a
thin layer of neat cement paste and the tile shall then be gently tapped against the wall
with a wooden mallet. This shall be done from the bottom of the surface to upwards.
The joints shall be tight and not larger than 1.5 mm and the work shall be vertical and
flush.
After the work has set, hand polishing with carborundum stones shall be carried out so
that the surface attains a high glossy finish, corners and junctions shall be finished
true. The workmanship shall confirm to IS: 1443
x. Sampling and Testing
Tiles required for carrying out tests shall be taken by random sampling. Each tile
sample shall be marked to identify the consignment from which it was selected. The
minimum quantity of tiles for carrying out the test and frequency of test shall be as per
IS: 13801.
No. of
Mandatory tests Results
samples
Concavity & convexity shall not exceed 1
a) For conformity to
mm Perpendicularity shall not exceed 2%
requirements of shape and
12 tiles of the length of edge.
dimensions, wearing layer
Straightness shall not exceed 1% of the
and general quality.
length of the edge.

No. of
Mandatory tests Results
samples
b) For wet transverse strength
6 tiles Strength shall not be less than 30 kgf/cm2
test
Average wear shall not exceed 3.50 mm
c) For resistance to wear test 6 tiles and wear on individual specimen shall
not exceed 4 mm
d) For water absorption test 6 tiles Shall not be more than 10%
13.11.13.7 Stone Flooring, Skirting and Facia
i. Materials
Stone should be of approved quality, hard, sound, durable and of uniform thickness.
Slabs should be of standard sizes and shapes.
Slabs supplied should meet all the required properties and test requirements as
stipulated in IS 1124. Edges shall be chisel dressed and the top surface shall be
machine polished with joints running true and parallel from side to side.
ii. Bedding / Backing Coat
Stones should be laid on a bed of lime mortar of proportion 1:2 or cement mortar of
proportion 1:3. Thickness of mortar bedding should not be less than 12 mm and not
more than 25 mm
iii. Fixing the Stone Slab / Tile
Before laying, the stone slabs should be thoroughly wetted with clean water. Thick
cement slurry should be spread over the mortar bed over as much area as could be
covered with the slabs within half an hour. The slabs are then laid and gently tapped
with mallet until they are firmly and properly bedded.
There shall be no hollows left. If there is a hollow sound on gently tapping the slab,
such slab shall be removed and reset properly. The joints shall be grouted with
matching cement slurry. Approved pigment shall be used in cement slurry to match
with shade of stone. Stones adjoining the walls shall go 12 mm under the plaster,
skirting or dado of the wall. All stone slabs tiles shall be laid to have continuous lines
from various rooms to the corridors.
No change of lines shall be permitted at junctions between rooms and corridors. Only
one piece machine cut, Kotah stone shall be used for treads and risers, unless
otherwise specified.
iv. Polishing and Cleaning
When the bedding and joints have completely set and attained required strength, the
surface shall be machine polished to give smooth, even and true plane to the flooring.
All flooring shall be thoroughly cleaned and handed over free from any mortar stains
etc. Polishing shall be as per IS-14223 (Specification for polished building stones).
v. Skirting and Dado / Facia

The specifications and workmanship for Kotah stone skirting shall be the same as per
Kotah stone flooring.
Kotah stones in skirting shall be laid against a bedding of cement mortar (1:3) 20 mm
thick to the full height of the skirting, to a true plane, level and plumb. The workmanship
shall be similar to flooring. The skirting shall be laid projected beyond the finished
plastered surfaces. Continuous horizontal grooves at the top of the skirting shall be
provided if required. The skirting surfaces shall be re- polished with hand to satisfaction
of the Engineer. Top of exposed skirting shall be machine cut and polished tiles used
at projecting corners shall be suitably bevelled to present a neat corner.
The Contractor shall touch up the plaster at the junction of skirting / dado after the
skirting/ dado/ facia work is completed.
vi. Other Materials
The specifications for Tandur Stone / Cuddappa Stone / Polished Shahabad Stone /
Blue Wadi Stone flooring/skirting/dado shall be similar to those for Kotah stone as
above.
13.11.14Aluminium works
13.11.14.1 General
The material, fabrication and hardware shall conform to the IS 1948.
Aluminium alloy for extruded sections for the above work shall correspond to IS 733 & 737
specifications or any further revision thereof (extruded sections shall conform to IS
Designation HE 9- WP. Hollow sections shall conform to IS Designation HV9-WP) and
shall be anodised before incorporating in the work. Anodic coating shall conform to IS
1868. The frame work, stiles, mullions, beadings, transoms and handles etc shall be of
aluminium anodised sections. The sections shall be structurally suitable to withstand all
loads the members have to sustain. Counter sunk screws, nuts, bolts, washers, rivets and
other miscellaneous fastenings devices shall be of approved cadmium plated brass or
stainless steel. Each door leaf shall be prepared to receive glazed panels of required
thickness. Glazing shall be done with neoprene dry set glazing gasket (of best quality and
approved make) with snap-in-bevelled white anodised matt finish aluminium metal glazing
stops inside and outside. All doors shall have offset pivots, double action (1800 minimum
swing) floor springs with oil check boxes of approved manufacture. All doors shall have 4
lever concealed brass body mortise lock with concealed flush cadmium plated brass tower
bolts provided at suitable locations. All doors shall have push plates.
All entrances shall be without thresholds. All aluminium surfaces in contact with masonry
or concrete shall be given a thick coat of bit mastic paint. After fabrication, aluminium
sections shall be protected from construction hazards that may damage their appearance
or finish. All exposed surfaces of aluminium entrance doors shall be protected by masking
tape during trans-shipment and erection. All sections and hardware shall have anodic film
and cover a minimum thickness of 0.015 mm.
13.11.14.3 Fabrication
The frames shall be manufactured square and flat, the corners of the frame being
fabricated to true right angles. All the fixed, sliding and opening frames shall be constructed

of sections which have been cut to length, mitred, welded and mechanically fixed at the
corners.
Where hollow sections are used with welded joints, argon-arc welding or flash butt welding
shall be employed (not gas welding or brazing). In the case that welded joints are used,
anodising shall be done after fabrication as a whole. All welding shall be on unexposed
sides in order to prevent pitting/discolouration or other surface imperfections after fixing
etc. Necessary allowances shall be made while manufacturing the aluminium door
entrances, wall spans and glazing for receiving plaster.
A thick layer of clear transparent lacquer based on methacrylates or cellulose butyrate

shall be applied on the finished sections of the aluminium work to protect the surfaces from
wet cement, lime, dirt, dust etc during the construction activities. The size for door, window
or ventilator frames shall not vary by more than (+/-) 1.5 mm.
13.11.14.4 Fixing
Fixing and glazing of doors, windows and ventilators shall conform to IS 1081, unless
otherwise specified. The frames shall be accurately fixed to the flooring, brick masonry or
RCC works. The fixing of the frame shall be withhold fasts as approved by the Engineer.
All aluminium works shall be fixed in position as per relevant Indian Standard
Specifications and code of practice for fixing and glazing of aluminium work. Joints
between metal and masonry shall be fully caulked with mastic / polysulphide compound in
order to ensure water tight joints as approved by the Engineer.
Joints shall be neatly painted with matching cement and excess materials shall be
removed. Fixing of aluminium door entrances, hardware etc shall be done using the best
workmanship like manner true to line, level, plane, plumb etc and all as approved by the
Engineer.
13.11.15Rolling Shutters
Rolling shutters shall be suitable for fixing in position outside or inside as appropriate on
or below lintels or between the jambs of the opening. Rolling shutters shall be hand/gear
operated. Hand operated shutters shall be push and pull type. Gear operated shutters
shall be provided with reduction gear operated by mechanical device with chain, crank,
shaft and handle. The shutter shall consist of 80 mm wide mild steel laths 1.25 mm thick
of best quality machine rolled mild steel sheet. Laths shall be inter-locked together
throughout their entire length and jointed together at the end with end locks. These shall
be mounted on specially designed shaft. The spring shall be of best quality and shall be
manufactured from tested tensile spring steel wire or strip of adequate strength to balance
the shutter in all positions. The spring, shaft etc shall be supported on strong mild steel or
malleable cast iron brackets. Both the side guides and bottom rails shall be joint less and
of single piece of pressed steel of minimum 16 gauge thickness. The top cover of the shaft,
spring etc. shall be of the same materials as that of lath. The reduction gear arrangement
operated by the mechanical device shall be of the best quality and shall be easy in
operation.
13.11.15.2 Fixing
Brackets shall be fixed on or under the lintel beam as required with rail plugs and screws,
bolts, washers etc. The shaft along with the spring shall then be fixed on the brackets. The

lath shutters shall be laid out and the side guide channels shall be bound with it. The
shutter shall then be placed in position. The side guide channels shall be fixed to the wall
through the plates welded to the guides. These plates and brackets shall be fixed by
means of steel screws, bolts and rail plugs drilled into the wall. The plates, screws and
bolts shall be concealed in plaster to make their locations invisible. Fixing shall be done
accurately in a workmanlike manner such that the operation of the shutter is easy and
smooth.
All the members of the rolling shutter shall be thoroughly cleaned of dust, scales, rust etc.
and shall be given approved priming coat of red oxide paint before fixing the shutter in
position and shall then be painted with two coats of flat/synthetic enamel paint of approved
quality and shade.
13.11.16Fitting and Fixtures
13.11.16.1 General
All fittings and fixtures shall conform to relevant IS code and be made of brass, anodized
aluminium, mild steel stainless steel or as otherwise approved. These shall be well, made
smooth and free from sharp edges, corners, flaws and other defects. Screw holes shall be
counter sunk to suit the heads of the appropriate screws.
All hinges pins shall be of steel for brass hinges and aluminium alloy NR-6 or steel pins
for aluminium hinges with nylon washers. All riveted heads pertaining to hinge pins shall
be well formed. Screws supplied for fittings shall generally be of the same metal and finish
as the fittings. However brass cadmium plated brass screws shall be supplied with
aluminium fittings. Fittings shall be fixed in their proper position as approved by the
Engineer. These shall be truly vertical or horizontal as the case may be. Screws shall be
driven home with a screwdriver and not hammered in. Recess shall be cut to the exact
size and depth for the counter sinking of hinges.
Mild steel fittings shall be bright satin finish black stone anodized or copper oxidised (black
finish), nickel chromium plated or as otherwise approved.
Brass fittings shall be finished bright satin finish or nickel chromium plated or copper
oxidised or as specified. Aluminium fittings shall be anodized to natural matt finish or dyed
anodic coating less than grade AC 10 of IS: 186
Stainless steel fittings shall be non-magnetic, rust and moisture proof, strong and sturdy.
Pins of hinges shall also be of stainless steel.
13.11.16.1.1 Butt Hinges
Brass and aluminium hinges shall be manufactured from extruded sections and shall be
free from cracks and other defects. Mild steel butt hinges shall be cranked and
manufactured from sheet steel. Butt hinges shall generally conform to IS 1341 (MS) IS :
205 (Cast brass & aluminium, IS : 362 (Parliament hinges); IS : 453 spring hinges, IS :
3818 (Piano hinges) etc. The size of butt hinges shall be taken as the length of the hinge
measured from the centre line of hinge pin to end of the flange.
13.11.16.1.2 Parliamentary Hinges
These shall be manufactured from extruded section for brass and aluminium and from MS
sheets for iron oxidised and shall be free from cracks and other defects. The size of the

parliamentary hinges shall be taken as the width between open flanges, while the depth
shall be as specified.
13.11.16.1.3 Piano Hinges
These shall be generally conform to IS 3818 and shall be made of either brass, aluminium
anodized, mild steel or as otherwise approved. Piano hinges shall be fixed along the entire
length of the item in a single piece. No joints shall be allowed.
13.11.16.1.4 Tower Bolts
Tower bolts shall generally conform to IS 204 (Part II & I). They shall be well made and
shall be free from defects.
Tower bolts shall be of the following types :
1) Mild steel semi barrel tower bolt with mild steel sheet pressed barrel and G.I. or mild
steel bolt.
2) Oxidised brass barrel tower bolt with brass sheet barrel and rolled or drawn brass bolt.
3) Anodised aluminium tower bolt with barrel and bolt of extruded sections of aluminium
alloy.
In case of mild steel tower bolts, plates and straps shall be firmly anodize or spot welded
properly after assembly.
The knobs of brass tower bolts shall be cast and the bolt fixed into the knob firmly as per
IS specifications.
Tower bolts shall be finished to the correct shape and pattern to have a smooth action.
Knobs shall be properly screwed to the bolt and riveted at the back. The size of the tower
bolt shall be taken as the length of barrel without top socket.
13.11.16.1.5 Door Latch
Door latches shall be of mild steel, cast brass or as otherwise approved and shall have a
smooth sliding action. Mild steel latches shall be copper oxidised (black finish) or as
otherwise approved. Brass latches shall be finished bright, cadmium plated or oxidised or
as otherwise approved.
13.11.16.1.6 Aldrops
Aldrops (brass sliding door bolts) shall be oxidised brass or anodized aluminium, mild steel
or as otherwise approved and shall be capable of smooth sliding action and shall be as
per relevant IS. Brass Aldrops shall be made from rolled brass generally confirming to IS:
2681. Mild steel sliding door bolts shall generally conform to IS 281. The hasp shall be of
cast brass and screwed to the bolt in a workman like manner or the hasp and the bolt may
be in one piece. All components shall be smooth and polished. The leading dimensions of
an Aldrops shall be the length and diameter of the bolt.
13.11.16.1.7 Door Handles – Bow/Plate Handles
These shall generally conform to IS: 208. Unless otherwise approved, door handles shall
be of 100 mm size and windows handles of 75 mm size. All edges and corners shall be
finished smooth and correct to shape and dimensions. Brass handles shall be finished

bright, chromium plated or oxidised as specified. The size of the handle is taken as the
inside grip of the handle. Mild steel handles shall be manufactured from mild steel sheet
pressed into oval section as per IS.
13.11.16.1.8 Mortice Lock and Latch
Mortice locks and latches shall generally conform to IS 2209. Handles shall conform to IS
4992. Mortice locks with latches and a pair of level handles shall be 6 levers with zinc alloy
pressure die cast/brass or as otherwise approved and shall be right or left handed as
required. The pair of handles shall be either brass chromium plated or anodized aluminium
of approved shape and pattern or as otherwise approved. The handles shall be of the best
Indian make of approved quality. The size of the lock shall be determined by its length.
The lock for single leaf door shall have plain face and that for double leaf door a rebated
face. Level handles with springs shall be mounted on plates and shall be of approved
quality, anodized aluminium or as otherwise approved.
13.11.16.1.9 Hydraulic Door Closer
Hydraulic door closers shall generally conform to IS: 3564. Hydraulic door closers shall be
of approved quality and make. The operation of the hydraulic door closer shall be very
smooth. Hydraulic door closers should be of HD 66 for external/main doors and Elegant
63 for all internal doors. The overall height should not be more than 170 mm for HD 66
and 160 mm for Elegant 63. The base shall be 110 x 60 mm for HD 66 and 100 x 55 mm
for Elegant 63. The units shall weigh not less than 4.5 kg for HD 66 and 4 kg. for Elegant
63. The speed of the hydraulic door closer shall be adjustable and the closing latch shall
also be the adjustable type. Suspension and lubrication of door closer shall be in to
approved line and level.
13.11.16.1.10 Mortice Night Latch
This is a mortice lock having a single spring bolt withdrawn from the outside by using the
key and from inside by turning the knob and with an arrangement whereby the lock can be
prevented from being opened by its key from outside while the night latch is used from
inside. The lock should generally conform to IS: 3847 and shall be cast or sheet brass,
cast or sheet aluminium alloy or mild steel as otherwise approved and of an approved
make. The locks shall be bright finished or copper oxidised (black) finish as approved. The
normal size of the latch shall be denoted by the length of the face over the body in
millimetres.
13.11.16.1.11 Floor Door Stopper
Floor door stoppers shall conform to IS: 1823 and be made of aluminium, brass finished
bright, chromium plated or oxidised or as cast brass of overall size as approved by the
Engineer and shall have a rubber cushion. The size of door stopper shall be determined
by the length of its plate. The body of the door stopper shall be cast in one piece. All parts
of the door stopper shall be of good workmanship and finish and free from surface and
casting defects. Aluminium stoppers shall have anodic coating of not less than grade AC-
10 of IS 1868.
13.11.16.1.12 Hardware
All cut outs, recesses, mortising or milling and operations required for fixing the hardware
shall be accurately made reinforced with packing plate as required to ensure adequate
strength of the connection. All the hardware accessories shall be of best approved type
and of a finish the same as for the frames and other sections. Each lock shall be supplied

with two keys and each key shall be with a number stamped thereon matching the number
on doors so installed. All hardware shall be free from defects, which may affect the
appearance and serviceability. Working and moving parts of locksets shall be accurately
fitted to smooth, close bearings and shall be free from rattle. Floor springs shall be of
heavy-duty type and should allow door operation smoothly and shall conform to IS 6315.
13.11.16.1.13 Incidentals
The Contractor shall provide for all the incidentals required for fixing these fixtures and
fittings such as cadmium plated screws etc. Mortice plates shall be used over holes where
the bolts enter in the wood work. Metal sockets shall be provided to all bolts where the
shoot enter brick, stone, concrete etc.
13.11.17Glass and Glazing
i. Glass
The glass shall be either of special or ordinary quality glass as required for the usage.
Toughened float glass of approved manufacturer shall be used wherever necessary.
The glass shall be free from bubbles, flaws specks, waves, air holes, distortion,
scratches, cracks or other defects.
ii. Glazing
Glazing shall be with the approved selected glass and be cut to fit the rebates of the
sashes truly and only slightly loose. The glass shall be fixed with double putty by means
of tack beads and sprigged to the sashes in workmanlike manner. All glazing shall be
properly cleaned from the outside and inside by means of chalk on completion of the
work.
13.11.17.2 Beading
In the case of steel or aluminium doors and windows, the beading shall be anodised
aluminium beading of channel section. The junction of the beadings shall be mitre jointed.
13.11.17.3 Dimensions, Thickness and Weight of Glass
Unless otherwise specified, the glass thicknesses shall be as per the table given below.
All panes shall have properly squared corner and straight edges
Normal thickness Range of thickness Weight in kg /m2

3.0 mm 2.8 to 3.2 mm 7.5
4.0 mm 3.8 to 4.2 mm 10.0
4.8 mm 4.6 to 5.1 mm 11.9
5.5 mm 5.2 to 5.8 mm 13.5
6.3 mm 6.0 to 6.6 15.5

The glass shall be cut to the required sizes of panels where it is to be fitted and it shall be
so cut that it fits properly in the frames without rattling. Each frame shall be properly
measured prior to the cutting of glass.
The beading shall then be fixed to glass panes and screwed at close intervals not more
than 10 cm. from each corner and intermediately not more than 20 cm apart. When the
glass panes are fixed with aluminium beading, epoxy resin or silicon sealant shall be
applied covering the area in contact between the glass panes and sash bars and also
between glass panes and the beading. In the case of louvres, all the exposed edges of the
glass shall be ground properly.
All glass panes shall be fixed within the aluminium framing by use of cadmium plated brass
or stainless steel screws and the joints sealed with epoxy resin or silicon sealant to make
the unit completely waterproof. Glazing or caulking compound around the perimeter of
glass shall not be permitted. Fixed glass panes shall be supported by setting blocks. There
shall be no rattling.
After inspection and approval the Engineer, glass panes shall be cleaned of any labels,
paints smears and spots and shall be washed from both the sides and all glazing left clear,
and free from rattling. In case of steel windows, any hardware if fixed in position shall be
removed temporarily before fixing the glass panes and then shall be re-fixed back in
position.
13.11.18Hand Railing
Hand railing and vertical posts shall be made from galvanised mild steel pipes and fittings.
The design of the railing shall be approved by the Engineer to whom the Contractor shall
submit manufacturer's drawings showing positions of vertical posts, joints, expansion joints
and joint details and all fixing details. Fabrication shall not start until these drawings have
Hand railing and vertical posts fabricated from galvanised mild steel pipes and fittings shall
conform to the following requirements.
The height of the top railing shall be 1050 mm above finished floor level unless otherwise
shown. The lower railing shall 550 mm above finished floor and Toe plate should be
provided at the bottom of the rail of the size100mm wide x5 mm thick subject to the
Engineer's approval these and other leading dimensions may be varied slightly to suit
manufacturer's standard products.
Unless otherwise shown, handrails and vertical posts shall be made of galvanised mild
steel tubes (medium class) of 32 mm nominal bore and fittings such as Tees, Bends, and
Crossed etc. of heavy class conforming to IS: 1239.
In general the vertical posts shall be spaced at 1.5 metre c/c and shall be built into the
concrete or bolted to the MS plate embedded in concrete as shown on detailed drawing.
Hand railing and vertical posts shall be painted with 2 coats of approved paint.
13.11.19Rungs
Rungs shall be provided in all manholes/inspection chambers/pumping stations over 0.6

mm in depth and shall be of cast iron conforming to IS: 5455. These rungs shall be fixed

staggered in two vertical runs, 300 mm apart horizontally and 300 mm c/c vertically. The
top rung shall be 450 mm below the manhole/inspection chamber cover and the lowest
not more than 300 mm above the benching. The rungs shall be of 20 mm diameter with
epoxy paint for corrosion resistance or equivalent as approved by Engineer-in-Charge.
13.12 Antitermite Treatment and Pesticides
13.12.1 General
Anti-termite treatment shall be applied to structures during the early stages of construction
in the foundation trenches for columns, plinth beams, pile caps, brick walls, service
trenches, lift pits, steps, ramps, in the top surfaces of plinth filling, at junction of walls and
floor, in expansion joints etc in stages as detailed in this specification. Unless otherwise
stipulated, the anti-termite treatment will be carried out as per IS6313 (part II) 1981 and/or
as per direction of the Engineer.
Soil treatment shall be applied during the construction stages of the sub-structure up to
plinth level.
13.12.2 Products
Pesticide and/or termiticide emulsions, recommended by the Indian Pest Control

Association (IPCA) and approved by the Engineer, shall be used uniformly over the area
to be treated. The Contractor shall comply with the requirements on Contractor’s licensing,
certification and record keeping.
The Contractor shall submit certification for the chemicals purchased and obtain
verification that the containers of the chemicals are sealed from the Engineer before
preparing the emulsion for the treatment.
The pesticide shall be dispersed uniformly in the soil and to the required strength to form
an effective chemical barrier.
13.12.2.1 Roadways, Pathways & Hard Standings
A comprehensive network of roadways shall be provided the around 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 internal roads shall be
of Asphalt pavement of approximately 400 mm thickness and minimum 5 metres wide
comprising of bituminous concrete as the top most layer to be followed by dense mix
macadam as the second layer and wet mix macadam as the third layer with subgrade as
the bottom most layer depending on soil conditions excluding shoulders and drains.
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.

13.12.3 Delivery, Storage and Handling
Pesticides shall be delivered to the site in sealed and labelled containers in good condition
as supplied by the manufacturer or formulator. The pesticides shall be stored, handled and
used in accordance with manufacturer’s instructions. Labels shall bear evidence of
registration as per the IS or appropriate regulations.
13.12.4 Site Preparation
In order to ensure uniform distribution of the chemical emulsion and to assist penetration,
the following site preparation shall be carried out:
1) Remove all felled trees, stumps, logs or roots from the site.
2) Remove any concrete formwork, levelling pegs, timber off-cuts and other builder’s
debris from the area to be treated.
3) If the soil to be treated is sandy or porous, preliminary moistening will be required to
fill capillary spaces in the soil to prevent the loss of emulsion through piping or
excessive percolation.
4) In the event of water logging of foundation, the water shall be pumped out before
application of the chemical emulsion and it should be applied only when the soil is
absorbent.
5) On clays and other heavy soils where penetration is likely to be slow and on sloping
sites, where the treating solution is likely to run-off, the surface of the soil should be
scarified to a minimum depth of 75 mm.
6) All sub-floor levelling and grading shall be completed, all cuttings, trenches and
excavations shall be completed with backfilling in place. If this is not done,
supplementary treatments shall be carried out to complete the barrier.
At the time of application, the soil shall have sufficiently low moisture content to allow
uniform distribution of the treatment solution throughout the soil. Application of the
chemicals shall not be made during or immediately following heavy rains or when
conditions may cause runoff and create an environmental hazard.
13.12.5 Application
The Contractor shall apply termiticide to the soil material which will be covered by or lie
immediately adjacent to the buildings and structures to provide a protective barrier against
subterranean termites.
The termiticide shall be applied as a coarse spray and in such manner as to provide
uniform distribution onto the soil surface. This treatment shall be applied prior to placement
of a vapour barrier or waterproof membrane and prior to concrete pouring. Where treated
soil or fill material is not to be covered with a vapour barrier or waterproof membrane, the
Contractor shall exercise adequate precautions to prevent its disturbance.
The chemical emulsion will be applied uniformly by sprayers at the prescribed rates as
detailed below in all the stages of the treatment.
13.12.5.1 Treatment in Foundation Trenches
In case of normal wall load bearing structures, column pits, wall trenches and basements,
the treatment shall be at 5 l/m2 of surface area of the bottom and sides to a height of at
least 300 mm. After the foundation work, the sides shall be treated at 7.5 l/m 2 of vertical
surface of substructure on each side. After the earth filling is completed, treatment shall

be by rodding the earth at 150 mm centres close to the wall surface and spraying the
chemical at a rate of 7.5 l/m2.
In the case of framed structures, the treatment shall start at a depth of 500 mm below
ground level. From this depth the backfill around the columns, beams and RCC basement
walls shall be treated at a rate of 7.5 l/m2 for the vertical surface and at 5 l/m2 for horizontal
surfaces at the bottom of trenches/pits.
The top surface of filled earth within plinth walls shall be treated with chemical emulsion at
the rate of 5 l/m2 of the surface area before sub-base to floor is laid. If filled earth has been
well rammed and the surface does not allow the emulsion to seep through, holes up to 50
to 75 mm deep at 150 mm centres both ways shall be made with crow bars on the surface
to facilitate saturation of the soil with the emulsion.
13.12.5.2 Treatment at Junction of Walls and Floors
Special care shall be taken to establish continuity of the vertical chemical barrier on the
inner wall surfaces from the finished ground level (or from level where the treatment has
stopped) up to the level of the filled earth surface. To achieved this, a small channel 30 x
30 mm shall be made at all the junctions of wall/column with the floor (before laying sub-
grade) and rod holes made in the channel up to the finished ground level at 150 mm
spacings and the iron rod moved backward and forward to break the earth and the
chemical emulsion shall be poured along the channel at 7.5 l/ l/m2 of the vertical
wall/column surfaces to soak the soil right up to the bottom. The soil shall be tamped back
into place after this operation.
13.12.5.3 Treatment for Expansion Joints
The soil beneath expansion joints shall be supplemented by treating through the
expansion joint after sub-grade has been laid at the rate of 2 l/m length of expansion joint.
Utmost care shall be taken to ensure that the chemical barrier is complete and continuous.
Each part of the area shall receive the prescribed dosage of chemical emulsion.
The treatment should not be carried out when it is raining or when the soil is wet with rain
or sub-soil water.
The Contractor shall ensure that these chemicals do not enter water supply systems or
potable water supplies or aquifers and those they do not endanger plants and animals.
The Contractor shall notify the Engineer at least 48 hours prior to the beginning of
treatment and perform any formulating, mixing and application.
Once formed, the treated soil barrier shall not be disturbed. If treated soil barriers are
disturbed, immediate steps shall be taken to restore the continuity and completeness of
the barrier system.
If soil or fill material has been disturbed after treatment, the Contractor shall provide further
treatment before placement of slabs or other covering structures. Treatment of the soil on
the exterior sides of foundation walls, grade beams and similar structures shall be
coordinated with final grading and planting operations to avoid disturbance of the treated
barriers by such operations.

13.12.6 Safety Requirements
The manufacturer’s warnings and precautions in the handling and use of materials and the
manufacturer’s method of application shall be followed by the Contractor. Where the
manufacturer’s method differs from this document then the Contractor shall submit his
method statement to the Engineer for approval.
The Contractor shall formulate, treat and dispose of termiticides and their containers in
accordance with the manufacturer’s instructions. The Contractor shall draw water for
formulating only from sites as approved by the Engineer and fit the filling hose with a
backflow preventer meeting local plumbing codes or standards. The filling operation shall
be under the direct and continuous observation of a Contractor’s representative to prevent
overflow. Pesticides and related materials shall be kept secure under lock and key when
unattended. Proper protective clothing and equipment shall be worn and used during all
phases of termiticide application. Used pesticide containers shall be disposed of in
accordance with guidelines and to the satisfaction of the Engineer.
All the chemicals are poisonous and hazardous to health. These chemicals can have an
adverse effect upon health when absorbed through the skin, inhaled as vapours or spray
mist or swallowed. Persons handling or using these chemicals shall be instructed of these
dangers and advised that absorption through the skin is the most likely source of accidental
poisoning and cautioned to observe carefully, as a minimum, the safety precautions given
in this document and as recommended by the supplier, particularly when handling these
chemicals in the form of concentrates.
These chemicals are usually brought to the site in the form of emulsifiable concentrates.
The containers shall be clearly labelled and kept securely closed.
Particular care shall be taken to prevent skin contact with concentrates. Prolonged
exposure to dilute emulsions shall also be avoided. Workers shall wear clean clothing and
wash thoroughly with soap and water especially before eating and smoking. In the event
of severe contamination, clothing shall be removed at once and the skin washed with soap
and water. If chemicals splash into the eyes they shall be flushed with plenty of soap and
water and immediate medical attention sought.
The concentrates are oil solutions and present a fire hazard owing to the use of petroleum
solvents. There shall be no naked flames in the proximity during mixing.
Care should be taken in the application of chemicals/soil-toxicants to ensure that they are
not allowed to contaminate wells or springs.
13.12.7 Inspections
For the duration of the Contract, following the treatment, the Contractor shall perform
annual inspections of all buildings treated.
If during the inspections or at any other time, live subterranean termite infestation or
subterranean termite damage is discovered and the soil and building conditions have not
been altered in the interim, the Contractor shall:
1) Excavate the soil and perform other treatment as may be necessary for elimination of
subterranean termite infestation;
2) Repair damage caused by termite infestation; and
3) Re-inspect the building approximately 180 days after the additional treatment.

In the event of a reappearance of termites within the building area due to defective
materials or workmanship or due to any other reason, the Contractor will carry out the
necessary post construction treatment to keep the entire area free from termites once
again.
The Contractor shall maintain a Pest Management Maintenance Record, identifying target
pest, type of operation, brand name and manufacturer of pesticide, formulation,
concentration or rate of application used and submit copies of records when requested by
the Engineer.
13.13 Roads and Pavements
13.13.1 General
The construction and reinstatement of roads and parking areas shall be carried out in
accordance with the specifications for road works, Kerb stone and water table works of the
Municipal Corporation of PUNE.
13.13.2 Materials
13.13.2.1 General
All materials shall be obtained from local sources and shall be subject to approval by the
Engineer prior to use. Substitution of material shall be on an approved equivalent basis as
determined by the Engineer and shall result in finished roads as designated in this
specification. Material aggregates shall consist of natural or crushed stone, gravel or
sands, shall be of reasonably uniform quality throughout and shall be clean and free from
soft or decomposed particles, excess clay, foreign, organic or other deleterious matter.
13.13.2.2 Sub base
Coarse aggregate shall be crushed or broken stone and shall conform to the physical
requirement given in the following table.
Physical requirements of Crushed Stone for Road Work

Limiting Value
Sr. For aggregates to For aggregate to
Test
No. be used for Road be used for
base and surfacing sub-grade
1. Specific Gravity Not less than 2.6 Not less than 2.0
2. Water Absorption Not more than 2% Not more than 5%
3. Flakiness Index Maximum 25% ----
4. Elongation Index Maximum 40% ----
Aggregate Impact Value or
5. Not more than 30% Not more than 40%
Aggregate Crushing Value
6. Los Angeles Abrasion Value Not more than 30% Not more than 50%
7. Stripping Test Maximum 15% ----
Crushed or broken stone shall be hard, durable and free from an excess of flat, elongated,
soft and disintegrated particles, dirt and other objectionable matter.

Crushed or broken stone shall conform to the grading given in the following table.
Grading Requirements of Coarse Aggregates
Grading Percent by Weight

Size Range IS. Sieve Designations
No. passing the sieve
100 mm 100
80 mm 65 - 85
1. 90 mm to 40 mm 63 mm 25 - 60
40 mm 0 - 15
20 mm 0-5
80 mm 100
63 mm 90 - 100
2. 63 mm to 40 mm 50 mm 35 - 70
40 mm 0 - 15
20 mm 0-5
63 mm 100
50 mm 95 - 100
3. 50 mm to 20 mm 40 mm 35 - 70
20 mm 0 - 10
10 mm 0-5
13.13.2.3 Screenings
Screenings shall consist of predominantly non-plastic materials such as sandy gravelly

murum or gravel (other than rounded river borne material) with Liquid Limit and Plasticity
Index below 20 and 6 respectively and the fraction passing 75 micron sieve not exceeding
10%. The materials shall be sound and hard, of a quality not affected by weather and shall
be screened at the quarry and shall be free from all impurities. Any large lumps of murrum
shall be broken to pass gradation given in the above table. Gravel shall be composed of
large, coarse, siliceous grains, sharp and gritty to the touch, thoroughly free from dirt and
impurities.
Screenings shall conform to the grading indicated in the following table.
Grading for Screenings
Grading Size of IS Sieve Percent by Weight

Classification Screenings Designations passing the sieve
12.5 mm 100
10.0 mm 90 - 100
A 12.5 mm
4.75 mm 10 - 30
150 microns 0-8
10.00 mm 100
B 10.0 mm
4.75 mm 85 - 100

Grading Size of IS Sieve Percent by Weight

Classification Screenings Designations passing the sieve
150 microns 10 - 30
75 microns 0 - 10
13.13.2.4 Blinding Material
To fill in the voids in the coarse aggregates, any non-plastic material such as gravel/ grit/
sand/ brick powder may be used. The plasticity index of the material shall not exceed six.
13.13.2.5 Binder Material
The binder shall be straight run bitumen of grade S35 or S65 and shall conform to the
requirements specified in IS 73 and the following table.
Requirements of Bitumen Binder
Requirement for Method of

Sr. Grade
Characteristic Test
No. Reference to
S 35 S 65
1. Specific gravity at 27 C, Min. 0.99 0.99 IS : 1202
2. Water prevent by weight, Max. 0.2 0.2 IS : 1211
Flash point, Pensky Martens closed IS : 1209
3. 175 175
type C, Min. (Method A)
4. Softening point, C 50 - 65 40 - 55 IS : 1205
Penetration, at 25 C, 100 g, 5 sec in
5. 30 - 40 60 - 70 IS : 1203
1/100 cm
6. Ductility at 20 C in cm, Min 50 75 IS : 1208
Loss on beating, percent by weight,
7.(a) 1 1 IS : 1212
Max.
Penetration of residue (expressed as
7.(b) 60 60 IS : 1203
percentage of item 5), Min
Matter soluble in carbon disulphide,
8. 99 99 IS : 1216
percent by weight, Min.
13.13.3 Setting Out
The Contractor shall provide all labour and materials such as lines, strings, pegs, nails,
bamboo, stones, mortar, concrete etc, required for setting out, establishing benchmarks
and giving profiles. The Contractor shall be responsible for maintaining the benchmarks,
profiles, alignments and other stakes and marks as long as they are required for the works.
The surface of the installed layers will be parallel and have the same grade as the designed
asphalt surface and all subsequent layers.

13.13.4 Earthworks for Roads
Profiles of road excavation shall be laid at 25 m intervals to conform to the required

alignment, sections, grades and side slopes and the lines of cuts shall be clearly marked.
The Contractor shall, on no account, excavate beyond the slopes or below the specified
grade on the drawings unless so directed by the Engineer in writing.
13.13.4.1 Preparation of Sub-grade
Immediately prior to the laying of the sub-base metal, the sub-grade shall be cleaned of
all foreign substances and vegetation etc. Any ruts or soft yielding patches that appear
shall be corrected and the sub-grade dressed off parallel to the finished profile. The
camber of sub-grade shall conform in shape to that of the finished road surface. Camber
boards shall be used to get the required section.
The prepared sub-grade shall be lightly sprinkled with water, if necessary, and rolled with
a power roller of 10-12 tonnes. The roller shall pass over the same area of the sub-grade
a minimum of five runs. Any undulations in the surface that develop due to rolling shall be
made good with approved earth and sub-grade re-rolled.
13.13.4.2 Granular Sub-base
A) Scope
This work shall consist of laying and compacting well-graded material on prepared sub-
grade in accordance with the requirements of these Specifications. The material shall
be laid in one or more layers as sub-base or lower sub-base and upper sub-base
(termed as sub-base hereinafter) as necessary according to lines, grades and cross-
sections shown on the Drawings or as directed by the Engineer.
B) Material Specification
The material to be used for the work shall be natural sand, Murrum, gravel, crushed
stone, or combination thereof depending upon the grading required. Materials like
crushed slag crushed concrete, brick metal and kankar may be allowed only with the
specific approval of the Engineer. The material shall be free from organic or other
deleterious constituents and conform to one of the three grading given in Table 1-1.
While the grading in Table 1-1 are in respect of close-graded granular sub-base
materials, one each for maximum particle size of 75 mm, 53 mm and 26.5 mm, the
corresponding grading for the coarse-graded materials for each of the three maximum
particle sizes are given at Table 1-2. The grading to be adopted for a project shall be
as specified in the Contract.
C) Physical Requirements
The material shall have a 10 percent fineness value of 50 KN or more (for sample in
soaked condition) when tested in compliance with BS:812 (Part III). The water
absorption value of the coarse aggregate shall be determined as per IS:2386 (Part 3);
if this value is greater than 2 percent, the soundness test shall be carried out on the
material delivered to site as per IS:383. For Grading II and III materials, the CBR shall
be determined at the density and moisture content likely to be developed in equilibrium

conditions which shall be taken as being the density relating to a uniform air voids
content of 5 per cent.
Table 13-2 Grading for Close-Graded Granular Sub-Base Materials
IS sieve Percent by weight passing the IS sieve

Designation Grade I Grading II Grading III
75.0 mm 100 - -
53.0 mm 80-100 100 -
26.5 mm 55-90 70-100 100
9.50 mm 35-65 50-80 65-95
4.75 mm 25-55 40-65 50-80
2.36 mm 20-40 30-50 40-65
0.425 mm 10-25 15-25 20-35
0.075 mm 3-10 3-10 3-10
CBR Value (Minimum) 30 25 20
Table 13-3 Grading for Coarse Graded Granular Sub-Base Materials
IS sieve Percent by weight passing the IS sieve

Designation Grade I Grading II Grading III
75.00 mm 100 - -
53.0 mm 100
26.5 mm 55-75 50-80 100
9.50 mm
4.75 mm 10-30 15-35 25-45
2.36 mm
0.425 mm
0.075 mm < 10 < 10 < 10
CBR Value (Minimum) 30 25 20
Note: The material passing 425 micron (0.425 mm) sieve for all the three grading when
tested according to IS:2720 (Part 5) shall have liquid limit and plasticity index not more
than 25 and 6 per cent respectively.
D) Strength of Sub-base
It shall be ensured prior to actual execution that the material to be used in the sub-
base satisfies the requirements of CBR and other physical requirements when
compacted and finished.
When directed by the Engineer, this shall be verified by performing CBR tests in the
laboratory as required on specimens remoulded at field dry density and moisture
content and any other tests for the “quality” of materials, as may be necessary.
E) Construction Specifications

i. Preparation of sub grade
Immediately prior to the laying of sub-base, the sub grade already finished shall be
prepared by removing all vegetation and other extraneous matter, lightly sprinkled
with water if necessary and rolled with two passes of 80-100 KN smooth wheeled
roller.
ii. Spreading and compacting
The sub-base material of grading specified in the Contract shall be spread on the
prepared sub grade with the help of mechanical grader, of adequate capacity, its
blade having hydraulic controls suitable for initial adjustment and for maintaining
the required slope and grade during the operation or other means as approved by
the Engineer.
When the sub-base materials consist of combination of materials mentioned in

section 2.70 mixing shall be done mechanically by the mix-in-place method.
Manual mixing shall be permitted only where the width of laying is not adequate for
mechanical operations, as in small-sized jobs. The equipment used for mix-in-
place construction shall be a rotavator or similar approved equipment capable of
mixing the material to the desired degree. If so desired by the Engineer, trial runs
with the equipment shall be carried out to establish its suitability for the work.
Moisture content of loose material shall be checked in accordance with IS:2720

(Part 2) and suitably adjusted by sprinkling additional water from a truck mounted
or trailer mounted water tank and suitable for applying water uniformly and at
controlled quantities to variable widths of surface or other means approved by the
Engineer so that, at the time of compaction, it is from 1 per cent above to 2 per
cent below the optimum moisture content corresponding to IS:2720 (Part 8). While
adding water, due allowance shall be made for evaporation losses. After water has
been added, the material shall be processed by mechanical or other approved
means like disc harrows, rotavator until the layer is uniformly wet.
Immediately thereafter, rolling shall start. If the thickness of the compacted layer
does not exceed 100 mm, a smooth wheeled roller of 80 to 100 KN weight may be
used. For a compacted single layer up to 225 mm. the compaction shall be done
with the help of vibratory roller of minimum 80 to 100 KN static weights with plain
drum or pad foot drum or heavy pneumatic typed roller of minimum 200 to 300 KN
weight having a minimum tyre pressure of 0.7 MN/m2 or equivalent capacity roller
capable of achieving the required compaction. Rolling shall commence at the lower
edge and proceed towards the upper edge longitudinally for portions having
unidirectional cross fall (camber) and super elevation and shall commence at the
edges and progress towards the centre for portions having cross fall (camber) on
both sides.
Each pass of the roller shall uniformly overlap not less than one-third of the track
made in the preceding pass. During rolling, the grade and cross fall (camber) shall
be checked and any high spots or depressions which become apparent, corrected
by removing or adding fresh material. The speed of the roller shall not exceed 5
km per hour.
Rolling shall be continued till the density achieved is at least 98 per cent of the
maximum dry density for the material determined as per IS:2720 (Part 8). The

surface of any layer of material on completion of compaction shall be well closed,

free from movement under compaction equipment and from compaction planes,
ridges, cracks or loose material. All loose, segregated or otherwise defective areas
shall be made good to the full thickness of layer and re-compacted.
iii. Surface Finish and Quality Control of Work
The surface finish of construction shall conform to the requirements of Section 902
of MORTH Specifications for Road and Bridge Works (IV Revision).
Control on the quality of materials and works shall be exercised by the Engineer in
accordance with Section 900 of MORT Specifications for Road and Bridge Works
(IV Revision).
iv. Arrangement for Traffic
During the period of construction, the arrangement of traffic shall be done

accordingly, by providing proper diversions as per the directives of Engineer.
13.13.4.3 Wet Mix Macadam (WMM) Sub Base
Providing and laying WMM (Wet Mix Macadam) Sub-base / base for required depth with
black stone metal, size specified in detailed specification on sub base. Metal shall be mixed
by approved mixing plant of suitable capacity having provision for controlled addition of
water and forced / positive mixing arrangement like pug mill or pan type mixer of concrete
batching plant, laying and spreading with mechanical spreader for required consolidated
depth. Including rolling with 8 / 10 MT power roller to required slope and camber, etc.
complete as per instruction of Engineer.
A) Scope
This work shall consist of laying and compacting clean, crushed, graded aggregate and
granular material, premixed with water to a dense mass on a prepared sub-grade /sub-
base / base or existing pavement as the case may be in accordance with the requirements
of these specifications. The material shall be laid in one or more layers as necessary to
lines, grades and cross-sections shown on the approved drawings or as directed by the
Engineer.
The thickness of a single compacted Wet Mix Macadam layer shall not be less than 75
mm. When vibrating or other approved types of compacting equipment are used, the
compacted depth of a single layer of the sub-base course may be increased to 200 mm
upon approval of the Engineer.
B) Materials Specification
i. Aggregates Physical requirements
Coarse aggregates shall be crushed stone. If crushed gravel / shingle are used,
not less than 90 percent by weight of the gravel / shingle pieces retained on 5.75
mm sieve shall have at least two fractured faces. The aggregates shall conform to
the physical requirements set forth in Table
Table 13-4 Physical Requirements of Coarse Aggregates for Wet Mix Macadam for
Sub-Base / Base Courses

Test Test Method Requirements

1. *Los Angeles Abrasion value IS : 2386 (Part-4) 40 percent (Max)
OR
*Aggregate Impact value IS: 2386 (Part-4) or IS : 5640 30 percent (Max)
2. Combines Flakiness and IS : 2386 (Part-1) 30 percent (Max)
Elongation Indices (Total)
* Aggregate may satisfy requirements of either of the two tests.
If the water absorption value of the coarse aggregate is greater than 2 per cent, the
soundness test shall be carried out on the material delivered to site as per IS: 2386 (Part-
5)
ii. Grading requirements:
The aggregates shall conform to the grading given in Table
Table 13-5 Grading Requirements of Aggregates for Wet Mix Macadam
IS Sieve Designation Per cent by weight passing the IS sieve

53.00 mm 100
45.00 mm 95-100
26.50 mm --
22.40 mm 60-80
11.20 mm 40-60
5.75 mm 25-40
2.36 mm 15-30
600.00 micron 8-22
75.00 micron 0-8
Materials finer than 425 micron shall have Plasticity Index (PI) not exceeding 6.
The final gradation approved within these limits shall be well graded from coarse to fine
and shall not vary from the low limit on one sieve to the high limit on the adjacent sieve or
vice versa.
Table 13-6 Frequency of tests for Subgrade GSB and WMM
Type of
Section Test Spec. Limits Frequency (min.)
Construction
1.4.1 Sub Grade Sand content - 2 tests / 3000 m3
Plasticity Index test - 2 tests / 3000 m3
Density of 97% 2 tests / 3000 m3
Compacted Layer

Type of
Section Test Spec. Limits Frequency (min.)
Construction
Deleterious content - Once per source
test
Moisture content - 1 /250 cum

test
C.B.R. test As specified in 1 / 3000 cum
RFP
1.4.2 Granular sub Gradation MORTH Table 1 /200 cum
base no.400.1,
grading–I
Atterberg Limit PI - < 6%, LL - 1 /200 cum
<25%
Moisture Content +1%, -2% of the 1 /250 cum
Prior to compaction OMC
Density of 97% 1 /500 cum
compacted layer
Water absorption of 2%, if water Initially one set of
aggregate absorption more 3 representative
than 2% do specimen for each
soundness test source of supply
as below subsequently
when warranted
by changes in the
quality of
aggregates
Soundness Max.12% Initially one set of
(Magnesium & Max.18% 3 representative
Sodium Sulphate) specimen for each
source of supply
subsequently
when warranted
by changes in the
quality of
aggregates
1.4.3 Wet Mix Aggregate Impact Max 30% Max
Macadam value Los Angeles 40%
abrasion value
Quality of LL max – 20%, Once per source
Screening Material PI – Max – 6%
Shape and Size As per tech. Once per source
spec.
Grading 1 test per 200 cum
C) Construction Specifications

1) Preparation of base
As per clause MoSRT&H specification.
2) Provision of lateral confinement of aggregates
While constructing wet mix macadam, arrangement shall be made for the lateral
confinement of wet mix. This shall be done by laying materials in adjoining
shoulders along with that of wet mix macadam layer and following the sequence of
operations described in Clause of MoSRT&H Specification.
3) Preparation of Mix:
Wet Mix Macadam shall be prepared in an approved mixing plant of suitable

capacity having provision for controlled addition of water and forced / positive
mixing arrangement like pugmill or pan type mixer of concrete batching plant.
Optimum moisture for mixing shall be determined in accordance with IS:2720 (Part-
8) after replacing the aggregate fraction retained on 22.4 mm sieve with material
of 5.75 mm to 22.4 mm size. While adding water, due allowance should be made
for evaporation losses. However, at the time of compaction, water in the wet mix
should not vary from the optimum value by more than agreed limits. The mixed
material should be uniformly wet and no segregation should be permitted.
4) Spreading of Mix:
Immediately after mixing, the aggregates shall be spread uniformly and evenly
upon the prepared sub grade / sub-base / base in requirement quantities. In no
case should these be dumped in heaps directly on the area where these are to be
laid nor shall their hauling over a partly completed stretch be permitted.
The mix may be spread either by a pavers finisher or motor grader. For portions
where mechanical means cannot be used, manual means as approved by the
Engineer shall be used. The motor grader shall be capable of spreading the
material uniformly all over the surface. Its blade shall have hydraulic control
suitable for initial adjustments and maintaining the same so as to achieve the
specified slope and grade.
The paver finisher shall be self-propelled, having the following features: Loading
hoppers and suitable distribution mechanism.
The screed shall have tamping and vibrating arrangement for initial compaction to
the layer as it is spread without rutting or otherwise marring the surface profile.
The paver shall be equipped with necessary control mechanism so as to ensure

that the finished surface is free from blemishes.
The surface of the aggregate shall be carefully checked with templates and all high
or low spots remedies by removing or adding aggregate as may be required. The
layer may be tested by depth blocks during construction. No segregation of larger
and fine particles should be allowed. The aggregates as spread should be of
uniform gradation with no pockets of fine materials.

5) Compaction
After the mix has been laid to the required thickness, grade and cross fall / camber
the same shall be uniformly compacted, to the full depth with suitable roller. If the
thickness of single compacted layer does not exceed 100 mm, a smooth wheel
roller of 80 to 100 KN weight may be used. For a compacted single layer upto 200
mm, the compaction shall be done with the help of vibratory roller of minimum static
weight of 80 to 100 KN or equivalent capacity roller. The speed of the roller shall
not exceed 5 Km/hr
In portions having unidirectional cross fall / super elevation, rolling shall commence
from the lower edge the progress gradually towards the upper edge. Thereafter,
roller should progress parallel to the centre line of the road, uniformly over-lapping
each preceding track by at least one third width until the entire surface has been
rolled. Alternate trips of the roller shall be terminated in stops at least 1 m away
from any preceding stop.
In portions in camber, rolling should begin at the edge with the roller running
forward and backward until the edges have been firmly compacted. The roller shall
then progress gradually towards the centre parallel to the centre line of the road
uniformly overlapping each of the preceding tracks by at least one- third width until
the entire surface has been rolled.
Any displacement occurring as a result of reversing of the direction of a roller or

from any other cause shall be corrected at once as specified and/or removed and
made good.
Along forms, kerbs, walls or other places not accessible to the roller, the mixture
shall be thoroughly compacted with mechanical tampers or a plate compactor. Skin
patching of an area without scarifying the surface to permit proper bonding of the
added material shall not be permitted.
Rolling should not be done when the sub grade is soft or yielding or when it causes
a wave-like motion in the sub-base/base course or sub grade. If irregularities
develop during rolling which exceed 12 mm when tested with a 3 meter straight
edge, the surface should be loosened and premixed material added or removed as
required before rolling again so as to achieve a uniform surface conforming to the
desired grade and cross fall. In no case should the use of unmixed material be
permitted to make up the depressions.
Rolling shall be continued till the density achieved is at least 98 per cent of the
maximum dry density for the material as determined by the method outlined in IS:
2720 (Part-8).
After completion, the surface of any finished layer shall be well-closed, free from
movement under compaction equipment or any compaction planes, ridges, cracks
and loose material. All loose, segregated or otherwise defective areas shall be
made good to the full thickness of the layer and re-compacted.
6) Setting and drying
After final compaction of wet mix macadam course, the road shall be allowed to
dry for 24 hours.

7) Opening to Traffic
Preferably no vehicular traffic of any kind should be allowed on the finished wet
mix macadam surface till it has dried and the wearing course laid.
8) Surface Finish and Quality Control of Work
Surface Evenness:
The surface finish of construction shall conform to the requirements of Clause of

MoSRT&H specification.
13.13.5 Quality Control
Control on the quality of materials and works shall be exercised by the Engineer in
accordance with Section 900 of MoSRT&H specification.
1) Rectification of Surface Irregularity
Where the surface irregularity of the wet mix macadam course exceeds the permissible
tolerances or where the course is otherwise defective due to sub grade soil getting
mixed with the aggregates, the full thickness of the layer shall be scarified over the
affected area, re-shaped with added premixed material or removed and replaced with
fresh premixed material as applicable and re-compacted in accordance with Clause of
MoSRT&H specification. The area treated in the aforesaid manner shall not be less
than 5 m long and 2 m wide. In no case shall depressions be filled up with unmixed
and un-graded material or fines.
2) Arrangement for traffic
During the period of construction, arrangement of traffic shall be done as per Clause
of MoSRT&H specification.
3) Construction Procedure
i. Preparation of Base
The base on which a tack coat is to be applied shall be prepared, shaped and
conditioned to the specific line, grade and cross section by repairing all potholes or
patches and ruts. The potholes shall be drained of water and cut to regular shape
with vertical sides. All loose and disintegrated materials shall be removed. The
potholes shall then be filled either with (i) coarse aggregate and screenings and
compacted with heavy hand rammers or approved mechanical tempers or (ii)
premixed chippings binders (bitumen grade S 35/ S 65) content of 3 percent by
weight of total mix, after painting the sides and bottom of the holes with a thin
application of bitumen, or a combination of both (i) and (ii) as approved by the
Engineer. The surface shall be thoroughly swept and scraped clean and free of
dust and other foreign matter.
ii. Application
The binder used for tack coat shall be bitumen of suitable penetration grade within
S35 to S65 conforming to IS: 73. The binder shall be heated to the temperature
appropriate to its grade and as approved by the Engineer. The binder shall be

sprayed on the prepared base at the rate of 1.0 kg/m2. The binder shall be applied
uniformly with the aid of either self propelled or towed bitumen pressure sprayer
with self heating arrangement and spraying nozzle arrangement capable of
spraying bitumen at the above specified rate and temperature to provide a uniform
unbroken spread of bitumen. The tack coat shall be applied just ahead of laying
asphalt macadam.
iii. Brushing
Prior to spreading of the asphalt surface, the water bound surface shall be swept
clean to remove blinding to expose the metal surface.
iv. Application of Macadam
The bituminous macadam shall be laid by mechanical compactor and finisher, the
final consolidation being by means of power roller weighing not less than 10 tonnes.
The finished surface shall not vary by more than 12.5 mm above or below the
designed level and the average thickness shall not be less than 65 mm after
consolidation. The grading, composition and characteristics of the bituminous
macadam shall be as follows:
Aggregate Grading
IS Sieve Designation Percentage passing

50 mm 100
40 mm 60 - 100
25 mm 30 – 70
20 mm 20 - 70
6.3 mm 10 - 20
2.36 mm 0–5
Bitumen (Grade S 65) Content: 3.7% to 4.3% by weight of total mix.
The bituminous macadam may be prepared in a hot mix plant or the bitumen may
be cut back with a suitable solvent so that the heated cut back bitumen may be
mixed with the aggregate. In either case mixing shall be carried out in a power
driven pugmill mixer and shall be continued until all the aggregate is coated.
The Contractor shall ensure that the installation temperature is adequate during
the rolling / compaction of asphalt.
v. Protection of Pavement
During the period between initial compaction of the coarse aggregate and
completion of the seal coat, the surface shall be protected from all traffic other than
that which is absolutely essential to its construction.
vi. Premixed Seal Coat
After the full grout has been rolled, the interstices shall be completely filled with
pre-coated grit of the following composition.

Aggregate Grading

6.3 mm 100
2.36 mm 70 - 100
600 micron 25 – 50
300 micron 0 - 10
Bitumen (Grade S 65) Content : 7% to 8% by weight of total mix.
The premixed seal coat may be prepared in a hot mix plant or the bitumen may be
cut back with a suitable solvent so that the heated cut back bitumen may be mixed
with the aggregate. In either case, mixing shall be carried out in a power driven
pugmill mixer and shall be continued until all the aggregate is coated.
The premixed seal must be brushed to fill in the interstices, additional material
being applied during rolling if found necessary. The quantity of premixed seal
required for this purpose shall be approximately 1.22 m3 per 100 m2.
vii. Liquid Seal
On the completion of consolidation, which may be assisted by opening the road to

traffic, a liquid seal coat of Grade 565 bitumen shall be applied at a temperature of
between 163O C to 191O C (325O F to 375O F) at the rate of 1.25 kg/m2. The
application of bitumen shall be immediately followed with a cover coat of clean dry
¼ cubical chippings at the rate of 1.22 m3 per 100 m2. The surface shall then be
rolled with a power roller weighing not less than 10 tonnes. The composition of this
seal coat shall be as follows :
Aggregate Grading

12.5 mm 100
10 mm 70 - 100
4.75 mm 20 – 40
2.36 mm 7 – 20
75 micron 0–4
Bitumen (Grade S 65) Content : 4.5% to 5% by weight of total mix.
viii. Quality Control
All works performed shall conform to the lines, grades, cross sections and
dimensions as specified or as approved by the Engineer subject to the permitted
tolerances described hereinafter.

These shall be reckoned with respect to the centreline of the carriageway as

specified. The edges of the carriageway as constructed and all other parallel
alignments shall be corrected within a tolerance of 20 mm.
The level of any point on the various surfaces after compaction shall comply with
the following :
Table 13-7 Surface Tolerance from the specified
Level
Sub-grade 25 mm
Sub- base 20 mm
Base-course 15 mm
Wearing course 10 mm
The negative tolerance for wearing course, shall not be permitted in conjunction
with the positive tolerance for the base course, if the thickness of the wearing
course is thereby reduced by more than 6 mm.
The longitudinal profile shall be checked with a 3.0 m long straight edge, along the
centreline of the road. The transverse profile shall be checked with a camber board
at intervals of 30m. Permitted tolerances are specified in the table below:
Permitted tolerances of surface regularity for pavement courses
Longitudinal profile
No. Type of construction (Maximum permissible undulation when
measured with a 3 m straight edge) (mm)
1. Sub-grade 18
2. Sub- base 18
3. Base-course 12
4. Asphalt macadam 10
Where the surface irregularity of the sub-grade and the various pavement courses
falls outside the specified tolerances, the Contractor shall rectify these in the
manner described below and to the satisfaction of the Engineer.
4) Treatment on Surface Irregularities
i. Sub-grade
Where the surface is high, it shall be trimmed and suitably compacted. Where it is
low, the deficiency shall be corrected by adding fresh material.
ii. Stabilised Sub-base
Where the surface is high, the same shall be suitably trimmed while taking care
that the material below is not disturbed due to this operation. Where the surface is
low, the same shall be corrected as described below.

When the time elapsed between detection of irregularity and the time of mixing is
less than two hours, the surface shall be scarified to a depth of 50 mm,
supplemented with freshly mixed material as necessary and re-compacted to the
relevant specification. When this time is more than two hours, the full depth of the
layer shall be removed from the pavement and replaced with fresh material to the
specification. In either case the area treated shall not be less than 5m long and 2m
wide.
Where the surface is high or low, the top 75 mm shall be scarified, reshaped with
added material as necessary and re-compacted. The area treated shall not be less
than 5m long and 2m wide.
iii. Bituminous Construction
For bituminous construction other than for a wearing course where the surface is
low, the deficiency shall be corrected by adding fresh material and compacting in
accordance with the specification. Where the surface is high, the full depth of the
layer shall be removed and replaced with fresh material and compacted to the
specification.
For wearing course where surface is high or low, the full depth of the layer shall be
removed and replaced with fresh material and compacted to specifications. In all
cases where removal and replacement of bituminous layer is involved, the area
treated shall not be less than 5m long and 2 m wide.
For ensuring the requisite quality of construction, the materials and works shall be
subjected to quality control test, as described hereinafter, by the Engineer. The
testing frequencies set- forth are the minimum required and the Engineer shall have
the authority to carry out tests as frequently as he may deem necessary to satisfy
himself that the materials and works comply with the appropriate specifications.
The tests and their frequency to be used for different materials and works shall be
as detailed in the following Table:
Sr. Type of
Test Frequency
No. construction
1. Sub-base i) Gradation 1 test per 2000 m²
ii) Plasticity As required
iii) Deleterious As required
Constituents
iv) CBR test As required
v) Moisture content 1 test per 250m²
prior to compaction
vi) Dry density 1 test per 500 m²
2. Water Bound i) Gradation 1 test per 1000 m²
Macadam
ii) Flakiness index 1 test per 2000 m²
iii) Plasticity of binding 1 test per 1000 m²

Sr. Type of
Test Frequency
No. construction
material
3. Bitumen Macadam i) Quality of binder As required
ii) Aggregate impact 1 test per 50 – 100 m² of
value aggregate
iii) Flakiness index 1 test per 50 - 100 m² of
aggregate
iv) Grading of Aggregates 2 tests per day plant, both
on the individual
constituents and mixed
aggregates from the dryer
(one at plant and one at
Municipal Lab)
v) Binder content Periodic subject to 2 tests
per day per plant
vi) Control of temp. of All regular close intervals
binder and aggregate
for mixing and of the
mix at the time of
laying and rolling
vii) Rate of spread of Regular control through
mixed material checks on layer thickness
4. Seal Coat i) Quality of binder As required
ii) Aggregate Impact 1 test per 2000 m²
Value
iii) Flakiness Index 1 test per 2000 m²
iv) Aggregate grading 2 tests per day
v) Temp. of application At regular close intervals
vi) Rate of spread 2 2 tests per day
materials
Where a specific procedure is not indicated for quality control tests in these
specifications, the same shall be carried out as per prevalent accepted engineering
practice and to the approval of the Engineer.
Control shall be exercised by taking at least one measurement of density for each
1000 m2 of compacted area or as required to yield the minimum number of test
results for evaluating a day’s work on a statistical basis. The determination of
density shall be in accordance with IS: 2720 (Part 28). Test locations shall be
chosen only through random sampling techniques. Control shall not be based on
the result of any one test but on the mean value of a set of 5 – 10 density
determinations. The number of tests in one set of measurements shall be five, as
long as it is felt that sufficient control over material and the method of compaction
is being exercised. If considerable variations are observed in individual density
results, the minimum number of tests in one set of measurement shall be increased

to ten. The acceptance of work shall be subject to the condition that the mean
standard deviation for any set of results is below 0.08 g/cc.
For earth work in shoulders and in the top 500 mm portion of an embankment below
the sub-grade, at lease one density measurement shall be taken for every 500
square metres of each set of measurements. In other respects the control shall be
similar as described earlier.
13.13.6 Slab Culvert
Where slab culverts are provided for cross drainage purposes, these shall conform to the
following specifications. The concrete works specifications for construction of RCC slab
and the rubble masonry specification for the supporting rubble walls are given in this
specification.
Two coats of grade S 35 bitumen shall be applied to the top of the bed concrete at the
point of contact with the RCC slab above.
On each side of un-coursed rubble walls supporting the slab culvert, a free draining backfill
of thickness 200 mm shall be provided. The material shall be granular, consisting of sound,
tough, durable particles of crushed or uncrushed gravel, crushed stone or brickbats which
will not become powdery under loads or in contact with water. The material shall be free
from soft, thin, elongated or laminated pieces and vegetation or other deleterious
substances. The material shall be graded and shall meet the grading requirements given
above.
Weep holes as required or as directed by the Engineer shall be provided in the masonry
to drain water from the backfilling. Weep holes shall be of PVC pipe in rubble walls with
M-10 concrete cushioning 75 mm thick. The weep holes shall extend through the full width
of the masonry at a spacing of 1.5 mm c/c and with a slope of 1 vertical to 20 horizontal
towards the draining face.
13.13.7 Stone Pavement
Hand cut rough/natural faced Shahabad stone shall be of the best quality and of suitable
thickness, size etc and shall be subject to the approval of the Engineer. The stone shall
be hard, sound, durable, tough, free from flaws, cracks, decay and weathering. The edges
shall be hand cut and dressed true and squares. The evenness of surfaces and edges of
the slabs shall not be marred by careless dressing or handling and no patching up shall
be allowed.
The under face may be left as required or rough dressed. Before taking up the work,
samples of stone slabs to be used and their dressing shall be subject to the approval of
the Engineer. The work shall be carried out strictly in accordance with the approved
samples.
In case of plinth protection or other pavements over a concrete sub base, the bedding shall
be of 12 mm thick 1:2 cement mortar
In case of pavement work for footpaths, approaches and other similar works, to be laid
directly over levelled and consolidated ground, the bedding shall be of 150 mm thick quarry
spoil and 60 mm thick stone grit or as otherwise approved by the Engineer.

The joints shall be pointed with 1:3 cement mortar and finished flush or with grooves as
approved. The joints shall be raked out uniformly to a depth of not less than 12 mm before
grouting and pointing the same.
The pavement work shall be kept well wetted for at least seven days.
When the bedding and joints have been completed, set and attained the required strength,
the surface shall be thoroughly cleaned and handed over free from any mortar stains, dust,
dirt etc.
13.13.8 Surface Water Drainage Systems
All surface storm water drains shall be constructed to the correct sizes and shapes as
required for a sustained storm of 100 mm per hour. The finished product shall be sound
and shall have smooth inside surfaces for optimum flow and be to the approval of the
Engineer.
i. Common Bricks
All common bricks shall be sound, hard, thoroughly baked, clean, of proper rectangular
size and give a clear ring when tapped. They shall comply with IS 2212. All bricks shall
be obtained from a manufacturer subject to the approval of the Engineer.
Testing of bricks shall be in accordance with IS 2212. Mortar shall be composed of one
part cement to three parts sand, mixed thoroughly on a clean watertight platform before
the appropriate amount of water is added. Mortar shall be used within one hour of
adding water to the mix and no softening or revival of mortar shall be permitted after
one hour of mixing.
ii. Plaster
Where specified, plaster shall be rendered 20 mm thick in cement mortar consisting of

one part cement to three parts sand. Plasticizer may be used with cement with the
approval of the Engineer.
As soon as the embankments or fill areas are completed in accordance with the
requirements of Sections 10 and 0 the Contractor shall set out the lines for road-side
and surface storm-water drains. The centre lines shall be marked with pegs at not more
than 30 metre intervals and at turning points and positions of manholes, with the lines
and levels of cut for drain laying clearly set out.
Surface drains shall be laid in trenches dug to the correct levels and alignment and
constructed to produce an even alignment and gradient. Over-excavation shall be
made good by selected fill well compacted and to the satisfaction of the Engineer.

13.14 Landscaping
13.14.1 Clearance
Clearance of large trees and structures shall include the removal of large trees, stumps
and structures or parts thereof lying within the site of the works as demarcated at the site.
13.14.2 Removal of Top Soil
All shrubs, vegetation and other plants shall be removed and cleared from the site and
disposed of.
Topsoil shall be carefully stripped and stored at a suitable location on the site, separate
from other excavated material. Excess topsoil and topsoil unsuitable for landscaping and
grassing shall be removed from the site and disposed of.
All debris and material unsuitable for re-use at the site shall be excavated to a depth of 30
cm shall be removed from the site.
13.14.3 Grading
Areas of exposed soil shall be graded, landscaped and planted to produce a neat and
attractive environment not subject to ponding.
Where required, areas shall be refilled to correct grade with selected suitable excavated
material from the site, or suitable material imported to the site. The quality and compaction
of such fill or embankments shall be in accordance with the requirements.
Backfilling and compaction shall be suitable for the final requirements at the given location.
As a minimum, backfilling shall include compacted hard-core to 300 mm below grade level
and granular fill or topsoil to grade as appropriate.
The Contractor shall, where necessary, refill and compact any existing pits, wells, existing
dry-wells or other areas where the levels are below the general finished grade.
13.14.4 Grassing and Landscaping
13.14.4.1 Landscaping:
1) In addition to top soiling, landscaping includes the supply, installation, laying-out and
stocking of flower beds and rockeries, planting of trees and shrubs and for the seeding
of lawns.
2) All parts of the site not covered by buildings or paving shall, as soon as practicable
after the completion of the earthworks, be covered with topsoil and sown with grass,
all as specified hereafter.
13.14.4.2 Top Soiling:
1) As far as practicable topsoil shall be obtained from material generated from

excavations and separately stored in temporary spoil tips as approved.
2) If, in the Engineer opinion the Contractor cannot reasonably obtain sufficient topsoil of
acceptable quality in this way, the Contractor shall if so approved by the Engineer
provide extra material from an approved source off the site.
3) Topsoil shall be evenly spread and trimmed over embankments and other areas to
appropriate slopes and grades. The depth after spreading and trimming shall be 300

mm, measured perpendicular to the surface. All clods and lumps shall be broken up
and any rubbish large stones, roofs and weeds shall be removed.
13.14.4.3 Grassing:
1) Areas to be grassed and which have been covered with 300 mm of topsoil shall be
sown with an approved species of grass seed suitable for local conditions.
2) The Contractor shall be responsible for maintaining all landscaped areas including
grassed areas, flower beds, rockeries, trees and shrubs in good condition throughout
the Contract including all watering, rolling, fertilizing, weeding, cutting and re-sowing
as necessary.
13.14.5 Fencing
Mild steel posts and struts shall be free from rust, scale, cracks, twists and other defects
and shall be fabricated to the required shape and size out of the suitably sized sections.
The posts and struts shall have split ends for proper fixing and shall be embedded in
cement concrete of mix 1:3:6. The exposed surfaces of the posts and struts shall be
painted with two coats of synthetic enamel paint of approved make and shade over a coat
of approved primer.
Reinforced concrete posts and struts shall be of a standard size and be cast in suitable
bases in cement concrete 1:2:4 mix and shall have appropriate reinforcement and
dimensions. The posts and struts shall be free from honeycombing, cracks and other
defects.
After casting, the posts/struts shall be cured for a minimum period of 7 days without being
moved. After 7 days curing the posts/struts shall be moved to a levelled area and stacked
for 14 days of further curing. After 21 days of curing, the posts/struts may be transported
for fixing in position.
Posts shall be installed at 3 m. centres unless otherwise specified or as approved by the

Engineer, to suit the dimensions of the area to be fenced. Every 10th post, last but one
end posts, corner posts and posts where the level of fencing changes in steps and end
post when the fencing changes its direction shall be strutted on both sides, or as approved
by the Engineer. End posts where barbed wire fencing is discontinued shall be strutted on
one side only.
Pits of size 45 x 45 x 45 cm. deep, shall first be excavated centrally in the direction of the
proposed fencing work, true to line and level to receive the posts. For struts, the pits shall
be excavated to receive a minimum of 15 cm concrete cover at any point to suit its
inclination.
The pits shall be filled with a 15 cm layer of cement concrete of 1:2:4 mix. The posts and
struts shall then be placed in the pits to the required height above ground level and held
true to line, plumb and position by providing adequate temporary supports and then filled
with cement concrete so that the posts are embedded. The concrete in foundation shall
be watered for at least seven days to ensure proper curing.
Barbed wire shall conform to IS 278-1978.
The chain link shall be plastic coated galvanised mild steel of approved manufacture and
colour and of appropriate size, gauge etc. The base materials of the wire shall be of good

commercial quality mild steel. The wire shall be circular in section, free from rust, scale,
cuts, welds and other defects and shall be uniformly galvanised.
The chain link fencing shall be fixed first to the end post with the approved GI U type
clamps threaded at both ends and GI nuts, bolts and washers and with a 6 mm diameter
full height galvanised anchor bar. After fixing the chain link at the end post, it shall be
stretched tightly and fixed to the next posts sequentially using the clamps and bars etc
leaving 50 mm ground clearance, if soil, or 20 mm if surfaced. At points of change in the
level of the fencing, the necessary links shall be adjusted suitably as per the
manufacturers’ recommendations.
All steel work, pipe frame work and crimp net shall be galvanised and of suitable sizes and
sections and shall conform to relevant IS specifications. The crimp net shall be minimum
25 x 25 mm x 8 g unless otherwise stated and of approved manufacturer.
For each leaf of the gate, the crimp net shall be welded to an internal angle iron frame of
suitable size. The iron frame shall then be fixed to the 50 mm dia seamless pipe outer
frame of by means of 65 mm long angle iron lugs welded together. Suitable cleats for the
locking arrangement shall be welded at a convenient height. Both the leaves of the gates
shall be fitted with suitable hinges provided on the galvanised mild steel channel posts.
The side post shall be welded with mild steel plates 250 x 150 x 5 mm at the bottom. These
posts shall be properly embedded in cement concrete foundations of suitable sizes and
be allowed to set properly. All the assembly shall be properly erected correct to line, level,
plumb and allow easy and proper movement of the gates.
The steel parts shall be thoroughly cleaned and painted with red oxide primer of approved
make and shade. Final painting with two coats of synthetic enamel paints of approved
shade and make shall be carried out to the approval of the Engineer.
13.15 Piping Works
13.15.1 Definitions
This section of the specification refers to buried pipes that are not in chambers or buildings.
Pipes that are above ground, in chambers and buildings are covered by the relevant
clauses in Volume 2 the General Mechanical Specification.
The following terms shall have the meanings hereby assigned to them except where the
context clearly renders these meanings inapplicable:
Term Definition
Pipes Pipes, bends, junctions and other specials including jointing parts
Valves Valves, air valves, hydrants, metering devices and the like and
includes jointing parts, operating gear, and associated fittings.
These items are covered in the Mechanical Specification.
Manholes Manholes, discharge chambers and inspection chambers on gravity
pipelines including pre-cast concrete manhole sections, access
covers and other fittings.
Installation Handling, placing and fixing in position ready for jointing pipes and
fittings within a trench.
Pipeline All items additional to pipes, required to complete a pipeline
appurtenances including, where relevant, internal and external protection systems,

supports and anchorages, washouts, vent columns and marker

posts.
Pressure pipelines Pipelines for the conveyance of liquid under pressure, normally by
pumping.
Gravity pipelines Non-pressure pipelines for drainage and for the conveyance of
liquids, inclusive of pipes, manholes and pipeline appurtenances.
13.15.2 Pipework Design
The pipework shall be laid out and designed to facilitate the installation and to give a
constant and uniform flow of working fluid with a reasonable minimum of head loss.
Flexible spigot and socket type joints shall be provided except where otherwise necessary
to facilitate removal of Plant. Wherever necessary, flexible joints shall be provided with tie
bolts or other means to transfer longitudinal thrust along the pipework as a whole.
Standard fittings shall be used in preference to fabricated or special fittings.
Facilities shall be provided for draining down 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 30 minutes.
Flanges shall conform to IS 13159 and be drilled in accordance with the appropriate
pressure rating. Where a pipe passes through a wall or is subject to thrust it shall
incorporate a thrust flange which shall conform to the dimensions stated in IS 13159 but
remain undrilled.
13.15.3 Materials and Equipment
13.15.3.1 General
The installed pipes and their joints shall be resistant to the corrosive effects of the fluid
being carried and the ground conditions in which they are placed.
Pipes shall be solid walled concrete, PVC-U, GRP, glazed vitrified clay, ductile iron, steel
or PE according to the duty required. Structured wall PVC-U pipe shall not be permitted.
The particular type, size, class and jointing system of pipes and fittings for each part of the
Works shall be as specified below or as approved by the Engineer.
Pipeline materials shall be capable of withstanding all the loads and pressures to which
they will be subjected. The Contractor shall consider compatibility with existing networks
and other operational considerations. Structural design shall be carried out based on soil
classifications and operating conditions such as internal pressures and external loads both
temporary and permanent.
Ductile iron pipes shall be cement mortar lined and steel pipes shall be lined with either
cement mortar or epoxy as detailed below.
Water and sewerage network materials (pipes, fittings, valves etc) must support loads
coming from earth weight, traffic or other special forces, as well maximum pressures that
can arise during service.

All materials in contact with potable water shall be approved for use in drinking water
supply systems.
13.15.3.2 Fabrication Tolerance
Tolerances for straight pipes and fittings shall conform to IS 3589.
i. Straightness
Finished pipe sections shall be truly straight with walls parallel to the axis of the pipe
and shall not be out of the alignment by more than 5 mm for every 3m of length.
ii. Length
Straight pipe shall not vary from the specified overall length or effective length by more
than plus or minus 1.0 percent; where exact or cut lengths are specified the tolerance
on length shall not exceed plus 15 mm or minus 10 mm
iii. Circumference
The outside circumference of the pipe shall not vary by more than 0.5 percent.
iv. Outside Diameter
The outside diameter of a pipe of nominal diameter of over 500 mm shall not vary by
plus or minus 0.5 percent.
The diameter of plain end of a pipe of nominal diameter over 500 mm shall not vary by
more than plus or minus 0.5 percent. Notwithstanding these tolerances and the surface
irregularities permitted, any dimensional variation or surface irregularity which permits
leakage past the joints shall be cause for rejection.
13.15.3.3 Concrete Pipes
All concrete pipes and fittings shall comply with IS 458.
The concrete shall be in accordance with Section 17 of this document.
Installation and testing of RCC pipes shall be in accordance with IS 783.
1) Concrete Pipes (pressure)
Non-circular concrete pipes shall not be used in pressure situations.
Higher pressure pipes shall be produced using a double layer of pre-stressing wires,
with each layer wound over a thin layer of concrete and then covered by another layer.
13.15.3.4 Un-plasticised Polyvinyl Chloride (PVC-U) Pipes
PVC-U pipes shall comply with IS 15328.
PVC-U pipes used for potable water shall not contain any matter which could impart taste,
odour, and toxicity or be harmful to health or adversely affect the water conveyed.

Unless specified otherwise, joints shall be of the flanged solvent or push fit type complying
with IS 15328 having an elastomeric sealing ring. Joints shall be made in accordance with
the manufacturer's instructions.
Fittings shall be injection moulded in PVC-U to the requirements of IS 15328. Fabricated

PVC-U fittings or fittings manufactured in other materials will only be permitted when the
material and method of manufacture are approved by the Engineer.
13.15.3.5 High Performance Polyethylene Pipes
All high performance polyethylene pipes (PE 100) shall comply with IS 7634.
The minimum pressure rating for pipes and fittings shall be 10 bar.
The density of the base polymer shall be determined on specimens prepared and tested
in accordance with IS 7634.
The internal and external surfaces of the pipe shall be smooth, clean and free from
grooving and other defects which might impair its functional properties. The pipe ends shall
be cleanly cut square with the axis and free from deformity. The pipe shall be
homogeneous throughout and uniform in colour, opacity, density and other physical
properties.
The pipe shall be delivered in the longest lengths practicable to keep site jointing to a
minimum.
13.15.3.6 Glass-fibre Reinforced Plastic (GRP) Pipes
Except where otherwise specified, glass-fibre reinforced plastic pipes and fittings shall be
in accordance with IS 14402. Pipes shall have dense, void-free walls and be manufactured
using the centrifugally-spun or externally-wound filament method.
The materials used in the manufacture of the pipes shall be resistant to abrasion and to
chemical and biological attack and shall not react with or be soluble in the liquid being
conveyed, or the surrounding ground or groundwater, within the temperature range to
which they are exposed. The composition of the pipe materials shall be such as to avoid
deterioration during transport or storage due to ultra-violet radiation.
All pressure pipes shall be tested at the manufacturer’s works to the pressures required
by the Employer’s Requirements and in accordance with IS 14402.
13.15.3.7 Polypropylene Pipework
Polypropylene pipework shall comply with IS 15801.
13.15.3.8 Ductile Iron Pipework
i. General
Ductile iron pipes and fittings shall generally comply with IS 1729, IS 8329 and IS 9523.
Except where indicated otherwise, all socket and spigot pipes and fittings and flanged
pipes and fittings shall be to the standard class designation. Socket and spigot pipes
and fittings shall be suitable for Tyton or Stantyte type joints or, where required, for
Viking Johnson type couplings. Flanges shall be PN 16.

Tests on pipes and fittings shall be carried out in accordance with the requirements of
the Ductile Iron Pressure Pipes and Ductile Iron Fittings for Pressure Pipes for Water,
Gas and Sewage (Quality Control) Order 2006 and IS 8329 and IS 9523.
ii. Gaskets and Sealing Rings
Gaskets and sealing rings for buried flexible joints shall comply with IS 5382, AWWA
C111/A21.11, of Styrene Butadiene Rubber (SBR).
The joints shall be flexible and sealed with elastomeric seals or flexible gaskets and
shall withstand the various tests specified for the appropriate class of pipe. Joints and
materials shall comply with BS EN 545 and EN 681-1.
The seals shall be capable of withstanding the permissible deflections claimed by the
manufacturer for the joint subject to a minimum deflection as per BS EN 545 or ISO
2531 depending on the manufacturing standard of the Supplier.
The Contractor shall provide an adequate supply of jointing lubricant suitable for use
with the jointing materials supplied. The supplier shall provide certification to confirm
that the lubricant will be non- injurious to public health when in continuous contact with
potable water.
The joint gaskets and rings shall be suitable for use in the prevailing climate, soil
conditions, transported water and ground water conditions.
A nominal additional quantity of spare jointing materials for pipes and fittings equivalent
to 5% of the nominal requirement for such materials based on the pipes and fittings
specified in the Contract.
iii. Linings
All ductile iron pipes and fittings, unless otherwise indicated, shall be cement motor
lined employing sulphate resisting cement to IS 12330 and shall comply with the
requirements of IS 8329 and IS 9523. A minimum thickness of 5 mm shall be applied.
iv. Coatings
Factory-applied coatings shall be in accordance with IS 8329 suitable for tropical

climates and applied in accordance with the manufacturer’s instructions. The external
zinc spray and bituminous finishing this shall be in accordance with IS 8329.
Factory-applied and site-applied polyethylene sleeving shall be in accordance with IS

8329.
Bituminous coatings shall comply with IS 8329.
Buried pipes shall have an external zinc spray coating below the bituminous coat.

Damaged areas of coating shall be repainted on site after removing any remaining
loose coating and wire brushing any rusted areas of pipe.
v. Sleeving
Where polythene sleeving is specified to be applied in addition to bitumen coating, the

sleeving shall be heavy duty black polythene of not less than 0.25 mm thickness.
Tubular polyethylene film for use as a loose protective sleeving for buried iron pipes
and fittings shall comply with the relevant provisions of IS 8329, except that the nominal
layflat width shall be 280 mm for use with 80 mm and 100 mm nominal internal
diameter pipelines incorporating push-in flexible joints and 400 mm for 150 mm
nominal internal diameter pipelines.
Sleeving shall be stored under cover, out of direct sunlight and its exposure to sunlight
during pipe laying shall be kept to a minimum.
Sleeving shall be drawn over the pipes during pipe laying. The sleeves over successive
pipes shall be carefully lapped and the surplus material folded over the top of the pipe.
Ends and overlaps shall be sealed and secured with nylon packaging tape or other
approved grease or bitumen impregnated, rubberised or other tape.
Sleeving for pipes for below ground use for potable water shall be coloured blue and
all other sleeving black. Joints in sleeving shall be taped to form a continuous barrier
and any damage to the sleeving shall be repaired prior to backfilling.
13.15.4 Steel Pipework
i. General
Steel pipes, fittings and joints shall conform to IS 3589 and IS 6631.
Pipes and specials shall be manufactured from seamless or welded carbon steel pipes
made from materials with mechanical properties and weldability at least equivalent to
those required by IS 3589.
The pipe thickness shall be suitable to comply with the required normal working
pressure. Suitable thicknesses and recommended test pressures are given in IS 3589
for pipes up to 2,540 mm outside diameter.
All pipework and fittings shall be new and entirely fabricated and corrosion protected
at the maker's works.
Steel pipelines shall have at least:-
i) an external coating comprising 3 layers: fusion bonded epoxy, fusion bonded

epoxy adhesive primer and 3 mm of hot applied polyethylene or polypropylene
ii) Additional external protection for regions of contaminated / aggressive ground
iii) Additional wall thickness and external protection for any tunnel sections and pipe
bridges.
iv) an internal coating comprising a minimum of 500 microns of fusion bonded epoxy
e. a cathodic protection system
v) an effective means of repair to the internal coating subsequent to welding
vi) an effective means to repairing external coating using heat shrink sleeving/
wrapping with an overlap onto undamaged external protection of at least 150 mm

The Contractor shall prepare a method statement for repair of the pipeline specific to the
chosen range of pipe materials, diameters, coating systems and pipe depths.
ii. Fusion Bonded Epoxy Coated Steel Pipe
All pipes and fittings shall be satisfactorily hydraulically pressure tested, prior to coating
at the manufacturer's works, to a pressure of 1.5 times the design pressure.
Prior to coating, the pipes shall be degreased, blast cleaned to IS 3589 and if seam
welded, the welds shall be ground smooth. Any grit or dust shall be removed by air
blast.
Before any visible surface corrosion has occurred, the pipes shall be heated to a
temperature not exceeding 245 °C and then epoxy powder applied inside and out
either by immersion in a fluidised bed or by spraying. The coating shall then be cured.
The coating material shall be a semi-flexible thermosetting dry powder fusion-bonded

amine-cured epoxy as approved by the Engineer.
The resulting coating shall have a minimum thickness of 0.3 mm. Spark testing shall
be employed to check for any imperfection and any defects found shall be repaired
using a compatible two-pack epoxy and the area re-tested.
In the event of a fusion-bonded epoxy coating being damaged after leaving the factory,
the item shall be returned to the factory for repair or be repaired at Site. Repairs shall
be effected in accordance with the following requirements:
1. repair materials shall be compatible with the original factory-applied coating
materials
2. the edges of the original factory-applied coating shall be ground off to a taper or
feather edge
3. exposed metal shall be treated
4. the relative humidity of the atmosphere in which the repair is to be effected shall
be maintained (if necessary, by the use of hot air blowers and tenting) at less than
85%
5. the surface temperature of the exposed metal shall be raised to at least 3°C above
dew point and the coating shall then be applied in stages, as recommended by the
manufacturer, to achieve a total thickness in accordance with Section 23.3.9(ii).
All repairs shall be checked with a holiday detector and any holidays shall be repaired,
after which the repairs shall be re-checked.
iii. Cathodic Protection
Cathodic protection (CP) shall be employed where steel pipes are used.
The Contractor shall propose an overall pipeline protection system relying on coatings
as the main corrosion protection mechanism. However, cathodic protection shall be
designed and installed by the Contractor to provide protection for the event that the
coating system is breached.
The Contractor shall submit his design proposals for review of the Engineer prior to the
commencement of pipe laying. Requirements for ensuring electrical continuity at joints
and flanges shall be clearly detailed along with all operation and maintenance
requirements.

13.15.4.1 Protective Cement Mortar Coating to External Surfaces (if required)
Where specified for steel pipeline to be laid underground, the external surfaces of pipes,
specials and fittings shall be provided with a minimum of 40 mm thick cement mortar
coating by guniting. A length of 150 mm at each end of the pipe shall be left un-coated to
facilitate site welding. This portion shall be lined after laying, welding and field testing of
the pipeline is completed satisfactorily.
Where the pipes/ specials are to be gunited externally or encased in concrete, the external
surface of the pipe shall be given a coat of cement wash. The pipe surface shall be blast
cleaned to the Engineer’s satisfaction. Immediately after the pipe/special is blast clean,
the Contractor shall commence coating of the surface with cement wash.
i. Mix Proportion
The proportion of cement and shall be 1: 3.5 by volume.
ii. Reinforcement
The welded fabric used shall be BRC fabric conforming to IS 1566 or equivalent MS
reinforcement. The welded fabric used shall be bent to proper shape to conform to the
surface of the pipe to be coated and shall be securely held 20 mm away from the
surface of the pipe by means of spacer blocks made from cement mortar (1:1) and
binding wire. Spacers shall be placed at least 30cm centre to centre both ways.
Adjacent sheets of fabric shall lap at least 80 mm and shall be securely fastened
together by binding wire at intervals not exceeding 300 mm
iii. Preparation for Surfaces
The interior surfaces of all pipes to be lined with Portland cement mortar shall be
thoroughly cleaned by sand or steel grit blasting.
iv. Hand Cleaning
Before blasting, all oil and grease on the surface of the metal shall be removed
thoroughly by flushing and wiping using suitable solvents and clean rags. The use of
dirty or oily rags will not be permitted. All other foreign materials shall be removed by
buffing or by scraping and wire brushing. After cleaning, the pipe shall be protected
and maintained free of all oil, grease and dirt that might fall upon the plate from
whatever source until the plate has received its cement mortar coating.
v. Mechanical Cleaning
All metal surfaces shall be thoroughly sandblasted to bright metal. Sandblasted

surfaces which acquire a coat of rust shall be reblasted. Adequate air separators shall
be used to remove all oil and free moisture effectively from the air supply to the blaster.
Any plate showing pits or structural defects shall be kept aside during examination.
vi. Rust Preventive Coating
Immediately upon completion of sandblasting, surfaces at the end of fittings which are
to be left bare shall be given a brush coat of a suitable rust preventive material. Rust
preventing coating shall be applied and shielded and maintained during the

subsequent application and curing of mortar lining and application of the exterior
coating to protect, from corrosion. Rust preventive material used shall be of such
character that the quality of the weld and other functions of the steel plate will not be
impaired by its presence.
vii. Application of Mortar Lining by Guniting
The compressor used shall be of an adequate capacity to maintain a pressure of at

least 2.8 kg/sq.cm at the gun end. The nozzle shall be held at such a distance (65 to
100 cm) and position that the stream of flowing materials shall impinge as nearly as
possible at right angles to the surface being gunited. All deposits of loose sand shall
be removed prior to placing any layer of gunite. Gunite shall be shot in one coat to the
specified thickness. Every precaution shall be taken to prevent the formation of sand
pockets and if any develop, they shall be cut out and replaced with satisfactory
machine placed material. No hand patching will be allowed. The Contractor shall apply
the coating in such manner that no sloughing shall occur at any time during or following
its application.
Gunite shall be placed in the top and sides of the pipe, then screeded to a uniform
thickness and the ground lines or blocks removed. All rebound and waste materials
shall then be removed by air blowing and gunite placed in the bottom of the fittings and
screeded. When completed, the lining shall be concentric with the barrel of an even
thickness. The entire surface shall then receive a final flash coat of gunite and shall be
steel trowelled to a true surface equal in smoothness to the spun lining in such a
manner not to impair the bond between mortar and steel plate. The guniting and
surface finishing shall complete in set and shall be applied continuously without the
fuse of construction joints. In case, for any reason whatsoever, the cement does not
adhere to the walls of pipes and sloughs off, swabbing the pipe with cement slurry shall
not be permitted.
If for any reason it is necessary to interrupt the placing of the gunite for a length of time
that will result in the material taking a permanent set, a square shoulder shall be formed
at the ends of the sections and or elsewhere by shooting against a backing up strip or
by cutting back with a trowel or other suitable tool the irregular edges of the material
last place to a clean unbroken surface perpendicular to the face that will provide a
suitable connection or construction joint between such material and the material to be
placed subsequently. When performing this work, care shall be taken not to shatter or
disturb the material remaining in place or disturb the embedded wire mesh. Before
placing fresh material against the surface of such joints, the joint shall be carefully
cleaned and wetted to ensure a good bond between the fresh material and that
previously applied. The joint shall be thoroughly wetted by sprinkling and maintained
in a moist condition.
The un-gunited portion at the ends of the pipe lengths left for the purpose of field
welding or bolting shall be encased with M15 concrete after the connection is made
and hydraulic testing is completed.
viii. Curing of Lining and Coatings
Immediately upon the completion of lining of special fittings, the fittings shall be closed
tightly at each end by bulkheads. After the mortar has set, but not later than twelve
hours after the application of the lining, curing shall be commenced by the water spray
method and continued thereafter for fourteen days. The water spray method shall
consist of sprinkling the mortar lining with water by means of sprinkled heads placed

within the barrel of fittings, of such capacity as to keep the entire surface of mortar
lining continuously wet throughout the entire period of curing.
The application of the exterior coating shall begin not less that seventy two hours after
the completion of interior lining but in any event, such water spray curing shall be
continued inside without interruption during the application of exterior coatings and
thereafter until the fitting is loaded for transportation to the trench, regardless of the
lapse of time after loading. Each fitting shall be closed at both ends during
transportation and storage and the Contractor shall continue the interior water
spraying. All the fittings will be laid within 24 hours after such water spray has been
discontinued.
The Contractor shall protect all cement mortar from damage during handling and
transportation. After the internal mortar has been cured, internal bracings shall be
placed at the ends of the fitting and elsewhere, if necessary, without damaging the
mortar lining to preserve the roundness of the barrel of the pipe. All such bracings,
except those that may interfere with the jointing operation, shall remain in position until
the fitting has been installed and back filled.
13.15.4.2 Cast iron Drainage Pipes and Fittings
Cast iron drainage pipes and fittings shall conform to IS 1538 or IS 1729 depending on
the application. Cast iron roof outlets shall be galvanised. Joints shall be caulked with
tarred hemp and sealed with mastic.
13.15.5 Pipe Fittings
i. Tees and Reducers
All welded tees, tees with flanged branch or all flanged tees shall be specifically
selected for the locations required.
Equal tees, reduced branch and invert level tees shall be selected to simplify site
installation and the number of site made joints required.
Reducers shall be concentric unless stated otherwise.
ii. Bends
The use of bends turning through angles greater than 45 degrees shall not be
permitted without the agreement of the Engineer.
Bends shall have the same, or better, internal and external protection as the relevant
pipe specification.
iii. Couplings and Flange Adaptors
Refer to Volume 2B, Mechanical Specification.
iv. Concrete Pipe Joints
Concrete pipe joints shall be either spigot and socket or sleeve joints. Joints shall be
sealed by elastomeric joint rings complying with IS 5382. Caulked joints shall not be
used.

13.15.6 Wrapping Material
Wrapping material, where required for the external protection of buried ferrous pipelines
and for site wrapping of completed joints or fittings shall be heavy duty, self-adhesive,
rubber-bitumen compound with PVC carrier strip together with primer and moulding putty.
The primer shall be a fast-drying bitumen solution type compatible with the wrapping
material and the pipeline materials including coatings to which it is to be applied.
The moulding putty shall be compatible with the wrapping materials and the primer and
shall be capable of being moulded cold by hand.
The wrapping material shall possess the following minimum physical characteristics:
1. Thickness (overall): 1.6 mm

2. Compound thickness 0.85 mm
3. PVC thickness 0.75 mm
4. Tensile strength: 12 N/mm
5. Elongation: 230 %
6. Tear resistance: 45 N
7. Impact resistance: 7 joules
8. Adhesion (180° peel): 2 N/mm
9. Dielectric strength (55% overlap): 20000 V minimum
10. Insulation resistance: 1000000 megohms
The materials shall be suitable for application in the environmental conditions at the site.
Wrapping for pipes shall be machine applied in controlled conditions. Tensile modulus of
the PVC shall suit the method of application.
13.15.7 Chambers and Manholes
13.15.7.1 General
All access covers or opening covers shall be 600 mm x 900 mm and be capable of safe
operation by one person and shall be fitted with locking devices and be secure against
vandalism.
A permanent marker on the top of a chamber roof shall clearly indicate the direction of
opening and closing of any isolation valves.
The requirements for anchors and thrust blocks in respect of excavation, backfilling and
forming shear keys in the concrete blinding for horizontal thrust blocks shall also apply to
valve chambers in which pipes are anchored.
If undisturbed ground has not been maintained next to a thrust bearing surface the gap
shall be backfilled with mass concrete.

All chambers and manholes shall be cleaned of any accumulation of silt, mortar, debris or
any other foreign matter and shall be free of any accumulation at the time of final
inspection.
13.15.8 Manholes on Gravity Pipelines
At each alteration of gradient or direction, changes in sewer size, at each intersection with
other sewers and at such other points as to comply with the Contractor’s requirements, a
manhole shall be constructed in accordance with the Engineer’s approval.
All manholes at the head of gravity sewers shall be vented.
Backfilling around manholes shall be carried out as construction proceeds. On no account

shall the concrete work be built up so far ahead of backfilling as to impede proper
compaction of the backfill material.
All manholes shall be watertight on completion. If any leaks appear in the manholes at the
inside joints they shall be sealed.
All chambers and manholes shall be cleaned of any accumulation of silt, mortar, debris or
any other foreign matter and shall be free of any accumulation at the time of final
inspection.
13.15.9 Pre-cast Concrete Manholes
Pre-cast concrete circular manhole sections and cover slabs shall be manufactured from
sulphate resisting cement.
All pre-cast cover slabs shall be heavy duty and shall be provided with 600 mm (minimum)
tapered opening over which the manhole cover will be set. The slabs shall be provided
with built-in lifting rings.
13.15.10Manhole Covers and Fittings
The covers and frames for all manholes shall conform to IS 1726 or IS 12592.
13.15.11Bricks
Where engineering brickwork is specified the bricks shall be in accordance with IS 2180.
All bricks shall be well-shaped, hard, sound, uniform in size and free from cracks and
flaking.
13.15.12Chemical Resistant Resin Mortar
i. General
The mortar shall be an intimate mixture of liquid resinous material and a setting agent
and may contain appropriately selected filler materials. When mixed these components
shall form a mortar, with a workability suitable for the proposed method of application
that subsequently hardens.
ii. Composition
The liquid resin shall be any solvent free resinous material capable of forming a
chemical resistant mortar when mixed with a suitable catalyst and, if required, a filler

material. The filler material if used, shall be compatible with the liquid resin, of the
chemical resistance required and of a size that will permit the preparation of a minimum
joint thickness of 3.0 mm. The mixed mortar shall not adversely affect or be affected
by other construction materials with which it will properly come into contact, including
fixtures and fittings.
iii. Colour
The colours of individual components of the chemical resistant resin mortar shall be
sufficiently different from each other that complete, homogeneous mixing of the
components will be apparent by visual inspection.
iv. Packaging
The components of the chemical resistant resin mortar shall be pre-measured and
packaged by the manufacturer in units sized to suit the method of application. All
packages shall be clearly marked as to size, contents, mixing instructions, safety
precautions, storage requirements and date of expiration of the contents.
v. Shelf Life
The unmixed components of the chemical resistant resin mortar shall have a minimum
shelf life after delivery to the site of 12 months when stored at a temperature between
5ºC and 50ºC.
vi. Pot life
Where it is proposed to apply the mortar by trowel, the working time after initial mixing
of the resin, filler material and hardener shall be a minimum of 60 minutes at a
temperature of 20ºC and 30 minutes at 50ºC. The pot life of the mortar shall be
considered exceeded when the mortar can no longer be applied to a prepared surface
without curling behind the trowel. If it is proposed to apply the mortar by some other
method (e.g. by gun), the working time after mixing shall be of a length suitable for the
proposed method of application. Mortar applied at any time during the pot life shall
have the specified properties when cured.
vii. Bond Strength
The chemical resistant resin mortar shall form a bond with brick, tile or concrete or with
a cured surface of itself, with a minimum strength subject to substrate cohesive
capacity, of 3 N/mm2. This bond strength shall be achieved regardless of whether the
mortar is applied to a dry, a damp or wet surface without priming or other form of
surface preparation. The bond strength shall be tested and measured using samples
of the actual construction materials.
viii. Compressive Strength
The chemical resistant resin mortar shall have a minimum compressive strength of 15
N/mm2 when tested and measured.
ix. Tensile Strength
The chemical resistant resin mortar shall have a minimum tensile strength of 5 N/mm2
when tested and measured.

x. Modulus of Elasticity
When tested and measured, the chemical resistant resin mortar shall have a maximum
elastic modulus of 9 kN/mm2.
xi. Chemical Resistance
The cured chemical resistant resin mortar shall be capable of resisting attack by any
constituents that may normally or occasionally be present in sewage or which may
form within the system by a combination of physical, chemical and biological reactions.
In particular, the mortar shall be capable of resisting attack from extended exposure to
sulphuric acid in concentrations up to 15%, oils, greases and petrol. The chemical
resistance of the mortar shall be tested and measured.
xii. Shrinkage
The chemical resistant resin mortar shall have a shrinkage not exceeding 0.5% when
tested and measured.
xiii. Absorption
The cured chemical resistant resin mortar shall have an absorption not exceeding
3.0%.
xiv. Thermal Compatibility
The cured chemical resistant resin mortar shall have properties of shrinkage and
thermal expansion to withstand prescribed tests.
13.15.13Coal Tar Epoxy Paint
Containers of epoxy paint shall be of a pack-size suitable for complete usage when
thoroughly mixed by one operator within the pot life of the material at the highest likely
ambient temperature. A mechanically operated mixer shall be used of a design which does
not entrain air in the paint. Except where otherwise specified, epoxy resin paints shall be
formulated so that the epoxy resin content together with its curing agent shall not be less
than 40% by weight of the solid binder.
The coal tar epoxy paint shall have the following properties as a minimum:
1. Pot life at 50 ºC 1 Hr
2. Touch free time 8 Hrs at 35 ºC
3. Initial cure 24 Hrs at 35 ºC
4. Final cure 96 Hrs at 35 ºC
5. Finished Film Thickness 300 microns per coat
13.15.14Granular Bedding and Surround Material
Material for granular bedding and surround shall be broken stone or irregular shaped
gravel with coarse sand and shall be inert to ground water, acids and sulphates. It shall

have a compaction fraction value of less than 0.15 and shall be nominal single size
complying to the following gradings:
1. Pipe Diameter Nominal Size
2. DN 100 10 mm
3. DN 150 10 or 14 mm
4. DN 200 – 300 10, 14 or 20 mm
5. DN 375 – 525 14 or 20 mm
6. DN 600 & above 14, 20 or 40 mm
The material shall be tested and shall have a 10% fines value greater than 50 kN. Material
retained on a 7 mm sieve shall have an index of flakiness less than 25% and an index of
elongation less than 45%.
Whenever necessary, the test for compaction shall be carried out on the material for
granular bedding.
13.15.15Geo-texile Fabric
Geotextile fabric shall be a pervious sheet of non-woven polyester, polyethylene, nylon, or

polypropylene filaments and formed into a uniform pattern. The material shall be resistant
to all naturally occurring acids and alkalis present in the soil and shall be resistant to
biological degradation. The fabric shall be strong enough to withstand stresses occurring
during placement and any subsequent pipe or soil movement.
The grade of the fabric shall be such that O95 (pore size) shall be smaller than D85 of the
native soil as established by the Particle Size Distribution Analysis.
The geotextile fabric shall have the following minimum properties when measured in
accordance with the reference standards:
Test Minimum Property Standard

Weight 125 g/m² IS 14716
Thickness under 2 kN/m2 load 4 mm IS 13162
CBR test 4750 N
Tensile Strength:
Longitudinal direction 22 kN/m
IS 15060
Transverse direction 36 kN/m
Elongation at rupture 50% - 80% IS 13162
Grab strength 1500 N IS 14293
Water permeability at 10 cm head 45 litres/m2/sec IS 14324

13.15.16Workmanship
13.15.16.1 Storage
Pipes and fittings shall be stored raised at least 75 mm from the ground and shall be
carefully supported, cushioned and wedged. Pipes shall not rest directly on one-another
and shall not be stacked more than four pipes high, or two pipes high in the case of pipes
larger than DN 500.
Valves shall be stored under cover until they are required for installation and particular
care shall be taken for the protection of any associated electrical or mechanical equipment.
Couplings and joints (and all components thereof) and other similar items shall be stored
in dry conditions, raised from the ground in sheds or covered areas.
Any period during which the pipes are strung out along the pipeline route or placed
alongside, the Works shall be kept to a minimum. Jointing parts and materials shall in any
case be stored under cover and jointing elements forming parts of the pipes shall be
adequately protected to prevent accidental damage. Subject to the foregoing and to any
restrictions on the duration of temporary occupation of parts of the Site, pipes may be
strung out along the pipeline route prior to installation providing that any necessary
temporary fencing has first been erected.
Storage areas shall be carefully set out to facilitate unloading, loading and checking of
materials with different consignments stacked or stored separately with identifications
marks clearly visible.
End covers and protection shall not be removed until incorporation into the works.
13.15.16.2 Transportation of Pipes and Fittings
Any vehicle on which pipes are to be transported shall have a body of such length that the
pipes do not overhang. The pipes shall be transported and handled in accordance with the
manufacturer’s recommendations.
Approved slings shall be used and all hooks and dogs and other metal devices shall be
padded. Hooks engaged on the inner wall surface at pipe ends shall not be used.
Under no circumstances shall pipes be dropped, be allowed to strike one another, be rolled
freely, or dragged along the ground.
13.15.16.3 Inspections of Pipes and Fittings
Before incorporation into the pipeline, each pipe shall be brushed out and carefully
examined for soundness.
Damaged pipes which, in the opinion of the Engineer, cannot be satisfactorily repaired
shall be rejected and removed from the Site.
If the Engineer considers that an unacceptable proportion of the pipes supplied by the
Contractor within a test length has failed the Contractor may be required to hydraulically
pressure test each pipe and joint on-site before pipe laying.
In this event, test results shall be submitted to and approved by the Engineer before any
further pipes are laid.

In addition to any inspection and tests made when delivery is taken, pipeline materials,
including lining or protective paintwork, pipeline and manhole construction shall be
inspected after installation and all damage identified shall be repaired.
Any special material required for the repair of pipe lining or necessary repairs shall be
made using materials obtained from the appropriate supplier and shall be used in
accordance with their recommendations.
13.15.16.4 Trench Preparation
Trench excavation and backfilling shall be co-ordinated with the construction of the
pipeline as a whole to ensure expeditious completion of the whole operation and shall
comply with Section 8.8 of this Specification.
For pressure and gravity pipelines the bottom of the trench shall be finished smooth and
be free from irregularities, so that the pipes bear uniformly and are supported throughout
their length. The holes required at each joint shall be made as small as possible.
Trench design shall comply with the standard trench details given in IS 3114 (steel pipes)
and IS 5822 (concrete pipes) and other material specific pipe standards. Exceptions may
be permitted where ground conditions dictate in which case the Contractor shall submit
trench embedment details to the Engineer for review prior to works on site.
Details of layered compaction shall be given, including proposed compaction layer

thicknesses, with a view to ensuring minimal post construction surface settlement.
13.15.16.5 Tunnelling
Where tunnelling is required the tunnelling technique and construction materials shall be
chosen to suit the ground conditions and the required pipe size and shall conform with the
Tunnelling Specification.
13.15.16.6 Installation of Pipelines
Pipes shall be laid in accordance with IS 783, IS 3114, IS 5822 and other relevant Indian
standards unless otherwise specified herein.
No metal tools or heavy objects shall be permitted to come into contact with the pipes or
fittings.
Externally coated pipes shall be handled at all times with wide non-abrasive canvas,
rubber, or leather belts or other equipment designed to prevent damage to the coating.
The use of chains, wire slings, or any other handling equipment found to be injurious to
the coating shall not be permitted. The timbers or skids used to support the coated pipe
prior to installation shall be properly padded for the purpose of protecting the coating. Pipes
and fittings shall be lowered into the trench with equipment suitable for the weight of pipes
and fittings. Pipes and fittings shall be carefully cleaned before jointing. Any injury to the
protective coating from any cause must be repaired before the pipes are tested.
Every precaution must be taken to prevent foreign material from entering the pipes or
fittings. Whether installed or when in storage, the pipeline ends shall be capped at all times
when not being worked on. During laying operations no debris, tools, cloth, or other
material shall be placed in the pipe. The Contractor shall provide sufficient ends caps for

this purpose and shall instil the practice of “If you leave it (unattended), seal it, no matter
how brief the period is”.
The equipment for checking and controlling the pipe alignment shall be robust and simple
to use and check and installed in such a way that it is not liable to accidental disturbance
and shall incorporate features to show whether any disturbance has taken place.
Pipes shall be laid accurately to the designed lines and levels within a tolerance of +/- 5
mm. Pipe alignments shall be straight between bends.
Pipelines on which work is being undertaken shall be kept thoroughly cleaned. Except
when cleaning or water testing, water shall not be allowed to flow through the pipes.
13.15.16.7 Cutting of Pipes
Pipes which are required to be cut to form closing pieces in any portion of the pipeline or
to terminate in manholes of other parts of the Works shall not be cut until after all adjacent
pipes have been installed and jointed and shall be cut to allow a 20 mm gap between
adjacent pipe ends.
Pipes shall be cut in accordance with the manufacturer’s recommendations, by a method

which provides a clean, square profile, without splitting or fracturing the pipe wall and which
causes minimal damage to any protective coating.
Where necessary, the cut ends of pipes shall be formed to the tapers and chamfers
suitable for the type of joint to be used. Any protective coatings shall be made good, the
ends sealed and the external face of the pipe made smooth for a suitable distance.
13.15.16.8 Precautions against Flotation
When the pipeline laid underground or above ground in a long narrow cutting gets
submerged in water collected in the trench of cutting it is subjected to an uplift pressure
due to buoyancy and is likely to float if completely or partly empty. In the design of
pipelines, provision is made to safeguard against flotation by providing sufficient
overburden or by providing sufficient dead weight by means of blocks etc.
In the case of works extending over one or more monsoon seasons however, special care
and precautions are necessary during the progress of work. The work of providing blocks,
refilling the earth to the required level, compacting the same etc shall always be done as
soon as the pipeline in the cutting has been laid.
The Contractor shall ensure that water shall not be allowed to accumulate in open
trenches. Where work is in an incomplete stage, precautionary work, such as blank-
flanging in the open ends of the pipeline and filling the pipeline with water etc shall be
taken up as directed by the Engineer.
Protection of the pipeline against flotation during the Contract period shall be the
responsibility of the Contractor.
13.15.16.9 Installation of Pressure Pipelines
Pipes shall be laid to even grades for as long a length as practicable, with a minimum
grade of 0.2%, irrespective of local changes of elevation of the ground surface. Changes

in direction or in grade of the pipeline shall be carried out by making use of any permissible
deflection of joints between straight pipes or by the introduction of bends.
Socket and spigot pipes shall normally be laid with sockets leading. Where the gradient
exceeds 5%, installation shall proceed on an ascending grade with sockets leading. After
laying and jointing, the invert level of each pipe shall be checked before the next pipe is
installed.
Joint holes shall be excavated to provide adequate clearance to enable joints to be made
satisfactorily and any specified wrapping to be completed and to provide a clearance of at
least 50 mm from the trench bottom below the joints.
13.15.16.10 Installation of Gravity Pipelines
Sight rails or other suitable methods shall be used to control the accuracy of pipe laying.
If used then strong sight rails shall be fixed and maintained at each change of gradient
and at as many intermediate points as may be necessary, but not more than 20 m apart.
Sight-rails shall be clearly painted in contrasting colours and be not less than 1 metre long
and 150 mm deep, straight and level, rigidly supported by stout wooden posts at each end.
Any pipes placed on end for affixing the base of the posts shall be not less than 225 mm
in diameter and shall be filled and rammed solid with earth or sand. Posts shall otherwise
have their bases concreted. Boning rods or travellers for use with sight rails shall be of
robust construction, clearly painted and accurately made to the various lengths required,
the lower ends being provided with shoes with sufficient projection to rest on the pipe
inverts. A third sight-rail shall be used wherever possible for ease of checking against
accidental displacement.
Where pipelines are to be bedded on concrete, pre-cast concrete bedding blocks shall be
set to a level allowing for the thickness of the pipe barrel and side string lines shall be used
for checking alignment.
13.15.16.11 Installation of Valves
Installation of valves shall include installation and fixing of any operating gear and
associated fittings.
Valves shall be fixed in manholes before the benching is constructed and shall be coated
with grease and with precautions taken against damaging and fouling during concreting
operations.
Where a valve is built into the benching it shall be surrounded by a 75 mm casing of lime
mortar to facilitate subsequent removal. The lime mortar shall be rendered with cement
mortar 20 mm thick.
After installation valves shall be cleaned inside and out and shall be left in the closed
position.
The spindles of all valves without actuators shall be arranged for ease of operation and
bracketed 150mm below tops of walls and at intervals not exceeding 2400mm
The provision for fixing sluice gates to walls shall be watertight on completion. Sluice gates
shall be bedded on and pointed up with cement mortar. Sluice gates shall be maintained
in the closed position during installation.

All bolts, nuts and washers on the sluice gates and the foundation bolts, nuts and washers
shall be of stainless steel.
13.15.16.12 Concrete Bedding and Surround
Concrete bedding and surrounds shall not be placed until the joints at each end of the pipe
have been completed. The full width and depth of bedding concrete shall be placed and
carefully vibrated beneath the pipe followed at once by the addition of any haunching and
surround concrete. Unformed surfaces shall be of spade finish. The pipe shall be
prevented from floating or other movement during concreting.
Wherever pipes are provided with concrete protection, they shall be supported temporarily
on pre-cast concrete blocks cast to the shape of the bedding and where they have a
concrete surround the depth of the pre-cast concrete block shall be increased to suit. The
pre-cast concrete blocks shall be positioned behind each socket. The width of the pre-cast
concrete blocks shall be half the diameter of the supported pipe subject to a minimum and
maximum of 115 mm and 300 mm, respectively. The blocks shall be left in and
incorporated in the in-situ concrete.
To ensure flexibility of the pipeline, a divider of fibreboard or other suitable material cut to
shape shall be placed at each pipe joint to make a complete break in the continuity of the
concrete protection.
Where two or more pipelines are laid in the same trench the joints shall coincide at the
points where the continuity of the concrete surround is broken, i.e. at the joints in the
pipeline with the longest pipe. Any intermediate joints in the other pipelines with shorter
pipes shall be surrounded in concrete.
13.15.16.13 Granular Bedding and Surround
Pipes for pressure and gravity pipelines shall be provided with a bed, embedment and
surround in the locations and to the dimensions as recommended by the pipe
manufacturer. Where required, granular pipe bedding and surround shall be wrapped in a
geotextile fabric to prevent migration of fine material into the granular surround.
Granular bedding shall be well compacted to the correct levels so that pipes are given full
support along the entire barrel length. Recesses shall be formed in the granular bedding
to accommodate sockets, collars or other pipe joints.
Bedding, pipe surround and backfill shall be compacted to at least 95% maximum dry
density except at road crossing where the compaction shall be at least 98%.
Pipes shall not be supported on timber wedges pre-cast concrete blocks, or similar
materials. After pipes have been correctly laid further granular material for haunching or
surround shall be placed and carefully compacted so no disturbance of the pipe occurs.
Compaction of backfill shall be suitably controlled to ensure that backfilling does not
adversely affect the integrity of the pipeline.
Following pipe laying, further granular material shall be placed in the trench with special
care being taken to fill under the sides of the pipe to ensure full contact with the barrel of
the pipe. The granular material shall then be compacted evenly on both sides of the pipe.

Clay, or other approved impermeable material barriers shall be constructed to limit the
uninterrupted length of granular bedding and backfill to a maximum of 500 m.
13.15.16.14 Joining Pipes
i. General
Joints shall be made in accordance with manufacturers' instructions or as specified

herein.
Before making any joint the interior of each pipe or fitting is to be cleaned. Immediately
before starting a joint the end of each pipe to be jointed will be cleaned and shall be
prepared as necessary.
Until required for incorporation in a joint, each rubber ring or gasket shall be stored in
the dark, free from the deleterious effects of heat or cold and kept flat to prevent any
part of the rubber being in tension.
Only lubricants recommended by the manufacturer shall be used in connection with

rubber rings and these lubricants shall not contain any constituent soluble in the liquid
being conveyed in the pipe. They shall be suitable for the climatic conditions at the Site
and shall contain an approved bactericide.
All pipe ends shall be cleaned free from grit or other extraneous material before
jointing.
Where the a change of direction is required to be achieved by the deflection of a flexible

joint of any kind, the deflection shall not exceed 50% of the design value for the size
and type of joint as recommended by the manufacturer.
After completing the joint, any protective or other coating shall be made good and any
lining completed without delay.
ii. Spigot and Socket Joints for Iron Pipes
Jointing iron spigot and socket pipes and specials with flexible joints will be carried out
in accordance with the manufacturer’s recommendations as to the methods and
equipment to be used in assembling the joints.
iii. Couplings for Iron or Steel Pipes
In jointing iron plain-ended pipes with couplings the manufacturer’s recommendations

as to the methods and equipment to be used in assembling the joint will be followed.
iv. Flanged Joints for Iron or Steel Pipelines
For flanged joints, elastomeric components shall be checked for deterioration and
damage immediately before installation and shall not be used if they are not in perfect
condition. Gaskets shall be fitted smoothly to the flange and the joint made by
tightening the nuts to finger pressure first. Thereafter the final tightening of the nuts
shall be made gradually and evenly, tightening the bolts in diametrically opposite
positions. Only standard spanners and wrenches of a type approved by the Engineer
shall be used.

v. Welded Joints for Steel Pipelines
Welding of joints in steel pipes shall be carried out in accordance with the General
Mechanical Specification.
vi. Joints for Plastic Pipes
The joints for PVC-U, polythene and HDPE pipes shall be of the mechanical type,
solvent welding or thermo-fusion techniques. The pipes shall be laid and jointed strictly
in accordance with the manufacturer’s instructions and shall conform to CP 312.
13.15.16.15 External Wrapping
Where necessary, pipes, fittings and valves which are to be buried in the ground shall be
protected with wrapping material.
All items not wrapped before installation shall be clean and dry and shall be given one coat
of primer supplied by the manufacturer of the wrapping material. Joint and fitting profiles
shall then be modified by the application of moulding putty supplied by the manufacturer
of the wrapping material to provide a suitable profile for wrapping.
Wrapping shall then be carried out and shall lap with the works-applied protection on the
pipes on each side of the joint. The wrapping shall be applied under tension to achieve
conformability and intimate adhesion without trapped air pockets. Wrapping shall be
carried out with a 55% overlap of adjacent strips.
End overlaps where a new roll joins a completed one shall be 150 mm minimum.
13.15.16.16 Pipelines in the Same Trench
Where two or more pipelines are detailed as being laid in the same trench the pipes shall
be laid so that there is a minimum distance of 150 mm between the barrels of the pipes,
measured in plan at mid- barrel height, unless a greater distance is required to enable
jointing to be properly completed. The invert levels of the pipelines shall be the same at
any cross section, unless otherwise required.
Firstly the larger of the pipelines shall be laid in a straight line. Where it is necessary to
increase the distance between the pipelines from that specified above to allow the
construction of air valve or washout chambers or for any other reason, the deviation of a
pipe from the line of the preceding pipe shall be made by deflecting the flexible joints.
13.15.16.17 Anchor and Thrust Blocks
The Contractor shall design and construct permanent concrete anchor blocks to resist
thrust according to the maximum permitted pipe pressures, the nominal pipe diameter and
soil.
Anchors shall be designed to immobilise the pipe for all foreseeable loads conditions and
cater, as required, for rotational forces as well as the orthogonal linear forces. The design
life of the anchors shall be the same as the pipe section to which it is attached.
The faces of anchor blocks must bear against undisturbed ground.

The Contractor shall design and construct temporary anchor blocks for the ends of pipe
sections being tested according to test pressure, nominal pipe diameter and soil. He shall
also ensure their demolition and removal at the end of the tests, unless the Employer
agrees otherwise.
Concrete thrust and anchor blocks shall be constructed at all tees, bends, tapers, valves
and hydrants for the anchorage of the pipeline.
Thrust blocks shall be constructed with the bottom and thrust side surfaces bearing against
undisturbed ground.
Shear keys shall be formed on the upper surface of concrete blinding for horizontal thrust
blocks.
13.15.16.18 Pipelines Built into Structures
Any pipeline which is built into a chamber, manhole or other structure, including a thrust
block, shall be provided with two flexible joints outside the face of the structure. Unless
otherwise required and approved, the first joint shall be not more than one pipe diameter
or 500 mm, whichever is the greater, from the outside face and the length of the short pipe
between the flexible joints shall be equal to two pipe diameters or 1000 mm, whichever is
the greater.
Pipes terminating in manholes and the like shall, except where otherwise specified, be cut
so that the end of the pipe is flush with the face of the structure into which it is built.
The flexible joints shall be flexible spigot and socket joints or other appropriate flexible
couplings.
The short lengths of pipe built into the wall shall be of the same material as the remainder
of the pipelines material and shall be surrounded in concrete.
Pressure pipes passing through the walls of valve chambers or other structures shall be
ductile iron, with anchorage flanges designed to transmit full end thrust with closed valve
under test into the structure’s wall. Boxouts, if used, shall be designed to fulfil the above
requirements.
Where no anchorage flanges are required for pipes passing through the walls of structures
the pipe shall be provided with a puddle flange integral with the pipe wall or bolted on to
resist movement of water along the pipe to concrete interface. Such puddle flanges shall
protrude at least 50 mm from the pipe barrel.
Where the pipeline is above ground level the short length of pipe providing flexibility shall
be self- supporting.
13.15.16.19 Plugging of Dead Ends
The dead ends of pipes and fittings shall be plugged.
13.15.16.20 Cables Sharing Pipeline Trenches
Where cables are to be laid in pipeline trenches, the pipes shall be installed and fine
backfill shall be placed to 150 mm above the crown of the pipe. The cable shall then be
laid before the remainder of the trench is backfilled.

13.15.17Construction of Manholes
13.15.17.1 General
Cast in-situ manholes shall be either circular or rectangular, with internal and external
protective coatings. The manhole base shall be cast on a blinding layer of concrete not
less than 100 mm thick. Sockets for connecting pipes shall be cast into the base of the
manhole while casting the structure. The socket shall be positioned to provide a flexible
joint at the outer face of the manhole. A further flexible joint shall be provided between one
and two pipe diameters from the manhole.
If pipe laying from the manhole is not to proceed immediately, a temporary closure shall
be provided to prevent material from entering the pipe and manhole. The closure shall be
removed only when pipe laying is about to restart.
13.15.17.2 Benching
Benching shall be formed with plain concrete class M 30. The surface of benching and
flow channel shall be protected with chemically resistant resin mortar, minimum thickness
of mortar shall be 12 mm.
13.15.18Manhole covers
The covers shall be carefully set to the slope of the ground or road surface. In open areas,
manhole covers shall be set 150 mm above the surrounding general ground level.
After setting in position the lifting and prising holes provided in the cover shall be cleaned
out and refilled with tarred hemp.
13.15.18.1 Brickwork
All brickwork shall be uniformly bedded, bricks always being laid frog upwards and each
brick floated, rubbed in or hammered down upon such a sufficient quantity of mortar that
the mortar may be squeezed up into the joints and each joint not already full shall be
flushed up with the mortar of the next succeeding bed. The whole of the beds and joints
shall be completely filled and compressed to ensure the greatest possible density.
Horizontal weathered jointing shall be provided to all external faces. Bricks with a very high
suction may be wetted, but not saturated, immediately before laying. Engineering
brickwork shall not be laid in wet weather.
All engineering brickwork shall be carried out using cement mortar.
13.15.18.2 Cement Mortar
The ingredients shall be thoroughly mixed while dry by machine or hand until the cement
colour can no longer be distinguished from the fine aggregate in any part of the mass and
then shall be uniformly wetted by means of a rose while undergoing further thorough
mixing.
The mortar shall be prepared and used at such places and times and in such quantities
that a longer time than thirty minutes shall not elapse between the first wetting and its
completed use upon the Works. If mixed by hand, no single mixing shall exceed a quarter
of a cubic metre.
The fine aggregate for cement mortar shall comply with IS 383, the grading being in
accordance with IS 2386.

13.15.19Washouts
Washouts shall provide drain pipework from a level invert tee on the main pipeline that is
able to provide drain down facilities at all low points along the pipeline.
The washout shall be fitted with a metal faced, isolation gate valve with a sleeved valve
spindle extension to the surface located in a standard valve surface box mounted in the
centre of a slightly raised concrete plinth with plan dimensions of at least 750 mm square.
Drainage pipework shall rise from the isolation valve to a Bauer coupling at the surface,
which can be attached to a potable pump suction main for drain down of the rising main.
Washouts shall provide a 600 mm x 900 mm lockable cover for the chamber.
The drainage pipework and Bauer coupling shall be appropriately sized for each specific
rising main.
13.15.20Drainage Work with NP2 Class Reinforced Concrete Pipes
13.15.20.1 Reinforced Concrete Spun Pipes
The pipes shall be Reinforced Concrete Spun pipes NP2 class, conforming to IS 458-2003
and shall be inspected by the Engineer for soundness before incorporation in the work.
13.15.20.2 Laying of RCC Spun Pipes
The laying of RCC spun pipes shall be executed in accordance with IS 783.
After the cement concrete cradle, if required, has been laid properly and approved by the
Engineer, the pipes shall be lowered gradually into the trenches over the concrete cradle
or bed. Laying of pipes shall proceed upgrade of the slope.
The pipe shall rest on the bed at every point through its length. It shall be ensured that the
load of the pipes and the superimposed load of the earth filling is evenly distributed on the
cradle or bed.
The Contractor shall take precautions to ensure that no dirt, earth or other foreign matter
is allowed on the surface of the cradle or bed of the pipe resting there-on, all to the full
satisfaction of the Engineer. After the alignment and grading of the pipes are checked by
the Engineer, the grouting shall be carried with the specified mix of cement mortar.
The cradle of concrete shall be allowed to set at least for three days before any pipe is
placed on it and the Contractor shall take due care in setting the pipe in the cradle so that
no damage is caused to the cradle. If any damage to the cradle occurs, it shall be rectified
to the satisfaction of Engineer and in any particular case where damage to the cradle is
beyond repair, in the opinion of the Engineer, the Contractor shall cut out the damaged
section of the cradle.
No pipe shall be laid or placed until the alignment of the pipe drain and its levels and
gradient have been carefully checked and found correct/approved by the Engineer.
The interior of the pipe drains shall be cleaned of all dirt, cement mortar and superfluous
materials and joints shall be cured for at least 7 days.

13.15.20.3 Joints
The joints between concrete pipes shall be spigot and socket with elastomeric joint rings.
Caulked joints shall not be used.
13.15.21Construction Tolerances
The final location of the completed pipeline shall not deviate from the position detailed in
the Contract by more than:
1 Line ± 10 mm
2 Level ± 5 mm
3 Max. lipping between edges of adjacent ± 2.5% of nominal internal diameter
pipes
No reverse gradient will be accepted on gravity pipelines.
Finished concrete surfaces shall not deviate from the positions detailed in the Contract by
more than:
1 Screeded finish or rough formwork ± 10 mm

2 Any other finish ± 5 mm
13.15.22Hydrostatic Testing of Pipelines
13.15.22.1 General
All pipelines shall be hydrostatically tested.
Test lengths greater than 1,000 m shall only be permitted in exceptional circumstances
and shall require the test duration to be commensurately longer.
Variations to the test length, duration or acceptance criteria shall be at the Engineer’s sole
discretion.
All tests shall be witnessed by the Engineer as notified to the Contractor by the Employer
at the relevant time.
If any pipeline fails to pass a test, the Contractor shall investigate the reason, carry out
remedial work as necessary to the approval of the Engineer, and re-test the pipeline. This
process shall be repeated until the requirements of the specification are met.
If the result of a test is “invalid test” the Contractor shall remedy the test procedure to be
compliant and re-test the pipeline.
13.15.22.2 Testing Pressure Pipelines
Pressure testing shall be carried out on all sections of pipeline as they are completed. The
fittings used at line valve and at break point for commissioning shall be such as to allow
the temporary fitting of a blanking spade for pressure test purposes. Pressure testing
against closed valves shall not be permitted. All air valves shall be removed after charging
the main and a blank flange fitted. Testing shall not be carried out against the air valve
isolation valve which shall be re-opened after fitting the blank flange.

The test pressure shall be 1.5 times the working pressure of the pipeline section or the
rated pressure + 5 bar whichever is the lower. All pressure tests shall be recorded using
an electronic data logger monitoring pressure and test water flow into the pipeline using
calibrated equipment. Pressure shall be recorded to the nearest 0.01 bar and flow to +/-
2% or better.
Before filling for pressure testing, pipes and valves shall be re-checked for cleanliness and
that all valves are operational. The open ends of the pipeline (or sections thereof) shall
normally be stopped off by blank flanges or cap ends additionally secured where
necessary by temporary struts and wedges. All thrust blocks and valve chambers shall
have been completed with backfill placed around them and the concrete shall have
attained its specified 28-day strength. All pipe straps and other devices intended to prevent
the movement of pipes shall have been securely fastened and backfilling of the trench
between pipe joints shall have been placed.
The test pressure shall be applied to the entire pipeline or section being tested in
accordance with the following procedure:
a) Fill each pipeline or section with water and displace all air from the pipeline;
b) Raise the pressure in the pipeline by pumping water until the test pressure is attained
in the lowest part of the section under test;
c) Maintain the pressure at this level by further pumping until it is steady for a period of
not less than 24 hours;
d) Monitor the pipeline over a further period of 24 hours without additional pressurisation;
e) At the end of this period measure and record the reduced pressure in the pipeline.
Restore the pressure in the pipeline to the original test pressure by pumping.
f) Draw off water or air to reduce the pressure in the pipeline to the pressure noted under
(e) above. Measure the quantity of water so drawn off.
g) Compare the loss to the permissible loss calculated as:
PL = 0.02 * D * L * P * t
Where:
PL = Permissible loss in litres
D = Diameter of pipe in mm
L = Length of section of pipe under test in km
P = Test pressure in bar
t = Length of time for which pressure has been applied in days (should be 1)
a) If the actual loss is less than the calculated loss then the pipeline has passed the 24
hour test and the test can proceed to the next stage. If not then the Contractor shall
locate the fault(s), repair the pipeline and retest.
b) After satisfactory completion of the 24 hour test, the pipeline shall be brought back up
to test pressure and the pressure shall be maintained 1 hour by pumping if necessary;
c) At the end of 1 hour the pump shall be disconnected and no water shall be added to
the pipeline for a period of 2 hours;
d) At the end of the 2 hour period the test pressure shall be restored by pumping and the
volume of makeup water necessary to achieve this shall be measured;
e) If the actual amount of makeup water is less than the permissible loss calculated in
accordance with the formula given at (g) above then the pipeline has passed the test.
If not then the Contractor shall locate the fault(s), repair the pipeline and retest.
13.15.22.3 Testing Gravity Pipelines
Testing shall be carried out on all sections of pipeline as they are completed.

Gravity pipelines shall be proved by passing through them a train consisting of a leading
element and a circular plastic foam plug followed by a wooden ball. The diameter of the
wooden ball shall not be smaller than 25 mm less than the diameter of the pipes under
inspection. Any obstruction found during these operations shall be removed.
Each length of gravity pipeline shall be carefully air tested after the trench is backfilled.
The pipeline shall be tested in convenient lengths and all necessary tester junctions,
expanding rubber plugs, testing equipment etc. shall be provided. Any defects, which may
become apparent shall be repaired and retested.
The Contractor shall make the pipe drains water tight against the entrance of land/sub-soil
water from outside and also against the leakages of water from the inside of the pipe drains
at the test heads specified above to the full satisfaction of the Engineer.
Water pressure testing as an alternative to air testing will be allowed in which case the
pipeline shall be tested in accordance with the procedure for pressure testing.

14 Standard Specification – Mechanical
14.1 General
Equipment should be selected to suit the selected process and performance rating
required of the equipment within the given situation as well as the prevailing site conditions.
Where mechanical equipment includes electrical appurtenances including motor and
control systems, these shall comply fully with the requirements of the Electrical
Specifications. Additionally, all fixing and erection requirements on foundations, etc. shall
comply with the requirements of the Civil Specification.
Specifications for the various Mechanical Items and Equipment used typically in the water
and wastewater sector, relevant to PMC Works Contracts are listed in the table below.
Details of the individual specifications are provided herein.
14.1.1 Scope of the Mechanical Specification
This Mechanical Specification is a generic document which covers all mechanical

materials, engineering practices, workmanship, equipment and appurtenances supplied
for use on all Water and Sewage Treatment engineering applications for Pune Municipal
Corporation (PMC), herein after referred to as PMC. This Specification shall be mandatory
for the scope of services on all Contracts including, but not limited to design, manufacture,
testing at works, supply and delivery at site, unloading, storing till the time of erection,
installation, testing and commissioning of mechanical equipment fully elaborated in this
specification.
14.1.2 Design Life
The works as a whole shall be new, of sound workmanship, robustly designed for a long
reliable operating life and shall be capable of 24 hours per day continuous operation for
prolonged period in the climatic and working conditions prevailing at the site, and with the
minimum of maintenance. Particular attention shall be given to 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 test. Routine maintenance and
repair shall as far as possible not requires the services of highly skilled personnel.
The Plant shall be designed to provide easy access to and replacement of component
parts, which are subject to wear, without the need to replace whole units. No parts in the
contact with water 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 of such part shall
not be less than ten years.
Design features shall include the protection of plant against damage caused by vermin,
dirt, dust and dampness and to reduce risk of fire. Plant shall operate without undue
vibration, and parts shall be designed to withstand the maximum stresses under the most
severe condition of normal service. Materials shall have a high resistance to change in
their properties due to the passage of time, exposure to light temperature and any other
cause, which may have a detrimental effect upon the performance, or life of the works.
Plant located outside lockable areas/buildings shall have additional features to prevent
unauthorized operation.

Part 14: Standard Specification – Mechanical
14.1.3 Allowance for wastage
The Contractor shall supply to the satisfaction of the Engineer-in-Charge reasonable

excess quantities to cover wastage of those consumable which will be normally subject to
waste during erection, commissioning and setting to work.
14.1.4 Compliance with Standards
Where reference is made in the Specification to a British Standard Specification

(hereinafter abbreviated to ‘BS’) issued by the British Standards Institution of 2, Park
Street, London W.I. or to an Indian Standard Specification (IS) issued by the Bureau of
Indian Standards, (earlier known as Indian Standard Institution), Manak Bhavan, 9
Bahadur Shah Zafar Marg, New Delhi 110 002, American Society for Testing and Materials
(ASTM) issued by ASTM 1916 Race Street,
Philadelphia, P.A., 19103, U.S.A or American National Standards Institute (ANSI) issued
by ANSI 1430, Broadway, New York, N.Y., 10018, U.S.A or to any other equivalent
standard it shall be to the latest revision of that standard at the tender opening date.
The Contractor may propose at no extra cost to the Employer, the use of any relevant
authoritative Internationally recognized Reference Standard, including Indian Standard.
All details, materials and equipment supplied and workmanship performed shall comply
with these standards. If Contractors offer equipment to other standards, the equipment/
material should be equal or superior to those specified and full details of the difference
shall be supplied.
In the event of conflict between this specification and the codes for equipment, provisions
of this specification shall govern.
14.1.5 List of applicable Standards
The design, manufacture, supply, storage of all equipment shall comply with all Indian
Standards, (or in the absence of Indian Standards, the appropriate International
Standards) Acts and Regulations in their latest amendment, including local statutes
covering:
• Health and Safety
• Dangerous Goods
• Factories and Commercial Premises
• Buildings
• Electricity Regulations and Codes of Practice
The Standards referred shall form part of this Contract. Other Standards, Codes of
Practice and Regulations not referred to, but which would be applicable to the design,
manufacture, installation, testing or commissioning of the equipment under this contract
shall be deemed part of the Contract.
The titles of various standards referred to in the Specification are indicated hereunder for
ready reference. This list does not necessarily covers all the Standards referred to

Standard # Title
IS 5 - Colours for ready mixed paints and enamels
IS 210 - Grey Iron Castings
IS 318 - Leaded Tin Bronze Ingots and Castings
IS 325 - Three Phase Induction Motors
Code of Practice for design, manufacture, erection and testing
IS 807 -
(structural portion) of cranes and hoists
IS 1239 - Mild Steel tubes, tubular and other wrought steel fittings.
IS 1536 - Centrifugally cast (Spun) iron pressure pipe for water, gas and sewage
IS 1537 - Vertically cast iron pressure pipes for water, gas and sewage
Specification for cast iron fittings for pressure pipes for water, gas
IS 1538 -
and sewage
IS 1554 - PVC insulated (heavy duty) electric cables
IS 2062 - Steel for general structural purposes
Degrees of protection provided by enclosures for low voltage switch
IS 2147 -
gear and control gear
IS 3109 - Short link chain, Grade M (4)
Code of practice for electric overhead traveling cranes and gantry
IS 3177 -
cranes other than steel work cranes.
Phosphate treatment for iron and steel for protection against
IS 3618 -
corrosion
IS 3624 - Vacuum and Pressure gauges
IS 3815 - Point hooks with shank for general engineering purposes
IS 3938 - Electric wire rope hoists
IS 4029 - Guide for testing three phase induction motors
IS 4460 - Method for rating of machine cut spur and helical gears
Degrees of protection provided by enclosure for rotating electrical
IS 4691 -
machinery
IS 6005 - Code of practice for phosphating of iron and steel
Centrifugally cast (spun) ductile iron pressure pipes for water, gas
IS 8329 -
and sewage
IS 11592 - Code of practice for selection and design of belt conveyors
IS 13349 - Cast Iron Single faced thimble mounted sluice gates
BS 436 - Spur and helical gears
Specification for power driven overhead traveling crane, semi-
BS 466 -
Goliath and Goliath cranes for general use
BS 545 - Specification for bevel gears (machine cut)
BS 721 - Specification for worm gearing
BS 970 - Wrought steels for mechanical and allied engineering purposes
BS 1397 - Specification for industrial safety belts, harnesses and safety
Specification for copper alloy ingots and copper alloy and high
BS 1400 -
conductivity copper castings

Standard # Title
BS 1452 - Specification for flake graphite cast iron
Specification for higher tensile steel chain Grade 40 (Short link and
BS 1663 -
pitched or calibrated) for lifting purposes.
Specification for classification, stress calculations and design of
BS 2573 -
mechanisms
BS 2600 - Radiographic examination of fusion welded butt joints in steel
Specification for higher tensile steel hooks for chains, slings, blocks
BS 2903 -
and general engineering purposes
Methods for radiographic examination of fusion welded
BS 2910 -
circumferential butt joints in steel pipes
BS 3017 - Specification for mild steel forged ram shorn hooks
BS 3017 - Specification for mild steel forged ram shorn hooks
BS 3100 - Specification for steel castings for general engineering purposes
BS 3923 - Methods for ultrasonic examination of welds
BS 4360 - Specification for weld-able structural steels
BS 4772 - Specification for ductile iron pipes and fittings
Specification for approval testing of welding procedures. Part - I :
BS 4870 -
Fusion Welding of Steel
Specification for approval testing of welders working to approved
BS 4871 -
welding procedures. Part – I: Fusion Welding of Steel
BS 4942 - Short chain link for lifting purposes
Specification for arc welding of carbon and carbon manganese
BS 5135 -
steels
Specification for acceptance tests Part - 2 for centrifugal, mixed flow
BS 5316 -
and axial pumps- Test for performance and efficiency
BS 6072 - Method for magnetic particle flaw detection
Specification for non-calibrated short link steel chain (Grade 30) for
BS 6405 -
general engineering purposes: Class 1 & 2.
BS 6443 - Method for penetrate flow detection
ASTM A-36 - Specification for Structural Steel
Specification for Steel Castings, Carbon suitable for fusion welding
ASTM A-216 -
for high temperature service
Specification for stainless steel and heat resisting steel bars and
ASTM A-276 -
shapes
Specification for castings, Austenitic - Ferritic (Duplex), for Pressure
ASTM A-351 -
Containing Parts
Specification for casting, Iron - Chromium, Iron - Chromium-Nickel,
ASTM A-743 -
and Nickel Base corrosion Resistant for General Application
Specification for casting, Iron Chromium - Nickel, Corrosion
ASTM A-744 -
Resistant
ASTM B-148 - Specification for Aluminium – Bronze Castings

Standard # Title
Low frequency cables and wires with Parts 1 & 2 PVC insulation and
IEC – 189 -
PVC sheath
AWWA C 501 - Casting Iron Sluice Gates
AWWA C520-10 - Knife edge gate valve
IS 8183/9842 - Specification for insulation material
IS 3144 - Method of test for mineral wool thermal insulation
14.1.6 Materials and Workmanship
This part of the specification sets out the general standards of materials to be supplied
and the workmanship required to be ensured by the Contractor and mention of any specific
material or plant does not necessarily imply that such is included in the works. All
component parts of the works shall, unless otherwise specified comply with the provisions
of this part or be subject to the approval of the Engineer.
The names of the manufacturers of materials and equipment proposed for incorporation
in the Works together with performance capacities, certified test reports and other
significant information shall be furnished by the Contractor.
14.1.6.1 Materials – General
All materials incorporated in the Works shall be the most suitable for the duty concerned
and shall be new and of reputed make/approved quality, free from imperfections and
selected for long life and minimum maintenance. Non-destructive tests, if called for in the
specification, shall be carried out.
All submerged moving parts of the Plant, or shafts spindles, etc. of the submerged moving
parts or faces etc. in contact with various chemicals, shall be corrosion resistant materials.
All parts in direct contact with various chemicals shall be completely resistant to corrosion
or abrasion by these chemicals and shall maintain their properties without aging due to the
passages of time, exposure to light or any other cause.
14.1.6.1.1 Materials Certificates
Equipment supplier / Material supplier/Contractor have to submit Quality assurance plan

(QAP) as per applicable standard for their scope of supply of item after award of contract.
Chemical and Mechanical test certificate of material shall be furnished by the contractor
for Important Equipment components as mentioned in respective technical specification or
recommended by applicable IS/International standard after award of contract. It should
comply as per respective Indian standard/ASTMA/ AWWA standard requirement.
14.1.6.2 Workmanship – General
Workmanship and general finish shall be of first class quality and in accordance with best
workshop practice.
All similar items of the Plant and their component parts shall be completely
interchangeable. Spare parts shall be manufactured from the same materials as the
originals and shall fit all similar items. Machining fits on renewable parts shall be accurate
and to specified tolerances so that replacements made to may be readily installed.

All equipment shall operate without excessive vibration and with minimum noise. All
revolving parts shall be truly balanced both statically and dynamically so that when running
at normal speeds at any load up to the maximum there shall be no vibration due to lack of
balance.
All parts, which can be worn or damaged by dust shall be totally enclosed in dust proof
housings.
All materials incorporated in the work shall be most suitable for duty concerned, free from
imperfections, selected for long life and minimum maintenance.
All necessary accessories required for satisfactory and safe operation of the plant shall be
supplied by the Contractor unless it is specifically excluded from his scope.
All valves shall be closing on clockwise rotation of the hand wheel. The effort required to
close/open under all operating conditions shall be limited to 7 kg. The direction of
opening/closing shall be cast on the hand wheel.
All flanges shall be drilled in accordance with requirements of IS: 1538.
All flanges shall be full or spot faced on the backside. The flange thickness be uniform
throughout.
Flange outside periphery shall be concentric with the bore. Flanges shall be finished
smooth on periphery also.
Castings and fabricated materials shall be finished smooth all over.
14.1.6.3 Occupational Health and Safety Management
In order to prevent industrial accidents, for example an accidental fall, injury, drowning,
toxic chemicals and Gas inhalation, dropping of heavy weights, flammable oil and Bio-Gas
releases, which may occur during Construction or during the O&M and stage, the
contractor shall submit for approval to the Engineer (or the Employer’s representative), a
suitable Safety Plan setting out all measures he will implement to mitigate the risk of such
accidents. All Risks shall be identified in the Plan complete with actions that must be taken
in the event that an unsafe situation arises including the provision of alarms in the event
of an unsafe situations arising.
With regard to the sludge handling facilities and specifically those concerned with the
highly explosive environment around the bio-gas digesters, the biogas electrical generator
and all ancillary plant, explosion proof safety equipment suitably rated to the applicable
intrinsically safe standards as specified in the Electrical Specification, shall be identified
and installed to monitor all processes and areas accessible to personnel. Safety related
equipment shall provide for effective control of the plant to ensure safe and stable
operations, and provide for safe shut down of the plant in the event of a dangerous
situation arising ensuring that explosion and fires are prevented. All areas at risk of fire or
explosion shall be suitably labelled with warning signs in accordance with the Specification
in Part 2 of Section 6, including prohibiting naked flames and smoking.
All safety related equipment and apparatus, shall be subject to a strict maintenance regime
with provision for routine legally binding documented endorsement of periodic safety
checks by suitably qualified inspection technicians.

The sludge treatment building housing the relevant machinery for sludge management
shall be provided with a ventilation system and gas detection and alarm system. Ventilation
shall be in accordance with the requirements set-out in the CPHEEO Manual.
14.1.6.4 Specifications of Mechanical Equipment
The supply and installation of Mechanical Equipment may also be subject to the
requirements of PMC’s Civil, Electrical, Instrumentation / Control Specifications. In many
cases, Mechanical Equipment is provided with Electrical drivers and Control Equipment
and therefore this Mechanical Specification must be read in conjunction with the related
Specification.
Generally, Equipment shall as a minimum, also comply with the requirements of

this Specification covering Materials and Workmanship.
Furthermore, Mechanical Equipment is often supplied as a ‘Packaged Item’ including

Delivery, Offloading, Storage, Installation or Erection on PMC sites. Consequently, sub-
contractors shall also observe the special requirements in Part 9, covering Testing and
Commissioning of Mechanical Equipment on site.
14.1.6.5 Documentation: Drawings, Data Sheets, and O&M Manuals
All equipment shall be supplied with data sheets, full detailed drawings, and Operating and
Maintenance (O&M) manuals. Drawings shall detail lubrication points, mounting points and
lifting lugs, etc., high-wearing parts that may need to be replaced, or maintained from time
to time, etc. Manuals shall include a list of normally used spares complete with re-order
details, including part or serial numbers, etc.
Should any modification be carried-out for the specific application, then drawings must be
amended to show the ‘As-Built’ situation.
Pressure drop (Total Differential Head) calculation to be submitted for all Centrifugal
pumps, Screw pump& dosing pump for over review before submission Equipment GA
drawing and data sheet
If two pumps are working parallel, system resistance curve for parallel operation to be
submitted by contractor/ Equipment supplier.
14.1.6.6 Precedent Hierarchy
Should any conflict arise between the many representation of specification or equipment
or as installed mechanical plant, then the following precedence hierarchy shall prevail:
• Legislation;
• The Contract;
• Technical Specifications, including Electrical, Civil and Instrumentation Specifications;
• Contract Drawings;
• Operation Maintenance Manuals
• Standard Design Drawings, and Guides
• Industry Standard Guidance Notes

14.1.6.7 Deviations from Specifications (Equipment Suppliers)
Any deviation from this specification, for whatever reason, including use of standard
supplier issue appurtenances, is subject to a formal application for a concession from PMC
or his representative.
14.1.6.8 Life Expectancy and Design Life
The design life of major components shall be 15-20 years or mentioned anywhere in tender
document or as recommended in CPHEEO Manual whichever is higher.
14.1.6.9 Vibration and Noise
balance.
balance.
Washers, locking devices and anti-vibrations arrangements shall be provided where

necessary and shall be subjected to the approval of the Engineer-in-Charge. Jointing
hardware for the entire plant shall be provided with sufficient spares to cater for site losses.
The noise level produced by any equipment like pump sets, compressor sets and blower
sets etc. shall not exceed 85 dBA measured at a distance of 1.86 m from the outer surface
of the equipment. At the time of operation, the mechanical vibration shall not exceed the
limits given below, at recommended points of measurement as per ISO 10816:1995.
Areas of high noise producing units shall be enclosed in buildings provided with sufficient
space for maintenance. At the entrance to these building, safety signs shall be mounted
instructing all personnel that wearing of ear defenders is mandatory. Furthermore, ares of
high noise shall be provided with noise measuring instrumentation for monitoring noise
levels.
Unless otherwise mentioned in any where in the specification, Vibrations on rotating

equipment shall be limited to the figures given in the table below:
Velocity of Vibration
Equipment
mm/sec
All rotating equipment not having reciprocating parts with motor 1.12
KW less than or equal to 15 KW
KW more than 15 KW and less than or equal to 75 KW
KW greater than 75 KW

14.1.6.10 Thermal Insulation of Equipment and Piping Systems
Insulation is required for any of the following purpose, as indicated in P&IDs and line list.
a) Hot conversation
b) Process stabilisation to assist process control
c) Steam tracing
d) Electric tracing
e) Hot water or solvent tracing (liquid)
f) Hot oil tracing
g) Steam jacketing
h) Fire hazard protection to prevent fast boil of liquid
i) Instruments and associated piping subject to operating flow and /or temperature
conditions prevailing in the connected piping or equipment shall be insulated to the
same requirements as that of piping or equipment
j) Personal protection.
k) Where exposed surface temperature exceed 50 Deg C in normal or short –term
operating conditions
l) Over internally insulated piping and equipment, provide open mesh metal guards and
for surface which are not internally insulated, provide insulation on that part of surface
with which operating and maintenance personnel may come in contact while
performing routine duties.
m) Exposed surface operating above 50Deg C and located within 600 mm horizontally or
2100mm vertically of normal access walkway or work area. Insulated piping system
shall have straight pipe, bends, tees and pipe fittings completely insulated.
n) Insulation shall be designed to provide as absolute minimum clearance of 25 mm
between the outside surface of any insulation finishing material and adjacent surface
Materials:
• All material shall be of high quality and good appearance. This materials cover
Rockwool, Glass wool, Calcium Silicate, Polyisocyanurate and cellular glass
• Insulation material shall be of low chloride content, chemically inert, on-sulphurous, rot
proof, vermin proof, impervious to hot water and steam, non-injurious to health and
non-corrosive to steel and aluminium (Even if soaked in water at ambient temperature
for extended period
• The using of insulation or finishing materials containing ASBESTOS in any form is not
permitted
• Insulation material have been classified into two categories-water absorbing and non-
water absorbing. Non-water absorbing insulations like polyisocyanurate and cellular
glass are recommended for services up to 125 Deg C. Water absorbing insulants like
fibrous insulants and calcium silicate can be used for all temperatures except for
electrically traced pipe. But for low temperature (i.e. up to 125 Degree C) services as
suitable moisture barrier shall be used since the substrata is at too low a temperature
to evaporate moisture, rain or hose water absorbed
• Unless otherwise specified herein, insulation material shall strictly confirm to all the
requirements of quality standards as per IS:8183/IS:9842 latest version
14.1.6.11 Lubrication
The Contractor shall furnish a complete schedule of recommended oils and other
lubricants. The number of different types of lubricants shall be kept to a minimum. The
schedule and the name of the supplier of the lubricants shall be submitted to the Engineer-
in-Charge for approval before incorporation in the Instruction Manuals. In the case of
grease lubricated roller type bearings lithium base grease is preferred.

Contractors shall indicate indigenously available equivalent lubricants, with complete duty
specification, to enable the Employer to arrange for regular supply.
Where lubrication is effected by means of grease, preference shall be given to a pressure

system, which does not require frequent adjustment or recharging. Frequent, for this
purpose, means more than once in a month and grease system having shorter periods
between greasing should be avoided. Where necessary for accessibility grease nipples
shall be placed at the end of the extension piping, and, when a number of such points can
be grouped conveniently, the nipples shall be brought to a battery plate mounted in a
convenient position. All grease nipples shall be of the same size and type for every part of
the plant. Arrangements shall be provided to prevent bearings being overfilled with either
grease or oil.
Where more than one special grease is required, a grease gun for each special type shall
be supplied and permanently labelled.
Oil containers shall be supplied complete with oil level indicator of the sight glass type, or
where this is not practicable, with dipsticks. The indicators shall show the level at all
temperatures likely to be experienced in service. The levels shall be clearly visible in the
sight glass type from the normal access floor to the particular item of plant and they shall
be easily dismantled for cleaning. All sight glasses shall be firmly held and enclosed in
metal protection in such manner that they cannot be accidentally dislodged.
All lubrication systems shall be designed so as not to cause a fire or pollution hazard and
particular care shall be taken to prevent leakage of lubricants and to avoid leaking
lubricants coming into contact with any electrical equipment, heated surfaces or any other
potential source of fire.
The Contractor shall supply flushing oil for each lubrication system when an item of plant
is ready for preliminary running and a sufficient quantity of the approved lubricants for the
commercial operation of the plant for two years after the Taking-over Certificate has been
issued.
14.1.6.12 Plant Signs, Labels, Terminology and Name Plates
Each item of the plant shall have permanently attached to it in a conspicuous position, a
nameplate and rating plate, each of stainless steel. Upon these shall be engraved or
stamped, the manufacturer’s name, type and serial number of Plant, details of the loading
and duty at which the item of plant has been designed to operate, and such diagrams as
may be required by the Engineer in-Charge. All indicating and operating devices shall have
securely attached to them or marked upon them designations as to their function and
proper manner of use.
Details of proposed inscriptions shall be submitted to the Engineer-in-Charge for approval

before any labels are manufactured. Such nameplates, rating plates and designations
shall be of stainless steel with engraved or stamped lettering items such as valves shall
have direction of rotation for closing and opening indicated.
Nameplates, rating plates and labels shall be of a non-flame propagating materials, either
no hygroscope or transparent plastic with engraved lettering of a contrasting colour. Fixing
shall be by means of non-corrosive screws, drive rivets or adhesives shall not be used.

Warning labels shall be provided where necessary to warn of dangerous circumstances or

substances. Inscriptions or graphic symbols shall be black on a yellow background and to
internationally recognized standards.
Instruction labels shall be provided where safety procedures such as wearing of protective
clothing are essential to protect personnel from hazardous or potentially hazardous
conditions. These labels shall have inscriptions or graphic symbols in white on a blue
background.
14.1.6.13 Lists of Mechanical Equipment included in this Specification
The following list of equipment is relevant to the water and wastewater sector in Pune,
which are identified in this Mechanical Specification. The detailed specification for each
item of equipment shall be the minimum standard to be adopted by the supplier of the
equipment.
Any equipment supplied under any contract, which is not covered by this Mechanical
Specification, shall be subject to formal acceptance by PMC or his representative. The
Contractor of Supplier shall propose such an acceptance based on full engineering data
sheets, complete with design criteria.
Tables to be extended to apply to ALL Pump Station s and ALL STPs in the PUNE Contract
– list below too limiting
Sr.
Particulars
No.
A Sewage Pumping Station- submersible pumps
Mechanically cleaned Coarse Screens before raw sewage sump
Manually cleaned coarse screen
B Sewage treatment plant
1 Mechanical Fine Screen
2 Manual fine screens
3 Mechanical Degritter
4 Decanter mechanism and mixers for SBR
5 Air blowers and diffusers
6 Air piping
7 Chlorination System with cylinders, Booster Pumps and accessories
9 Return sludge pumps
10 Excess sludge pumps
11 Centrifuge feed pumps
12 Centrifuge
13 Sludge agitator
14 Filtrate transfer pumps
15 Polyelectrolyte dosing tanks and pumps

14.1.6.14 Spares
Sr.
Particulars Quantity
No.
1. Pumps
(i) Impeller 1 set
(ii) Bearings 1 set
(iii) Shaft Sleeve 1 set
(iv) Seals, gaskets 1 set
(v) Pump set Power Cables 1 set
2. Mixers
(i) Oil seal for housing 1 set
(ii) Oil Seal for Gear Box 1 no.
(iii) Gear Box Bearing 1 no. ( 1 set)
3. Air Blower
(i) Oil Seal 1 set
(ii) Bearing 1 set
(iii) Suction Filter 1 set
4. General Utility
(i) Racking Arms (M.S.) 4 Nos.
(ii) Wheel Barrows (M.S.) 2 Nos.
(iii) Tokari (Ghamela) Paras Miracle Brand Plastics of 6 Nos.
Versatile quality
Note:
Contractor should provide spares and list of spares required for one year after handing
over the plant.
All other miscellaneous items necessary for completing the installation and commissioning
of the equipment under this contract, as per the existing codes of practice.
Technical specific requirements shall conform to Section 6, Part 6 – Mechanical

Requirements as well as the Electrical Specifications.
Mechanical Equipment
14.2 Pumps
14.2.1 General
14.2.1.1 Design standards
The design, manufacture and performance of all the Pumps shall confirm to the following
latest applicable Indian and International standards.
• IS 5120: Technical requirements for Roto-dynamic special purpose pumps.
• IS 5600: Specification for Sewage and drainage pumps
• IS 6595 Part 2: Horizontal centrifugal pump for clear, cold, fresh water

• IS 9137: Code for acceptance tests for centrifugal mixed flow and axial flow pumps-
class “c”
• IS 14536 : Selection installation, operation & maintenance of submersible Pump set
code of practise
• IS 14220 : Specification for open well submersible pump set
• ISO 2858 : Horizontal centrifugal pumps manufacturing standard (End suction
centrifugal pump (Rating 16 Bar)-Designation, nominal duty point &dimension)
• HIS: Hydraulic Institute Standards
14.2.2 Submersible Pumps
This specification covers all submersible type pumps used in connection with sumps or
wet wells. They may be connected in dry well mode or be fully submersible. In all cases,
the following general criteria shall apply:
14.2.2.1 Design Requirements
a) The total head capacity curve shall be continuously rising towards the shut off with the
highest at shut off. The shut off head of the pump shall be at least 120% of the total
head.
b) Pumps shall be suitable for single as well as parallel efficient operation at any point in
between the maximum and minimum system resistance. The pump shall be capable
of developing the required total head at rated capacity. When parallel operation is
specified, the head rise shall be at least minimum 10 percent of the head at rated
capacity. The contractor to be submitted the system resistance curve for parallel
operating pumps.
c) The pumps shall be designed to handle solid sizes of up to 100 mm for handling raw
sewage and 50 mm for handling sludge. Specific gravity of sewage is 1.05
d) Pumps shall run smooth without undue noise and vibration, Cavitation, oil or water
leaks over the range of operation. To ensure free operation, all rotating components of
pump shall be statically and dynamically balanced to BS 6861 / as per zone A & B of
ISO 10816-1. Vibration level shall not exceed the levels given in BS 4675 and Noise
level shall be limited to 85 dBA at 1.86 M at sites.
e) The pump set shall be suitable for starting with discharge valve open and/or closed.
f) Pump sets shall be capable of withstanding accidental rotation in reverse direction and
phase monitoring provision to give fault indication in case of phase reversal. Reverse
rotation switch shall be provided
g) Pumps shall have a preferred operating region of 70-120 percent of best efficiency
capacity of the furnished impeller. Rated capacity shall be within the region of 80-110
percent of best efficiency capacity of the furnished impeller.
h) The pump shall be compatible with VFD and selected automation system as
mentioned in anywhere i.e. Data sheet/process document/ P&ID, etc.,
14.2.2.2 Construction Features
The following general features shall apply to the manufacture of all submersible pumps;
a) Pump shall be centrifugal, vertical spindle, non-clog, and wear resisting, single stage
type.
b) Pump casing shall be of robust construction. Liquid passages shall be finished smooth
and designed as to allow free passage of solids. The volute tongue shall be filed to a
smooth rounded edge. Pump casing shall be conforming to relevant I.S and the internal
surfaces shall be free from rough spots and must have central line discharge
c) Double Mechanical seals shall be provided to protect the motor from ingress of sewage
along the shaft. The preliminary and secondary seals shall be oil-lubricated with

tungsten carbide or silicon-carbide faces and they shall be equipped with an electrical
monitoring system for seal failure detection.
d) Impeller shall be non-clog enclosed type with smooth blunt edges and large water ways
so as to allow free passage of the large size solids. It shall be free from sharp comers
and projections likely to catch and hold rags and stringy materials. The number of
impeller vanes for pumps up to 1000 m3/hr shall be limited to two and shall be limited
to three for the pumps higher than 1000 m3/hr. The impeller shall be properly balanced
dynamically as well as statically. The impeller shall be properly machined for liquid
passage. Enclosed impellers shall be adjustable. In such a case, the pump shall be
designed to take care of the additional thrust produced. Impellers shall be surely
fastened directly to the extended shaft of motor with keys, taper housings of lock nuts.
The impeller shaft shall be made of stainless and it shall have a surface finish between
0.75microns or less. The shaft shall be straight within 0.125 mm for 3 meter length
total dial indicator reading
e) The critical speed of the rotor shall be at least 30% above the operating speed.
Complete rotor shall be balanced dynamically as per ISO 9906
f) Pump sets shall have double bearings. The bearing life shall be minimum 100,000 hrs
of operation. Bearing shall be of the anti-friction type. Bearing shall be capable of taking
the static weight of the rotating parts and any thrust generated by the operation of the
pump.
g) Each pump shall be complete with a cast iron delivery connection arrangement for
fixing to the concrete floor of the suction well. The joint between the pump discharge
flange and the delivery piping shall be made by merely lowering the pump into guide
rails / rope from access level. It shall be provided with all necessary fixings for guiding
the pumps during lifting/lowering. Each pump shall be provided with a stainless-steel
lifting chain conforming to BS 1663 and BS 4942.
h) The pump delivery size shall not be less than 200 mm.
i) Each pump shall be provided with an automatic coupling device for attaching the chain
pulley block hook to the pump at low level, even whilst the pump is submerged, without
the need for personnel to enter the well. This automatic coupling device shall easily
and automatically couple and uncouple the hoist hook and be complete with necessary
accessories. All links and cables shall be multi-stranded stainless steel.
j) The pump guide rail assembly will have pedestal, bracket, delivery duck foot bend,
guide rail pipe, upper guide rail holder complete. The pedestal and bracket shall
provide automatic coupling between pump delivery and discharge bend.
k) Pumps shall be provided with SS steel lifting chains of suitable capacity. One end of
the chain shall be adhered to the pump and the other end fixed near the upper bracket
for guide rail/wire rope assembly by the mean of D-shackle. The chain shall give rings
fixed at an interval about 1 m for engaging the hook of chain pulley
l) Efficiency of Pump shall not be less than 75%. Pump speed: 1,500 RPM (Maximum)
m) Hydrostatic test shall be 1.5 X the shutoff head or twice the rated discharge head
n) Washout or flushing arrangements to be provided for sludge pumps to facilitate easy
and rapid cleansing
o) When connected in dry-well mode, integrated cooling shall be provided wherein
pumped liquid or coolant is circulated through cooling jacket for continuous operation
of the pump motor set.
The power rating of the pump motor should be the larger of the following
i) 115% of the power required (BKW) at the duty point.
ii) 115% of the power input to the pump at duty point at a speed corresponding to the
frequency of 48.5 Hz.
iii) 110% of the maximum power required by the pump from zero discharge to run off point
total head.

14.2.2.3 Materials of Construction
Pump Materials
Pump casing : Cast Iron IS 210 FG 260 / 1.5 to 2% Nickel

Impeller : Stainless Steel : ASTM A 743 CF8M
Shaft : Stainless Steel : BS 970 Gr.316
Bush : Bronze IS 318 Gr. LT B2
Impeller key & bolt : Stainless Steel : AISI 316
Lifting Chain : Stainless Steel : AISI 316
Guide Rail pipe : Stainless Steel : BS: 970 Gr.316
Eye Bolt : Stainless Steel : AISI 316
Bearing Bracket : CI IS : 210 FG 260
Motor casing : CI IS : 210 FG 260
Fasteners and Foundation Bolts : Stainless Steel : AISI SS316
Casing wear ring : CI IS : 210 FG 260
O-ring : Nitrile rubber (NBR)
Shaft Seal
Type of seal : Double mechanical seal

Arrangement : Tandem
Seal on medium side : With elastomer bellows
Mechanical seal, pump side : Silicon carbide/NBR
Mechanical seal, bearing side : Silicon carbide/NBR
Monitoring Devices
Thermal winding protection : Bi metallic sensors in all three phase winding

Motor housing leakage : Moisture sensor
monitoring
Junction box leakage monitoring Moisture sensor
Mechanical seal leakage : Moisture sensor
Detection
Bearing temperature monitoring : Bi Metallic sensor
Installation Arrangement
Type of installation : Wet well installation design for automatic connection to a

permanently installed discharge elbow will neoprene seal to
avoid metal to metal contact
Flange dimension to : EN 1092-2, PN 10
Claw : Bolted to the pump
Installation depth : As per data provided

Guide system : Stainless Steel

Lifting device : Stainless steel lifting chain
Length of lifting device : Suitable
Lifting loops : suitable
Installation accessories : Discharge elbow, fasteners, claw, bracket lifting chain,
guide bars etc. complete.
Motor
Type : Squirrel cage induction motor

Motor efficiency : Premium efficiency motors according to IE2
Degree of protection : IP 68
Insulation class : H,
Coolant temp : </= 40 Deg. C
Temp rise limit : Class B
Starting mode : Direct on line/ Star delta starter/Soft starter / Variable
frequency drive
Rated voltage : 3ph, 415 V
Rated frequency : 50 Hz
Nominal speed : Less than 1500- rpm (Synchronise)
Motor casing : CI IS 210 IS FG 260
Main cable : IEC:60227, IEC:60228; IEC:60332; IS:1554 Complete with
cable length as per requirement
Motor feature :For VFD application Vacuum Pressure Impregnated (VPI)or
Inverter Grade Treatment (IGT). Insulated bearing with shaft
grounding ring, as applicable.
* Material test certificates from Government approved metallurgical laboratory shall be
formally submitted for all pumps by Suppliers / Contractors
14.2.2.4 Induction Motors (for Submersible Pumps)
The motor shall be squirrel cage type, three phase submersible motor for continuous duty
with class ‘H’ insulation. Winding of the motor shall be impregnated by resin in order to
achieve required thermal withstanding capacity. Motor shall have integral cable port and
cable entry shall be sealed. There shall be thermal protection against overheating of motor
–winding. The motor shall be designed for non-over loading characteristics. Motor shall be
sealed against entry of pump liquid in the motor by using mechanical seal. Moisture sensor
tripping unit shall be located inside in the motor chamber.
Performance and Characteristics
The submersible motor shall conform to IS: 9283: and the submersible cable shall conform
to clause no. 4.4 of the IS: 9283:
Motors shall be capable of giving rated output without reduction in the expected life span
when operated continuously under the following supply conditions:
Variation of supply voltage from rated motor voltage : ± 6%

Variation of supply frequency from rated frequency : ± 3%

Combined voltage and frequency variation : ± 10%
The starting current of motor shall not exceed 200% of rated full load current for star/delta
starting and 600% of rated full load current for DOL starting, under any circumstances.
Motors shall be suitable for full voltage direct-on-line starting or star-delta starting or Soft
starter or variable Frequency drive.
Motors shall be capable of starting and accelerating the load with the applicable method
of starting, without exceeding acceptable winding temperatures, when the supply voltage
is in the range 85% of the rated motor voltage to maximum permissible voltage.
The locked rotor current of the motor shall not exceed 600% of full load current (subject to
tolerance as per the applicable standard) unless otherwise specified.
Motors shall be designed to withstand 120% of rated speed for two minutes without any
mechanical damage in either direction of rotation.
The motor vibrations shall be within the limits specified in applicable standard unless
otherwise specified for the driven equipment.
Except as mentioned herein, the guaranteed performances of the motor shall be met with
tolerances specified in applicable standard, IS 9283.
The enclosure for motor shall be IP-68.
Protection against increase in stator winding temperature (150°C) bearing temperature,

leakage in stator housing and terminal box shall be provided. Minimum three number
thermistors in series are to be provided to sense the stator winding temperature. Sensors
are to be provided to detect if leakage of sewage into the oil housing is above 30%
concentration
Bimetallic thermal switch to trip the motor against increase in temperature shall be
provided.
The power rating of the motor shall be larger of the following: 115% of the power input to
the pump at duty point at a speed corresponding to the frequency of 48.5 Hz.
Maximum Power input while operating single pump corresponding to the speed of 50 Hz.
For pumps that are run with variable frequency derive then System Curve shall be
submitted along with Motor Curve for the entire operative range of RPM for approval.
Submission of pump data sheet shall be tagged as Variable Frequency Drive /Normal
Operation.
Submersible Cable
The umbilical cable between the control panel and the submersible pump shall comply
with IEC:60227; IEC:60228; IS:1554 to cover the following requirements;
a) The power cable shall be PVC insulated and PVC sheathed, flexible, 3.5 core type.
The size of the conductor shall be adequate for continuous use under water and air.
The half core shall be used for earthing.

b) The control cable shall be PVC insulated PVC sheathed, flexible, flat type and shall be
adequate for continuous use under water and air. The control cable for stator winding
temperature sensor (Thermistors) shall be 3 core x 2.5 sq. mm copper conductors and
for bimetallic thermal switch 2 core x 2.5 sq. mm copper conductor shall be provided.
c) In case a joint is required to be made between the lead cable supplied with the motor
and the user's cable connectors, a detailed procedure of cable jointing to make a
watertight joint shall be provided by the manufacturer.
Earthing
a) Earthing of the motor shall be done in accordance with the relevant provisions of
IS:3043:
b) For the purpose of earthing these motors, earthing connection may be made to
discharge pipe.
Insulation
a) Any joints in the motor insulation such as at coil connections or between slot and end
winding sections shall have strength equivalent to that of the slot sections of the coil.
b) The insulation shall be given tropical and fungicidal treatment for successful operation
of the motor in hot, humid and tropical climate. The tropicalizing treatment shall be as
per the applicable standard.
c) The stator winding shall be made from high conductivity annealed copper conductor.
PVC insulated winding wires conforming to IS: 8783: for wet type motors. The stator
winding shall be of high conductivity annealed copper enamelled insulated wires
conforming to IS 4800 (Part - VII): for dry type motors.
Temperature Rise
The temperature-rise test of the motor shall be taken with the motor coupled to the suitable
pump to give the full load output of the motor. When the various temperatures are
stabilized, the set is stopped and the temperature-rise of the stator winding by the
resistance method shall not exceed 35°C. During the test, the temperature of the cooling
water may not exceed 45°C. As the cable resistance will also be substantial, it is necessary
that while calculating the temperature rise by resistance method, due care is taken to
account for the correct hot and cold resistance of windings.
Constructional Features (of the Electric Motor)
The motor shall be suitable for continuous use in fully or partially submerged condition. A
built in cooling system if required shall allow the motor to operate continuously at its rated
output regardless of whether the electric motor is submerged or not, by providing either
external or internal cooling arrangement.
Terminal Box
Terminal box shall be of weatherproof construction to eliminate entry of water and

suspended matter. The terminals shall be of the stud type with necessary plain washers,
spring washers and check nuts. They shall be substantially designed for the current
carrying capacity and shall ensure ample phase to phase and phase to ground clearance.

14.2.3 Horizontal Centrifugal Pumps
14.2.3.1 Design requirements – centrifugal pumps:
a) The pump design shall be as per ISO 2858/IS:1520/IS:5120. The pump shall be
designed to operate satisfactorily without detrimental surges, vibration, noise or
dynamic imbalance over the required head range. The head-capacity curve of the
pump shall have a continually rising head characteristic with decreasing capacity over
the whole range of total head. The shut off head of the pump shall be at least 120% of
the total head.
b) The pump should be capable of developing the required total head at rated capacity.
Pumps should be suitable for single as well as parallel efficient operation at any point
in between the minimum and maximum system resistance indicated in the system
resistance curves. When parallel operation is specified, the head rise shall be at least
minimum 10 percent of the head at rated capacity
c) Pumps shall have a preferred operating region of 70-120 percent of best efficiency
capacity of the furnished impeller. Rated capacity shall be within the region of 80-110
percent of best efficiency capacity of the furnished.
d) The required NPSH at duty point should be at least 1.0 M less than the available NPSH.
e) Pumps shall run smooth without undue noise and vibration. The velocity of vibration
should be within 4.5 mm/sec. The noise level should be limited to 85 dBA at a distance
of 1.86 M.
f) Operating range - system curve shall be submitted along with that of motor if the
pump/s are subjected to VFD application with the data sheet tagged as VFD
application.
g) Efficiency of the pump shall not be less than 85%
h) The pump set should be suitable for starting with discharge valve open, as well as
closed.
i) Pump sets shall be capable of withstanding accidental rotation in reverse direction and
protection for drive also to be taken care (i.e., Reverse rotation switch to be provided).
j) The pumps shall be designed to handle solid sizes of up to 50mm
k) Hydrostatic test: 1.5 times shutoff head or twice the rated discharge head whichever
is greater
l) Pump speed – 1,500 RPM (Maximum)
Features of Construction
a) Pump should be suitable for applications in municipal sewage handling or sludge

handling as per process requirement, with back pull out design. It shall have end
suction and side discharge. It should be of self-venting type.
b) Pumps should be identical for particular application and suitable for parallel operation
with equal load division. Components of identical pumps should be interchangeable.
c) Pump casing should be of robust construction Liquid passages should be finished
smooth and designed so as to allow free passage of solids. The volute tongue should
be straight across and filed to a smooth rounded edge. Casing should be provided with
hardened renewable wearing ring.
d) Impeller should be suitable for application, enclosed type with smooth blunt edges and
large water ways so as to allow free passage of large size solids. It should be free from
sharp corners and projections likely to catch and hold rags and stringy materials.
Impellers should be provided with hardened wearing ring. Hardness of the Impeller
ring should be at least 50 BHN more than that of casing ring.
e) The first critical speed of the rotor should be 30% above the operating speed. Complete
rotor should be statically and dynamically balanced as per ISO 9906

f) Replaceable shaft sleeves should be provided to protect the shaft where it passes
through stuffing boxes. Surface hardness of shaft sleeve should be minimum 400 BHN.
g) Pumps should be provided with anti-friction bearings. Bearings should be easily
accessible for inspection and maintenance. Bearings should be grease lubricated. The
Bearings shall have a minimum working life of 100,000 hours of working.
h) Stuffing box should be of such design that they can be repacked without removing any
part other than gland and lantern ring. Stuffing box drain with pipe connection should
be provided at the lowest point so that no leakage accumulates in it.
i) Lantern ring should be of axially split type. Grease should be used for stuffing box
sealing. Water will not be available for this purpose. Gland should be of split type.
j) Pump and motor shall be coupled through flexible coupling.
k) Coupling guard bolted to the base plate should be furnished.
l) Base plate for pump and motor should be common. Suitable holes should be provided
for grouting. Foundation bolts should be complete with nuts and washers.
m) Tapping should be provided at suction and discharge nozzles for pressure gauge
connection.
n) Hand holes should be provided in the casing to allow easy access to the impeller as
well as to the casing throat. Casing drain connection with stainless steel collared plug
should be provided.
o) Impeller wear ring hardness shall be min 50 BHN higher than that of Casing wear ring
p) Washout or flushing arrangements to be provided for sludge pumps to facilitate easy
and rapid cleansing
Material of Construction
Casing : CI to IS:210 Gr. FG 260 with 1.5 to 2% Nickel.

Impeller : Stainless Steel: ASTM A 743 CF8M
Impeller Wearing rings : St. Steel ASTM A743 CA-15
Casing rings : St. Steel ASTM A743 CA-15
Shaft : Stainless Steel BS: 970, Gr 431 S29
Shaft sleeves : St. Steel ASTM A743 CA-15-(Minimum hardness-400 BHN
Shaft Seal : Mechanical
Base plate : CI/MS fabricated IS 2062 epoxy painted.
Coupling : CI
Coupling guard : MS fabricated from IS 2062 Epoxy painted
Material test certificates from Government approved metallurgical laboratory shall be
Electrical drive: -
The motor shall be squirrel cage type, three phase induction, Horizontal foot mounting
motor for continuous duty with class ‘H’ insulation.
The power rating of the pump motor should be the larger of the following
i. 115% of the power required (BKW) at the duty point.
ii. 115% of the power input to the pump at duty point at a speed corresponding to the
iii. 110% of the maximum power required by the pump from zero discharge to run off point
total head.
Refer the respective electrical specification for other specification

14.2.3.2 Primary Scum Pumps
Scum generated in primary clarifier shall be collected in scum pit wherein submersible
chopper pumps shall be installed to handle all the latex, plastic material and hair from the
top of clarifier. The operation of scum pumps shall avoid downstream clogging of the
equipment. Scum line of 100 mm dia from each clarifier is also to be laid.
14.2.4 Chopper pump specification
14.2.4.1 General
The chopper pump shall be specifically designed to pump waste solids at heavy
consistencies without plugging or dewatering of the solids. Materials shall be
chopped/macerated and conditioned by the pump as an integral part of the pumping
action. The pump must have demonstrated the ability to chop through and pump high
concentrations of solids such as plastics, heavy rags, grease and hair balls, wood, paper
products and stringy materials without plugging, both in tests and field applications.
Sludge chopper pumps for digester mixing shall incorporate, as a minimum
Construction Features
Impeller:
The impeller type shall be Non-clog, solids handling, semi-open, with pump out vanes.
Inlet side of vanes sharpened for cutting up against cutter bar across the suction opening.
Additionally, another upper cutter behind the impeller designed cut any material near the
mechanical seal area. Impeller fastened to shaft by keying and lock nuts.
Casing and Back Pull-Out Plate:-
The pump casing shall be of volute design, spiralling outward to the flanged centreline
discharge. Back pull-out design shall incorporate jacking bolts for accurate adjustment of
impeller-to-cutter bar clearance and shall allow removal of pump components. Casing &
back plate shall be ductile cast iron with all water passages to be smooth, and free of
blowholes and imperfections for good flow characteristics. Back plate shall include a
replaceable Rockwell C 60 alloy steel cutter adjustable for 0.005” – 0.050” clearance to
cut against the rotating impeller pump out vanes for removing fibre and debris.
Solids handling:-
Ability to cut/macerate/shred wastewater solids to particles under 6mm in size
Cutter Bar Plate:-
Shall be recessed into the pump bowl and shall contain at least 2 shear bars extending
diametrically across the intake opening to within 0.010” – 0.030” of the rotating cutter bolt
tooth, for the purpose of preventing intake opening blockage and wrapping of debris at the
shaft area. Chopper pumps utilizing individually mounted shear bars shall not be
acceptable. Cutter bar shall be alloy steel heat-treated to minimum Rockwell C 60.
External Cutter:-

The impeller shall be secured to the shaft using a cutter bolt, designed to cut stringy
materials and prevent binding using a rotating cutter tooth. The cutter bolt shall be alloy
steel heat treated to minimum Rockwell C 60.
Upper Cutter:-
Shall be threaded into the casing or back pull-out adapter plate behind the impeller,
designed to cut against the pump-out vanes and the impeller hub, reducing and removing
stringy materials from the mechanical seal area. Upper cutter shall be cast alloy steel heat
treated to minimum Rockwell C 60. The upper cutter teeth are positioned as closely as
possible to the centre of shaft rotation to minimize cutting torque and nuisance motor
tripping. The ratio of upper cutter cutting diameter to shaft diameter in the upper cutter
area of the pump shall be 3.0 or less.
Pump Shaft:-
Shafting shall be heat treated alloy steel, with a minimum diameter of 1.5 inches in order
to minimize deflection during solids chopping.
Bearing Housing:-
Shall be ductile cast iron and machined with piloted bearing fits for concentricity of all
components. Piloted motor mount shall securely align motor on top of bearing housing.
Thrust Bearings:-
Bearing type shall be back to back angular contact ball type or face to face tapered roller
type.
Shaft thrust in both directions shall be taken up by a matched set of face to face tapered
roller bearings, with a minimum L-10 rated life of 100,000 hours. A pump mechanical seal
shall also be provided to isolate the bearings from the pumped media. The pump seal, as
well as the thrust bearings shall be oil bath lubricated in the bearing housing.
Pump Mechanical Seal:
The mechanical seal shall be located immediately behind the impeller hub to maximize the
flushing available from the impeller pump out vanes. The seal shall be a cartridge-type
mechanical seal with Viton O-rings and silicon carbide (or tungsten carbide) faces. This
cartridge seal shall be pre-assembled and pre-tested so that no seal settings or
adjustments are required from the installer. Any springs used to push the seal faces
together must be shielded from the fluid to be pumped. The cartridge shall also include a
heat-treated seal sleeve and a ductile cast iron seal gland.
Automatic Oil Level Monitor:
An oil level switch shall be mounted at the top of the wet well, with a hose feeding down
to the side of the bearing housing to monitor oil level and shut off the motor in event of low
oil level. A relay shall be included for mounting in the motor control panel.
Electrical Drive (Motor):
As mentioned in pump section with addition requirement if any.

Stainless Steel Nameplate:
Shall be attached to the pump giving the manufacturer's model and serial number, rated
capacity, head, speed and all pertinent data.
Material of Construction:
Casing : Ductile cast iron ASTMA 536

Impeller /Upper cutter : Cast alloy steel ASTMA 148, heat treated to minimum
Rockwell C 60
Shaft & Sleeve : AISI 4140 (SS) / Heat treated alloy steel
Cutter bolt /Cutter bar : Cast alloy steel, heat treated to minimum Rockwell C 60
Mechanical seal : Cartridge type with silicon carbide (or tungsten carbide) seal
faces and stainless-steel sleeve.
Bearing housing : Ductile cast iron ASTMA 536
Foundation bolt : HTS galvanised steel
14.2.5 Inline Sludge Grinder
In line sludge grinders shall be utilized on all raw pumping applications, pumping raw
sludge for anaerobic digestion. The Grinders shall be designed to match the flow rates
expected for pumping raw sludge and installed on the suction side of each pump with
isolation valves and bypass piping.
The grinders shall be inline pipe type fastened to the pipework through the use of pipe
flanges and shall incorporate the following as minimum.
a) Sludge inline grinders to consist of a flanged main housing, internal dual set of parallel
cutters/shafts and a drive assembly all designed for continuous operation cutting solids
in dry or wet condition
b) Main housing of ductile iron ASTMA A536-84, single piece body inlet /outlet pipe
flanges designed of stay in line without taking pipe apart Interior of housing with special
concave shape to match tight fit of the radial cutters. There shall be a maximum 8 mm
clearance between the housing and the cutter edges. The housing shall have a top
flanged access /maintenance port and a large connection port for fastening the drive
system
c) The removal of the cutters/shafts shall be by removing the drive system only, without
removing any pipework. The main housing shall be provided with a heavy duty integral
ductile iron mounting base.
d) Internal dual cutters shall be AISI 4130 heat treated alloy hardened to Rockwell C45-
50. Cutters and spacers shall consist of individual series of plates alternating in such
a way that the cutter only line up with a spacer on the opposite shaft. Each cutter plate
shall have a series of about 13 sharp cam/teeth edges no more than 13mm above the
root cutter plate diameter. The cutter edge on each opposite shaft shall overlap with
not being outside the range 1.6 to 6 mm. The cutters/ Spacers shall have centre
openings in a hexagon shaped designed to fit on to the hexagon shaped shafts with
clearance not more than 0.38 mm on mating surface.
e) Internal hexagonal shaped cutter shafts shall be solid AISI 4140 heat treated alloy steel
with a tensile strength of not less than 1000 MPa. The shaft shall not be less than
51mm thick in any direction. The cutter shafts shall not rotate at a speed of more than

2/3 that of the drive shaft and they shall be designed to impart a minimum force at each
tooth tip of 2,680 N/kW continuously and 8,530 NkW instantaneously.
Bearings/Seals/Housing
a) A Bearing/Seal housing shall be provided for the top of the main housing, designed to
accommodate the weight of the drive system. The housing material shall be ductile
iron ASTMA A 536-84.
b) Each end of the cutter shafts shall have sealed steel ball bearings designed to take up
the radial and axial loads of the oversized deep groove (Conrad) type.
c) The bearing shall be protected using sealed cartridge type mechanical seals with
tungsten carbide mating surface, all designed to work without use of flushing water or
lubrication and rated for 620kPa
Drive System:
a) Electric drive motor with integral gear box directly mounted on top of the main housing
incorporating the following as a minimum:
b) Gear reducer of the grease filled planetary type with heavy shock load classification
with a 29:1 reduction ration. The gear box shall be connected to the cutter drive shaft
using a two-piece coupling.
c) The motor shall be maximum 1800 rpm premium efficiency type, TEFC,415v/50HZ/
3ph, reversible type with heavy cast-iron finned frame (for noise reduction), single
direction cooling fan and directly mounted to the gear reducer. Design motor with
running torque per kW of 152 N-m continuously minimum and 500N-m (3,300 in-lbs)
instantaneous peak load.
The power rating of the pump motor shall be the larger of the following
i. 115% of the power required (BKW) at the duty point.
ii. 115% of the power input to the pump at duty point at a speed corresponding to the
iii. 110% of the maximum power required by the pump from zero discharge to run off point
total head
a) Control panel: Each grinder shall have control panel for complete automatic operation
incorporating the following as a minimum.
i) 316 stainless steel wall mounted type suitable for wash-down/outdoor wet weather
and lockable
ii) Fused interlock disconnect switch
iii) Combination starter with motor protection breaker.
b) MANUAL-OFF-AUTOMATIC three position selector switch. In MAUAL mode the
grinder rums locally accordingly to the push button. In AUTOMATIC mode, the grinder
will run interfaced with other pump/equipment as required and as per control panel
function. In OFF mode the grinder shall not operate.
c) With the control panel functions in MANUAL or AUTO modes the grind, when
encountering the jam condition, will stop and go into reverse and then revert to normal
rotation operation. If the jam persists, the grinder will stop and go into revers operation
and additional two times and revert back to normal operation. If the jam still persists
the control will stop the grinder and signal an overload condition sending a local and
remote fail alarm and as well as to stop any associated pump/equipment. After the jam
is cleared (Mostly manually) then the reset function can be initiated.
d) Power on, run fail and alarm lights (Push to test type).
e) HAND mode start /stop button.

14.2.6 Axial Flow Pumps
14.2.6.1 General Requirement
The MLR (Mixed liquor recycle) pump shall be a Submersible Propeller type, single stage
pump suitable for pumping screened waste water with fibrous solids /MLSS sludge water
from aeration tank where larger volumes must be pumped at relatively low heads. Pump
should be single-stage close-coupled submersible pump unit with axial propeller for wet-
well installation in vertical column.
Its Self-sealing and self-centring design shall enable the installation and removal even
when the column pipe is submerged. The propeller blades shall be self-cleaning by
passing across a sharp relief groove in the wear ring the blades are cleared from debris
upon each rotation. Motor and pump shall be directly coupled and be manufactured by the
same manufacturer.
The pump set shall be mono-block type driven by squirrel cage induction motor. The motor
shall be an integral part of the pump set. It shall be a totally sealed unit suitable for
completely as well as partially submerged condition.
Each pump shall be provided with a positively driven dual, tandem mechanical shaft seal
system consisting of two seals, each having an independent spring system. The seal
material shall consist of Silicon carbide / Corrosion resistant tungsten carbide. The seals
shall require neither maintenance nor adjustment and shall be capable of operating in
either clockwise or counter clockwise direction of rotation without damage or loss of seal
function
Washout or flushing arrangements to be provided for sludge pumps to facilitate easy and
rapid cleansing
The motor shall be induction type with a squirrel cage rotor, housed in an air filled
watertight chamber. Motor shall be, 3 phase Squirrel Cage Induction Motor, 415V +10%,
50 Hz, with IP-68 Enclosure with Class H Insulation, Temperature rise: According to class
A, IE3 Premium Efficiency Motor. The stator shall be heat-shrink fitted into the stator
housing. Propeller pump, pumps the liquid upwards in the steel pipe which will flow around
the motor with this action motor cooling happens automatically.
Water pressure sealed connection chamber, with two stage cable entry, protected against
excessive cable tension and bending. The cable shall be EPR insulated Double sheathed
designed and certified for permanent use in sewage water and suitable for a conductor
temperature of 80 °C. The motor and cable shall be capable of continuous submergence
without loss of watertight integrity to a depth of at least 20m.
Bi-Metallic Thermal sensors should be provided in the each phase of motor winding & both
(Upper & Lower) bearings to monitor temperature rise in motor windings and bearings.
The sensors shall be connected in series and shall be coupled to the motor contactor coil
such that any one-switch opening will shut down the motor. The temperature setting shall
be 140°C +/-5°C and shall automatically reset once the stator temperature returns to
normal.
DI Moisture sensors shall be provided in motor housing, mechanical seal oil bath and
connection chamber of the motor for the purpose mentioned here below:
i) For Oil chamber - To detect the Mechanical Seal Failures.
ii) For Motor housing - To monitor leaks in Motor housing.

iii) For Connection Chamber - To detect failure through Cable entry.
Mating surfaces shall be watertight and fitted with nitrile O-rings
14.2.6.2 Design Requirement
a) Pump shall be vertical Shaft, wear resisting, single stage, submersible Propeller type.
b) The pump shall be designed to operate satisfactorily without detrimental surges,
vibration, noise or dynamic imbalance over the required head range. The head-
capacity curve of the pump shall have a continually rising head characteristic with
decreasing capacity over the whole range of total head.
c) Each pump must be capable of running satisfactorily in parallel with other sets in the
system without throttling and by itself, without cavitation or overload under all operating
conditions within the system resistance; Components of identical pumps should be
interchangeable.
d) The efficiency / pump shall be high at duty point and remain reasonably high during
the full duty range at the pumping system.
e) The pump shall be compatible with VFD and selected automation system.
f) The pump should be capable of developing the required total head at rated capacity.
g) The power rating of the pump motor should be the larger of the following:
i) 110% of the maximum power required by the pump from zero discharge to run off
point total head.
ii) 115% of the power required (BKW) at the duty point.
h) Minimum hydraulic efficiency of pump at duty point shall be 75% & the motor shall be
premium efficiency motors in accordance with IE3. The highest efficient pump set shall
be considered for selection.
i) For pumps that are run with variable frequency derive then System Curve shall be
submitted along with Motor Curve for the entire operative range of RPM for approval.
Submission of pump data sheet shall be tagged as Variable Frequency Drive /Normal
Operation.
j) Pump operating speed shall be less than 1000 rpm
k) Pumps should be provided with anti-friction ball or roller type bearings, lubricated-for-
life, maintenance-free designed for a L10 bearing life of 100,000 hours at BEP and
shall be of sufficient size to transfer all radial and axial loads to the pump housing and
minimize shaft deflection.
l) Pump should be equipped with double mechanical seals by means of a SIC/SIC or
Corrosion resistant tungsten carbide, independent of the direction of rotation.
Pumps
Pump casing : EN GJL-250 or IS 210 to FG 260

Connection chamber : EN GJL-250 or IS 210 to FG 260
Diffuser / Inlet Diffuser : EN GJL-250 or IS 210 to FG 260
Propeller hub : Cast Iron EN-GJS-400-18
Propeller Blades : CF 8M ASTM A 743 / Stainless Steel 1.4340
Shaft : AISI 431 / AISI 420
Impeller key & bolt : AISI – 316
Wearing ring : AISI 316 or EN 1.4408
Chain : Stainless Steel 316 as per DIN5688 Gr.5

Lifting Hoop : AISI 316 / EN-GJS-400-18

Bearing Bracket : EN GJL-250 or FG 260 as per IS 210
Motor casing : EN GJL-250 or FG 260 as per IS 210
Bolts, nuts : Stainless Steel 316 / 1.4401
O-ring : Nitrile rubber (NBR)
Coupling ring : AISI-316 / Cast Steel 1.0446
Shaft Seal
Type of seal : Double mechanical seal

Mechanical seal, pump side : Silicon carbide/NBR or Corrosion resistant Tungsten
carbide WCCR
Mechanical seal, bearing side : Silicon carbide/NBR or Corrosion resistant Tungsten
carbide WCCR
Monitoring
Thermal winding protection : Bi metallic sensors in all three phase winding

Motor housing monitoring : Moisture sensor
Mechanical seal leakage detection : Moisture sensor
Bearing temp monitoring : Bi Metallic sensor
Motor
Type : Squirrel cage induction motor

Motor efficiency : Premium efficiency motors according to IE3 as defined in
IEC60034-30
Insulation class : H, Thermal Sensors set for 140 Deg. C
Coolant temp : </= 40 Deg.C
Temp rise limit : NEMA Class A
Starting mode : Direct
Rated voltage : 3ph, 415 V
Rated frequency : 50 Hz
Nominal speed : Less than 1000- rpm (Synchronise)
Motor casing : EN GJL-250 or FG 260 as per IS 210
Main cable : Complete with cable length as per requirement & shall be
suitable for VFD operation.
*Material test certificates from Government approved metallurgical laboratory shall be
14.2.7 Sump Dewatering Pump
a) Pump should be suitable for handling settled sewage containing grit and suspended
particles.

b) The pump motor should be suitable for working with or without submergence in
sewage. The motor rating should be more than the maximum power required by the
pump.
c) The pump set should be portable with necessary hooks.
d) The pump should be suitable for dewatering from a pit 900mm x 900mm x 100mm
deep.
e) The pump should be vertical, centrifugal, non-clog type.
f) The pump impeller should be mounted on the extended shaft of the motor.
g) The pump should be provided with mechanical seal.
h) The pump should be supplied with flexible hose pipe of 50mm, 50M length.
i) Suitable cable of 25 M length should be supplied with the pump
j) Pumps shall be supplied with all necessary pipe work to discharge to surface drainage.
Each pump shall be provided with delivery reflux and isolating valves, and suitable
lifting gear for lowering and lifting the pump from the sump.
k) Pumps weighing 40 KG or more shall be lowered in to the sump on guide rails and be
located to their respective discharge pipe work with an angle flange connection and
self-locating clamps.
l) Pump impellers shall be designed to pass solids of the sizes which pass through the
inlet ports of the pump and shall be capable of pumping solids of up to 50 mm diameter.
m) Efficiency of the pump shall not be less than 30%
n) Hydrostatic test: 1.5 times shutoff head or twice the rated discharge head whichever
is greater
o) Washout or flushing arrangements to be provided for sludge pumps to facilitate easy
and rapid cleansing
p) Pump speed: 1,500 RPM (Maximum)
Casing : Cast Iron IS 210 FG 260 with 1.5 to 2% Nickel

Impeller : Stainless Steel ASTMA 743CF 8M
Shaft : SS BS: 970, Gr 431 S29
Electrical drive:
Refer to the submersible motor specification as elaborated above and refer to the
respective Electrical specification.
Valve chamber / valve pit shall be provided for housing valves and instruments of
submersible pumps. The open valve pit shall be provided with a 1 m wide staircase with
hand railings. A small pump pit of 400 mm x 400 mm x 300 mm deep (minimum) shall be
provided at a suitable corner of the chamber to pump out water. Suitable rain hood shall
be provided at minimum 2.20m height to prevent ingress of rain water.
A suitable drain pump set with accessories shall also be provided in the valve chamber.
14.2.8 Positive Displacement Pumps
14.2.8.1 Screw and Progressive Cavity Pumps
Unless otherwise stated, the design of pump shall be in accordance with API 676 /ISO
15136

The progressive cavity pumps shall be self-priming and designed to handle abrasive,
shear sensitive and viscous materials, solids in suspension and liquid/solids mixtures.
Automatic Variable stroke frequency / stroke length arrangement shall be incorporated

wherever remote application with PLC/SCADA is envisaged and process demands these
changes through remote, Local Control Panel shall also be envisaged with each pump
with auto/manual selector switch and knob for these variations done manually.
General Design Considerations
Progressive Cavity Pumps comprising a stator manufactured from a resilient material and
a helically ground rotor shall be considered for pumping industrial sewage, sludge or highly
abrasive and corrosive products without rags and grit.
Features of Construction
Pumps shall be manufactured with a short compact block design with close coupled drive
or alternatively foot mounted drive via flexible coupling connection.
a) The pump shall be restricted to cavitation free operation throughout its rated band of
speeds at its duty points. Pump shall be screw type, slow speed maximum 200 rpm
having following construction features:
b) Pumps shall be of the type, in which a pumping action is generated by a helical rotating
eccentrically within a resilient stator in the form of a double internal helix. The eccentric
motion of the rotor shall maintain a constant seal across the stator as it travels through
the pump to give a uniform positive displacement. The pumps shall consist of externally
mounted stuffing box for easier maintenance of seals.
c) Pumps shall be arranged generally with a single shaft seal at the suction end.
Mechanical seals shall be used. If a flexible shaft is used to accommodate the eccentric
motion, a corrosion resistant shroud shall be fitted to prevent fibre build up on the shaft.
Enlarged inspection access holes shall be fitted to the suction chambers of all pumps
for periodic removal of accumulated debris.
d) The shaft bearings shall be positively isolated from the fluid being pumped. The
bearing shall of taper roller bearings to ensure rigidity and concentricity of shaft.
e) The rotor material shall be selected for corrosion and abrasion resistance for the fluid
being pumped and for prolonged service life. Hard chrome or other approved coatings
shall be not less than 250 micron thickness and shall be diffused in to the base
material. The rotor shall generally be single-stage and shall incorporate not less than
360 o of twist, but for high-head applications, it may be necessary to use more than a
single – stage.
f) The stator shall be of a resilient material selected for chemical and abrasion resistance
for the fluid being pumped.
g) Pump speed shall suit the application, where variable delivery output is needed, the
pump shall be provided with a variable speed drive. The size and speed range of the
pump shall ensure that the highest expected duty point shall lie within the available
speed range.
h) The pumps shall be provided with a universal joint employing two sets of pins
perpendicular to each other, each providing freedom of angular movement for
facilitating smoother transmission of angular load and to withstand the axial forces.
i) Pumps shall be driven by a fixed – speed electric motor through reduction gearing and
the combined drive shall be continuously rated. Pump and motor shall preferably be
mounted in-line on a common base plate.

j) Coupling guards shall be provided, which shall be rigid, securely fixed, and designed
so that removal is not necessary during normal operation, routine maintenance and
routine inspections.
k) All motor enclosures shall be provided with ingress protection to IP 55. Motor anti-
condensation heaters shall be provided and shall be suitable for use on a 415V Three
phase /220 V single-phase, 50 Hz supply as applicable.
l) All bearings shall have a B10 design life of not less than 40,000 running hours and
shall be designed for loading 20% in excess of calculated maximum loading.
m) Pumps shall be fitted with individual dry-running protection to initiate pump trip – dry
running pump protection by ‘under-current’ monitoring. ‘Pipeline-intrusive’ devices
shall not be used.
n) The pump must be protected from operating at pressures higher than recommended.
A glycerine filled diaphragm pressure gauge with integrated magnet switch shall be
installed in the discharge pipe work directly after the pump. When the pressure reaches
the maximum set point a signal from the pressure switch must stop the pump drive.
o) Pumps shall be arranged generally with a single shaft seal at the suction end.
Mechanical seals shall be used. Each pumps shall be provided with safety relief valve.
having following construction features:
p) Efficiency of the pump shall not be less than 40%
q) All rotating parts shall be statically and dynamically balanced as per ISO standards.
r) The pumps shall run smooth without undue noise and vibration
s) Hydrostatic test: 1.5 times shutoff head or twice the rated discharge head whichever
is greater
Casing : CI IS 210-FG 260

Rotor : AISI SS316 Hard Chromed plated
Base Frame : ISMC Fabricated Epoxy coated
Bearing Housing : CI IS 210-FG 260
Shaft : Stainless Steel BS: 970, Gr 431 S29
Foundation bolt : HTS GALVANIZED STEEL
Stator : Hypalon/Equivalent lining
Coupling : Flexible pin bush type
Coupling guard : MS Fabricated
Stator:
a) Vulcanised synthetic rubber stators shall be manufactured with extended ends to form
a collar to prevent twisting of the stator within the pump casing.
b) Optionally, slotted stators are required for retrofitting with a stator tensioning device to
provide even clamping of the stator to rotor to prolong service life.
c) Suction casings shall be provided with clean-out/inspection ports.
d) Washout or flushing arrangements to be provided for sludge pumps to facilitate easy
and rapid cleansing
Rotor:

Rotor design shall incorporate low wear geometry by providing an elongated pitch, wider
sealing line and reduced peripheral velocity of the rotor within the stator thus reducing rotor
slip back. Rotor surfaces shall be ground finish or coated with a minimum 250 micron
thickness non porous hard chroming compound diffused into the base material.
Rotating Drives:
a) Drive torque shall be transmitted through two universal joints or flexible shafts. They
shall be designed for continuous transmission of the maximum torque at the maximum
speed and pressure. Joints shall be designed to enable replacement pins and bushes
to be fitted, manufactured from wear resistant steel.
b) Universal joints shall be protected from damage by the fitting of sleeves with AISI 304
stainless steel guards to prevent ingress of pumped media. Sleeves shall be secured
by two holding bands. Joints shall be lubricated with grease to provide a 10,000 hour
life guarantee.
c) Drive shafts shall incorporate a ‘plug-in’ type design to allow dismantling of drive shaft
and seal without dismantling the bearing housing
Over pressure Protection:
A device to protect against overpressure shall be fitted and in addition to a pressure relief
circuit fitted with an adjustable valve to return flows to the suction of the pump a pressure
switch shall also be installed in the delivery port to stop the pump.
Suction/Flow Failure Protection:
Suction protection shall take the form of a flow sensing device or, when installed, a low
flow inhibit signal from a flow meter. The systems shall be complete with all necessary
instrumentation for free issue to the control panel manufacture.
The pumps must be sourced from a supplier that is ISO 9001:2000 certified to ensure that
the pump is manufactured to certified standards.
14.2.8.2 Dosing Pumps
a) Unless or otherwise mentioned elsewhere, the pump design shall be as per API 675
b) The dosing pumps shall be selected to achieve optimum dosing technology and control
safety with safety relieve valve. The pump shall have a resistant plastic enclosure that
can safely be used for the selected application and shall provide soft and low-pulsation
dosing.
c) Unless otherwise stated, chemical Dosing pump shall be the piston, piston diaphragm
or mechanical diaphragm type as specified. Pump may be Simplex or duplex type
diaphragm type hydraulically operated. These shall permit manual override and
variable flow control at both side of the chosen median duty point for the duty already
stated herein. These shall be able to handle a flow variation of plus 25% of the required
flow.
d) The pump design shall incorporate positive stroke return. The maximum stroking
speed shall not exceed 100 strokes per minute (spm). Pump, motor and driving
arrangement shall be mounted on a robust combined baseplate. The pump shall
incorporate sensitive sensors that monitor the dosing flow and the diaphragm and
provide process stability. The pumps shall be designed to have separation of
hydraulics and electronics, to protected process from equipment failure, complete with
motor, base plate, coupling bars, foundation bolts and pump flanges. Pump liquid ends
shall be selected for compatibility with the pumped liquid. Suction and discharge valves

shall be the single ball type allowing a free flow self-cleaning action. Ball and seat
materials shall be resistant to abrasion.
e) Pumps shall incorporate a variable stroke mechanism to allow the output to be varied
while the pump is running. Stroke adjustment shall be manual or where specified by
electrical or pneumatically controlled stroke positioner. A stroke length indicator and
digital stroke counter shall be fitted. Pumps shall be driven by a flange mounted IP 55
motor, via an oil bath reduction gearbox and variable stroke mechanism giving step
less adjustment between zero and maximum stroke length. Where flow proportional
dosing is required the variation of output shall be achieved by varying the speed of the
pump motor and not the pump stroke length.
f) Each pump shall be provided with inlet and outlet isolating valves and where
necessary, with pressure relief and non-return valves. Dosing pumps shall be provided
with back pressure loading valves and pulsation dampeners.
g) Pump Efficiency shall not be less than 40%
h) The pumps shall run smooth without undue noise and vibration.
i) Hydrostatic test : 1.5 times shutoff head or twice the rated discharge head whichever
is greater
j) Washout or flushing arrangements to be provided for chemical handling pumps to
facilitate easy and rapid cleansing
Diaphragm Valve, Gasket : PTFE, or Hypalon

Liquid End : Stainless Steel 316
Foundation Bolt : Mild Sleet Epoxy Paint
Wetted Part : SS 316
Base Frame : Carbon Steel with epoxy Painted.
Flanges : Carbon steel
Plunger : Carbon Steel
Check Valves : SS-316
Other details
Accuracy : ±3%
Voltage : 415 ±10%
Motor Speed : 1,440 RPM
14.2.8.3 Diaphragm Pump
Diaphragm Pumps are defined as positive displacement pumps that uses a combination
of reciprocating action and either a flapper valve or a ball valve to transfer liquids.
Diaphragm pumps must be self-priming and suitable for viscous liquids.
The material of construction of the pumps shall be as follows.
Wetted housing (Water chamber, inlet/discharge manifold) : Polypropylene

Centre block and air valve AISI Stainless steel 316

Diaphragm PTFE
Gasket PTFE
14.2.9 Mixer Pumps
a) Submersible propeller type mixer shall not be used where excessive rags, fibrous
matter etc., may be contained in the process fluid. The use of proprietary mixer pumps,
suitable for handling such matter, shall be considered instead.
b) Submersible mixer shall be removable/ adjustable and consist of a submersible drive
motor and close coupled shroud propeller. Mixer shall confirm to ISO 21630:2007.
c) Sludge mixer shall be suitable for mixing a sludge of at least 6% dry solids (DS) w/w.
d) Mixer propeller shall be of pitched type blade of either a hydrofoil / tapered or boat
propeller type and designed to induce a horizontal mixing pattern in the tank.
e) Mixer shall have a hollow mounting bracket attachment designed to slide up and down
on a vertical support shaft/post to allow the entire unit to be positioned and totally
removed from tank. The hollow bracket made of 316L stainless steel, the vertical
support shaft/post structure made of galvanised structure grade steel. The lower end
of the support shaft fixed to the tank floor. The upper end of the shaft fastened with a
wall type support bracket to allow remove of the mixer.
f) The mixer support shall be designed to allow the unit to be rotated within a horizontal
angle of about 100 degree and lock in place. An extended handle shall be provided at
the top of the vertical support to rotate the mixer in the horizontal plane.
g) The mounting bracket attachment on the mixer shall be designed to allow the unit to
be rotated within a vertical angle of about 45 Degrees and lock in place.
h) A manually operated hoist/ winch/davit system shall be provided to move the mixer in
the vertical plane, off the support shaft and swing the mixer onto the operating
floor/deck.
i) The hoist/winch system shall include a positive locking device.
j) The mixer shall be driven by a submersible high efficiency 3 phase motor IP 68
class H. Motor shaft and rotor shall be dynamically balanced.
The mixer shall be provided with the following:

i. Stainless steel (SS 316L) rope for lifting and lowering the mixer.
ii. Rope block for holding the stainless steel 316L rope where the lighting frame is used
in different locations.
iii. Support rope for reliable support and guidance of power supply cable.
iv. Support clamps and hooks to support the power supply cable in such a manner that it
is not under strain
v. The Propeller and motor housing, Heavy duty guide pipe, and all fasteners shall be of
SS316L.
vi. The propeller shaft shall be of SS431. The lifting winch shall be of stainless steel 316
construction.
14.3 Screens
14.3.1 Mechanically Raked Coarse (Medium) Bar Screens
14.3.1.1 Scope of Supply/General Design Considerations
Automatic mechanically raked screen systems shall be supplied with all necessary
accessories and appurtenances as listed below for full functionality, and sound and
efficient operation which is easily maintained. The systems shall not be limited to at least
the following components, including:
• Mechanically operated raking mechanism screen;

• Screenings collection, (dewatering) sweeping, washing and disposal system;

• Automatic screen control system;
• Electrical & Instrumentation for compliance of Automatic System (Electrical wiring
between all screen components, instruments, control devices and the local control
panels and the screen controls)
• Additionally, covers shall be easily removable and re-fixed to facilitate operational
maintenance
• Unless otherwise mentioned Screen shall confirm to IS:6280 and as recommended in
CPHEEO manual
14.3.1.2 Downstream Water Level
Bidders should state the maximum and/or minimum allowable water levels downstream of
the screen in order to pass the required flow. To reduce the height of the screen above
ground level, the screen might be located at a level such that there is a constant static
water level in the screen chamber due to downstream tank water levels.
14.3.1.3 Guaranteed Flow Rate and Head Loss
The screen shall effectively screen all flows up to the design flow. The Contractor shall
guarantee the following screen performance parameters:
• Clean water flow rate capacity (l/s) at the maximum allowable water depth downstream
of the screen
• Clean water head loss at the max flow rate and maximum allowable water depth
downstream of the screen
• Maximum sewage flow rate capacity (l/s) at the maximum allowable water depth
downstream of the screen based on their expected screen blinding in sewage
14.3.1.4 General requirements
The following list is a description of the general requirements of coarse raked bar screen:-
a) The screen shall be of the front raking type.
b) The aperture size of the screen shall be 20 mm.
c) The screen shall be capable of performing the duties set out in this Specification. All
the materials and sub-assemblies used shall be suitable for outdoor application. They
shall be constructed so that maintenance is kept to a minimum.
d) The mechanically cleaned screens shall be constructed from stainless steel (AISI 316)
i.e. screen bars, screen body, carriage, rake and all other parts except for drive motor,
gear reducer and wastewater non-contact parts such cog wheels, chains etc. The
screen with all its functions and accessories shall be completely lubrication free and
fully automatic operated for minimum operational costs.
e) There shall not be any moving part, sprocket, bearings, etc. continuously immersed in
sewage.
f) All lubricating points shall be conveniently accessible from the deck level.
g) The screen shall be suitable for discharging 75% of the screened material lifted from
the screen into the chute.
h) The screen shall be designed such that in case of heavy accumulation of solids the
same is to be removed gradually without overloading or damaging the screen bars or
mechanism.
i) The complete screen above slab level (except for drives & gear reducer) shall be
enclosed in a stainless sheet metal of enclosure using SS-316 sheets of thickness not
less than 2 mm and be suitably braced with stainless steel angle frame. The enclosure
shall be such that the covers can be easily removed for inspection & maintenance.

j) The screen will be factory assembled and tested unit and has to be installed at the site
in factory assembled condition to avoid chances of misalignments.
k) Torque switch shall be provided to protect the screen from damages resulting from
excessive torque.
l) The operating locus of the rake shall be designed in a way that before engaging the
bars the rake performs digging action. This action will allow rake to penetrate, collect
& remove the waste settled at the bottom most section of the screen.
m) The bars of the screen shall preferably be curved at the bottom to match the locus of
the rake operation with a view to enable the rake to obtain support / guide from the
moment it start its upward raking operation.
n) The rake shall be fitted with heavy-duty helical coil spring, which creates pressure on
rake, so that the rake will always run in proximity to the bars & dead plate. This will
avoid fall back of material during upward travel of rake.
o) These screens shall be provided with integrated scrape & wiper mechanism for
discharging the screenings to discharge chute. The wiper mechanism shall be spring
loaded.
p) The profile should have non-clogging feature and should offer lesser head loss than a
rectangular profile bars.
14.3.1.5 Frame Work
The frame work of the screen shall be of robust construction with intermediate cross
bracing. The lower ends and sides of the frame shall be grouted in concrete. Each screen
shall have an independent canopy at the top for weather protection.
14.3.1.6 Bar Screens Assembly
Screen bar assembly shall be fitted across the screen chamber. Screen shall have a series
of vertically oriented bars spanning the inlet channel and spaced as specified. Bars shall
be sufficiently rigid to prevent vibrations in stream wise and lateral modes and to withstand
the maximum differential head that will occur with the screen totally blinded. Bars shall
have tapered cross section to prevent jamming of screenings between bars. Bars shall
have supports only at both ends. The bar rake shall be made of stainless steel half rounded
flats of SS-316, 10 mm thick and 50 mm wide in section. The profile should have non
clogging feature and should offer lesser head loss than a rectangular profile bars.
14.3.1.7 Rake Carriage
The rake carriage shall comprise a stiffened frame work to which is attached replaceable
rake tines. The rake tines shall be suitable to accommodate bulky screenings. Rake
carriage shall incorporate suitable devices to enable the rake to ride over any small
obstacles wedged in the screen and automatically stop the drive motor in the event of the
rake jamming against a large obstruction. There shall not be any mechanical damage
resulting from obstruction wedged in the screen bars. The rake carriage shall always come
to rest in a parked position with the rake above the sewage level.
The screen shall be cleaned automatically through an adjustable timer. The rake lowered
will clear screen bars at the beginning of a cycle and accurately engage with the screen
bars at the bottom of the channel. The tine profile and rake motion shall be designed to
elevate screenings to the discharge chute at deck level without debris falling back or being
forced through the screen. The rake shall be suitable for elevating debris encountered at
any level. Rake tines shall be replaceable.
The screenings shall be discharged from the unit by a wiper mechanism down to a
discharge chute leading to a shaft less screw conveyor. Arrangement shall be such as to

ensure that screenings are discharged to the discharge chute leading to the conveyor. The
rake tines shall then be retracted and the unit ready for the next cycle.
14.3.1.8 Rake Lifting Mechanism
Lifting mechanism shall consist of a steel wire rope or chain and sprocket.
14.3.1.9 Inspection Platforms
An inspection platform shall be provided for periodic checking and maintenance of the
drive and other critical parts. A ladder with handrails for access to this platform shall be
fixed. Suitable hand rails shall be provided for safety on the inspection platform and also
at deck level.
14.3.1.10 Dead Plate
Dead plate extending from the top of the bars to the deck level shall be provided to ensure
that screenings do not fall back. Dead plate shall be made of minimum 5 mm thick plate.
The clearance between the tines and the dead plate shall not exceed 5 mm. The materials
of construction of the dead plate shall be SS 316L
14.3.1.11 Driving Mechanism
The driving mechanism shall consist of a sturdy reduction gear unit driven through multiple
'V' belts or directly by an electric motor. Motor shall be mounted in such a way that the
tension of the 'V' belts can be adjusted. A manually reset torque limiter shall be provided
between the motor and gear unit, incorporating a limit switch to cut off the supply to motors
in the event of an overload.
14.3.1.12 Gear Reducer
a) The reducer shall be sized and selected with a minimum service factor of 2.0 times the
motor nameplate horse power rating in accordance with applicable American Gear
Manufacturer's Association Standards. The reducer shall have a life of 40,000 hours
based on the motor name plate horse-power. The reducer shall have an efficiency of
not less than 90% based on reducer input.
b) All gear meshes shall be oil lubricated. All gears shall be provided with an oil reservoir
for instant lubrication on starting. The gear reducer housing shall be provided with an
oil level indicator and oil drain with necessary fittings.
c) The gear reducer shall be of cast iron construction. The reducer housing shall also
include suitable lifting lugs and external gear train inspection covers for each gear train.
The gears shall be matched for maximum tolerance variation. The gear reducer shall
be suitable to reduce the motor asynchronous speed to achieve the required speed of
raking.
14.3.1.13 Control System
a) The screening operation shall be carried out through adjustable timers which are
adjustable at site for 0-60 minutes for interval between two operations.
b) Control system for the conveyor shall be designed to achieve the following:
i. Conveyor shall be started when any of the rakes starts it’s upwards travel.
ii. Conveyor shall be stopped with a time delay (by adjustable timer) after rake is
stopped.

c) Weatherproof, lockable, emergency mushroom headed stop push buttons shall be

provided near each motor for screen and conveyor operation of stop push button shall
be included in the control scheme.
d) Differential pressure switches shall be provided to annunciate screen jamming.
Note: The screen shall also be designed to operate automatically when level differences
between upstream and downstream reaches a preset value & stop at preset
differential level. The level controller shall be Ultrasonic type level controller. The
screen will start from bottom of screening chamber at peak water level as well as near
zero water levels.
e) The control panel shall have IP 65 protection, painted with epoxy paint and shall be
comprising of:
i. MCBs
ii. Mushroom head emergency stop.
iii. Overload relays for motor protection.
iv. Electronic Equipment (Circuitry) to operate the screen with ultrasonic type level
sensor.
v. Selectors switch to operate the screen in Auto, off and JOG mode.
vi. Provision to run the screen on timer in case of failure of level sensor.
14.3.1.14 Screenings Conveyance, Compaction and Dewatering.
General
The screening system shall be supplied with a duty and standby screw conveyor that will
be used to convey the screenings to the automatic screenings press and discharge system
that compacts, dewaters and discharges the screenings through a chute to the screenings
storage system.
The screenings dewatering and compaction system shall compress and dewater the
screenings such that the screenings from a consolidated mass with no free water entering
the screenings bag.
Belt conveyors may be used in place of screw conveyors, where horizontal transfer of
screenings is required.
14.3.1.15 Screenings Dewatering Screw Compactors
The screw compactor shall confirm to ISO 20474-11:2008 and consist of an Archimedean
type screw driven through a helical gear, a screw trough, a water catchment tray,
compression chamber, outlet chute, wash water and water return pipework and trough
support legs.
A self-aligning bearing protected by double lip seals shall be provided at the driven end of
the screw. The Screw, trough, compression chamber, outlet chute, water catchment tray
and trough supports shall be fabricated from grade 316 stainless steel.
The screw shall be of sufficient weight to prevent lifting and robust enough to start-up with
the trough full of screenings.
Wash water shall be supplied to both the screw trough and compression chamber and
shall discharge to a water catchment tray via a pipe connection.
The water from the screenings shall be return to the main sewage flow for treatment. The
motor shall be suitable for a 3 phase supply and shall be protected to IP 55.

Screen Organics Washing:
If sufficient cleaning of organic material is realised from the screens themselves or the
Screw compactor, the organics must be washed out from the screened debris and returned
to the wastewater flow using an additional washing stage. The organics washing system
shall consist of a series of water jet nozzles and a mesh type drum both running the width
of the screen. A splash plate shall be provided to prevent over-splash.
Common Screenings Conveyor System:
General :
Screenings conveyors may be either a continuous belt type or a screw auger.
The safety requirement as specified in IS 7155 (part3) Code of practice for Conveyor
safety shall be followed in the selection, design and operation of conveyors.
Screw Auger Conveyors:
The screw conveyor shall consist of an Archimedean type screw driven through a helical
gear and confirm to ISO 20474-11. The screw shall be fabricated from high strength steel
with a minimum 250 Brinell hardness. The screw shall be of sufficient weight to prevent
lifting and robust enough to start-up with the trough full of screening.
The trough shall be made of minimum 3 mm thk 316 stainless steel U- shape up to 100 mm
above top of the screw. A trough liner of friction resistant replaceable PE of 15mm
thickness and in 1 m sections shall be provided, which shall be replaceable without
removing the screw.
Belt Conveyors
Belt conveyors shall confirm to IS 11592, IS 4776 (Part 1), IS 8531, IS 8598, ISO 1536,
ISO 1537 & ISO 1537.
The carrying side shall have self-aligning/guide rollers with the necessary support to
ensure straight and smooth running of conveyor belt.
The drive pulley shall be driven by gear motor directly coupled to the shaft of pulley or
through suitable sprocket and chain. Drive, drive and snub rollers shall be coated to
increase the tracking effect.
The required contact pressure of the conveyor belt to the driving pulley shall be made by
means of a tensioning device.
The belt material shall be of standard conveyor rubber type materials but suitable for the
materials conveyed.
The conveyor belt shall have return rollers at regular interval for support and smooth
movement of return side of conveyor.
Portable Screenings Container
Portable screenings containers made of galvanised steel duly epoxy painted shall be
provided to store the screenings until time of pick up. The container shall have capacity of

approximate 5 m3and shall be of a convenient height to permit the discharge of screenings

directly into the container without having to transfer the screenings manually. The
containers shall have hinged covers and their design shall permit them being lifted by an
overhead hoist or packer truck. The container will have four wheels each of about 20 cm
diameter and two of which shall be swivel castors. The maximum height of container
including wheels shall be 0.6m. The sides shall be constructed of minimum 12 gauge steel.
The bottom of container shall be made minimum of 6mm plate steel. The containers shall
be reinforced with 50mm x 50mm x 5mm angle iron.
Motors
An Electro brake motor shall be provided to operate the rake mechanism. Motors shall be
squirrel cage type conforming to IS 325. The power rating of motor shall be at least 125%
of maximum power requirement. The other features of motors shall be as follows:
i) Type of duty: Intermittent (S4)
ii) Method of Starting : DOL
iii) Class of insulation : H(Temperature rise limited to class B)
iv) Type of enclosure : TEFC
v) Degree of protection : IP 55
Automatic Jam Removal System
The screen shall have automatic electronically controlled Jam removal facility to ensure
smooth Operation.
14.3.2 Automatic Drum screen (Rotary Drum Type)
14.3.2.1 General
The automatic drum screen shall be composed of screen, screw conveyor, washing unit,
dewatering unit and drive unit, etc. The automatic drum screen shall have 6 mm opening
and shall be used to block, scrape, wash, and dewater the suspended solid or scum in the
influent or sludge.
One set of anchor bolts and nuts shall be suppliers with each unit.
Design condition:
a) This equipment shall be designed with sufficient safety factor in strength.
b) This equipment shall be of integrated type and shall be constructed such that it can be
installed easily.
c) The difference of water level, the characteristics of suspended solid, and flow rate shall
be considered in design.
Fabrication:
Drive unit
Cycloidal reduction gear or worm reduction gear shall be used as drive unit. Drive unit
shall transmit the power by means of gear transmission or direct connection with coupling.
Gear box shall be provided in case of gear transmission.
Screen

The screen shall be made of cylindrical perforated stainless-steel plate. The screen shall
have a smooth finishing order to prevent the attachment of screenings and shall be
arranged with equal spacing.
An electrical pole shall be installed in front of the screen in order to detect the overflow
and control operation.
Rake
The rake shall be connected with the screw conveyor along the same axis and shall rotate
with it. The raked screenings shall be scraped down into the screw conveyor by the
scraper. The rake shall be constructed such that the screenings never remain on the
screen after raking.
Screw conveyor
The impeller and shaft of the screw shall be a welded structure of stainless steel and shall
endure the incurred stress. A dewatering device shall be provided at the upper portion of
the screw conveyor. The dewatering device shall be sealed and shall have sufficient
strength to endure the pressure of screenings and scum. The inspection hole and washing
water pipe shall be provided for the dewatering device. The inspection hole shall permit
easy inspection and the washing water pipe shall be used to wash the casing for filtrated
liquid.
Shaft and bearing
The shaft of screw shall be made of stainless steel and shall have sufficient strength to
endure the incurred stress. The submerged bearing shall be an oil-less pneumatic type.
For a bearing installed above the water level, an automatic oiling device shall be provided.
Washing unit
Washing nozzles shall be provided at the inlet of the screw conveyor in order to wash
down the screening or scum with pressurized water.
Chute
A stainless-steel chute shall be provided at the discharge part of the screw conveyor. The
chute shall be constructed such that the screenings are blocked from being discharged.
Material of construction for Automatic drum Screen:

• Screen : Stainless Steel AISI 304
• Rake : Stainless Steel AISI 304
• Screw Conveyor : Stainless Steel AISI 304
• Chute : Stainless Steel AISI 304
Protection Equipment – mechanical protection
For cycloidal reduction gear, a built-in torque limiter shall be provided.
Protection Equipment – electrical protection

An over-current detector with instantaneous converter shall be provided in case the

mechanical protection is not provided.
14.3.3 Manual Bar Screens (Medium)
a) The screen shall be installed in inlet bypass channel to grit chamber.

b) The aperture size of the screen shall be 10 mm and at an inclination of 50 Deg.
c) The screen shall be fabricated out of galvanized M.S flats and fixing bolts shall be of
stainless-steel.
d) The rectangular trash screens shall comprise galvanized M.S flats, 10 mm thick and
50 mm wide in section.
e) The screen shall be rigidly fixed to the frame.
f) All the bypass screens shall be provided with 2 sets of SS 304 cleaning rakes with
appropriate grip handle
14.3.4 Step Screens
a) Screenings shall be retained on the screen curtain until they pass over the discharge
chute, where they shall be positively removed from the face of screen. Screenings to
be discharge onto the conveyor system for disposal.
b) All components of the step screen coming into contact with the sewage shall be
constructed of grade 316L stainless steel. The Screen curtain shall be designed to
prevent the trapping and compaction of screenings on to the channel floor, or against
the sides of the support frame. Screen elements shall be designed to withstand the
maximum different head across the screen, be readily accessible and replaceable and
fitted with intermediate spacers to maintain the correct screen element gap.
c) A close fitting 316 L stainless steel enclosure complete with screenings discharge
chute shall fully enclose the screen.
d) The motor shall be protected by thermal sensors fitted to the motor. The motor speed
shall not exceed 1,500 rpm, shall be protected to IP 65 and shall be suitable for a
3-phase supply.
e) The screen control shall permit either continuous manual operation, automatic timed
operation or automatic continuous operation based on ultrasonic level measurements
in the channel.
14.3.5 Fine Screens
14.3.5.1 Scope of Supply
The scope of supply shall provide complete automatic mechanical screen systems with all
accessories and appurtenances, including, but not limited to:
• Mechanically operated screen;
• Screenings collection, (dewatering) sweeping, washing and disposal system;
• Automatic screen control system;
• Electrical & Instrumentation for compliance of Automatic System (Electrical wiring
between all screen components, instruments, control devices and the local control
panels and the screen controls)
14.3.5.2 Downstream Water Level
Bidders should state the maximum and/or minimum allowable water levels downstream of
the screen in order to pass the required flow. To reduce the height of the screen above
ground level, the screen might be located at a level such that there is a constant static
water level in the screen chamber due to downstream tank water levels.

14.3.5.3 Guaranteed Flow Rate and Head Loss
The screen shall effectively screen all flows up to the design flow. The Contractor shall
guarantee the following screen performance parameters:
• Clean water flow rate capacity (l/s) at the maximum allowable water depth downstream
of the screen
• Clean water head loss at the max flow rate and maximum allowable water depth
downstream of the screen
• Maximum sewage flow rate capacity (l/s) at the maximum allowable water depth
downstream of the screen based on their expected screen blinding in sewage
14.3.5.4 Screening Arrangements
Screening shall be done in single stage. The contractor shall provide automatic
mechanical fine bar screens to remove particles larger than 6mm size.
It is proposed to install automatically operated mechanical fine screens (stainless steel

grade – SS316) of opening size 6mm for Screening out floating materials such as plastic
pouches, bags, rags, floating debris, weeds, paper wastes and other floating materials
from the raw sewage coming from the pumping station. Capacity of each channel shall be
equal to peak flow. Fully automatic mechanical screen along with the level sensing
instrument for automatic operation of screen mechanical and allied accessories, (local
control panel near screen,) shaft less screw conveyor with/cum compactor are to be
provided.
The fixed as well as movable bars/ perforated band, mechanism, support frame, fixings
discharge chute shall be manufactured from stainless steel grade 316 for long life in the
aggressive sewage environment.
14.3.5.5 Automatic Screen Clearing and Screenings Removal
The screen shall be provided with the necessary controls and sensors to anticipate
blockage of the screen, and automatically clear the screen and remove the accumulated
screenings from the screen surface. The screen shall operate automatically when the
upstream water level increases beyond a pre-set limit and it shall stop when the upstream
level decreases to pre-set low level.
14.3.5.6 Screenings Conveyance, Compaction and Dewatering
The screening system shall be supplied with a duty and standby shaft less screw conveyor
that will be used to convey the screenings to the automatic screenings press and discharge
system that compacts, dewaters and discharges the screenings through a chute to the
screenings storage system.
The screenings dewatering and compaction system shall compress and dewater the
screenings such that the screenings from a consolidated mass with no free water entering
the screenings bag.
14.3.5.7 Screen Washing System
The Contractor shall supply and install spray washing system that effectively cleans the
screen area and screening press. The Contractor shall provide a high-pressure clean
water supply for the washing system.

14.3.5.8 Dewatered Screenings Discharge Chute
The screenings discharge chute shall terminate 1.5 meters above ground level. A plastic
screenings bag shall be secured around the chute, thereby creating a totally enclosed
screenings collection system.
14.3.5.9 Screen Covers
All screenings equipment shall be supplied with integral stainless steel covers that prevent
access to moving and wash water sprays. The covers need to be airtight to ensure that no
odours emanate from the screen.
14.3.5.10 Portable Screenings Container
Portable screenings containers made of galvanised steel duly epoxy painted shall be
provided to store the screenings until time of pick up. The container shall have capacity of
approximate 5 m3and shall be of a convenient height to permit the discharge of screenings
directly into the container without having to transfer the screenings manually. The
containers shall have hinged covers and their design shall permit them being lifted by an
overhead hoist or packer truck. The container will have four wheels each of about 20 cm
diameter and two of which shall be swivel castors. The maximum height of container
including wheels shall be 0.6m. The sides shall be constructed of minimum 12 gauge steel.
The bottom of container shall be made minimum of 6mm plate steel. The containers shall
be reinforced with 50mm x 50mm x 5mm angle iron.
14.3.5.11 Electrical Motor
The motor shall be TEFC type with IP 55 protection & Class H insulation and shall be
suitable for operation on 3 phase, 415V + 10% and frequency of 50Hz + 5%. Motors shall
be squirrel cage type, IE3, conforming to IS 325. The power rating of motor shall be at
least 125% of maximum power requirement.
14.3.5.12 Screens Control Panel
The Control Panel shall have IP 65 protection, painted with Epoxy paint and shall be
comprise:
• Mushroom Head Emergency stop.
• Overload relays for motor protection.
• MCB’s, HRC Fuses and Glass Fuses.
• Circuitry to operate the screen with level sensors.
• Selector Switch to operate the screen on JOG mode.
14.3.5.13 Access
Safe access shall be provided to all screen equipment and instruments to allow for
cleaning, inspection and maintenance activities.
14.3.5.14 Corrosion Resistance
All metal parts of the screen equipment that are in contact with the sewage shall be
constructed of a suitable grade of corrosion resistant stainless steel, aluminium or plastic.

14.3.5.15 Installation, Testing, Commissioning and Training
It is the Contractor’s responsibility to install the screen system correctly and achieve the
required operation. The Contractor shall provide a representative who has knowledge and
experience in the proper installation, start-up and operation of the screen equipment to
inspect the final installation and supervise the commissioning tests.
14.4 Grit Removal System (Cyclonic / Vortex Type)
After screening, the sewage will flow to grit chambers.
Grit chambers are designed to remove grit, consisting of sand, gravel, or other heavy solid
materials that have a settling velocity substantially greater than those of the organic
putrescible solids in sewage. Grit chambers shall be of vortex type with centre drive and
independent washer and /or classifier.
Unless mentioned elsewhere, the design of Grit removal system shall confirm to IS 6279
or CPHEEO manual.
14.4.1 Type of Grit Chamber
The type of Grit chambers shall be of vortex type with centre drive and independent washer
& classifier. Grit Basin equipment, complete with all accessories including, but not
necessarily limited to, gear motor, turntable, propeller drive tube, axial flow propeller shall
be provided.
The Vortex Grit Basin equipment shall be installed in concrete basins. The equipment to
be supplied shall be suitable for installation in these basins. The grit chamber shall be
designed to operate on the vortex principle.
To maximize grit removal efficiency, Grit chamber hydraulics shall incorporate a toroidal
flow path enhanced by a slow vortex.
14.4.2 System Description
a) Vortex Type Grit removal chamber with low head loss systems shall be proposed for
this project. Each grit chamber shall be complete with all the required equipment and
not limited to gear motor, gear head, axial flow propeller and scrapper with drive, grit
removal pump and auxiliary equipment, washer and classifier system complete in all
respects required for proper operation.
b) The grit removal unit shall have low head loss and shall be capable of removing grit
from raw waste or process water and depositing the grit in a storage hopper.
c) An integral grit transporting system shall be provided to transport the grit from the
storage hopper to the grit classifier and for grit washing and the dewatered grit shall
be temporally stored in tilt able trolley.
d) To minimize the possibility of clogging, all internal openings in the piping to the grit
pumping device as well as the grit pumping device shall be large enough to pass a 100
mm solids.
e) No bends or elbows shall be allowed in the piping on the suction side of the grit pump.
f) All drives, bearings and lubrication shall be readily accessible from walkways above
the operating water level.
g) To minimize the possibility of organic capture, the floor of the grit separation chamber
shall be flat/sloping as per manufacturers design and there shall be no greater than a
80 mm opening for grit to pass through to the storage hopper.

h) To ensure the efficient transport of the grit and simultaneous lifting and discharge of
the organic material, the bottom of the upper chamber covering the storage hopper
shall be constructed suitable corrosion proof / or thick steel plate, free from rotation,
and shall be flat.
i) The grit moving across the bottom of the chamber shall be hydraulically scoured by an
air lift pump or a propeller pump.
j) The grit shall pass from the removal chamber through an opening in the transition plate
and drop into a grit storage hopper. The flow in the removal chamber shall travel
between the inlet and the outlet a minimum (270°), providing maximum travel of the
liquid for effective grit removal.
k) The Grit Chamber shall handle all flows equal to or less than a hydraulic peak flow.
l) The influent flume, transporting the liquid waste to the grit chamber, shall be of the size
and shape to assure that grit does not settle in the inlet flume and to provide for proper
operation of the grit chamber.
m) Grit pump will be either an air lift educator pump or a turbo grit pump close-coupled,
vacuum primed type with curved multi vane impeller.
n) A regenerative (side channel) type blower shall have the capacity to provide sufficient
quantities of air at the required pressure to ensure efficient operation of the air
wash/airlift system.
o) Alternatively, hardened stainless steel grit pumps can be used
p) Grit Classifier / Washer shall be Shaft less screw type.
q) All the equipment below top slab shall be removable through access hatch provided in
basin cover.
Material of Construction:
• All wetted parts shall be in SS 316.
• Air Lift pump (if used) SS 316
• Turbo Grit Pump (if used): Hardened SS316 impellers, Ni hard volute, Stainless Steel
shaft, heavy-duty bearings and mechanical seal
• All parts above water, i.e. components like mechanism support etc shall be in Hot Dip
galvanised structure
• Hand Railing in SS316 Drive Mechanism of Grit Scrapper
• Classifier: SS 316 with hardened scraper / tips
• Portable grit container shall be Hot dip galvanised structure.
14.4.3 Performance Requirements
The grit removal device shall be capable of removing the following at the specified
hydraulic peak flow rate, and no decrease in efficiency will be allowed at flows less than
this design rate.
i) 90-95% of the grit greater than 150 microns in size,
ii) 75-85% of the grit greater than 100 but less than 150 microns in size,
Documentary evidence in support of the removal efficiency of the offered equipment shall
be furnished by Contractor.
Equipment Description
The grit chambers shall generally conform to the following construction, operation
guidelines and have the accessories as indicated below:
Grit Collection Mechanism:

a) It shall be consisting of vortex type, non-aerated, grit removal mechanism, each

complete with drive unit, mechanical gear head, paddle drive tube and all the items
necessary for complete grit removal
b) It shall be capable of removing grit from raw waste water and suitable for installation
in a circular concrete basin.
c) Mechanism shall have no moving parts below the water surface which require
lubrication or which will be subject to wear or blockage.
d) Drives, bearings, and support equipment for grit mechanism shall be supported by and
readily accessible from a concrete walkway above the water surface.
Grit Paddle Mechanism:
a) It shall be designed to promote removal of grit and assist in sweeping grit to a circular
grit wet well located within the centre of the basin.
b) Grit moving across the bottom of the grit chamber shall be hydraulically scoured as the
propeller blades pass over the moving grit and cause hydraulic currents to maintain
the organics in suspension.
Grit Removal Mechanism:
It will generally consist of:

a) Axial flow pitch propeller driven by drive tube powered through a helical gear motor.
b) Alternately, air lift pump, driven by an external blower and complete with all required
arrangements.
c) Helical gear motor shall be oil lubricated
d) Spur-Tooth Bull Gear:
i. It shall be enclosed in grease packed heavy cast irin gear case.
ii. It shall be of forged steel with minimum Brinell hardness of 200.
iii. Pinion shall be cut from high strength normalised steel
iv. It shall be mounted on turn table bearing.
Bearing:
i. All bearings of Drive Unit shall be having bearing life of 50000 hours
ii. Turntable Bearing Supporting Propeller Assembly shall be having bearing life of20
years.
Pinion & Bull Gear
i. The service factor for the Pinion & Bull Gear shall be Five or greater.
ii. Gear Box shall be sealed type and furnished with air bell around bottom opening of
drive tube to prevent water from entering gear box.
Other Accessories:
Other accessories shall include Lifting Lugs and Anchor Bolts
14.4.4 Grit Classifier Mechanism
a) Grit classifier shall consist of shaft less spiral screw conveyor and hopper. Grit from
vortex grit tank shall be delivered to Grit classifier at determined time intervals. Screw
conveyor shall convey and dewater the grit prior to being disposed into container. The
screw conveyor shall also be fitted with washers to remove organic matters from the
grit.

b) The grit classifier must be capable of separating small, fast settling materials. Provision
shall be made to receive grit from the grit pumps in a storage reservoir allowing
sufficient retention time allowing the grit to separate from the raw sewage.
c) The grit must then be removed from the storage reservoir using a shaft-less screw
conveyor.
d) Sufficient clearance must be provided between the shiftless screw conveyor and the
trough to allow liquid above the storage reservoir level to flow back to the reservoir. A
30% dry solid product must be discharged from the end of the screw conveyor into a
container to be supplied under this contract. The clarified liquid must pass over a weir
and be discharged into the inlet channel upstream of the grit removal equipment. The
equipment shall be complete with electric motor and gearbox, screw conveyor trough
and storage reservoir with supports and pipe work, etc.
e) Discharge pipe work from the pumps in separate rising mains must be provided and
connected to the storage reservoir, complete with support brackets from the vortex
degritter to the grit classifier equipment.
Grit classifier related Pipe Work
a) The Contractor shall include for the supply and delivery to site and for the erection and
testing of all pipe work and fitting between the degritter and screw.
b) All pipe work shall be stainless steel. Flanges shall comply with BS: 4505. Bends shall
provide non- turbulent flow conditions and the layout of pipe work shall be such to
facilitate dismantling and inspection. The pipes shall be properly supported and so
arranged that all stress created in the pipeline by static and dynamic forces, including
recoil shock will be taken up by suitable anchors.
Painting
Painting of different units shall be done as follows:
a) Painting of Wetted Parts: Surface preparation- blast cleaning, one coat of Epilux 610
or equivalent primer, Dry Film Thickness (DFT)/coat of 35 microns and three coats of
Epilux 5 coal tar epoxy or equivalent, DFT /coat of 100 - 125 microns. Total DFT shall
not be less than 300 microns.
b) Painting of Non Wetted Parts: Surface preparation: blast cleaning, coats of anti
corrosive red oxide primer, each of 30 microns & 2 coats of anti corrosive synthetic
enamel paint (DFT per coat of 30 microns). Total DFT shall not be less than 120
microns.
c) All fixtures and bolting shall be of SS 304
Electrical Installation & Controls

a) Provision must be made for supply and installation of the control panel as well as all
electrical equipment controlled from this panel. A red mushroom head push lock
emergency stop switch with key operated lock-out facilities must be provided in close
proximity of the driven equipment.
b) The entire process shall be controlled by a dedicated control system to provide
automatic (timed) and manual grit removal operation; opening and closing of control
valves; air/water scour operation; grit pump and classifier duty cycles along with Grit
system remote control and alarm monitoring.
14.4.5 Mechanical Degritter
Unless specified otherwise, the design of Grit removal system shall conform to IS 6279 or
CPHEEO manual.

a) The grit removal system shall be provided for grit removal. It shall include Classifier
type grit scraping mechanism, adjustable influent deflector and reciprocating rake
mechanism to remove the grit and organic return pump.
b) The grit separator shall be square in size of single unit construction. A Central drive
mechanism of worm reduction type driven through helical gear and motor or by geared
motor shall be mounted on the RCC platform spanning the tank. An overload alarm
shall be provided to trip the machine in case of overload.
c) The tank shall have stainless steel 304 scraper duly fitted with rubber squeezers driven
by TEFC induction motor, reduction motor, and reduction gear along with necessary
drive mechanism. Grit removal for the tank shall be with the help of SS304
Reciprocating rake classifier to lift the grit from the tank.
d) The classifier shall be driven by TEFC induction motor, complete with gears and
suitable drive mechanisms. The rake classifier shall be suitably mounted in the grit
wash channel so that it can withstand all types of pressures.
e) The detritus tank shall be provided with series of vertical adjustable type S.S.304
baffles at the inlet for breaking the velocity of the flow to ensure that there is no short
circuiting in the flow of sewage.
f) The weirs at the outlet of grit chamber shall be SS 304 with minimum 6mm thickness.
The spacing of anchor bolts of SS 304 for the fixing of the weir shall not be more than
450 mm.
g) Equipment shall conform to latest relevant IS standard. Equipment with ISO
certification shall be preferred. The enclosure of Control panel should confirm the
standard of IP 55.
h) All the MS parts shall be epoxy/fibre coated.
i) The reciprocating rake mechanism shall lift the grit up. The reciprocating rake
mechanism shall be installed at about 350 inclinations. Chute is located at the top
through which, grit will fall in a wheeled trolley of approximate 0.5-m3 capacity. This
trolley will be housed in a roofed enclosure with proper access, screen washing
arrangement and drain etc.
j) A grit cleaning arrangement shall be provided to remove organic particles from the grit
and shall be pumped back to the inlet by an organic pump. The grit pump shall have
volute and impeller of Ni-CI with Ni content of not less than 2%.
k) The sewage separation pump shall have separate drive including TEFC motor. The
gears used shall have minimum service factor of 2.50 for 3 HP motor.
The electrical requirements shall be as follows:
a) All drive shall be Premium efficiency motor (IE3), 3 phase, IP 55, 415 V ± 10%, 50 c/s
AC motors of suitable rating with 15% reserve capacity with mechanical overload
indicating arrangement and trip contacts. The mechanical trip contacts as well as the
electrical overload relays shall be provided.
b) One set of push buttons shall be provided near the motors and another set of contacts
shall be provided in the starters which will be housed in the control room attached to
sub-station.
c) Industrial hooter type alarm to be provided in control room attached to sub-station. All
electrical control panels when in open shall be all weather proof suitable for corrosive
H2S atmosphere made in SS304.
14.5 Primary and Secondary Clarifiers
Bridge Scrapper
Bridge Superstructure spanning half the tank diameter with central maintenance platform,
Drive assembly complete with drive head, chain & sprocket, geared motor etc.

To remove Suspended Solids / Biomass from mixed liquor

Objective
/ influent
Type of Clarifier Centre feed with peripheral Overflow
Located at 1/2 tank diameter with scum box. Flows under
Skimmer
gravity to scum sump for disposal with sludge.
Collected at centre by scrapper & hydraulically withdrawn
Sludge
by sludge pump.
Bridge Type Fixed bridge
Duty Continuous operation
Rake Tip Speed Between 3 and to 4 cm / sec
Scraper sludge loading 25kN/m minimum
Electrical TEFC Motor with Insulation Class H and IP 55
Clarifier rake driver
Protection
Peak torque = 2.5 times continuous design torque based on
Continuous Design
Torque (in kg-m) = Load factor x (diameter)2 where
Operating Torque
load factor = “8” for primary and = “6” for secondary clarifiers
Feed Well SS 304, minimum 3 mm thick
Bridge MS with hot dip galvanized (80 micron minimum thickness)
(welded/nut bolted/riveted truss in a consolidated single
component and no site welding shall be allowed)
Rake Arm MS with hot dip galvanized (80 micron minimum thickness)
Centre Cage MS with hot dip galvanized (80 micron minimum thickness)
Rake Blades Stainless Steel Grade 316L; minimum 5 mm thick
V-notch weir SS 304, minimum 6 mm thick and 300 mm wide
Squeegees Neoprene rubber, 10 mm thick, adjustable type
Walkway MS grating minimum 6mm thick with hot dip galvanized (80
micron minimum thickness)
Handrail 32 NB (Medium duty) Galvanised steel Pipe, 32 NB vertical
and top rail with 25 NB (Medium duty) Galvanised steel,
middle level. The hand railing on clarifier shall have a 6 mm
toe guard made of hot dip galvanised and be 100 mm wide
x 5 mm thick (both ways in two layers minimum 1 m high)
Scum skimmer assembly SS 304, minimum 5 mm thick and 300 mm wide
Scum Box SS 304, minimum 3 mm thick
Scum Baffle SS 304, minimum 3 mm thick and 400 mm wide
Fasteners – Under Water SS-316
Fasteners – Above Water Galvanised
Corrosion allowance of 2 mm shall be provided on all structural component sections of
the scraper arm, bridge etc. The equipment shall be fabricated out of mild steel plates at
least 6 mm thick
Chain Scrapper

To remove Suspended Solids / Biomass from mixed liquor /

Objective
influent
Type of Clarifier Rectangular
The collector chain shall be manufactured of high polymer and
high-tension material. The chain links shall be manufactured of
polyacetal and the pins of polyamide. The bottom side of chain
link shall be rounded to match the radius of the idle wheels,
which have smooth rim (no teeth).
The scraper flights shall be attached directly to any chain link,
Collector Chain
and the flight pulling line shall be from the centre of the flight.
The chain shall have a pitch of 150 – 250 mm. The bearing area
of chain joint shall be at minimum 1300 mm2 and the bearing
area of driving tooth/notch at minimum 1600 mm2. The allowed
load based on bearing areas shall be at least 2300 kg. The
breaking strength shall be at least 28 KN
It is desirable that the scraper be equipped with electro-
mechanical safety and monitor system, which prevents chain
skipping, monitoring flight synchronization and in overload
Chain Watch with
situations stops the system before any damage can occur also
Integrated Overload
sending trip alarm signal to control system of plant. The
Switch
materials of system shall consist of stainless steel and
polypropylene.
The scraper flights shall be manufactured of reinforced

fibreglass. The content of glass fibre shall be minimum 60-70 %
to ensure member strength.
The scraper flights shall be attached to chain in a way that the

flights shall be driven from the centre line of flight to ensure
smooth, vibration free travel of flights
Scrapper Flights The scraper flights shall be equipped with wear pads, which are
shaped to provide lateral guidance for the flight. The wear pad
material shall be polyamide or equal.
In each collector at least two scraper flights shall be equipped

with a rubber blade to optimize the cleaning of the tank floor.
The flight height shall be at least 200 mm and width 100 mm.
The drive wheel shall be made of stainless steel / polyurethane.
The drive wheel shall preferably be adjustable pitch model, to
Collector Chain Drive ensure that always the maximum number of teeth/pins are in
Wheel drive operation thus reducing wear. The wheel shall be
constructed so that the drive pitch can be easily adjusted
without taking the chains off the wheel.
The idler wheels shall be totally round, one part moulded
Collector Chain Idler toothless idlers with no wear-prone teeth. Material shall be
Wheels Polypropylene (PPG).

The drive shaft shall be solid, of AISI 304/316 stainless steel,

and shall turn in the bearings mounted to tank walls. The shaft
diameter shall be 80 mm and the diameter of the tubular centre
part of the shaft assembly shall be at least 160 mm for shafts up
Drive Shaft
to 6 m and 210 mm for shafts 6 – 12 m. The wall thickness of
the tube shall be min. 2.5 mm. The sprockets shall be fastened
by bolts to the flanges at each end of the shaft.
The idler wheel shafts shall be AISI 304/316 stainless steel stub
shafts.
The idler shaft diameter shall be at least 75 mm.
All the idler shafts shall be adjustable to any direction to ensure
Idler Shaft easy chain alignment procedures. In addition, in each tank 2
idler shafts shall be mounted on a sliding base making chain
tensioning possible.
The idler wheels shall be secured sideways with two (2) AISI
304/316 stainless steel retaining rings.
All underwater bearings shall be made of high molecular
polyethylene, designed for water lubrication. The bearing
Wall Bearings supports shall be of AISI 304/316 stainless steel. The bearings
shall be adjustable and self-aligning type.
Return rails shall be made of reinforced glass fibre, width

106mm and depth 95.5mm and profile thickness minimum
4mm. The profile should be U-shaped with some stiffening
construction. The attaching brackets must be made of
polypropylene with glass fibre on which the return rails can
be attached by screws made of AISI 316. The attaching
brackets must have width and height adjustment for the return
rails to keep the line straight horizontally and vertically. The
Return Rails brackets shall be fastened to tank walls by chemical anchor
bolts with the distance of 2 meters between brackets.
Alternatively return rails shall be of AISI 304/316 stainless
steel measure 110 x 50 x 30 x 3 mm -profile). They shall be
welded to adjustable support brackets, which in turn shall be
fastened to tank walls by chemical anchor bolts. The distance
between supports shall be approx. 2 m.
The scraper flights run on these rails on their return travel.

The bottom rails shall be of polypropylene and shaped to
Bottom Rails provide lateral guidance for the flights. The rail system shall
feature an allowance for thermal expansion
The drive unit speed reducer shall be of the helical gear type,
fully housed, running in oil, with antifriction bearings throughout.
The drive units shall be pre-assembled in the shop and shipped
as a complete unit to ensure proper assembly of all
components.
Drive Unit
The motor shall be totally enclosed, ball bearing, fixed speed, of
ample power for starting and continuously operating the
mechanism under normal operating conditions without
overloading. The motor shall conform to IEC standards and be
suitable for operation on 380 – 415 volts, 3 phase, 50 Hertz.

Protection class to be at least IP55. The motor shall be directly

connected to the speed reducer/ gear box and mounted as a
common unit.
The drive chain shall be roller chain type of AISI 304/316
stainless steel. The weight shall be more than 3.5 kg/m and
Drive Chains
breaking load at least 65 KN. The bearing area shall be at least
290 mm2.
The drive chain’s driven and driver sprockets shall be of AISI
Drive Chain Sprockets
304/316 stainless steel.
All attachment bolts and anchor bolts shall be of A4/AISI 316
stainless steel, furnished with the equipment and shall be of
Attachment Bolts and
ample size and strength for the purpose intended. All
Anchor Bolts
attachment and anchor bolts shall be included.
Reciprocating Sludge Scraper
The reciprocating sludge scrapers are installed in the pre - settlement tanks(primary
clarifier) to transport settled solids from the tank floor to the end hopper for sludge draw
off.
Wedge shaped profiles are driven back and forth along the tank floor. The sludge is
transported towards the sludge hopper when the profiles move slowly forward and on the
faster return movement the profiles slide below the sludge layer. The speed of this return
movement is approximately double that of the forward movement.
For low total solids content where no sludge layer is formed, the scraper creates a flow of
sludge along the tank floor. The constantly recurring movements of the scraper thicken the
sludge as it moves towards the sludge hopper.
The scrapper shall be capable of continuous, automatic operation without the operator
attention under all weather conditions.
Scum removal facilities are not required.
To remove Suspended Solids / Biomass from mixed liquor /

Objective
influent
Type of Clarifier Rectangular
Consist of link rod system and a number of wedge formed
Scrapper profiles which slide on rows of gliding strips on the based on
the tank
SS 316 L
of Scrapper
Upper link arm and angled link arm shall connect the power
Link arms, Pilot & Pilot drive to the scrapers via the pilot rod.
Tube Pilot rod slides in the pilot tube and the scrapers are fixed to
the pilot rod.
Profiled Scrapers are welded together in a framework of
Scrapers, Flat Bars and longitudinal and diagonal flat bars.
Gliding Strips The longitudinal flat bars slide over the glide strips fixed to the
based of the tank

Note:
i. The stainless steel and mild steel including hot dipped galvanised components where
both are connected to the water / wastewater should be electrically isolated to prevent
galvanic corrosion to the stainless-steel surfaces
ii. The sludge drawl pipe shall be provided with telescopic pipe with valve of suitable size.
Replace the existing sludge draw-down valve with timer controlled motorised valve of
same size.
iii.
iv.
14.5.1 Submersible Mixers in Aeration Tank / Sludge Storage Tank
Submersible mixers could be used in the bio reactor for the following purposes
i) In Anoxic Tank to keep Solids in suspension
ii) In Aeration Tank to keep solids in suspension and to improve aeration capacity .
iii) In Sludge Storage Tank
The specification for the mixer design is as follows :
Power
Mixer Application / Minimum
Mixer transmitted to
Duty Pumping Rate
fluid (minimum)
1.5 times tank Tip velocity not more As specified in
Anoxic Bio Reactor
volume than 16 m / sec Part 4
Aeration tank –
0.5 to 0.75 times Tip velocity not more As specified in
aeration efficiency
tank Volume than 3 m / sec Part 4
improvements
Sludge Sump More than 5 times Tip Velocity not more 8 watts per m3 of
(digested/undigested) tank Volume than 16 m / sec tank volume
The mixers shall be of robust construction, designed for continuous operation under the
most difficult operating conditions installed in aeration basins.
The mixers shall be energy efficient with submersible type mixer with motor housing in CI
IS 210 Gr FG 260 and 2 or 3 blades propeller in SS 316 construction with suitable IE3
premium efficiency motor at 415 ± 10% V, 50 C/S. IP 68 Class H insulation
Not less than 2 mixers hall be provided for each tank.
The submersible mixer shall be provided complete with lifting device in SS-316 of 60 mm
tube, MS winch and stainless steel rope and handle with all accessories.
Bearings shall be lubricated-for-life with a calculated life of more than 100,000 operating
hours.
Material of Construction: -
Propeller : Stainless Steel 316 (1.4571) or Duplex Stainless

Steel 1.4460 (AISI 329)
Shaft : Stainless Steel 316 1.4401 (AISI 316)

Lifting Chain / Rope : Stainless Steel (AISI 316)

Guide Tube : Stainless Steel (AISIS 316)
Support brackets & fasteners : Steel (AISI 316)
14.6 Air Blowers
14.6.1 General requirements – all blowers
All type of Blowers shall be fitted with the following appurtenances

• suction air filter and silencer,
• outlet silencer,
• pressure safety valve,
• delivery pressure gauge and
• delivery isolating and no-return valve, and
• acoustic enclosure to comply with the specified limits to noise.
A metallic bellow joint shall be provided on the delivery side of each blower. Antivibration
pads shall be provided at foundation level to keep vibration of the equipment within limits
as specified in this specification.
Casing of the blower shall be robust construction and shall be machined to proper
tolerance. Rotor along with other un-machined rotating part shall be properly balanced so
as not to cause any vibration during operation. Rotor shall be made in one piece and
securely keyed to the shaft. Means shall be provided to prevent loosening during operation
including rotation in reverse direction
The Designer shall propose energy efficient air blowers/compressors of proven design
working satisfactorily with documentary evidence. For large aeration capacities
considering high efficiency, low maintenance cost, minimal foot print, minimize breakdown
time and over all low life cycle cost energy air efficient compressors shall be preferred as
per the duty application. The minimum number of standby blowers should be 50 % if
numbers of installed blowers are 2 or more otherwise 100 % stand by.
The manufacture must be ISO 9001:2000 certified to assure the conformance to the
highest quality standards of the industry each blower shall be designed according to the
climatic conditions at site listed below.
Differential pressure required As per duty Condition

Maximum air inlet temperature 45˚C
Average air temperature 20˚C
Lowest air temperature 10 ˚C
Maximum temperature in the blower room 40 ˚C
Maximum humidity with maximum air inlet temperature 80 ˚C
Average humidity 65 % RH

14.6.2 Turbo Blower:
14.6.2.1 General Specifications
a) The high speed turbo blower should be gearless & direct driven with high frequency
permanent magnet motor. The motor should be premium efficiency type with H class
insulation. Motor & the blower should have lubrication-free air-foil bearing or Magnetic
bearings. Shaft material of construction of the shaft will be either Stainless steel Super
alloy or Aluminium alloy or Titanium or any other rigid material suitable for the duty
application preferred.
b) The material of construction of the blower’s impeller should be of stainless steel or
aluminium alloy and preference will be for a corrosion resistant material and be rigidly
fixed to the shaft and the shaft and impeller be dynamically balanced at the operating
speed.
c) The motor should have perfectly matching integrated invertor (VFD) which should be
used for smooth start-up as well as capacity control from minimum of 45% to maximum
of 120% output, it should be possible at all temperature. VFD control shall be based
upon constant motor current, not constant rpm.
d) The starting current should be less than 1.5 times of full load current of the motor /
blower.
e) Both, the motor & Invertor (VFD) should be air-cooled/ fluid cooled type. All cooling
shall be accomplished with ambient or cooled dry air. Heated air from the motor &
inverter shall not be mixed with intake fresh air or water / fluid cooled.
f) The blower package should be microprocessor controlled with graphical touch screen
display HMI. It should be able to control following parameters – constant pressure,
constant flow, and constant power & dissolved oxygen control with direct connectivity
to D.O. sensor.
g) The blower should be equipped with pressure, differential pressure, On-line flow meter
vibration, speed, & temperature monitoring devices.
h) The flow measuring device can be an orifice or a bell mouth design with the flow being
measured based on differential pressure. Actual ambient & discharge temperatures
should be measured using temperature instrumentation. No assumptions or
calculations regarding flow, pressure, temperatures or relative humidity shall be made.
All process & performance conditions shall be measured, not calculated.
i) The HMI should display set value, actual instantaneous value & on-line trend of
discharge pressure, flow, input power, rpm, suction temperature, performance curve /
map with actual instantaneous operating point. It should also have provision to send
this data for logging purpose.
j) Static pressure measurement should be carried out at exit of diffuser of the blower to
ensure that it is equivalent to the total discharge pressure.
k) The microprocessor controller should be able to accept external analogue input for
remote setting of the parameter to be controlled.
l) The supplier should guarantee the total input power to the blower as per specified
discharge flow & pressure.
m) Blower shall have built in automatic surge protection. Blower with high ‘rise to surge’
will be preferred.
n) Blower package shall be supplied with acoustic enclosure covering the entire blower
package to restrict the noise level. 85 dBA at 1.85m distance Vibration measurement
of the compressor shall be less than 1mm/s (RMS). Each blower shall be factory tested
by the standard methods based upon ASME PTC-10:1997 measuring kW input for
Wire to Air power at the inlet of the package and/or applicable test codes such as ISO
5389:2005, JIS B 8340. Acceptance criteria is 2% tolerance on power and flow. No
negative tolerance on flow and pressure is allowed. All Blowers should be cooled by

either Air or water cooling as per the area duty operating conditions to cool the VFD or
the motor.
o) Suitable Air cooling system shall be provided to reduce the temperature of compressed
air from discharge of air blower before entering in to the Aeration tank. Delivery header
line from Air blower up to Aeration tank SS-316 shall be provided with suitable type of
insulation to avoid any accident during O&M due to expected high temperature on pipe
surface.
p) Blower virtually should not have any maintenance costs except to change the cooling
and process air filter elements when required. On average this should be once a year
and should not take more than one hour. Other than that, over the expected 20 years
operational lifetime of the blower, it is expected to replace the back-up battery once
every 3 to 5 years and cooling fans in the VFD and MBC after every 50,000 hours
operation (5 to 7 years)
14.6.2.2 High Speed Turbo Motor
The high efficiency motor will make it possible to have IE3 premium efficiency (. . The
motors will have low starting current to a maximum of 4 to 10 % of the Full Load Current.
Motor to be suitable for

i. Input Power: 3Ø, 415Vac, 50 Hz (± 5%)
ii. Motor Power Range: including 15 % overload of duty point FLC
iii. Harmonics Frequency filters to be an integral part of the motors to prevent Total
Harmonic Dissertation to the electrical system. The THD shall be limited to +/- 5 % of
the operating frequency.
iv. Blowers should have optimized VFD needs and small starting current (< 5% Full load
current) and providing premium efficiency Machine shall be designed for surrounding
temperature of 50 Degree.Celcius.
v. Motor shall be IP55 grade
vi. Motors meant for Variable Frequency Drive (VFD)or Variable Speed Drive (VSD)
application shall be manufactured using Vacuum Pressure Impregnated (VPI)or
Inverter Grade Treatment (IGT)process.
vii. Motors shall have insulated bearings and shaft grounding ring, as applicable, to suit
VFD/VSD application.
viii. Motors shall have H class of insulation to suit VFD/VSD application.
Impeller :
Stainless Steel or High Strength Aluminium Alloy.
Shaft :
Alloyed Stainless Steel, Titanium or 6Cr16 steel.
Bearing
Oil free Teflon-S Air foil or Permanent Magnet bearings made from corrosion free material
like nickel, titanium alloy steel.

Acoustic enclosure
Al-Zn coated steel, isolated with glass wool, IP55 enclosure
14.6.3 Single Stage Centrifugal Blower/Compressors:
14.6.3.1 General
The general specification of single stage centrifugal blowers shall include:

a) The compressors shall be motor driven, single-stage centrifugal, integrally geared,
horizontal/vertical split type. Each compressor shall be provided with end-suction and
side discharge, with discharge adjustable radially increments every 15 degree angle.
Each compressor shall be equipped with an integral intake filter/silencer, modulating
inlet guide vanes and discharge variable vane diffusers, integral speed-increasing
gear, discharge cone - silencer, direct coupled motor, coupling and guard, inlet and
discharge flexible connectors; discharge check valve, backflow barrier, isolation valve,
motorized blow-off valve with silencer, lube oil system, instrumentation and control
system.
b) The compressor equipment shall include all the ancillaries with local control panels for
each compressor and the master sequence controller integrated in the local control
panels or can be external MCP.
c) The compressor equipment specified herein is intended to pressurize ambient air for
the supply of oxygen to waste water treatment aeration tanks.
d) The compressors will receive filtered air and will discharge to the main header. The
capacity of each compressor shall be automatically controlled to provide the airflow
rate through the compressor as required by the process. The blow-off valve shall be
open during start-up and shutdown to allow unloaded start and stop, and to avoid surge
conditions All the piping system from the blowers shall be interconnected to feed to all
the basins.
e) Regulation shall be possible in the range of 120-45% (or less) of the projects design
flow at all project design temperatures and at design pressure. The regulation should
be achieved with the help of dual vane control i.e. Inlet Guide Vanes (IGVs) and
Variable Vane Diffusers (VVDs) so as to ensure maximum energy saving during
complete range. The blower shall be constructed with two independent regulation
possibilities to optimize the efficiency when regulating in the;
i. Isentropic Head (compression and temperature) regulation and
ii. When regulating the flow.
f) The regulation should be fully automated and contain a program for continuous
optimization of compressor efficiency with respect to changes in inlet temperature,
differential pressure and the required flow. The Isentropic efficiency should not drop
more that 5% when regulating the flow from 120% to 45%, at max project design
temperature and pressure.
g) Blower package shall be supplied with acoustic enclosure covering the entire blower
package to restrict the noise level up to 85 dBA at 1.86 mt distance. Vibration
measurement of the compressor shall be less than 1mm/s (RMS).
h) Suitable Air cooling system shall be provided to reduce the temperature of compressed
air from discharge of air blower before entering in to the Aeration tank.
14.6.3.2 Impeller Type
The impeller shall be of the semi open radial flow type, induced S-shaped with strong
backward leaning blades, machined as one, not welded, casted or riveted.

The impeller shall be statically and dynamically balanced. The Supplier must demonstrate
that the impeller/shaft design is designed for operating at peripheral speeds up to 115%
of the rated operating speed. The axial gap between the impeller and compressor casing
must be adjustable by means of machined spacers in order to assure the prescribed gap.
14.6.3.3 Shaft Seals
The shaft seals shall be of double mechanical seal non-contact, multi-point, labyrinth type
with small clearances and sufficient touch points to minimize air leakage out of or into the
casing while the compressor is running in the specified operating range or during start and
shutdown and to ensure a 100% oil free air supply.
14.6.3.4 Gear Box
1) The gearbox shall be of ample size and rated to transmit the maximum torque and
power input requirements to the compressor under all operating conditions and
continuous duty. The service factor shall be minimum 1.4. All exposed machined
surfaces shall be coated with a corrosion-resistant compound prior to shipment.
2) The gear drive housing shall be of close grained cast iron GG20 or lightweight
aluminium Di casted suitable for high temperature and sufficiently rigid to maintain the
shaft positions under maximum loads. The gear housing shall be horizontally or
vertically split in order to allow easy inspection and maintenance. The gear housing
assemblies shall be machined to close tolerances for bearing fit, gear alignment and
oil tightness.
14.6.3.5 Oil Lubrication System
a) A complete lube oil system shall be provided with each compressor. The system shall
be capable of supplying clean lube oil at suitable pressure and temperature to lubricate
the speed increasing gears and bearings. All components of the lubricating system
shall be installed integral with the compressor base plate and arranged to permit ease
of accessibility for operation, maintenance, inspection and cleaning.
b) The package shall include one gearbox drive shaft driven primary oil pump and one
electric motor driven pre-lubrication oil pump, each of adequate capacity to supply
lubrication for the air compressor/gearbox when operating under normal duty, during
normal start/stop and during run down in case of power loss. The electric motor driven
oil pump will operate at start/stop of compressor and at low oil pressure, activated by
the control system located in the local control panel.
c) The lube oil filter shall be duplex cartridge type suited for the oil pump capacity, with
replaceable cartridges which can be replaced without stopping the compressor. The
filter grade shall be capable of removing particles over 10 microns with a clean oil filter
and a pressure drop not exceeding 350 mbar at design temperature and flow. Filter
cases shall be suitable for operation at a pressure not less than the relief valve setting.
A visual gauge or an electric pressure switch shall indicate when the filters are
contaminated and requires replacement.
d) Strainers shall be manually cleaned and equipped with a magnetic trap Design and
installation shall permit ready access for cleaning.
e) An oil cooler for each compressor shall be furnished and shall be of the air-to-oil type.
The cooler shall be capable of maintaining required cooling rate at all specified ambient
temperatures. Each cooler shall be rated to dissipate the total emitted heat from the
compressor gearbox. Air-to-oil cooler shall be furnished with an electric motor-driven
air blast fan.

14.6.3.6 Local Control Panel
a) Each compressor shall be furnished with an integrated and dedicated rack based PLC,
All controls shall go into a safe condition by failure and not allow the machine to be
operated with any defective control.
b) The Local Control Panel set-up shall include the Load Sharing functionality with Master
Control Panel of adequate features.
c) The local control panel shall consist of the following:
d) Low voltage system with main switch and motor overload relays for auxiliary equipment
such as blow-off valve, variable diffuser, and inlet guide vanes. Further, monitoring of
the drive motor's temperature sensors, and relay for control of drive motor's main
switch, with wiring to:
e) Control system - with automatic PLC (Not applicable to integrally geared units), and all
necessary control circuits for oil pressure, oil temperature, surge limit, and
recirculation.
f) The front panel shall be equipped with Human Machine Interface with a screen of
minimum 6" colour touch panel with indication of process values Low voltage and
control systems mounted in a steel panel, IP55, and internally wired.
g) Terminal strip for external wiring.
14.6.3.7 Inlet filter / Silencer
a) Each compressor shall be provided with an inlet filter / silencer designed for maximum
air flow at absolute minimum pressure drop and connected directly to the inlet of the
compressor via a flexible connection.
b) Filters shall be removable through easily accessible doors and have a removal
efficiency of 99% on 10 micron. The filter has to have a minimum standard of EU3 in
accordance to DIN 24185.
14.6.3.8 Bearings
The bearings could be;

i) Hydrodynamic type sleeve type bearings
ii) Magnetic Bearings
iii) Hydrofoil Bearings
All bearings shall be rated for a bearing life of minimum 100,000 hours.
Vibration levels (P≤ 300 kW) ≤ in accordance to ISO 10816-1
Vibration levels (P>300 kW) ≤ in accordance to ISO 10816-1
Noise level ≤ in accordance with relevant standards (to 80 dB at 1 m)
Blowers shall be fitted with:

• Outlet pressure transmitters, inlet temperature transmitter and a thermal mass flow
meter. The unit should allow for profibus communication to main SCADA control
system.
• Inlet Air Filter Differential Pressure Switch
• Oil Temperature Transmitter
• Oil Pressure Transmitter
• Oil Filter Differential Pressure Switch
• Variable Vane Diffuser Position Transmitter
• Inlet Guide Vane position transmitter

• Gear vibration accelerometer transmitter

• Blower reverse rotation detector
14.6.3.9 Material of Construction
Casing : Inner Volute Aluminium, Cast Iron GGG40

Outer volute Aluminium Al Cu Alloy / cast iron GGG40
Impeller : Aluminium AlCu2MgNi, open radial flow type with
backward leaning blades
Gearwheels : High tensile SS316 / High Tensile 15CrNi6
Shaft fast : High tensile SS316 /High Tensile 15CrNi6
Shaft slow : High tensile SS316 / High Tensile 34CrNiMo6
Coupling : Geared High Torque Steel Coupling with spacer
Filter material : As required
Machine mounts : St. SIS 1312, f or damping natural rubber hardness 60
Oil Cooling : Air cooled
Acoustic enclosure : Al-Zn coated steel, isolated with glass wool, IP55
enclosure
Motor : IE3 Premium efficiency motor, IP55, insulation class H
with temperature rise H limited to B and temperature
measurement in the winding as well as of anti-
condensation heater.
Cone diffuser : Stainless Steel 316
Compensator : Stainless Steel 316
14.6.3.10 Performance Test Run
One compressor in each type/model shall be fully inspected and functionally tested at the
factory for performance and proper operation. Performance test and acceptance according
to ISO 5389 should be performed on manufacturer test stand and attested. The design
values of the performance table according the contract must be within a manufacturing
tolerance of ± 2% and a measuring tolerance of ± 2%.
The Employer should be given an opportunity to witness the factory acceptance tests
14.6.4 Air blower- Positive Displacement (Twin / Tri lobe type) Type
a) Rotary type Blower shall be capable of developing the required total pressure at the
rated capacity or continuous operation. The rotary type blowers shall be Twin lobe /Tri
lobe type. One number VFD drive shall be provided for each set of Blowers. Directly
coupled design shall be preferred. If Bidder quotes for motors with VFD motors shall
be suitably de-rated.
b) Design of Twin/Tri lobe Air blower shall be as per BS 1571 Part-I
c) Performance testing of Twin/ Tri lobe Air blower shall be as per BS 1571 Part-II / ISO
1217:2009
d) The blowers shall be provided with the following components.
i) Common base frame for Blower & Motor.
ii) Inlet silencer and filter.

iii) Discharge Silencer & non-return valve in delivery branch.

iv) Pressure relief valve or excess pressure safety device.
v) Expansion Bellows type couplings on inlet and delivery branches.
vi) Acoustics Enclosure.
vii) V-Belt drive arrangement with Belt Guard.
e) Vibration shall be within 85 dB(A) and less than 4.5mm/s at a distance of 1.86 m
respectively. The blower shall be driven by squirrel cage induction motor.
f) The speed of the blowers shall be below 1,000 rpm.
g) The power rating of motor shall be at least 15% above the maximum power
requirement by the blower.
h) The blowers shall be mounted at a level necessary to avoid back flow or siphoning of
sewage into the blower.
i) Appropriate cooling arrangement shall be provided at the blower discharge line so as
to bring down the outlet air temperature within tolerable limits ( i.e less than 50 Deg.
C), so as to safeguard the life of fine bubble diffusers and satisfactory performance of
the same and also for human protection
14.6.4.1 Material of Construction:
• Casing: CI conforming to IS: 210 Gr FG 260

• Rotor: Alloy steel or equal
• Shaft : Carbon steel C40/EN 24/19
• Timing gear: Cast alloy steel or equal
• Pulley and gear side plates and cover: CI conforming to IS 210 Gr FG 260
• Acoustic enclosure: Al-Zn coated steel, isolated with glass wool, IP55 enclosure
14.6.4.2 Design Parameters:
• Type : Twin lobe/ Tri lobe

• Discharge pressure to suit process requirement
• Power transmission Direct drive preferred
• Cooling Air cooled / Water cooled
• Code BS 1571
14.6.4.3 Tests Specification
• Hydrostatic tests Twice the maximum working pressure

• Performance test As per BS : 1571 Part-I
• Strip test Clearances with tolerance limit
• Mechanical balancing ISO 1940 Gr. 6.3 or better
• Visual Inspection Before painting
• Electrical drive Specification
a) The motor shall comply IE3 premium Efficiency, squirrel cage type, three phase
induction, IP 55, Horizontal foot mounting motor for continuous duty with class ‘H’
insulation.
b) The power rating of the Blower motor shall be 115% of the power input to the
Blower at duty point at a speed corresponding to the frequency of 48.5 Hz.
c) Motors meant for VFD or VSD application shall be manufactured using Vacuum
Pressure Impregnated (VPI)or Inverter Grade Treatment (IGT)process.
d) Motors shall have insulated bearings and shaft grounding ring, as applicable, to
suit VFD/VSD application.
Refer to the respective electrical specification for further details about the electrical
components for the positive displacement blowers.

14.7 Diffuser
A aeration system shall be provided to meet the aeration requirement as per the process
design requirement. Sufficient design calculations are to be provided along with
manufacturer standard one having supplied diffuser during last five years to various waste
water treatment plant.
Where a diffuser system is selected (or specified) the type and number of diffusers
selected shall be substantiated by design and subject to approval by the Employer. The
aeration system shall comprise Fine Buddle Diffuser membrane diffuser fitted to a fixed
piping system. Tube or disc type diffusers shall transfer the maximum quantities of oxygen
at standard pressure conditions, subject to the following criteria:
i) For Disk Diffusers 18 gm O2/m3 air per m water depth at SOTE1
ii) For Tubular Diffusers 16 gm O2/m3 air per m water depth at SOTE
The Maximum Air to diffuser shall not exceed the following criteria:
i) For Disc Diffusers, a maximum of 60 m3/m2 of the installed membrane area
ii) For Tubular Diffusers, a maximum of 45 m3/m2 of the installed membrane area
The design shall be based on the recommended formula specified in Part 4 of the
Employer’s requirements and where the AOR2 shall consider the following field correction
factors:
i) The maximum Alpha factor shall be 0.60 for fully submerged diffusers
ii) The Beta factor shall be 0.95 for submerged diffusers, and
iii) Fouling factor for fixed non-retrievable diffusers that cannot be cleaned without
draining the tank) shall be 0.70
14.7.1 Material of Construction for Diffusers & Air Piping
Diffusers Membranes : Silicone with laser drilled holes

Diffuser Support : Non-Corrosive material cPVC or equivalent
Under Water Air Piping to : SS 316 diffusers including downers and aeration grid
Pipework from Blower to
: Galvanized steel piping (above water pipes)
underwater pipes
14.7.2 Assembly of Fine Bubble Diffusers
General
The subsurface aeration system shall take into account that the assembled air and diffuser
pipework is fully submerged in wastewater subject to significant buoyancy and buffeting
forces. To ensure satisfactory robustness of the system, the assembly shall consider:
a) A fixed pipework header arrangement using a complete mixing pattern which will
ensure efficient and adequate distribution;
b) All components necessary for a complete mixing system within each Aeration Tank
shall be provided in accordance with the detailed specification as follows;
• Flanged connections (SS 316) at the upstream side of each drop leg for connection
to an isolation butterfly valve.
• Stainless steel (SS 316) Drop legs.
• Stainless steel (SS 316) Slip joint connections to the air distribution header.
1 SOTE is Standard Oxygen Transfer Efficiency

2 AOR is the Actual Oxygen Transfer Rate

• Stainless steel (SS 316) Air distribution headers.

• Stainless steel (SS 316) Diffuser connectors.
• Stainless steel (SS 316) Anchored Supports
• Gaskets.
• Stainless steel (SS 316) Header joints.
• Stainless steel (SS 316) Bolts, nuts and washers.
c) Two diffusers are to be provided at each header connection. These are to be mounted
onto a reinforced tee located on the bottom centreline of the header. The reinforced
Tee shall be adjustable to allow accurate alignment of the diffuser.
d) For tube type diffusers, a single piece injection moulded polypropylene / ABS tube
surrounded by a membrane sleeve should be considered and kept in position by 2
stainless steel grade 316 ear clips.
e) The external diameter of aerator pipework, shall not be less than 65-68 mm. The
effective length of each section between supports shall not be less than 1,000 mm.
f) Tube diffusers where specified, shall comprise a complete system i.e. air header,
support pipes, locking bolts etc.
g) The design of membrane sleeves shall be self-closing to prohibit clogging of the pores
when air flow/pressure is interrupted. The membrane shall be of an anti-adhesive
material with the surface resistive of grease, oil, hydrocarbons & precipitating
chemicals.
h) The free end of Aerator / polypropylene support pipe should be open to ensure low
buoyancy force. The leak preventing washer should be made up of stainless steel
grade 316 and rubber seal should be of EPDM rubber.
i) Tubular aerators shall be designed and suitable for intermittent operation as a fine-
bubble aeration system. Rubber membranes should have two grooves on opposite
sides of the membrane circumference as the defined fold line when air supply is
switched off.
j) The air distribution pipes or tubes should extend over the entire effective length for an
even distribution of air for bubble formation.
k) These membranes shall be provided preferably with lower perforation sizes with
suitable perforation pattern which when applied with a lower diffuser throughput rate
and correct distribution of the diffusers on the aeration tank floor will result in very high
oxygen transfer efficiency (OTE).
l) The diffuser perforations shall not be less than of 0.5mm with a special perforation
pattern with staggered pattern. Surface area shall be higher at the designed throughput
rates so that bubble sizes less than 0.65mm can form. The rising velocity of bubbles
should ideally be lowered.
m) The bubble should retain a solid spherical shape. Bubble should move in a helical
fashion for smaller bubble diameters so that it travels a longer path.
n) The distribution of these bubbles should be uniform resulting in more energy being
transmitted to the waste water, leading to better mixing.
o) Bottom deflector to prevent debris from entering diffuser assembly shall be included in
the design.
p) Orifice flow control is to be provided to ensure orifice head loss is at least 2.5 times the
head loss in the air header at all air flow rates in the diffuser’s design operating range.
q) Diffusers are to be spaced along air header to provide uniform mixing of the pre-
aeration tank contents.
r) The Standard Oxygen Transfer Rate (SOTR) operating shall be achieved with all
aeration zones operating at varying air supply rates. Contractors shall provide their
recommended minimum airflow rate for each zone in order for their diffuser to maintain
the activated sludge mixed liquor suspended solids (MLSS) in suspension and avoid
deposition of sludge in the bioreactor.

s) Fine bubble membrane type diffusers shall be provided of a type that will prevent
backflow. The Aeration system shall be suitable for prolonged isolation of the air
supply. The membrane shall be provided fixed to the membrane holder in a manner
which does not introduce unbalanced stresses and increases sealing pressure as the
air flow rate to the diffuser risers. Provide a back flow prevention device built integrally
with the diffuser that prevents backflow into the diffuser and air piping.
t) A maximum diffuser flux rate shall be provided such that the stress in the diffuser
material is within elastic loading limits with a safety factor of at least 10. The contractor
shall submit test result, calculations and any other documentation to exhibit that the
membrane material will be able to withstand operating loads without undue stress or
strain leading to failure in compression or shear or creating significant mechanical
creep of the material which would impair functioning or would cause enlargement of
the membrane perforations or holes.
u) The tolerances of the diffusers mounted bases shall be provided such that the stress
in the diffuser material is within elastic loading limits with such that any diffuser and
any gasket may be assembled onto any mounting base and provide a seal capable of
withstanding the applied hydrostatic and/or pneumatic head.
v) The contractor shall provide diffuser mounted by the action of a threaded component
that shall require measurement of the applied torque to the threaded component during
tightening. The torque measurement shall lie within the range of torques specified by
the diffuser equipment supplier.
w) All rubber components shall be manufactured from synthetic proven to be resistant to
corrosion, degeneration or abrasion in the environments proposed. Provide diffuser
material resistant to chemical attack, UV light, weathering and aging. Submit test
results, certifying the integrity of the membrane. Provide data indicating the
susceptibility of the membrane material to attack by various chemicals.
x) The diffusers shall be capable of withstanding a maximum differential pressure of 30
kPa and a maximum air temperature of 80 Deg. C.
y) Protective storage of rubber and plastic components of diffusers shall be provided prior
to installation. Effective cover shall be provided to the diffuser after installation to
protect them against physical damage and the ingress of dust and dirt before filling the
new water. Documentary evidence of satisfactory service operation shall be provided.
Aeration Pipework
All pipe work, header and drop legs support bracket and fasteners shall be constructed of
grade 316 stainless steel. All necessary pipe work shall be provided including but not
limited to, all gaskets, fasteners, flanges, isolating valves, header pipe work, down comers,
distribution pipe work and purge or drainage lines of each aeration zone located on the air
header pipe work.
Manually operated isolation valves to each of the banks of diffusers shall be provided. A
purge system shall be provided to permit the bleed off of any accumulated water in the
diffuser lateral pipe work. The details an design of the purge system shall be submitted for
approval by the Contractor at the time of detailed engineering. All material shall withstand
all operating temperature at the top of the drop leg in the range of 20 Deg. C to 80 Deg.
C.
Prior to shipment all stainless steel piping shall be treated to the pickling process to provide
a de scaled surface finish.
Prior to commissioning all pipe work shall be cleaned internally to remove all dust,
construction material or any other foreign matter, which could block the pores or damage
and reduce the design life of the diffusers.

Air Header and Drop-legs
a) Air distribution header shall be fabricated in sections up to a maximum of 12 meters in

length.
b) Bottom elevation of the air distribution header shall be same throughout the tank.
c) Removable end cap at header ends shall be provided.
d) Connections between sections of the air distribution header shall be designed to allow
individual header sections to rotate independently of adjacent header sections.
e) Header dimensions shall conform to dimensional tolerances specified in ASTM A554-
89 and ASTM A530-87.
f) A drop leg shall be furnished from the air main connection at the top of the tank.
g) A slip joint connection shall be provided between the drop leg and distribution header.
h) The drop leg shall be supported from the connection at the air header.
i) Only factory welding shall be used. No field welding shall be allowed. Outside of each
weld area are to be wire brushed. All discoloration and deposits left by welding by
pickling are to be removed. All diffuser connections are to be welded at Factory. Both
the diffuser connectors and the headers are to be stiffened to withstand a moment of
56.5 Newton.M at the connector without permanent deformation.
j) All SS 316 assemblies and parts after fabrication are to be passivated by immersion
in a pickling solution of 6 percent nitric acid and 3 percent hydrofluoric acid at 60 Deg.
C for a minimum of 15 minutes. These shall be neutralized by immersion in a tri-sodium
phosphate rinse. Certificate shall have to be submitted in conformation of the above
activity.
Supports and Anchors
a) Necessary wall and floor mounting supports shall be provided for all drop legs and air
headers to anchor firmly on the wall and to the bottom of the tank and as specified
herein.
b) Anchor supports to concrete walls and floors using stainless steel expansion bolts
sized and spaced as required for the loads encountered.
c) Supports shall be designed to allow leveling the air header and diffuser assemblies to
within specified tolerances.
d) Necessary expansion couplings shall be proved in the drop legs and air headers as to
accommodate anticipated thermal expansion and contraction. Designs of expansion
coupling as well as computations for sizing are to be submitted.
On-line Diffuser Cleaning

An on-line cleaning system shall be provided as an option to allow for cleaning of diffusers
without taking aeration system off-line. The cleaning system may entail addition of formic
acid (or other chemicals which are not detrimental to the biological process) through a
tapping point in the down comers. All necessary tapping points, access and portable
chemical mixing and injection equipment shall be provided. The recommended chemicals
shall be able to permeate the pores of the diffusers where it shall dissolve the minerals
and eliminates micro-organisms present in the deposited material. This combined action
shall be sufficient for full restoration of the original quality of the diffuser. The cleaning shall
be able to be carried out without interruption to the treatment process. The material of
construction of pipework, fittings, valves and diffusers shall be chosen to withstand the
exposure of applied chemicals.
Spare Parts
The Contractor shall include in his offer a priced schedule of recommended spares.

Special Tools
The Contractor shall include in his offer any special tools for the equipment to be supplied.
Installation
It is the Contractor’s responsibility to install the diffuser system correctly. The Contractor
shall provide a manufacturer representative who has knowledge and experience in the
proper installation, start-up and operation of the diffuser equipment to inspect the final
installation and supervise the commissioning tests.
Installation of all components shall be ensured in accordance with the manufacturer’s

instructions and recommendations.
Field Testing
The Contractor’s manufacturer representative shall subject each bank of the diffuser
system to the following tests. The tests shall include, but not be limited to:
a) Checking alignment of all components and adjust if necessary;
b) Checking that each bank can be removed without interference;
c) Checking that all equipment, safety devices and equipment protection devices function
properly;
d) Examining protective coating and repair as necessary;
e) Running equipment for an appropriate time at the full range of design conditions and
combination of operation duties and check for correct operation;
f) Checking the operation of all equipment under field control.
g) All Fine bubble diffused aeration systems will be field tested.
h) Testing will verify the installation as well as the diffuser’s ability to deliver the specified
air flow rates at the manufacturer’s stated pressure loss. Testing will also verify the
uniformity of mixing provided.
i) Levelling tests:
• Clear water shall be introduced into each tank to the top of the diffuser elements.
• The level of the diffusers is to be checked that all element horizontal surfaces are
within 10 mm of a common horizontal place and at the specified elevation
Leakage and Distribution of Flow Tests
The contractor shall demonstrate that the diffuser pipe work does not have air leaks under
maximum and minimum flow condition by operating the diffusers under shallow
submergence. In this regard, following activities shall be ensured:
a) After successful completion of the levelling tests, raise the water level to 50mm above
the manifold.
b) Visually inspect the water surface to ensure that the airflow is uniformly distributed
across the tank.
c) Pressure test:
• All of air supply pipe line shall be tested by pressure. Test pressure shall be at least
2 times higher than normal operation pressure.
• If Engineer is unsatisfied with any test results, repeat the test until the installation
is essentially void of air leaks.
• Repair any leaks in the elements holders, elements, pipes or the like.

Diffuser Pattern Testing
Ensure that the diffused Aeration system is adequately protected to prevent any damage
or blockage for the duration of the contract. Demonstrate uniform air distribution through
under minimum and maximum aeration flow rates. Demonstrate no significant “wave like”
action of the liquid. Demonstrate that all diffusers are operating simultaneously.
Diffuser Clean Water Performance (SOTR) Testing
The Engineer shall have the right to require the Contractor to carry out Standard Oxygen
Transfer Rate testing of all the aeration zones. The water depth in the tank for the tests
shall be 6 meters. During the test the contractor shall demonstrate the guaranteed
maximum and minimum oxygen transfer rates (SOTR) at the guaranteed airflows and
pressures. The contractor shall carry out tests generally as set out in the American Society
for Civil Engineers “Standard Measurement for Oxygen Transfer to clean water” Latest
Edition.
The following shall be provided during testing:

a) At least three correctly calibrated portable dissolved oxygen probes in lieu of the
Winkler test. Demonstrate calibration of the dissolved oxygen probes;
b) All chemicals, chemical mixing, instruments (including air flow measuring devices),
equipment, monitoring devices, recording systems or data acquisition and labour to
carry out the clean chemical dispersion water oxygen transfer test;
c) A written summary of the test procedure, including a schedule, calibration certificates
of all equipment and monitoring devices, any special precautions required for the
handling of chemicals and special disposal requirements;
d) Monitoring of the airflow to the diffused air system for clean water oxygen transfer tests.
e) Supply complete detailed and summary test reports to the Contractor within 14 days
of the completion of each test.
All necessary corrections and adjustments made shall be recorded. A written statement
shall be provided by the Contractor’s manufacturer representative at the completion of the
tests, certifying that the equipment has been properly installed and operates satisfactorily
– all test records are to be appended.
Reliability Tests
Reliability testing shall not be commenced until the tests described above including the
SOTR test if required, have been completed and approved by the Engineer.
The diffusers shall be required to operate under the normal operating conditions within the
limits of performance offered by the Contractor, and their continuous or intermittent
performance as may be more convenient for the operation of the works. The diffusers shall
operate without failure of any kind for a period of one calendar month. Should any failure
(other than that of an entirely minor nature) occurs in any portion of the diffusers, due to
or arising from faulty design, materials or workmanship or staff training (but not otherwise)
sufficient to prevent commercial use of the plant, the test shall be deemed to have failed.
The test period of one month will recommence after the Contractor has remedied the cause
of the failure. The onus of proving that any failure is not due to faulty design, materials,
workmanship or training will lie with the Contractor.
In cases where the responsibility for failure cannot be determined initially, the Contractor
is to attend to such failure as though they were his responsibility. The taking-over certificate

will not be issued until the Reliability Test has been completed to the satisfaction of the
Engineer along with his written approval. When the Reliability test has been completed to
the satisfaction of the Engineer, the Defects Notification Period shall commence.
14.8 Travelling Bridge Filters
14.8.1 General
The Travelling Bridge Filters shall be capable of filtering effluent from secondary clarifiers
with daily average flow of as per the requirement condition mentioned Part 4 and achieve
the desired treated effluent quality. The Traveling Bridge and Traveling Hood Filters should
be capable of providing continuous water and wastewater filtration with automatic, on-line
backwashing, specifically designed for low head filtration with shallow beds. The filters
may be single media or dual media. The traveling hood shall be equipped with a single,
centre-mounted traction unit, a pneumatic travel lift, and spring-loaded outboard
stabilizers. Control is provided by a programmable controller through an interface of
electrically actuated pneumatic valves.
14.8.2 Description
a) Minimum 10 filters in the concrete basin of traveling bridge type for end discharge of
filter effluent shall be provided. The filter bed depth shall be minimum 0.30m.
b) The total backwash water volume required shall not exceed 5% of the design influent
flow. The backwash water shall be taken to the sump of Drain water pumping station.
c) Each filter component shall be designed to withstand with a prudent safety factor all
stresses that may occur during fabrication, erection, intermittent, or continuous 24 hour
per day operation. The equipment and controls shall be provided as a complete
package to ensure coordination and compatibility.
d) Each filter shall include a traveling bridge assembly, backwash hood, a single
submersible pump, nozzles with integral tailpieces, air distribution header, under drain,
Single or dual media i.e. consisting of high grade silica sand and if dual media
anthracite media shall be provided, indexing tabs, power cable, rail, influent ports,
backwash discharge launder, and controls.
14.9 Cloth Media Filters
The cloth Filters/Disc Filters shall be capable of filtering effluent from secondary clarifiers
with daily average flow in accordance with those stipulated in Part 4, and achieve the
desired treated effluent quality. Each filter shall be
a) Installed in a concrete basin and each filter basin shall be provided with a butterfly
drain valve. Each basin shall be fitted with 304 stainless steel mounting brackets to
accommodate attachment of the filter components to inside of the basin.
b) All mounting brackets shall be attached to the inside of basin wall with 304 stainless
steel wedge anchors and hardware. All piping including external & puddle piping shall
be provided by the Contractor.
c) Cloth/frame assemblies shall be constructed such that each segment is easily
removable from the centre tube, without special tools, to allow for removal and
replacement of the cloth at the point of installation. Cloths shall have a nominal filtration
rating of 10 microns.
d) Isolation valve upstream shall be provided upstream. The cloth depth shall provide
storage of captured solids, reducing backwash volumes while maintaining an
operational head loss. The filter system shall provide for the collection of filtered solids
on the outside of the cloth media surface to allow for the direct contact of cleaning
systems.

e) Filtered (clean) effluent shall be used for backwashing. The effective filtration area will
considered the actual media area which will be submerged and available for filtration
100% of the time. Hence framework and glued surfaces of filter will be considered
while calculating the effective filtration area. Contractor shall submit calculation and
sufficient evidences for verifying the effective filtration surface area.
f) The filtration system shall be complete with PLC controlled operation and backwash
system as per the recommendation of technology vendor.
g) Access walkways, handrails and stair cases etc. shall be provided as per the tender
specifications.
14.10 Membrane Filtration System
The membrane filtration system shall be either the submerged or low pressure type and
shall be capable of filtering effluent from secondary clarifiers with daily flows in accordance
with Part 4, to achieve the desired treated effluent quality. The design shall include the
necessary pre-treatment system for the membrane filtration unit selected. Concurrently,
the supplier of the membrane filtration unit shall certify that the pre-treatment system has
been adequately designed and based on the water quality information provided.
14.11 UV Disinfection System
14.11.1 General
All materials, equipment and appurtenances required to provide an open channel, gravity
flow, low pressure high output (LPHO) / medium pressure ultraviolet lamp (UV) disinfection
system complete with an automatic chemical/mechanical cleaning system and variable
output lamp drivers. The UV system shall be complete and operational with all control
equipment and accessories as shown and specified herein. This system shall be capable
of disinfecting effluent to meet the effluent water quality standards.
14.11.2 Quality Assurance
14.11.2.1 Pre-qualification Requirements:
Any UV manufacturer that is not named or listed shall meet the following requirements.
1. The manufacturer should be regularly engaged in the design, manufacture and

servicing of UV systems for municipal wastewater disinfection. Manufacturer
should demonstrate evidence of a proven track record with at least five (5)
operating UV installations at municipal wastewater treatment plants over a
design flow of 30 MLD.
2. The manufacturer should have documentation of previous experience with
municipal UV disinfection systems in wastewater applications with variable
output electronic drivers and automatic cleaning systems.
3. The manufacturer should be able to submit a reactor (bioassay) validation
report and calculation justifying the sizing for the proposed reactor, without
exception. The bioassay should have been completed by an independent third
party and have followed applicable sections and protocols described in the
NWRI Ultraviolet Disinfection Guidelines for Drinking Water and Water Reuse
(2003, 2012) and 2006 USEPA Ultraviolet Disinfection Guidance Manual
(UVDGM). The bioassay must demonstrate that the proposed UV system
design and number of lamps shall deliver the specified Reduction Equivalent
Dose (RED) based on the water quality and operating conditions specified
herein.

4. Independent certification of the lamp aging factor must be submitted if values

other than the specified default values are being proposed. The lamp aging (or
end-of-lamp-life) factor must be determined using the protocol described in the
(2003, 2012).
5. Independent certification of the fouling factor shall only be accepted if
performed on the UV lamp and quartz sleeve combination equal to that being
proposed by the UV manufacturer. The fouling factor must be conducted on
municipal wastewater effluent using the protocol described in the NWRI
Ultraviolet Disinfection Guidelines for Drinking Water and Water Reuse (2003,
2012).
6. Documentation of UV manufacturer's service capabilities including location and
experience.
14.11.2.2 Performance Requirements:
1. Provide a UV disinfection system complete with UV Banks and automatic lifting

mechanism or EOT Crane as applicable, System Control Center, Power
Distribution Centers if applicbale, and Motorized Weir Gate / Other suitable
mechanisms as Water Level Controller(s).
2. The ultraviolet disinfection system effluent quality performance shall be
evaluated through grab samples taken in accordance with the Microbiology
Sampling Techniques found in Standard Methods for the Examination of Water
and Wastewater, 21st Ed.
3. The UV system shall be designed to deliver a minimum MS2 RED of 30
mJ/cm2 at peak flow, in effluent with a UV Transmission of maximum 60%, at
end of lamp life (EOLL) after reductions for quartz sleeve fouling.
4. The RED shall be adjusted using an end of lamp life factor of 0.5 to compensate
for lamp output reduction over the time period corresponding to the
manufacturer’s lamp warranty. The use of a higher lamp aging factor shall be
considered only upon review and approval of independent third party verified
data that has been collected and analysed in accordance with protocols
described in the NWRI Ultraviolet Disinfection Guidelines for Drinking Water
and Water Reuse (May 2003, 2012).
5. The RED shall be adjusted using a quartz sleeve fouling factor of 0.8 to
compensate for quartz sleeve transmission reduction due to wastewater
effluent fouling. The use of a higher quartz sleeve fouling factor shall be
considered only upon review and approval of independently verified data that
has been collected and analysed in accordance with protocols described in the
(May 2003, 2012). The data recorded for the determination of the validated
fouling factor must be obtained by testing in secondary wastewater effluent
utilizing the same lamp, quartz sleeve and cleaning system proposed by the
UV manufacturer.
14.11.3 Products
14.11.3.1 Design, Construction, and Materials
A. General:
1. All UV Bank metal components in contact with effluent shall be Type 316
stainless steel.

2. All wiring exposed to UV light shall be Teflon™ coated.

3. Each channel should have 01 extra connected online standby UV bank or the
system should have one stanby channel with connected online standby UV
banks.
B. Lamp Array Configuration:
1. For in-channel systems, the lamp array configuration shall be in a staggered

inclined arrangement perpendicular to water flow or horizontal lamp uniform
array with all lamps parallel to each other and to the flow.
2. The UV system shall have minimum of two UV banks per channel.
3. The system shall be designed for complete submersion of the UV lamps under
all flow conditions including both electrodes and the full length of the lamp arc.
C. UV Bank:
1. Each UV bank shall consist of UV lamps, quartz sleeves and an automatic

chemical/mechanical cleaning system mounted in a Type 316 stainless steel
frame. UV System not having in-situ chemical cleaning mechanism should
provide offline chemical cleaning tanks, agitation system and air compressors
suitable for cleaning complete 01 bank at a time and should have 01 bank spare
offline.
2. Each lamp shall be enclosed in its individual quartz sleeve, one end of which
shall be closed and the other end sealed by a lamp end seal. To be considered
as an alternate, lamp quartz sleeves that are open at both ends shall be
supplied with twice the amount of specified spare seals and lamps.
3. The closed end of the quartz sleeve shall be held in place by a retaining O-ring.
The quartz sleeve shall not come in contact with any steel in the frame.
4. Each UV bank shall be rated Type IP65. UV banks that are not Type IP65 rated
are not acceptable.
5. To minimize maintenance, equipment must be provided by the UV
manufacturer to enable lifting a complete bank of lamps from the channel at
once for inspection and/or servicing.
D. UV Lamps:
1. Lamps shall be high intensity low pressure amalgam design. Lamps that are
not amalgam shall not be allowed.
2. The filament shall be significantly rugged to withstand shock and vibration.
3. Lamp wiring shall be Teflon insulated stranded wire.
4. Lamps shall be rated to produce zero levels of ozone.
5. The lamp shall withstand an average of four (4) on/off cycles per day without
reducing lamp life, warranty or causing any damage to the lamp.
6. Lamps shall be operated by electronic lamp drivers with variable output
capabilities ranging from 30% to 100% of nominal power. The lamp assembly
shall incorporate active filament heating to maintain a minimum lamp
efficiency of 35% across varying water temperatures and between the
minimum and maximum stated lamp power levels.
E. Lamp Plugs:
1. Each lamp plug shall be accessible from the top of the UV bank to facilitate
lamp removal without moving the UV banks or any other components.
2. An integral safety interlock in the lamp plug shall prevent removal of energized
lamps.

3. The lamp plug shall be rated Type IP65.
F. Lamp Drivers:
1. Each lamp driver shall independently power two (2) UV lamps. Failure of one
lamp shall not affect operation of the other lamp.
2. The lamp driver shall have a power factor correction circuit to ensure minimum
98% power factor and less than 5% total harmonic distortion (THD) current at
the maximum power level and nominal input voltage.
3. The lamp driver should be able to withstand voltage fluctuation of + 5%.
4. The lamp driver electrical efficiency shall be minimum 95% at the maximum
power level.
5. A ground fault in the output circuit shall be detected and communicated as a
warning to the external controls system while the corresponding lamp operates
undisturbed.
6. The communication protocol shall be Modbus implemented on an RS485
electrical interface, or equivalent.
G. Quartz Sleeves:
1. Quartz sleeves shall be clear fused quartz circular tubing containing 99.9%
silicon dioxide.
2. Sleeves shall have minimum UV transmittance at 254nm of 87% (1mm wall
thickness).
3. Sleeves shall be open at one end only and domed at the other end.
H. Cleaning System:
1. An automatic in-situ cleaning system shall be provided to clean the quartz

sleeves using chemical/ mechanical methods. Wiping sequence shall be
automatically initiated with capability for manual override. UV System not
having in-situ chemical cleaning mechanism should provide offline chemical
cleaning tanks, agitation system and air compressors suitable for cleaning
complete 01 bank at a time and should have 01 bank spare offline.
2. The cleaning system shall also incorporate an integrated debris removal device
to clear the quartz sleeves of any large solids or debris to maximize the life of
the chemical/mechanical cleaning system.
3. The wiper on the cleaning system shall be parked out of the effluent when not
in use.
4. The cleaning system shall be fully operational while UV lamps and modules are
submerged in the effluent channel and energized.
5. Cleaning sequence frequency shall be field adjustable to enable optimization
with effluent characteristics.
6. Cleaning system operation shall be remote auto (default) or remote manual.
7. The cleaning system shall be provided with the required solutions necessary for
initial equipment testing and for equipment start-up.
8. The UV intensity sensor shall be cleaned utilizing the same chemical/mechanical
cleaning method as that of the lamp quartz sleeves.
I. Effluent Level Controller - Modulating Weir Gate / Downward Opening Weir Gate:

a) Modulating Weir Gates (MWGs) shall be self-contained and shall be

designed and manufactured by an experienced and reputable
manufacturer, based on the AWWA C561 Standard for Fabricated
Stainless Steel Slide Gates and AWWA C542 Standard for Electric Motor
Actuators for Valves and Slide Gates in effect as of the date of this
specification or equivalent BIS Standards for these parts.
b) Modulating weir gates shall be designed to maintain the minimum channel
effluent level required to keep lamps submerged at all times
c) MWGs shall be designed for the following performance criteria:
i. MWG actuation speeds shall be between 250 mm and 350 mm per

minute.
ii. MWG maximum design rate of change of flow shall be limited to
25% of the Peak Design Flow/Channel per minute, or alternatively,
flow shall be ramped up (zero to peak) or down (peak to zero) in no
less than 4 minutes.
iii. MWG actuators shall employ AWWA S4-50% duty class motors
with a rated minimum 900 starts per hour capability.
iv. MWG actuators shall employ AWWA Class B solid-state Thyristor
based switchgear capable of at least 5,000,000 modulating steps
before overhaul; electromechanical type actuators and controls
shall not be permitted.
J. Electrical:
1. All applicable electrical components shall be UL-listed to ensure safety

standards are met.
2. Each UV lamp within a bank shall be powered from a Power Distribution
Center.
3. UV Manufacturer to supply all cabling between lamps and drivers.
4. Each electronic lamp driver shall power two lamps.
5. Power factor shall not be less than 98% leading or lagging.
K. Power Distribution Center (PDC):

1. The Power Distribution Centers shall be installed in a temperature controlled
room.
2. PDC enclosure material shall be MS Painted Type 12
3. All Power Distribution Centers to be UL approved or equivalent.
4. An internal heater shall be provided in the PDC to prevent condensation when
the external temperature drops below the dew point.
5. Each PDC shall be able to electrically isolate each bank of lamp drivers and
safely replace a lamp driver without de-energizing any other operating banks.
L. Control and Instrumentation:
1. System Control Center (SCC):

a) The monitoring, operation and control of UV System Control Center (SCC)
should be through HMI screen.
b) Alarms shall be provided to indicate to plant operators that maintenance
attention is required or to indicate an extreme alarm condition in which the
disinfection performance may be jeopardized. The alarms shall include,
but not be limited to:
i) Individual Lamp Failure

ii) Multiple Lamp Failure

iii) Low UV Intensity
iv) Bank Communication Alarm
c) Mode of operation for UV Banks can be manual, automatic or remote.
d) Elapsed time of each bank shall be recorded and displayed on the display
screen when prompted.
e) The System Control Center should be connected to the main STP PLC for
providing operational and alarm feedback.
2. Low Water Level Sensor:

a) The UV Manufacturer shall provide one (1) low water level sensor for each
UV channel.
b) During all modes of system operation (manual, automatic and remote), the
water level sensor shall ensure that lamps extinguish automatically if the
water level in the channel drops below an acceptable level.
3. UV Intensity Sensors:
a) A UV sensor shall continuously monitor the UV intensity produced within
each UV Bank.
b) The sensors shall measure only the germicidal portion of light emitted by
the lamps.
c) The UV sensor shall be factory-calibrated to US National Institute for
Standards and Technology (NIST). Sensors requiring field-calibration are
not acceptable.
d) The sensor shall be digitally calibrated to ensure calibration accuracy.
e) To ensure continuous disinfection, the sensor shall be accessible without
shutting down the system, lifting a bank/module or removing lamps.
f) Sensors shall be designed to provide UV intensity data for dose monitoring
and control functions. Dose pacing program shall enable use of measured
UV intensity along with flow rate and UVT to determine the delivered dose
during operation.
g) Sensors shall be designed such that reference sensor readings can be
taken without interrupting disinfection and without removing UV lamps,
banks/modules or sleeves.
4. Dose-Pacing:
a) A dose-pacing system shall be supplied to modulate the lamp UV output in
relationship to a 4-20 mA DC signal from an effluent flow meter (supplied
and installed by Others) and UV intensity sensor(s).
b) The system to be dose-paced such that as the flow and effluent quality
change, the design UV dose is delivered while conserving power.
c) The dose-pacing system shall allow the operator to vary the design dose
setting. Logic and time delays shall be provided to regulate UV Bank
ON/OFF cycling.
5. On-Line UV Transmission Monitor:

a) An on-line UVT monitor based on UV Absorption measurement (2 beam
technique, reagent free) shall be provided to automatically and continuously
track the UV transmission of the effluent at the 254 nm wavelength.
b) The UVT monitor shall measure transmittances from 25 to 100%.

c) A shielded twisted pair cable to be provided by the Contractor for

connecting the UVT monitor (4-20 mA signal) to the System Control Center.
The SCC shall modulate the lamp intensity in response to the effluent UV
Transmission.
d) Power feed of 100 – 230 VAC ± 10%, 50/60 Hz, 1 phase, 2 wire (plus
ground), 50 VA required to the sensor located at the UV channel as shown
on the Drawings.
M. UV Bank Lifting Device:
1. The lifting device for UV Banks shall be supplied by the UV Manufacturer.

2. An Automatic Raising Mechanism (ARM) shall be designed and supplied to
facilitate lifting a UV bank from the channel without use of ancillary equipment.
3. The ARM shall be integrated into the UV Bank for simple and seamless
operation.
4. The UV Bank shall be raised from the channel for easier access and
maintenance.
5. The ARM design shall provide access to components without having to break
electrical connections thus reducing wear on connectors.
6. Alternatively, UV system not having Automatic Raising Mechanism shall provide
a full length 3-way EOT crane for the complete Bank Removal.
14.12 Chlorination System
14.12.1 General
Before the final treated sewage effluent is assimilated back into the environment, it shall
be disinfected using chlorine gas at the required concentrations. After dosing, it shall be
allowed to react in the tank with adequate retention time.
a) Chlorine shall be injected into the effluent at the inlet of the chlorine contact tank, which
is designed with adequate baffles and mechanical mixers to ensure effective contact
time for the chlorine.
b) The design shall include the necessary flow paths and patterns for the flow through
the contact tank to facilitate proper mixing and allows sufficient reaction time for the
chlorine to be assimilated.
c) The basis of design for quality and quantity of disinfecting agent shall be sufficient to
achieve the microbial count specification appropriate to the design conditions for
treated sewage. The dosing system shall be suitable for continuous operation.
d) The design shall include a complete dosing system with 50% standby capacity
including all necessary ancillary equipment and plant to meet the particular flow
conditions, including, but not limited to service water supply, safety equipment, leakage
detection equipment, chlorine handling equipment, in accordance with IS 10553 (Parts
1 to 4) regarding the handling, storage and all safety related issues of dealing with
chlorine liquid and gas.
e) Chlorine cylinder storage capacity shall typically be for 15 days operation at the
minimum design dosing rate of 15 mg/l, plus the on-line connected cylinders.
f) Authorized inspector from any one of the following shall test and inspect tonne
containers during manufacturing and afterwards, as required under adopted
specifications and approval procedures of C.C.E. Nagpur:
i) Lloyd’s Register of Shipping
ii) Box Council Pvt. Ltd.
g) The chlorine gas cylinder shall be fitted with standard valves confirming to IS: 3224 –
1979 which should also be approved by C.C.E. Nagpur.

h) The Chlorination system shall consist of storage, liquid conveyance, vaporization, gas
conveyance, injection into a solution of carrier water, conveyance of the solution,
dosing and Chlorine leak detection, absorption and neutralization in case of a gas leak.
i) Vacuum type Chlorinators shall be installed. Pressure type units are acceptable. The
design of the chlorination system allows for higher withdrawal rates from the on-line
cylinders than can be accommodated by drawing off chlorine in the gas phase only.
Higher withdrawal rates require chlorine to be drawn-off the cylinders in liquid form,
under pressure, and be piped through an Evaporator to convert the liquid chlorine to
gas prior to the vacuum regulator.
j) The basic Chlorination System (Evaporators, Chlorinators and Ejectors, Motive Water
Booster Pumps, associated controls and safety devices, and all interconnecting liquid,
gas and solution piping from the cylinders to downstream of the ejectors) shall
preferably be the responsibility of a single equipment supplier. The Chlorine Gas
Neutralization System and the emergency ventilation systems shall similarly be the
responsibility of a single equipment supplier. Contractors or persons responsible for
the implementation of the chlorine system, shall ensure specialist suppliers take the
necessary liability for the overall final design, the overall control systems as well as the
final commissioning and putting the equipment into service to ensure proper
functioning of the system.
k) The specification for booster pumps and motors shall be covered by the appropriate
pump and electrical motor general specification.
l) Notwithstanding anything specified herein, Contractor and Suppliers shall comply with
the provisions in IS 10553 (Parts 1 to 4) regarding safety related issue of dealing with
chlorine liquid and gas.
14.12.2 Chlorinators
Chlorinators shall be supplied as specified in Part 4. Chlorine gas shall be supplied through
a common manifold from Chlorine Evaporators operating in parallel which shall supply gas
to all the Chlorinators. Either 1 or all the Chlorinators may operate together depending
upon the dosage rate required.
a) Each Chlorinator (gas feeder) shall be of the vacuum operated, solution feed, sonic
flow type. The gas feed rate shall be manually or automatically controlled in response
to a 4 to 20 mA DC signal.
b) Chlorinators shall consist of cabinet controlled modules including rotameters, ejector
vacuum gauges and actuated control valves, a wall or ton-weight container mounted
vacuum regulator, and a wall-mounted, fixed orifice water ejector (educator). The
vacuum regulator shall incorporate a positive-acting gas shut-off valve, a diaphragm
operated pressure relief valve, and an excess vacuum shut-off valve. Use of the sonic
flow principle shall eliminate the need for a differential pressure regulator.
c) The rotameter and the vacuum gauge shall be mounted on the control module face to
indicate gas flow rate and ejector vacuum respectively. They shall be graduated in
metric units. Computer compatible control switches for manual/remote control and
auto/manual selection for the automatic control valve shall be mounted on the front of
the control module. The vacuum regulator shall be provided with an integral liquid trap
and a removable inlet filter having an effective area of 32 square centimetres and a
pore size of 90 microns. Manufacturers that do not have integral filters are required to
supply a filter in each header manifold. An inlet heater shall also be provided to prevent
liquid from reaching the regulator.
d) The heater shall operate on 110v single phase 50 hz power. The ejector shall be
provided with ball check and diaphragm actuated drain valves to prevent back flow of
water into the gas feed system. High, low vacuum and out-of-gas alarm switches shall
be provided. Units that do not have out-of-gas switches are to supply low pressure

switches with an isolation valve in each gas header. Chlorinator accuracy shall +4% of
indicated flow rate over a 20 to 1 range.
e) The control valve shall be designed to automatically control gas feed rate in response
to a 4-20 mA DC signal. The valve shall incorporate a precisely contoured, corrosion
resistant plug and orifice which shall provide a linear control characteristic. For flow
paced units, a manual dosage adjustment shall be provided. The control valve shall
be provided with a gas flow transmitter. In the event of power failure, gas flow shall be
regulated by manual knob adjustment of the automatic valve. No separate manual
valve shall be required.
f) The control valve actuator shall utilize a heavy duty stepping motor operating on 110
V single phase 50 Hz power. The valve actuator signal conditioner and positioner shall
incorporate state-of- the-art integrated circuitry. Printed circuit boards shall be coated
for corrosive resistance,. All valve actuator components, all electronics, and
terminations shall be housed within a gas-tight corrosion resistant NEMA 3R, or
international equivalent enclosure. The Chlorinator shall have integral computer
compatible circuits to provide status information to the SCADA system to which it will
be interfaced.
g) All parts of the Chlorinators, the injector and its accessories shall be of suitable material
resistant to the corrosive attack of chlorine (silver, silver plated Hastelloy C, PVC,
Teflon, Borosilicate glass, ebonite lined cast iron). All operating components of the
Chlorinator, except the vacuum regulator and ejector assembly, shall be housed within
a polyester impregnated fiberglass cabinet.
h) Each Chlorinator shall have its own individual ejector (educator) to induce the chlorine
gas into solution. Gas shall be conveyed by the vacuum created by the flow of motive
water through the ejector unit. The Chlorination System manufacturer shall base their
ejector designs on a minimum available utility water service pressure of 30 m in the
Evaporator/Chlorinator Room. The ejectors shall be of the sonic type with a fixed-throat
(orifice). If the manufacturer’s ejectors require more water pressure than this to function
properly, then the Chlorination System manufacturer shall furnish Motive Water
Booster Pumps to increase the service pressure to meet their requirements.
14.12.3 Evaporators
A common bank of Chlorine Evaporators (vaporizers) shall serve the Chlorinator units.
The liquid chlorine manifold from the 2 duty Chlorine Cylinders shall serve all Chlorine
Evaporators in parallel. The Chlorine Evaporators shall be provided with 100% standby
unit.
a) Each Evaporator unit shall be of the electrically heated type, with the water chamber
temperature controlled by an integral electronic temperature controller. Each
Evaporator shall automatically vaporize and superheat liquid chlorine at a rate
controlled by the capacity of the Chlorinators.
b) The vaporizing chamber shall be constructed of ANSI/ASTMA - Schedule 80 (or
equivalent wall thickness) welded steel pipe having a minimum wall thickness of 12
mm. All fittings and flanges shall be made of forged steel. The chamber shall be
designed, constructed and tested to conform to the lethal substances section of the
ASME Code, Section VIII, for unfired pressure vessels, or the international equivalent.
The vaporizing chamber shall be hydrostatically tested at 50 kg/m2. A gas pressure
relief valve complete with a safety head/rupture disc and a pressure switch with a
diaphragm protector shall be provided for emergency pressure relief. No process
connections shall be permitted at the bottom of the pressure vessel.
c) The water chamber shall be constructed of stainless steel. The water heater shall be
of the three element, electric immersion type, 10 kW maximum capacity, designed for
220/440V/3phase/50Hz operation. The electric heater shall be mounted in the lower
portion of the water jacket to insure proper heat distribution by natural convection. No

additional circulating apparatus shall be required. The water chamber shall include
both an integral overflow and a vapor vent. A magnetic contactor shall be furnished for
operating the heater, or shall be integral to the evaporator. The interior of the water
chamber and the exterior of the vaporizing chamber shall be protected from corrosion
by a system of four sacrificial magnesium anodes coupled with an electronic cathodic
protection system.
d) Each unit shall be equipped with a front panel-mounted electronic temperature
controller, a water level sight gauge, and gas pressure and temperature gauges. A
water level switch shall be provided for low alarm and for shut down of the heater and
closure of the electrically actuated gas pressure reducing valve in the event of low level
in the water chamber. The temperature controller shall cause the closing of the gas
pressure reducing and shut-off valve in the event of low water temperature. The
temperature controller shall have a direct reading digital display and alarms for high
and low water temperature. Dry contacts for alarms shall be provided for actuation of
both local display and remote annunciation. The controller shall also provide
automatic, self-adjusting, electronic cathodic protection with “on” and “failed” status
lights. The controller shall be menu driven through a front panel mounted keypad. All
control circuitry shall be 110 V, and shall be factory pre-wired to customer terminal
strips. All controls and switches shall be rated NEMA 4X, or international equivalent.
Additional controls and switches shall be furnished:

i) Automatic fill system with water rate rota meter
ii) Water level control switches with solenoid valve.
iii) Magnetic contactor: integral or remote.
e) The Evaporator shall be housed in a corrosion-resistant, high impact polystyrene or

fiberglass cabinet that shall be completely removable for service. Each unit shall be
supplied with PVC closed-foam insulation for the water chamber in order to conserve
energy.
f) Fluorolube-filled, diaphragm-protected pressure gauges, vacuum gauges and
switches for gas and liquid chlorine service lines shall be provided. Each gauge, switch
or pressure gauge/switch assembly shall be provided with a shutoff valve for servicing
the pressure indicators.
g) Provide a pressure switch with a NEMA 4X, or international equivalent, enclosure with
normally open, single pole contact, rated at 110 volts, 10 amperes to be mounted in
the outlet gas piping between the vaporizer and pressure reducing valve to provide for
maximum operator safety. Provide a contact, which closes on increasing pressure at
10-12 kg/m2 to warn operating personnel of a high pressure condition in the system.
The pressure switch shall be adjustable with an operating range of 0-20 kg/m2.
14.12.4 Chlorine Scale
Chlorine scales shall be of the hydraulic load cell type. For each cylinder, the weight shall
be transferred via a lever to a single load cell of the shear beam strain gauge type. The
scale frame shall be epoxy finished and sized to accept Two number chlorine cylinders. At
least 4 heavy-duty bushed bearing trunnions shall be installed for each container to allow
easy container rotation. The scale frame shall be constructed of structural steel and shall
tilt up for easy cleaning. Each scale shall be of such a size that it is within the dimensions
of the cylinders it supports.
The load cell shall be of the temperature-stable, rolling diaphragm type. The load plate
shall be able to tilt 4 degrees without affecting accuracy. Flexible hose shall lead from the
load cell to allow easy remote installation of the weight indicator 6 m in length. The load

cell system shall require no electric power and shall be immune to all power failures and
lightning strikes. Full scale accuracy shall be better than 0.5%.
The weight indicator shall monitor 2 channels. The remote mounted LCD indicator shall
be housed in a NEMA 4X, or international equivalent, enclosure. All operations shall be
keypad operated & menu driven in order to avoid compromising the NEMA 4X seal at
anytime. The alphanumeric LCD readout shall have backlighting for readability in low
light conditions. Power requirement shall be 220 V/1phase/50 Hz.
A 6 digit numerical display shall give operator the ability to monitor chemical by weight
(kg). A bar graph display shall read 0-100% for the net contents. A dual mode TARE key
shall allow user to enter the tare weight of the vessel or enter the net weight of the
chemical depending on application needs. A diagnostics menu shall allow recalibration
without the need to apply field test weights. A user adjustable filter function shall stabilize
display in the event of vibration from pumps or mixers in the immediate vicinity of the
scale.
Indicator shall output net weight via a 4-20mA signal and full scale output shall be user
adjustable via the keypad. Indicator shall have four adjustable set points to display low
or high level conditions on the indicator.
14.12.5 Motive Water Booster Pumps
Booster pumps shall be required on the motive water supply system to the ejectors. The
number of booster pumps shall be as specified in Part 4. The Motive Water supply shall
be from the treated effluent chlorine contact tank. The Booster Pumps shall be installed in
the Evaporator/Chlorinator Room.
Booster Pumps shall be of either the end suction or split case, horizontally mounted,
centrifugal type. The impeller shall be of the enclosed type, having the ability to pass a
sphere size not larger than 15 mm.
Each pump shall be supplied with sluice type isolation valves and the pressure gauges on
the delivery and suction lines and a swing type check valve on the discharge side. A
pressure release valve shall be provided between the discharge and suction headers. The
pumps shall be connected to the motive water main by a common suction header.
The pumps shall be directly coupled to drive motor by flexible couplings. The pump and
the drive motor shall be mounted on a common base plate. Foundation or ground bolts
shall be supplied for each base plate.
The drive motor shall be of horizontal spindle, totally enclosed fan cooled squirrel cage
motor and shall be manufactured, tested and provided with Class B or higher rated
insulation. The rating of the motor shall be at least 20% higher than the maximum power
required by the pump over its operating range. The operating voltage of drive motor shall
be 440 V/3phase/50Hz.
14.12.6 Chlorine Piping
Duplicate (Two number) chlorine gas lines shall be provided with isolation valves from the
Chlorinators to the ejectors. Similarly duplicate chlorine solution lines with isolation valves
shall be provided from the ejectors to the dosing points. The isolation valves shall be
provided at the chlorinator and ejector ends for the chlorine vacuum lines and ejector and
dosing point ends for the chlorine solution lines.

The gas and water piping system shall be designed according to the chlorine and injection
water flows and the hydraulic/pressure conditions. The pipes shall be laid as straight as
possible on the shortest route from the cylinders to the Chlorinators. They shall be fixed
on well supported trays / brackets and shall slope upward from the cylinders to the
Evaporators at a slope of at least 1.5%. All steel supports shall be heavily painted with
chlorinated rubber paint to at least 0.6 mm DFT.
The connections of the chlorine gas pipes to the cylinders and the Chlorinators shall be
coiled for flexibility during operation and maintenance. Each connection shall have a valve
and a pressure gauge. All pipes and valves in the cylinder storage area shall be located
out of the way of gas cylinders hanging on the monorail hoist during manipulation.
Materials of Construction:
Test Pipeline
Service Piping materials
Pressure accessories
Expansion
Chlorine Liquid Seamless SS 304 /
CPVC-80 Sch
25 bar Chamber, Pressure
(Cylinders to Evaporators)
Switch and Gauges
Pressure Relief
Valve, Pressure
Chlorine Gas
Gauges, Automatic
(Evaporator to Vacuum 25 bar
Pressure Reducing
Regulator)
Valve, Gas Vacuum
Regulator
Chlorine Gas
(Vacuum Regulator to CPVC 80 Sch - 700 mbar Vacuum Gauges
Ejectors)
Chlorine Solution
15 bar Pressure Gauges
(Ejectors to Dosing Points)
Galvanized Iron Class
Motive Water (to Ejectors) 15 bar Pressure Gauges
C, piping and fittings
Note: Valves on a common manifold shall be sized for the combined gas flow to
Chlorinators
After installation, the chlorine liquid and gas piping system shall be cleaned and dried.
After drying, the system shall be pressurized with dry air up to the test pressure and tested
for leaks by application of soapy water to the outside of all joints and connections. Leaking
joints shall be repaired, and only when all joints are made leak-proof chlorine gas shall be
gradually introduced and the system shall again be tested for leaks. The pipes for utility
water and chlorine solution shall be tested with water at the respective test pressure.
14.12.7 Chlorine Diffusers
The chlorine solution shall be injected into the Treated Sewage Effluent flow streams
through a ANSI/ASTMA - Schedule 80 CPVC pipe diffuser. Each diffuser shall be
supported from the channel floor by FRP angle bracket, of a minimum thickness of 5 mm
each. The brackets shall be spaced at a maximum of 900 mm apart. The centreline of
each diffuser shall be 75 mm above the channel floor elevation. Holes shall be located
only on the upstream side of the diffuser pipe, and shall be at the pipe centreline.
Connection of the diffuser to the vertical chlorine solution piping shall be by a threaded
PVC connection. The vertical chlorine solution piping shall be supported on the channel

wall at 600 mm intervals. Location of Chlorine diffuser shall be at the inlet of the Chlorine
contact Chamber.
14.12.8 Automatic Chlorine Drum Changeover Panel
The automatic drum changeover panel shall be a specially designed unit capable of
selecting liquid chlorine containers for duty on an alternate basis. The unit shall be capable
of working in conjunction with two liquid chlorine drums (one duty, one standby).
The panel shall satisfy the following duty functions in chronological order:
i. Check pressure in the line initiate automatic changeover and alarm if pressure is low;
ii. Shut the delivery valve of the drum that has just become empty and open the valve of
the standby drum on-line;
iii. Re-check pressure as in (1) above and initiate alarm if pressure is still low;
iv. Proceed until next changeover is initiated, then repeat the sequence;
v. At each step, the operation of valves shall be monitored using position feedback limit
switches and valves failing to operate in a set time shall immediately initiate an alarm.
14.12.9 Chlorine Gas Neutralization System
A (one) Chlorine Gas Neutralization System shall be installed adjacent to the Chlorine
Building along the exterior wall of the Chlorine Cylinder Room (in the long dimension).
The Chlorine Gas Neutralization System shall consist of the following components at the
stated rated capacities and design parameters:
Component / Parameter Unit Value Remarks

Chlorine Leak Absorption Capacity kg/hr 200
Maximum Chlorine Absorption Capacity kg 900
Air to Chlorine Mixture (volume/volume) 6 to 1
Packed with Rashig
Absorption Tower -- --
Rings or Equivalent
Caustic Soda (50% NaOH) Storage
kg 1,035
Capacity
Water Storage Capacity m3 8.5
Solution Temperature after Absorption Deg-C 60
Recirculation Pump
Connected Power kW <5
Only
Emergency Ventilation Fan kW a As required to ventilate
the Cylinder and/or the
Emergency Ventilation Rate m3/min a Evaporator
/Chlorinator Rooms
Signal from Chlorine leak Detection
Control of Gas Neutralization System -- --
System
with a Canopy Roof
Installation -- -- Outdoors
Covering
Note: a- As per Chlorine Gas Neutralization System manufacturer’s design
The Chlorine Gas Neutralization System shall operate on the principle of introducing the
mixture of chlorine gas and air to a mixture of sodium hydroxide (caustic soda) NaOH and

water. These chemicals react to produce sodium hypochlorite and sodium chloride
solution, thus removing the chlorine from the gaseous state. The Chlorine Gas
Neutralization System shall be designed with suitable capacity to neutralize the contents
of a full tonne cylinder.
When the system is activated, the caustic soda is pumped from the holding tank and
sprayed over the top of the packing within the absorption tower. As the extracted air,
contaminated with chlorine gas, is blown up through the column the caustic soda reacts
with the chlorine. The recirculation pump shall continue to recycle the diluted caustic soda
solution until the leak condition has stopped. Liquid is sprayed and uniformly distributed
by means of distributors or sprayers of the solid cone type with large passages, easily
detachable for revision or change. A vertical flow demister, of high efficiency and low loss
of head, shall be provided to prevent carryover of liquid mist from the tower’s outlet.
14.12.10Emergency Ventilation System
An Emergency Ventilation System shall be provided to serve the Chlorine Cylinder and
Evaporator/Chlorinator Rooms. This Emergency Ventilation System shall operate
separately and independently of the normal ventilation system which utilizes exhaust fans.
The Emergency Ventilation System shall consist of a fan or series of fans connected to
the Chlorine Gas Neutralization System. The fans shall be designed to either discharge
exhausted air into the Absorption Tower or pull exhausted air through it, at the system
manufacturer’s discretion.
The emergency ventilation exhaust fans shall be designed in accordance with the Chlorine
Gas Neutralization System manufacturer’s design parameters. These ventilation fans and
the Chlorine Gas Neutralization System shall be designed to vent the entire Cylinder
and/or the Evaporator/Chlorinator Rooms and not only a hooded or segregated portion
thereof.
On detection of a chlorine leak, the normal ventilation fans shall be stopped automatically
and the emergency ventilation fans and Chlorine Gas Neutralization System’s recirculation
pump shall start automatically evacuating and neutralizing the leakage.
14.12.11Chlorine Gas Leakage Detection System
Chlorine leakage sensors connected to chlorine leak detectors shall be provided at

following locations:
i) Four (4) sensors shall be located in the Cylinder Room, with 1 of these located at the
Chlorine Scale.
ii) Two (2) sensors shall be located in the Evaporator/Chlorinator Room.
The chlorine (or toxic gas) leak detector shall be of the electrochemical sensor type. The
sensors shall be easily replaceable, one at a time, without removing the other sensors from
service. Two leak detector units shall be provided with 3 sensors each, for redundancy. One
(1) sensor from each unit shall be located in the Evaporator/Chlorinator Room.
Each leak detector unit shall have a range of 0-10 ppm, with a resolution in 0.1 ppm. Each
unit shall be wall mounted with an IP 67 class enclosure. The display shall be LED: 3 digit,
12 mm height, 7 segment minimums. Each unit shall operation off of a 240v/1ph/50hz AC
power supply, and shall have a battery back-up power supply which shall be rechargeable
in-place. The sensors shall emit a 4-20 mA DC signal. The recorder and alarms shall send
a signal to the SCADA system. Sufficient cable lengths shall be provided to route the
signals to the Chlorination System Control Panel. Chlorine leakage alarms shall
annunciate audibly locally and sent to the SCADA system.

The Contractor shall provide a visual and audible alarm system. Flashing warning lights
shall be provided over each door of the Evaporator/Chlorinator Room store and The
Chlorine Cylinder Room. The lights shall be RED in colour and shall be clearly visible at a
distance of 20 meters under normal daylight conditions. They shall be activated
automatically from the leak detection devices. Behind the lights a rear engraved perplexes
label having red letters on a white background shall be mounted at each door and at visible
place. The lettering shall be a minimum of 50 mm high and one legend shall read in
English, and two others each in Hindi and Marathi languages:
“DANGER:- WEAR BREATHING APPARATUS BEFORE ENTERING

WHEN LIGHT IS FLASHING”.
A calibration kit, 500 ml of electrolyte solution and 2 spare sensors shall be furnished with
the leak detectors.
14.12.12Chlorine Safety Equipment
The following safety equipment shall be provided, which shall be common for the Chemical
Storage and Mixing areas and the Chlorine Building:
i) Canister type respirators with full face coverage masks suitable for chlorine gaseous
atmosphere – minimum 6 each.
ii) Spare canisters for the respirators - minimum 6 each.
iii) Self-contained compressed air breathing apparatus (SCUBA) complete with working
whistle and two spare air cylinders - minimum 6 each.
iv) A facility to recharge the compressed air cylinder or from a self-contained machine - 1
each.
v) Protective clothing such as PVC overalls and gloves and rubber boots shall be
provided - minimum 5 sets.
vi) One (1) Safety Showers with Eyewash fountains with accessories shall be provided at
the Chlorine Building at easily accessible locations.
vii) Warning Lights – 5 each
viii) Hoses – 3 each
This equipment shall be stored in glass fronted non-locking steel cabinets so that any
deficiency in the equipment shall be apparent. Three 15 m long hoses 25 mm in diameter
with jet and spray nozzle and valve shall be provided near the Chlorine Cylinder Room
and Chemical House in non-locking steel cabinets. They shall be connected to the utility
water system. The cabinets shall be located at strategic places for easy and safe
accessibility in case of a chlorine leak event.
14.12.13Other Chlorination Accessories
i. Two (2) emergency drum leakage repair kits shall be provided in the Chlorine Building
Storage Room.
ii. An automatic shutoff valve (2 duty + 1 spare) shall be provided for each Chlorine
Cylinder on the Chlorine Scale.
14.12.14Operation and Control of the Chlorination System
A dedicated Chlorination System Control Panel shall be provided in the Control Room.
The operational parameters of the Chlorination System shall be basically as outlined in the
table below. This Control panel shall be equipped with a PLC controller.

Operation of the Chlorination System
Operational Mode of
Control Scheme
Parameter Operation
Manual dosage The dosage in mg/l shall be set manually at the
Regulation of the PLC and a signal from the Treated Effluent flow
chlorine dosage rate Automated flow meter shall vary the chlorine solution feed rate
pacing based upon the variations in plant flows
Regulation of the Based upon a demand signal from the Treated
motive water flow Automatic Effluent flow meter, with a minimum set point to
rate assure the ejectors pull enough vacuum
Manual Normally
Automatic When the Treated Effluent flow is zero
Stop of chlorine gas Automatic If an ejector fails
flow
Automatic If both cylinders on the Chlorine Scale are empty
If both motive water supply flow/pressure is not
Automatic
sufficient.
Manual Normally
Stop of utility water
to the ejectors If both cylinders on the Chlorine Scale are empty or
Automatic
in case of a gas leak
Stop of chlorine flow Manual Normally
at the chlorine If both cylinders on the Chlorine Scale are empty or
cylinders Automatic
in case of a gas leak
Actuated in case of leakage in the Chlorine Cylinder
Acoustic alarm Automatic
Room or the Evaporator/Chlorinator Room
Normal ventilation Manual On/Off,
exhaust fans and Thermostatically controlled and will shutoff and
exhaust louvers Automatic
louvers will close if a gas leak is detected
Actuated in case of leakage in the Chlorine Cylinder
Start of emergency
Automatic Room or the Evaporator/Chlorinator Room and
ventilation fans
must be shutoff manually
Start chlorination
Manual
system
Start of Chlorine Gas Actuated in case of leakage in the Chlorine Cylinder
Neutralization Automatic Room or the Evaporator/Chlorinator Room and
System must be shutoff manually
14.12.15Chlorine Residual Monitors
Chlorine residual monitors shall be provided at the plant outlet. The monitor installation
shall be located in a covered location easily accessible for viewing and maintenance and
shall be provided complete with sample pumps as necessary to ensure the continuity of
the sample.
The sampling pipe work complete with isolation valves etc. shall be designed to ensure
the sample reaches the monitor in a time not greater than 1 minute. The monitor drainage

pipework shall permit the visual checking of the presence of flow and shall discharge to
the foul drain. Sample sewage not passed through the monitor shall be returned to the
process.
The residual signals shall be displayed at the local control panel. High and low chlorine
residual levels shall raise alarms at the local control panel.
14.12.16Layout and Chlorination Building Design Consideration
A Chlorine Building shall be constructed at the suitable location It shall be a single story
(level) generally divided into a Chlorine Cylinder Room; an Evaporator / Chlorinator Room;
an Electrical Room; a Control Room / Office; a Storage Room and a Janitor’s Closet. Air
conditioning shall not be provided in the chlorine building. The floor of the chlorine building
shall be placed at such an elevation above adjacent ground level that ingress of storm
water is prevented, but entrances shall not be higher than 200m above finished ground
levels. Switchboards, motor control centers and any other panels and electrical or
electronic equipment shall not be housed in areas where there is a potential for chlorine
gas or solution leak. Any electrical equipment required to be located in such areas such
as leak detectors, changeover panels etc. shall have enclosures protected to IP 65.
All pipe work and cables to and from chlorine store and chlorinator room shall be taken
through the wall. All threaded tubes carrying cables and pipes respectively out of the
chlorine store and chlorinator room shall be sealed to prevent any chlorine leaks being
transmitted to other areas. Arrangement and layout of pipe work shall comply with the
specification for chemical pipe work. Air intakes shall be through louvered grills at high
level and extraction shall be at low level in the room with high level discharge to outside.
The minimum space and height requirements shall be as follows:
A. Chlorine Cylinder Room
i) A floor to roof (to the bottom of any roof beams) minimum vertical clearance of 5 m.
ii) Adequate area to store required nos., 1-tonne cylinders side by side in a single row: 2
on a weigh scale and remaining on trunnions.
iii) A minimum of 2.5 m of horizontal clearance in front of the cylinders (on the outlet valve
side), between the face of the cylinders and the interior wall.
iv) A double door (2 leafs) shall be located in the exterior wall in-line with the row of
cylinders. The doors and frame shall be made of Aluminium and powder coated. Each
leaf shall be 1,250 mm in width and approximately 3,500 mm in height, depending
upon the headroom required by the hoist and trolley and the depth of the monorail
beam. This door height shall be verified after the equipment selection has been made.
Each leaf shall be notched to accommodate the monorail beam passing through it. The
centre of the doors (where the leafs meet) shall be aligned with the centreline of the
monorail beam.
v) A monorail beam with an electric motor driven hoist and trolley shall be installed with
the monorail beam running directly above the centre of the cylinders. The monorail
beam, hoist and trolley shall have a load capacity of 3,000 kg and be of the low
headroom type. The headroom (minimum working distance from the bottom of the
monorail beam to the hook) shall not exceed 500 mm.
vi) The monorail beam shall extend 3,500 mm out past the exterior wall and double door
to allow a delivery truck to be off-loaded using the hoist and trolley.
vii) Ventilation (Normal) shall be installed in the Chlorine Cylinder Room to exhaust the
ambient air to cool the room. Exhaust fans shall be installed near the roof level to
exhaust the room at a rate of 12 air changes per hour (acph). These exhaust fans shall

have louvers, which shall close and the fans shutdown when a chlorine gas leak
condition is alarmed and the emergency ventilation system is started.
viii) Ventilation (Emergency) shall be installed in the Chlorine Cylinder Room to evacuate
the escaped chlorine gas in case of a leak. The exhaust fan for the Chlorine Gas
Neutralization System shall have the capacity to exhaust the room at the rate as
designed by the Neutralization System manufacturer. This system shall start
automatically off of a high chlorine gas concentration signal from the leak detection
sensors.
ix) No floor drains shall be provided in the Chlorine Cylinder Room.
B. Evaporator / Chlorinator Room
ii) Adequate area to install all Evaporator Cabinets and all Chlorinator Cabinets with
horizontal clearance between the units.
iii) The Evaporator / Chlorinator Room shall have a double door (2 leafs) located in the
exterior wall and a single door exiting into the Chlorine Cylinder Room. The doors and
frame shall be made of Aluminium and powder coated. Each leaf shall be 800 mm in
width and 2,100 mm in height. The exterior door leafs shall each have a wired glass
window with a 1 hour fire rating, 250 mm wide by 250 mm high. The minimum glass
thickness shall be 6.8 mm.
iv) The Evaporator / Chlorinator Room shall have 1 interior wall common with the Chlorine
Cylinder Room. The common wall shall have a window 1,500 mm wide by 600 mm
high, facing the Chlorine Scale. The window shall have a 1 hour fire rating and shall
contain wired glass with the wire mesh in a diamond pattern. The minimum glass
thickness shall be 6.8 mm.
v) Ventilation (Normal) shall be installed in the Chlorinator Room to exhaust the ambient
air to cool the room. Exhaust fans shall be installed near the roof level to exhaust the
room at a rate of 12 air changes per hour (acph). These exhaust fans shall have
louvers, which shall close and the fans shutdown when a chlorine gas leak condition
is alarmed and the emergency ventilation system is started.
vi) Ventilation (Emergency) shall be installed in the Chlorinator Room to evacuate the
escaped chlorine gas in case of a leak. The exhaust fan for the Chlorine Gas
Neutralization System shall have the capacity to exhaust the room at the rate as
designed by the Neutralization System manufacturer. This system shall start
automatically off of a high chlorine gas concentration signal from the leak detection
sensors.
vii) Floor drains shall be provided in the Chlorine Cylinder Room in the vicinity of the
Evaporators (1 floor drain between each pair) and the Chlorinators (1 floor drain
between each pair).
C. Electrical Room
ii) Adequate area to install the switchgear and Motor Control Centres, with horizontal and
vertical clearances in accordance with IEC and Indian Standards (IS).
iii) The Electrical Room shall have a double door (2 leafs) located in the exterior wall.
Each leaf shall be 800 mm in width and 2,100 mm in height. The doors and frame shall
be made of Aluminium and powder coated. The exterior door leafs shall each have a
wired glass window with a 1 hour fire rating, 250 mm wide by 250 mm high. The
minimum glass thickness shall be 6.8 mm.
iv) Ventilation (Normal) shall be installed in the Electrical Room to exhaust the ambient
air to cool the room. Exhaust fans shall be installed near the roof level to exhaust the
room at a rate of 12 air changes per hour (acph). These exhaust fans shall have

louvers, which shall close and the fans shutdown when a chlorine gas leak condition
is alarmed and the emergency ventilation system is started.
v) All electrical switchgear and motor control centers shall be set on a 150 mm high RC
housekeeping pad to be elevated off the floor.
vi) One floor drain shall be provided in the Electrical Room.
D. Control Room
ii) The floor area to be provided as required as per standard engineering practice.
iii) The Control Room shall have a single door located in the exterior wall and a single
door exiting into the Chlorinator Room. Each leaf shall be 800 mm in width and 2,100
mm in height. The door and frame shall be made of Aluminium and powder coated.
The exterior door leafs shall each have a wired glass window with a 1 hour fire rating,
250 mm wide by 250 mm high. The minimum glass thickness shall be 6.8 mm.
iv) The Control Room shall have 1 interior wall common with the Chlorinator Room. The
common wall shall have a window 1,200 mm wide by 600 mm high. The window shall
have a 1 hour fire rating and shall contain wired glass with the wire mesh in a diamond
pattern. The minimum glass thickness shall be 6.8 mm.
v) The Chlorination System Control Panel shall be located within this room.
vi) The Control Room shall be equipped with a wall mounted air conditioning unit of
sufficient capacity to cool the room to 18o C at all times.
vii) No floor drains shall be provided in the Control Room.
viii) The following furniture shall be provided in the Control Room / Office:
a. An L-shaped Computer Workstation for a corner location. The workstation top and
side panels shall be made of PVC laminate and the Workstation shall have its
frame and legs made from anodized aluminium tubing. The Workstation L’s shall
be 1,500 mm by 1,500 mm by 750 mm deep. The top shall set 750 mm above the
finished floor. The Workstation shall have a pull-out keyboard tray. The Workstation
shall be beech in colour.
b. Two (2) Office Tables 1,500 mm long by 800 mm deep by 750 mm high with 2
drawers each shall be furnished. The Office Tables shall be the L-shaped
Computer Workstation.
c. The Workstation and each Office Table shall have a high back Computer Operator
Chair with gas lift; with single position arms, a nylon base, an ABS seat and back,
with an articulated push back system. The chairs shall be on castor rollers.
d. A half-height steel powder coated Cupboard with 2 sliding glass doors shall be
furnished. The unit shall be 1,000 mm high by 900 mm wide by 500 mm deep. The
Cupboard shall have 1 shelf and be suitable for library or box file storage.
E. Storage Room
ii) The floor area to be provided as required as per standard engineering practice.
iii) The Storage Room shall have a double door (2 leafs) located in the exterior wall. Each
leaf shall be 800 mm in width and 2,100 mm in height. The doors and frame shall be
made of Aluminium and powder coated. The exterior door leafs shall each have a wired
glass window with a 1 hour fire rating, 250 mm wide by 250 mm high. The minimum
glass thickness shall be 6.8 mm.
iv) Ventilation (Normal) shall be installed in the Storage Room to exhaust the ambient air
to cool the room. Exhaust fans shall be installed near the roof level to exhaust the room
at a rate of 12 air changes per hour (acph). These exhaust fans shall have louvers,
which shall close and the fans shutdown when a chlorine gas leak condition is alarmed
and the emergency ventilation system is started.

v) 2 floor drains shall be provided in the Storage Room.

vi) A service type (mop) sink shall be installed in the Storage Room close to the exterior
door. The sink shall be floor mounted and made of 16 gauge type 304 stainless steel
or terrazzo. A wall mounted faucet shall be provided with a 20 mm inlets and a 20 mm
male hose thread (MHT) on the end spout. The spout shall be nominally 150 mm long.
The faucet shall be of brass construction and be equipped with a vacuum breaker.
Utility water service shall be provided, but no hot water service need be provided.
F. Chlorine Gas Neutralization System Canopy
i) A concrete roof structure, supported on columns, shall be constructed adjacent to the

Chlorine Cylinder Room to cover the Absorption/caustic soda Tank, emergency
ventilation fan and recirculation pumps. The roof structure shall overhang from the
exterior wall of the Chlorine Cylinder Room. The Absorption Tower shall protrude
through this roof overhang with the tower outlet above the roof line.
ii) The slab on grade to roof (to the bottom of any roof beams) minimum vertical clearance
shall be high enough to allow the discharge piping from the emergency ventilation fan
to enter the Absorption Tower below the roof.
iii) The minimum roof coverage area shall be adequate to cover the Absorption/caustic
soda Tank, emergency ventilation fan and recirculation pump.
The architectural layout of the Chlorine Building shall be functional, adapted to the regional
climate conditions and has to give an aesthetic appearance bearing in mind the local
environment and culture.
G. Chlorine Cylinder Storage
The storage and withdrawal of chlorine liquid from the 1-tonne steel cylinders shall take
place in a room separated from all other chlorination functions by RC and/or masonry
walls. The Chlorine Cylinder Room shall be adjacent to the Evaporator/Chlorinator Room
along 1 interior wall and have exterior walls on at least 2 adjacent sides.
The Chlorine Cylinder Room shall have the capacity to store required tonne cylinders side
by side in a single row. Two (2) cylinders shall be placed on a weigh scale and the
remaining placed on trunnions. The trunnions shall be concrete supports with two steel
rollers on each end of a cylinder for easy rotating of the cylinder as per the relevant BIS
code. The remaining cylinders on trunnions may be full awaiting use or emptied waiting to
be collected by the chlorine supplier.
Only the 2 tonne cylinders setting on the weight scale shall be available for duty (chlorine
liquid or gas withdrawal). Each duty cylinder shall be provided with 2 isolation valves: a
liquid draw-off valve and a gas valve. The 2 duty cylinders shall be manifolded together
with 1) a liquid chlorine manifold which will convey liquid chlorine to the Evaporators, and
2) a gas pressure equalizing manifold. This gas manifold pipe shall be mounted above the
liquid manifold pipe and only interconnect the 2 duty cylinders. The gas manifold pipe shall
be 25 mm in diameter.
A minimum of 2,500 mm of horizontal clearance shall be provided in front of the cylinders

(on the outlet valve side), between the face of the cylinders and the interior wall. This space
shall be used to install the draw-off piping and provided access to the cylinders.
Each section of liquid chlorine piping between valves shall be equipped with an Expansion
Chamber. All Expansion Chambers shall be located within the Chlorine Cylinder Room
and not the Evaporator/Chlorinator Room. The Expansion Chamber shall have a volume

of at least 25% of the volume of the piping which it protects. This will be the pipe volume
between the Cylinders and the Evaporators. Each Expansion Chamber assembly shall
have a pressure gauge and a high pressure switch which will send an alarm signal to the
Chlorination System Control Panel and the SCADA system.
Special consideration shall be given to any floor drainage system in the Chlorine Storage
Room. Adequate traps shall be provided to ensure that chlorine gas cannot escape. All
leading tubes carrying cables or pipes out of the building shall be sealed at either end to
prevent any chlorine gas leaking out.
Gas lines from the Chlorine Storage Room into the Chlorination Room shall run in ducts
to be sealed after installation and prior to commissioning.
14.13 Sludge Thickener
The raw sludge from primary clarifier shall be pumped to Gravity sludge thickeners before
transferring sludge to sludge digester. Similarly excess sludge from secondary clarifier
shall be pumped to DAF sludge thickeners before transferring sludge to sludge digester.
The sludge thickeners shall be capable of providing continuous thickening of sludge to
increase concentration and to reduce the size of digester.
14.13.1 Gravity Sludge Thickener
Gravity Sludge thickener shall be Circular (radial), fixed bridge, central turn table type or
central drive. The circular reinforced concrete thickeners tapering at bottom shall be
provided for the thickening process. The design shall be such that the sludge after
thickening can be extracted from the bottom of the hopper. Interstitial liquid flows shall
pass through peripheral weir at top. Tanks shall be deep enough to allow the sludge to
settle by gravity, by providing at least 50 cm freeboard. Provision shall be made for
collection of thickened sludge and pumping it to the digester units/dewatering units.
Central drive arrangement shall be provided to rotate trussed rake arms having blades to
sweep the sludge into sludge hopper. Full diameter bridge with central drive shall be
provided with central platform for the installation of the scrapers and their drives and for
the local control panel a radial scraper system with bottom scraper blades, suspended on
the bridge.
Additionally,
a) The thickener shall have walkway for personnel access to the centre, access stairs to
ground level and SS hand railing, a motor driven sludge scraper complete with all
necessary controls, delivery pipe work, a stilling well and overflow steel weir plates.
b) The scraping gear shall be supported from the tank base and from a fixed bridge
carrying the central electrical drive for the rotating gear. The equipment including
driving motor, gears, shafting and scrapers shall be designed for continuous operation
and sized for the most arduous operating condition including starting from rest with an
accumulation of sludge in the thickeners.
c) The electric motor, gearbox etc., shall be provided with a sunshade. The main gear
drive shall be of cast Iron construction and shall be enclosed in a dustproof enclosure
with oil bath lubrication. Suitable overload protection for the drive shall be provided to
ensure that the sludge shall not overload the equipment and emergency stop
pushbutton shall be provided.
d) The scrapers shall be fitted with rotation monitors and over torque protection to alarm
in the event of a failure.
e) The underwater parts shall have minimum 2 mm allowance for corrosion and structural
design calculations shall be submitted for all structures including scraper arm, bridge
etc. and also the calculation for drive head selection including the Torque Rating.

f) V-notch weir shall be provided along the launders for uniform draw-off of the overflow.
The weir plate shall be fixed to the launder by means SS 304 grade clamping plates
and fasteners. The hydraulic equipment will consists of the inlet pipe (runs along the
bridge) to the central feed well of the thickener; sludge draw-off pipe with an manual &
motorized knife gate valve for intermittent operation according to an adjustable timer;
a drain pipe with manually operated gate valve for the complete emptying of the unit;
a discharge pipe/channel from the peripheral collecting channel to the main channel
leading to the Supernatant sump.
The sludge thickener mechanism shall be suitable for installation in a circular tank and
shall include the following:
i) Mechanism support beam spanning the diameter of the tank.
ii) Walkway and hand rails from the edge up to 1 meter beyond the centre of the tank.
iii) Drive mechanism with internal gear type
iv) Reduction gear box.
v) Chain & sprocket with guard.
vi) Central shaft with scrapper arm and picket fence.
vii) Inlet well of MS outside the central weir.
viii) Overflow weir.
ix) Vertical pickets.
x) Torque Indicating Device.
xi) Overload Alarm protection.
xii) Auto lifting device.
g) The main structural and centre drive mechanism including centre mechanism shall be
designed for a peak instantaneous torque which shall be 2.5 times the continuous
design torque calculated using following formulae;
T in kg-m = LF x (Diameter)^2
where Diameter is in meters and load factor (LF) is “12” for Radial Centre Pier
Thickeners.
Bridge : MS with Hot dip Galvanized (galvanizing minimum

thickness shall be 80 micron)
Walkway : MS grating minimum 6 mm thk with Hot dip Galvanized
(minimum thickness of Galvanizing shall be 80 micron).
Rake Arm : MS with Hot dip Galvanized (galvanizing minimum
thickness shall be 80 micron)
Feed Well : SS 316
V-notch weir : SS 316
Squeegees : Neoprene
Handrail : 32NB (Medium Duty), Galvanised steel
Anchor Bolt & fasteners : SS 316
Note :
i) The stainless steel and mild steel including hot dipped galvanised components where
both are connected to the water / wastewater should be electrically isolated to prevent
galvanic corrosion to the stainless steel surfaces
ii) The sludge drawl pipe shall be provided with telescopic pipe with valve of suitable size.
Replace the existing sludge drawl valve with timer controlled motorised valve of same
size.

14.13.2 DAF Thickener
The Dissolved Air Floatation (DAF) thickener, when specified, shall be designed to thicken
the waste excess sludge from the Secondary Clarifiers. Thickened sludge from the DAF
Thickener shall be pumped on a continuous or intermittent basis to the Anaerobic Sludge
Digester as required for anaerobic degradation using Thickened Sludge Pumps. The
supernatant from DAF Thickener shall be recycled back to the inlet of Primary Clarifier
Distribution Chamber by gravity if possible or otherwise by pumping through filtrate /
supernatant sump. The size of DAF Thickener shall be designed on basis of the process
criteria specified in Part 4.
The material of construction of the parts of DAF system which are submersed in waste
water shall be Stainless Steel 316 or non-corrosive materials. The other parts which are
not in contact with waste water shall be hot dip galvanised (80 micron) Mild Steel or other
non-corrosive materials. 32NB (Medium duty), Galvanised steel handrails of approved
grade shall be provided on walkways, platform and staircases.
14.13.3 Mechanical Thickener (Rotating Drum Thickener)
The drum of a rotating drum thickener, shall works on the principle of conveying flocculated
(treated with polyelectrolyte) sludge through a slowly rotating drum filter which has sludge
holding compartments. Two of more scrolls fitted on the inner part of the drum assembly
shall provide such compartmentalisation. The sludge shall be retained within the drum up
to the (thick) sludge outlet, while the water component shall passes through the filter cloth.
a) The drum thickener shall be designed for continuous operation.
b) The drum thickener shall be designed to thicken sewage and other sludges and shall
not be adapted from other type of rotating filter units. The rotating filter cloth must be
made of flexible polyester (wedge wire or perforated steel drum shall not be permitted)
in order to eliminate the problem of "pegging". Filter cloth washing procedures shall
only be permitted on the outside of the filter cloth thus avoiding contamination of the
filtrate by wash solids.
c) The drum thickener shall be equipped with a drum flushing system consisting of a
water spray bar. Water consumption shall be minimised by intermittent cleaning of the
drum using either potable water, final effluent or treated filtrate. The drum thickener
shall be designed in such a way that the sludge is handled extremely gently to
maximise sludge recovery. The drum thickener must be totally enclosed. Drum
thickener’ s process performance shall be optimised by varying the feed rates, the
polymer type and dosage, drum speed and spraying intervals.
d) The drum thickener panel shall include a VFD to enable variable speed for drum.
Additionally, the thickener shall:
e) The rotary drum thickener shall be capable of thickening an input sludge of 0.5% dry
solids (DS) to a final thickened sludge of 8% DS. Solid recovery shall be minimum 90-
95%
f) Drum Operating speed shall be 3 -10 RPM
g) All wetted parts in contact with the sludge or moisture shall be made of 316 stainless
steel. The drum thickener shall be pre-mounted on a self-contained skid support
arrangement.
h) The perforated screen or filter element may be manufactured from 316 stainless steel
or Polyester spiral filter cloth, suitably reinforced for the intended purpose and
pressures involved

i) Bearing type shall be HDPE plain bearing with manual grease lubrication type or
bearing type may be as recommended by Equipment manufacture with proven track
record for sewage treatment application
j) The a drive system shall include an electric variable speed drive motor suitable for
outdoor wet weather and wash down conditions, IP 55 Class protection, TEFC and an
enclosed gear reducer unit (oil bath type).
k) The entire drum assembly shall be adjustable for angle of tilt. A gauge shall be fitted
to the side of each drum casing and shall display the selected tilt angle.
l) The rotating drum shall be mounted on self-lubricating bearings.
m) The sludge inlet shall include a specially designed sludge / polymer conditioning
(mixing/ blending) apparatus.
n) Filtrate liquid shall be collected in a trough beneath the rotating drum. The trough shall
be equipped with a filtrate outlet pipe which shall incorporate sampling and cleaning
points.
o) Washing system: The perforated screen or filter element shall be washed with a
medium pressure spray nozzle system to clean the screen and remove any sludge
sticking to the internal surface. The wash water shall be collected on a trough and
blended/ mixed with the filtrate liquid removal system.
p) The thickened sludge shall be discharged at the high end of the unit onto an inclined
collection chute. The chute shall be made of 316 stainless steel highly polished top
surface or coated wit Teflon.
q) The drum thickener shall be provided with an enclosure housing designed to reduce
the release of odours. The housing shall be equipped with removable maintenance
panels and viewing windows. A viewing window shall be provided at the discharge end
of the drum for monitoring of the sludge thickening process. The viewing window shall
be safe to open during operation and shall be made of shatter-proof thermoplastic.
Maintenance access shall be provided at the sludge discharge end.
r) A local control panel shall be provided to control all associated equipment, including
the sludge feed pumping, polymer feed system, any discharge conveyor system, etc.,
s) Thickener shall be provided with a common pre-designed polymer make -up system,
pre-mounted on skid, incorporating, as a minimum, a dry polymer loading and hopper
system, a dry polymer/water flash mixing/blending system, mixing tank, transfer
pumps, piping system, storage tanks. Individual dosing pumps, metering and controls,
etc.,
t) Maintenance of the drum thickener should be limited to lubricating the two drum
bearings and inspection of the spray nozzles and the filter cloth every week.
u) The bearings and filter cloth shall have an anticipated life of over 100,000 and 20,000
hours respectively.
Cover : Fiberglass
Housing : Minimum AISI 304
Drum : Minimum AISI 304
Base frame : Minimum AISI 304
Bearing : High Density Polyethylene (HDPE)
Cloth : Polyester
14.14 Sludge Dewatering Units
Sludge dewatering shall be achieved mechanically using a sludge dewatering unit such as
Solid Bowl Centrifuge for 100% of the digested sludge or Belt Press or Screw Press.

Sludge Drying Beds shall be provided for 10% of the digested sludge produced as a
backup to the mechanical dewatering plant in case of unforeseen problems. The
dewatering units shall include but not limited to the following equipment:
• Powder or liquid Polymer storage tanks/ Bach tanks with mixers
• Polymer metering pumps
• Mixers and solution tanks
• Polymer service tanks
• Supply line & flush line
• Plant Water supply pumps
• Sludge feeding pumps
• Dewatering unit
• Cake hopper
• Flow meters for feeding Sludge, and for feeding chemical solution
• Control valves on sludge feeding line, and on Chemical feeding line
• Drainage system
a) The dewatering system shall be strategically located so that the dried sludge cake can
be directly loaded into trolleys, drums or bins without the need for additional handling.
b) The dewatered sludge shall be transferred into truck-able conveyancing system
suitable for disposal by open body trucks. The minimum concentration of the solids
cake shall be no less than 25% +/-2% measured as dry solids on a weight for weight
basis.
c) The dewatering unit should have a 95% solid recovery.
d) The centrifuge concentrate should not contain more than 1,000 mg/l of solids.
e) The centrifuge should be capable of being operated at lower solid feed concentration
in case of maintenance.
f) Dewatering units shall be located in a separate Sludge Dewatering Building. Feed
pump station shall be located on a lower floor level, while the dewatering units shall be
located at upper level/ floor.
g) The centrifuge station system shall work in damp and dust laden atmosphere.
Consequently, the sludge building shall provide a conducive working atmosphere
inside the room by providing adequate ventilation to better manage odour and dust
levels.
The specification of different plant components are given below:
14.14.1 Sludge Balancing Tank and Agitator
Sludge balancing tank shall be provided to store and pump at an even rate sludge to the
centrifuge/dewatering unit. Each tank shall be provided with submersible mixers to
adequately agitate the sludge contents. The sludge paddle drive shaft shall be supplied in
an appropriate SS. Suitable mechanism support, walkway, handrails, drive system and
overload protection shall be provided.
14.14.2 Sludge Feed Pump
Sludge feed pumps shall be provided for pumping thickened/digested sludge to the
centrifuge or belt presses units. The pumps shall be positive displacement diaphragm type
pumps. The pump shall be complete in all respects with the generic details included
elsewhere in this specification. Sufficient number of pumps including redundancy/ standby
shall be provided to suit the particular requirement specified in Part 4.

14.14.3 Polyelectrolyte Solution Preparation and Dosing System
Polyelectrolyte solution is required to aid sludge thickening and dewatering by prepared

and dosing with polyelectrolyte. Polymer Dosing system complete with Tanks,
Agitators/stirrers and Dosing pumps shall be provided. Two independent units shall
provide 100% standby capacity.
a) Each tanks shall be cylindrical, vertical with closed hinged lids, and nozzles / branches
for connecting to various external inputs facilities, to allow for changing polymer,
including make-up water inlet, Agitator, Level Gauge, Level Switch, Overflow, Drain
and Solution Outlet. The tank shall be provided with a propeller type agitator and drive
unit.
b) The Dosing Pumps shall be positive displacement type. The dosing pump shall have
PLC controlled dosing rate adjustable capacity controller.
c) The material of construction of tank shall be FRVE as Liner + FRP (with is phthalic
resin). Agitator and wetted parts of Pump shall be SS-316.
d) The system design shall be based on unit quantities of dry polymer per tonne of
dewatered sludge and allow for sufficient quantities of made-up polymer for one
working shift operation efficiently. Batches of polymer shall be made-up on a daily
basis.
The polyelectrolyte solution shall be prepared and dosed as follows: Polyelectrolyte

Solution dosing is envisaged at:
Sludge Thickener : When specified, polyelectrolyte may be dosed into the sludge
at the point of thickening to improve the thickener’s
performance.
Sludge Dewatering : Dosing of polyelectrolyte is considered essential for
dewatering and the system shall be designed for a minimum
dose of 2.5 kg per 1,000 kg of sludge as dry solids.
e) Polymer solution strength shall not exceed 0.2 %.

f) The tank agitators shall have a rotational spend not exceeding 100 rpm.
g) There shall be 100 % stand by poly dosing pumps with one dosing pump for each tank
of polymer solution. The dosing pump shall be sized for the feed solution concentration
complete with pulsation damper, suction valves, NRV Pressure Safety Valves &
isolation valves.
h) Dosing rates shall be adjustable on the dosing pumps as elaborated in section 14.2.8.2
“dosing pumps”.
Material of construction
Polyelectrolyte solution preparation and dosing tank : HDPE

Agitator for Polyelectrolyte solution preparation and dosing tank : SS 316
14.14.4 Dewatering Centrifuge
a) If selected, Centrifuges shall conform to IS: 10037 (Part 3) or any other international
specifications which exceed the requirements of this specification. It shall be capable
of handling thickened/ digested sludge. The dewatered cake shall have a minimum
dryness of 25% (+/-) 2% w/w as specified in Part 4. The centrifuge shall comprise a
solid bowl of co-current/counter-concurrent design.
b) The centrifuge shall have sufficient clarifying length and differential RPM, so that
separation of solids is effective. The centrifuge shall have adjustable weir plate, so that

its pond depth can be raised. The centrifuge bowl, scroll support frame and its
accessories shall be mounted on a common fabricated steel base frame so that entire
assembly can be installed on an elevated structure. The base frame shall be fabricated
in CS and provided with anti-vibration pads.
c) The number of centrifuges shall be 200% of the total number required for the full
process capacity
The centrifuge shall comprise the following components:

• Sludge feed system;
• Collecting vessel and support frame;
• Variable speed drive;
• Differential Scroll drive;
• Centrifuge washing;
• Concentrate collection; and
• Control system.
d) The centrifuge shall comprise a conical cylindrical bowl and scroll feed horizontally
mounted in bearings on a frame.
e) The rotor shall consist of a solid bowl which rotates about a central shaft. An inner
scroll shall be provided to convey separated sludge from the periphery of the cylindrical
bowl to the beach at the conical end of the rotor.
f) The bowl and scroll and other wetted parts shall be fabricated from stainless steel AISI
316. The tungsten Carbide hard surfacing on conveyor scroll surface, feed chamber
and solid discharge outlet shall be provided. The bowl shall be protected with solid
strip liners.
g) Suitable drive with V-belt arrangement and turbo coupling shall be provided along with
overload protection device. Differential speed and bowl speed can be adjusted by
changing the pulleys.
h) The feed inlet cake discharge and centrate outlet shall be provided with flexible
connections so that vibrations are not transmitted to other equipment.
i) The drive motor shall be of 1,450 rpm, 3 phase, 415 V +/- 10 %, 50 Hz +/-5%. It shall
have class H insulation: temperature rise B, Type of protection: IP 55, Ambient
temperature, squirrel cage, foot mounted
j) The operation of each centrifuge and its associated dedicated sludge feed pumps,
polyelectrolyte dosing system, flushing system and other plant shall be automatic once
the start-up procedure has been initiated by the operator.
A typical start-up sequence shall proceed as follows:

• Start lubricating oil pumps
• Start bearing seal water pumps
• Start cake conveyors
• Start centrifuge
• Start polyelectrolyte pump
• Start sludge feed pump
k) The polyelectrolyte and sludge feed pumps shall not start until centrifuge has reached
its full speed.
l) The shutdown sequence shall be a reversal of the aforementioned procedure. After
stopping the sludge and polyelectrolyte pumps, the centrifuge shall be flushed out with
clean water. This shall be carried out while the centrifuge is still running. Means shall
be provided to divert the flushing water to the centrate drain.
m) The operation of low level sensor in the thickened storage tank shall automatically start
the flow of sludge to the centrifuge.

n) Polyelectrolyte shall be dosed to the sludge flow via an in-line injection system and to
be designed to achieve rapid and even distribution throughout the sludge.
o) The whole rotating assembly shall be enclosed by a Stainless steel (AISI316)
fabricated casing incorporating a Centrate discharge hopper and outlet pipe, and a
rectangular solids hopper which shall discharge the dewatered sludge into the disposal
system.
p) The main scroll bearings shall be arranged for lubrication by an external central oil
lubrication system. The complete rotating assembly shall be dynamically balanced and
test certificates are also to be provided before final inspection & testing at works..
q) Sludge shall be fed into one end of the rotor through a centrally positioned feed tube
and dispersed to the bowl through an inlet chamber.
r) The bowl shall be provided with an adjustable 360° peripheral weir at its cylindrical end
to control the depth of the centrate in the rotor.
s) The fixed outlet castings of the rotor shall be designed to collect the centrate and
dewatered sludge from the rotor. Baffles within the casing shall direct the separate
phases to the relevant discharge points and prevent cross-contamination.
t) The centrifuge shall be mounted on heavy-duty vibration isolators, located between
the machine and the supporting steelwork or foundations, to damp vibrations and
prevent vibration transmission. Two axis vibration monitors shall be provided to stop
the centrifuge automatically when excessive vibration is detected.
u) Flexible connections shall be provided on the sludge fed system and the centrate
system at the centrifuge. The dewatered sludge discharge system shall incorporate
flexible chutes.
For operation of the Centrifuge, variable and differential speeds shall be used to maximise
the efficiency of dewatering
Variable Speed Drive
A variable speed drive shall be provided to accelerate the rotor to operational speed and
maintain that speed during the centrifuge’s duty period. The bowl drive shall be electric
and shall be coupled to the drive shaft by a multiple ‘V’ notch belt drive.
Differential Scroll Drive
The scroll drive shall be provided with a separate drive mechanism to control its rotation
in the same direction but at a different speed to the outer bowl. The differential speed shall
be adjustable.
The drive shall be linked to the main bowl drive by an epicyclic gearbox. The differential
speed of the scroll shall be automatically and manually adjustable so that the moisture
content of the dewatered sludge can be controlled as required.
For safe operation, contractor shall provide control panel showing proper Sequence of
operation with interlocking.
Chutes and interconnecting piping shall be provided with flexible joint (minimum 10 mm
flexible in all direction) to avoid vibration.
Bowel, Conveyor & Casing : SS 316

assembly

Protective : Tungsten carbide hard lining on the conveyor flights.

Feed nozzle : Solids discharge ports with tungsten carbide lining.
14.14.5 Screw Press
The Screw Press Dewatering Machine shall have an inbuilt flocculation & sludge
thickening system and a flow control tank to limit sludge flow, and a water level adjuster to
return the excess amount of sludge when necessary. The Screw Press shall have a
flocculation tank(s) to mix sludge with polymer to separate solids and liquid with a suitably
designed agitator mechanism duly fitted. The sludge shall further flow in to a thickening
mechanism where dilute sludge is suitably thickened to at-least 3% solids content.
Thickening mechanism must be a part of the dewatering machine and the size / volume
should not exceed 5min HRT. Thickened sludge should flow in to dewatering mechanism
by gravity & intermediate pumping is not acceptable.
a) Sludge feed pump and polymer feed pump shall be interlocked with the equipment.
The main body of Screw Press shall have a cylinder and a screw going through inside
the cylinder. ‘Cylinder Unit’ having Thickening and Dewatering Sections should be
composed of rings and a screw going through inside the unit. Solids and liquid
separation shall occur by the pressure caused by the screw for thickening,
dewatering and discharging process.
b) Filtrate water shall be discharged either from the first part of the cylinder, or along the
length of the mechanism. The separated solids shall be discharged from the end of
the cylinder.
c) The screw press shall have the capability to directly dewater thin sludge of 0.2% and
thicken sludge from inbuilt thickener and discharge sludge cake with the design solids
content. Overall sludge capture rate of the equipment shall not be lower than 90%.
d) The MOC of Screw Press shall be SS304.
e) The noise caused by screw press shall be less than 65dB.
f) The screw press operation shall be automatic with a programmable logic controller.
The control shall have automatic ‘Anti Clogging System’. Component of control panel
and component of the control panel must be reputed international brands.
14.14.6 Belt Press for Mechanical Dewatering
Design of the Belt Press
Pressure filtration uses a positive pressure differential to separate suspended solids from
liquid slurry. Recessed-chamber filter presses are operated as a batch process. Solids are
pumped to the filter press under pressure ranging from 100 to 300 psi, which forces the
liquid through a filter medium, leaving a concentrated solids cake trapped between the
filter cloths that cover the recessed plates. The filtrate drains into internal conduits and
collects at the end of the press for discharge.
The Belt Filter Press shall continuously dewater sludge using two or three moving belts
and a series of rollers. The filter belt shall separate water from sludge via gravity, utilising
drainage and compression. Sludge shall be sandwiched between two tensioned porous
belts, which are passed over and under rollers of various diameters. Increased pressure
is created as the belt passes over rollers.
Solid recovery rate shall be more than 95%, or as recommended by the CPHEEO manual
latest revision.
The equipment shall include the following basic features:

• Polymer conditioning zone,

• Gravity drainage zones,
• Low pressure squeezing zone
• High pressure squeezing zones.
Belt width of filter press shall be in the order of 1 m to 2 m
The main components of a belt filter press shall include following components:
• Feed equipment, including feed pump and piping frame,
• Belts, and belt-tracking and tensioning systems,
• Belt wash system,
• Rollers and bearings,
• Cake-discharge blades and chutes,
• Cake conveyance,
• Drive system, and belt-speed control
• Chemical conditioning, and flocculation of centrate.
Personnel safety shall be mandatory and incorporated into the design.
The design must provide for and facilitate maintenance, provide safety stops, for instance
with ultraviolet sensor and trip wires around the belt press and any cake conveyors,
convenient and safe equipment access, drainage and spill containment, non-slip walkways
and floors, sufficient lighting, noise reduction, ventilation and odour control.
System interlocks should be provided to inhibit the solids and polymer feed pumps when
the press is shut down.
Filter Plates:
Plates shall hold pressure tight during filtration and capable of forming a sludge cake of
nominal thickness min.30mm. The thickness of plate web shall be a minimum of 1" duly
ribbed for drainage.
Each filter plate shall be supported by handles which slide on side bars. The end filter
plates in the filter assembly (installed on the head stock and on the movable followers),
shall contain sludge cake recesses on the side facing the adjacent filter plates only. The
filter plates shall be constructed with top and bottom internal drain ports with a four-valve
discharge to permit effective use of an air blowdown manifold which will expel excess
filtrate before opening the press.
Stay bosses shall provide stability against pressure differentials across the press. Stay
bosses shall be an integral part of the plates. The plate filtration surface shall have grooves
to facilitate flow beneath the filter media. Flow passages shall be of adequately size to
permit operation uniformly over the surface of the plate.
Filter Media
The filter media shall be selected to provide good cake release and optimum solids capture
without the use of pre-coat material. Standard media normally acceptable is
polypropylene. The material shall be of heavy duty yarn with adequate strength to provide
long life in excess of 1,000 filter cycles, with normal operator attention. Filter media shall
not deteriorate if acid washed.
The number of filter plates shall be adequate for the design though puts in accordance
with Part 4.

Drive System:
The drive system may be an hydraulically actuated closure system. Suitable alternative
drive systems may be suitable depending on a proven track record of the equipment
manufacture.
• Plate: Stainless steel 316

• Other wetted parts: Polypropylene
• Cloth: Polypropylene
• Frame: Mild steel with epoxy painted
• Sealing: EPDM/Silicon
14.14.7 Sludge Interconnecting Pipework
Interconnecting pipework shall serve the following items of plant;

• Sludge Balancing Tank to Centrifuge feed pump;
• Centrifuge feed pump to centrifuge, or to Belt Press where specified;
• Centrate pipe work from centrifuge/belt press to supernatant and centrate pump
house.
• Water pipe work to Polymer Dosing Tank and Centrifuges/Belt Press (for flushing)
• Polymer Dosing pipe work from Dosing Tanks to Centrifuge inlet.
• Sludge balancing tank to supernatant & centrate pump house.
The pipe work shall include all fittings, specials, valves, supports etc. and shall be
completed in nature. Additionally, a service water line shall be connected to all sludge and
chemical lines for easy of cleaning.
The sludge, centrate and water pipe work shall consist of pipes of Ductile Iron, rating K9
and Cast Iron Gate Valves / Gun Metal Globe Valves. The pipe works shall be of
Polypropylene and valves shall be PP ball valves. Suitable flexible connections shall be
provided in the pipe work connecting centrifuge to prevent transmission of vibration
Hoist
One overhead hoist/crane of suitable capacity shall be provided over the centrifuge/belt
press and any related operations and maintenance areas to facilitate operation of the
plant.
Interlocking for safety
Complete electrical isolation of the centrifuge/belt press shall additionally be assured with
appropriate interlocks between the mechanical plant and the MCC panel.
14.15 Gas Mixing System for Digesters
The gas mixing system shall be independent, efficient in operation, simple in maintenance
and suitable for tropical climate of Delhi. Mixing of the Digester contents shall be achieved
by recycling of the biogas through bio gas compressors at adequate pressure. The
minimum design pressure of the gas compressor shall be sufficient even for de-clogging
of the gas lancers (SS 316) after shut off period of digesters. The sludge within the digester
shall be mixed by continuous gas recirculation. Gas extracted from the roof space at low

pressure shall be compressed and fed back, via a roof mounted splitter manifold, into the
bottom of the digester through diffusers on individual lines.
Gas mixing system shall be complete along with necessary accessories such as gas meter
for each digester at outfall of each digester, drip traps at suction and discharge pipes,
electric controls, and spare parts.
All gas mixing pipe work shall be designed and installed in accordance with best practices
with velocities as specified under pipework. The Gas Main pipe work shall be sized to
enable the fast and smooth transfer of gas from the gas holder to the digester to make up
the volume metric capacity left by grit and sludge evacuation. The gas pipe work shall be
in accordance with SS 316.
14.15.1 Gas Compressors
The Gas Compressors shall be provided with adequate capacity and rating as required.
One duty and one stand by gas compressor shall be provided per digester. Each gas
compressor shall be a gas tight, single stage, sliding vane machine, displaying positive
displacement characteristics and specifically designed for use on digester gas. The
complete gas compressor unit shall be rated for continuous duty. Automatic change over
from one unit to the other unit at an interval of 12 hrs. shall be provided.
Design Requirement
a) Compressor shall be of positive rotary, sliding vane type, air cooled and oil lubricated,
robust in construction, reliable, cost effective with low power consumption and easy to
maintain. The gas compressors shall be designed and works tested complete with
compressor unit, motor, base plate, water cooling system, gas and water pipework,
valves, water separators, and all regulating and control equipment as required to
provide an adequate and efficient compressed high pressure gas supply.
b) The compressors shall be designed to compress wet bio gas comprising about 60-
65% methane and 35-40% CO, with trace elements including H, N & H2S. The gas
shall be assumed to be water saturated.
c) Due to the H2S presence, no brass or copper based materials shall be used in the gas
compressor or come in contact with the gas.
d) Gas compressor gearbox shall be suitable for continuous running and intermittent
starting under maximum load with the resultant high torque and shock loads. The
gearbox shall have a service factor of 2 (Minimum).
e) A pressure relief system shall be included to operate on shut off pressure of
compressors. This shall consist of actuated bypass and main gas valves which shall
operate to dissipate the high pressure in the delivery main to the low pressure digestion
tank.
f) A temperature sensor shall be installed to give a warning alarm and shut down facility
in the event of the pressure relief valve operating.
Each duty standby package shall be supplied with:

• Gas compressors - sliding vane, air cooled, oil lubricated.
• Drive Motors – Flameproof, Zone 1, thermistors. Max speed 1,440rpm.
• Stainless steel oil tanks with sight level indicator & low oil level switch.
• Flexible connectors – 316L Stainless steel, flanged and braided either side of the gas
compressor.
• Isolation valves – Butterfly inlet.
• Inlet pipe line filters
• Discharge gas non return valves – wafer pattern, stainless steel with viton liner
(horizontal mounting).

• Discharge oil separators with manual/auto drain valve assembly

• Common inlet condensate trap with syphon drain assembly
• Common discharge condensate trap with manual/auto drain assembly
• Inlet and discharge gas pressure gauges with isolation valves.
• Inlet gas pressure cut out switches
• Discharge gas pressure cut out switches
• Discharge high temperature cut out switches.
• Low oil level cut out switches.
All the above is to be mounted on mild steel galvanised skid, pre-piped in thin wall 316L
stainless steel tube, with SS 304L non gas contacting spinning flanges, to form a
duty/standby package.
Mode of Operation
a) The compressor shall operate on a duty / duty assist basis

b) Manual control via start / stop pushbuttons at the control panel with auto switch off in
case of temperature bypass or over pressure switch operating.
c) The compressors are to run on either a timed or continuous control selected by a two
position selector switch mounted on the control panel.
d) When ‘continuous’ is selected, the compressor is to run continuously. Where ‘timed’ is
selected the compressor is to run for fixed duration and to be off for fixed duration. The
timed cycle shall be controlled by two adjustable timers (0-60 min) provided for each
compressor.
e) Compressor is to trip and lock out due to the following but the work shall include but
not necessarily be limited: (reset shall be manual)
• Electrical overload
• Earth fault
• Motor over-temperature, monitored by thermistors in each phase
• Over-temperature in the compressor gas delivery pipeline
• Cooling water over-temperature
• Rise in discharge pressure
• Vacuum in suction line
Electric Control System
Electrical controls shall be designed to suit the operational philosophy. All electrical
motors, local control units and instrumentation, etc. mounted in the digester area shall be
certified for use in a zone 1 hazardous area and have an IP 55 enclosure.
Electric Motor
Motors shall be flame proof squirrel cage type conforming to IS 325. The power rating shall
be at least 125% of maximum power requirement. The other features of motors shall be
as follows:
Type of duty : Continuous (S1)

Method of starting : Start-Delta
Class of insulation : H (Temperature rise limited to Class B)
Type of enclosure : TEFC & Flame proof

14.16 Gas Blower
14.16.1 Design Requirement
a) Blower shall be provided for necessary capacity and rating as required and shall be of
rotary or reciprocating type, water cooled, single stage oil free gas compressors. The
cylinder shall be cast such that gas and water passage shall be separated by metallic
wall and shall not have any gasket separating the two.
b) The gas blowers shall be designed and works tested complete with blower unit, motor,
plate, water cooling system, gas and water pipe work, valves, water separators, and
all regulating and control equipment as required to provide an adequate and efficient
compressed high-pressure gas supply.
c) The blowers shall have water seals.
d) The blowers shall be designed to compress wet and sludge gas comprising methane
CO2 with trace elements including H, N & H2S. The gas shall be assumed to be water
saturated. All metal parts in contact with gas shall be of stainless steel (type CF8M or
316)
e) Gas blower gearbox shall be suitable for continuous running and intermittent starting
maximum load with the resultant high torque and shock loads. The gearbox shall have
a service factor of 2 (Minimum).
f) A pressure relief system shall be included to operate on shut off pressure of blowers.
This shall consist of actuated bypass and main gas valves which shall operate to
dissipate the high pressure in the delivery main to the low-pressure digestion tank.
g) A temperature sensor shall be installed to give a warning alarm and shut down facility
in the event of the pressure relief valve operating.
14.16.2 Mode of Operation
The blower shall operate on a duty / duty assist basis.
Manual control via start / stop pushbuttons at the control panel with auto switch off in case
of temperature bypass or over pressure switch operating.
The blowers are to run on either a timed or continuous control selected by a two position
selector switch mounted on the control panel.
When ‘continuous’ is selected, the blower is to run continuously. Where ‘timed’ is selected
the blower is to run for fixed duration and to be off for fixed duration. The timed cycle shall
be controlled by two adjustable timers (0-60 min) provided for each blower.
Blower is to trip and lock out due to the following but the work shall include but not
necessarily be limited: (reset shall be manual)
• Electrical overload
• Earth fault
• Motor over-temperature, monitored by thermistors in each phase
• Over-temperature in the compressor gas delivery pipeline
• Cooling water over-temperature
• Rise in discharge pressure
• Vacuum in suction line
14.16.3 Motor
Motors shall be squirrel cage type conforming to IS 325. The power rating shall be at least
125% of maximum power requirement. The other features of motors shall be as follows :

• Type of duty: Continuous (Sl)

• Method of starting: Star-Delta
• Class of insulation: H (Temperature rise limited to class B)
• Type of enclosure: TEFC and Flame proof
• Degree of protection: IP 55
14.17 Bio Gas Holder
14.17.1 Bio Gas Holder Floating roof (Floating Bell) type
The floating bell gas holder shall have floating Mild Steel circular cylindrical shape made
out of M.S. sheet welded suitably over a properly designed structural steel frame work with
M.S. dome top and open bottom shall be provided. The gas holder shall also have,
separate gas inlet and outlet piping, control valves, vacuum and pressure relief valves with
flame arrestors. There shall be a pipeline header coming through digesters to feed gas
holder tank. All gas pipelines shall be provided with isolating valves and drip traps and
flame arrestors. All the control valves, drip traps and flame etc. shall be housed inside
chambers at GL. The chamber shall be plastered in cement mortar from inside and outside
both, provided with RCC removable precast cover and DI steps for getting down and
coming up. The chamber shall have concrete flooring and plastered with cement mortar
1:4 from inside/outside. Access to the top of gas holder walkway shall be by means of 1.2
m wide RCC staircase with hand rails. The scope shall also include the cast iron piping
including valves upto the top of gas holder. The gas holder shall also be provided with
level indicator and alarm system. Necessary opening with manhole of 900 mm dia. In the
wall at the formation level shall be provided with CI frame and removable cover for entry
into the gas holder. Necessary CI steps shall also be provided. An over flow pipe at suitable
elevation of required size shall be provided and connected to nearest drain/effluent
channel. Necessary water connection for filling the gas holder tank shall be provided near
the periphery of the tank.
14.17.2 Bio Gas Holder - Membrane type
14.17.2.1 General
The gas holders shall be dual membrane type without heating. The internal & external
membrane, i.e. gas membranes shall be made of polyester fabric coated with polyvinyl
chloride (PVC) and sized to accommodate the specified volume of bio gas and shall be
resistant and impermeable to digester gas. The membrane type gas holder shall provide
the necessary gas holding capacity with easy and quick installation. The gas holder
membrane shall not have effect of UV and should be wind resistant. The membrane gas
holders are ideal for plants that use excess bio gas and are environment friendly. The
membrane design shall provide completely separate chambers for air and bio gas. This
prevents any possibility of gas leakage into controlled air volume. Accurate pressure
control shall be maintained while the bio gas is filling the gas holder. The gas holder shall
be provided with level control system.
14.17.2.2 Tank mounted (Digester based)- Membrane type Gas holder
It shall be suitable to mount on digester tank top ( Roof of digester tank and as well as
gas holder)

Membrane made of double-sided PVC coated polyester fibre fabric, UV-microbial

abrasion- biogas resistant, flame retardant B1 according to DIN4102, built with strips of
membrane cut.
The Working pressure shall be minimum 5 mbar or as per the system requirement
whichever is higher.
The following Accessories shall be provided for Biogas holder as a Minimum requirement.
a) Gas Holder Mounting (Perimeter) flanges shall be in SS-304 or Superior Grade

b) Suitable Inspection windows with stainless steel flange ø 230mm-1 Nos. and acrylic
glass panel.
c) Aluminium and stainless-steel air overpressure valve that works with indirect
mechanical pneumatic start.
d) Stainless steel AISI 304 over pressure cum vacuum safety valve as liquid trap with
stainless steel venting pipe with a flame cutting grid, it shall be with automatic water
refill system made with a stainless- steel water tank and valve with floating control.
e) Ultrasonic level transmitter – 1No.
f) Air blowers (1W+1S) suitable capacity and pressure to be provided with NRV in SS-
304, On/Off Valve, flexible air pipe, pressure gauge, and flame proof motors.
g) Material of construction of Air blower shall be Mild steel IS:2062 /ASTMA A36
h) SS 304 Anchor fastener/Nut bolts for anchoring of mounting flanges to be provided.
i) Control panel with MCC starters and hooter.
j) Support system with mesh and webbings and webbing flanges in SS-304.
14.17.2.3 Floor mounted (Ground based)-Membrane type Gas Holder
This type of Gas holder to be installed on a concrete foundation.
Air Membrane shall be made of double side PVC coated polyester fibre fabric and GAS
Membrane welded with bottom carpet made of double side PVC coated polyester fibre
fabric or as per manufacture recommendation with suitable proven track record.
The Working pressure shall be minimum 5 mbar or as per the plant requirement whichever
is higher.
The following Accessories shall be provided for Biogas holder as a Minimum requirement.
a) Suitable inspection window -acrylic glass panel and stainless-steel flange ∅ 230mm, 1
No.
b) Aluminium and stainless-steel air overpressure valve 2 Nos. to be provided and these
should work with indirect mechanical-pneumatic start .
c) Stainless steel gas safety valve for Vent to atmosphere design 1No. Vent to
atmosphere design shall maintaining a tight seal until the set pressure of the valve.
Automatic water refill system constructed with a stainless-steel water tank and floating
control valve to be provided.
d) Suitable mechanical seal anchoring system to be installed on concrete foundation
using stainless steel flanges attached with AISI 316 anchor bolts, AISI 304 special
profiles and a complete set of sealing strips.
e) Air blowers (1W+1S) suitable capacity and pressure to be provided with NRV in SS-
304, On/Off Valve, flexible air pipe, pressure gauge, and flame proof motors.
f) Material of construction of Air blower shall be Mild steel IS:2062 /ASTMA A36
g) Control panel with MCC starters and hooter.

14.18 Bio Gas Scrubbers (For H2S Gas Removal)
14.18.1 General
Hydrogen sulphide is a highly toxic and corrosive gas and is a major pollutant. At high
concentrations it will lead to almost instantaneous poisoning and death. The biogas
scrubber should be on biochemical scrubbing principal and improve quality of biogas to
reduce corrosion in the engine parts and to reduce pollution.
The system should be with zero liquid discharge and no gases/ effluent emission in the
process of scrubbing. The biogas contain mainly methane, H2S and CO2 shall be scrubbed
for removal of H2S up to required level before it is utilized for power generation in the
biogas generator. The proposed scrubber system shall be complete in all respects and
shall generally include but not limited to the followings:
• Pre scrubbing or washing tower
• H2S scrubbing tower
• Tank for pre scrubber
• Tank for scrubbing tower
• Pumps each for wash tower & scrubbing tower
• Piping and valves arrangement
• Control panel
• Dehydration system.
The biogas shall be washed first with lean NaOH solution to remove any suspended
material in the gas. The washed biogas then shall be passed through scrubbing packed
tower for removal of H2S to the required accepted level. The scrubbing solution is to be
pumped from the solution tank and sprayed on the packing of the scrubbing tower through
which the sour gas is passing.
To supply all equipment and devices, Contractor shall submit all related technical
information such as calculation sheet, gas component analyses and evidence at inlet an
outlet at the equipment to obtain client approval in advance.
Contactor shall provide all necessary equipment and low cost operation system essential
to meet the requirement of Gas Engine.
Desulfurization equipment:
Highly concentrated H2S chemical substance shall be removed to proper level by sodium
hydroxide tower or catalytic action or biological method to protect loss in Gas Engine and
boiler efficiency and its break-down due to high corrosive nature of the gas.
The package shall include complete set of mechanical and electrical Equipment,
instrumentation control and automation required for satisfactory and efficient operation of
the plant.
All electrical drives (Motor) shall be Flame proof type (FLP), IE3 only.

14.18.2 Material of Construction
Sr. Part or Equipment or

No. system
1 Scrubber MS inside FRP/PP lining of 3mm thk
2 Scrubber internals
a Internal pipes SS 316
b Gas distribution tray SS 316
c Spray nozzle PP
d Packing Material PP
2 Gas Holder MS inside Epoxy painted
3 Settling Tank MS inside FRP lining of 3mm thick
4 Caustic Day Tank HDPE
5 Nutrient Tank HDPE
6 Bio reactor RCC OR as recommended by system supplier
7 Bio reactor internals SS 316
Refer Air blower specification as mentioned in the
8 Air Blower
same document.
9 Pump All wetted parts shall be SS 316
10 Pipes and fittings
a Process liquid piping SS316
b Gas piping SS 304
c Air piping SS 304
d Water Piping SS 304
11 Civil tank Inserts
a Bioreactor Internal Inserts SS 316
b All external Insert MS
14.19 Clean Gas Holder
Clean Gas Holder for emergency operation of Biogas Engine in absence of power in the
treatment plant shall be supplied. Pressurised scrubbed biogas of adequate capacity shall
be stored in clean gas holder for emergency operation of biogas engine. Capacity of clean
gas holder shall be supplied as per the recommendation of engine manufacture and shall
have adequate capacity to run biogas engine for 15 minutes. All component of clean gas
holder shall be SS-316 construction.
14.20 Power Generation System and Heat Recovery System
Cleaned Bio gas shall be supplied to Bio gas engine to produce electric power and take
advantage of energy during running engine by heat recovery system so called “co-
generation unit”.
The work shall include but not necessarily be limited to the following:
• Gas Engines along with alternators and all other accessories
• Gas supply line and valves.

• Pressure relief valves with flame arrestors.

• Flame arrester and trapping assembly.
• Gas filter.
• Water trap.
• Gas flow meter
• Gas line distributor valves.
• Pressure meter.
• Pressure switch for gas – low/high pressure indication
• Solenoid valve
• zero pressure regulator
• Drain.
• Switchgear system and synchronizing panel
• Scrubber System
• Heat Recovery System
Biogas shall be utilized to run Gas engine and produce electric power by generator.
Produced electric power shall be supplied to main power line to run the Plant.
14.20.1 Bio-Gas Engines
General requirements
It is proposed to generate maximum possible power out of the available sewage gas by
using highly efficient gas generators. The power generated from Power Plant will be used
for In-house consumption of the Sewage treatment plant equipment. The Generators have
to be designed to operate at maximum gas generation to give the optimum power output
from in house captive consumption.
The CH4 (Methane) content in bio gas shall be in the range of 60% to 65%. Bio gas will
also have concentration of H2S @ 1.0% to 3.0% and H2S which is highly corrosive in nature
has to be removed from the sewage gas before feeding the gas to the gas gen-sets. This
H2S has to be removed from this sewage gas by using bio chemical gas cleaning
scrubbers.
The generator sets have to be designed to run on base load operation continuously during
the peak gas generation; The H2S content in the sewage gas generated shall be removed
by a H2S scrubbing system. The scrubber shall be capable to reduce the concentration up
to 200 ppm level or below as desired level by biogas genset manufacturer. Engine should
have operating hours minimum 60000 hrs with the above H2S level before any major
overhaul.
Gas Engines shall be designed for running on 100% biogas with a high level of fuel
efficiency with lean burn combustion technology. The electrical efficiency of the gensets
at the alternator terminal under site conditions and 100 % load shall be highest but not
less than 38% (without any negative tolerace). Minimum capacity of each gas genset at
alternator terminals shall be 800 KW x 3nos. (2 working + 1 Standby) at 415V, 3 ph., 50
c/s and unity power factor & 100% load at site condition. Capacity of all gas engines shall
be same & the gas gensets shall not be overloaded more than 100% since gas gensets
are meant for base load operation and cannot be overloaded.
Gas engine shall be hooked to the main LT panel. Gas engines shall be running on
continuous operation. The gensets shall be designed for running on 100% bio gas with a
high level of fuel efficiency / electrical efficiency. The engine shall be 4 stroke Otto gas V
engine type.

Genset Components
Base Frame, Coupling, Pre – Lube Pump, Air Filter, Zero Pressure Gas Control Line with
Connection Accessories, Crankcase, Driving gear, Cylinder head, Valve drive, Ignition,
Carburetion, Mixture charging, Starter, Lube oil system, Engine cooling system, Sensor
technology/actuator technology and cabling etc.
Rotary Current Internal Pole Synchronous Generator
Three-phase synchronous generator, brushless, self-induced, self-adjusting, with

dampening cage for 30% inclined load and parallel operation, artificial star point, protection
type IP 23, with tropical atmosphere and humidity protection insulation, degree of radio
shielding "N", voltage target value setting ± 5%, Insulation Class H.
Main Components
The engine shall have minimum following sensors:

• Jacket water temperature sensor
• Jacket water pressure sensor
• Lube oil temperature sensor
• Lube oil pressure sensor
• Charge pressure sensor
• Minimum and maximum lube oil level switch
• Exhaust gas thermocouple for each cylinder
• Knock sensors
• Carburettor position control
The main components of the gas engine but not limited to shall be as described below :
Coupling
High-stretch, axial plug-in flange /flexible coupling for torsional elastic connection of engine
and generator. The disc-shaped rubber body cushions torsional oscillations to a large
extent. The rubber element is radially interchangeable.
Lubrication (Lube) Pump
Pre-lubrication though an electric pump on the genset; emptying also possible with the
same pump after changing the position of a built-in three-way tap. It should be equipped
with auto lube oil replenishment system.
Crankcase
One-piece sphero cast casing, maintains its rigid shape due to steep side walls and
diagonally screwed bearing blocks; suspended crankshaft; lateral drive chamber
apertures; wet cylinder bushings made of highly wear-resistant special centrifugal casting;
crank chamber ventilation via oil trap into the mixture line upstream of the turbocharger
compressor
Base Frame
Steel bend and torsion-resistant construction to take the engine and the generator. Elastic
bearings are mounted under the base frame.

Cylinder head
Single cylinder heads made of special cast iron with valves and seat rings optimally
arranged for fuel mixture generation with optimised angular momentum; mixture supply
from the intake pipe from the inside of the combustion chamber; exhaust gas discharge
outward into the exhaust manifolds that are arranged laterally at the respective cylinder
rows; sparkplugs centrally in the combustion chambers with intensive plug seat cooling.
Valve drive
One toothed wheel driven camshaft for each cylinder bank in the combustion chamber;
valve operation for respectively 2 inlet and outlet valves by flat or roller tappet, push rod;
rocker lever and valve bridge; O ring oil gaskets at the valve stems.
Ignition
Microprocessor-controlled high-voltage ignition system with low-voltage distribution;

respectively one ignition coil per cylinder; without moving parts; wear-free; triggered via
tooth rim of the flywheel and a pick-up sensor at the camshaft; variable ignition times;
ignition energy and distribution via calculator at primary side of the ignition coils; high-
performance industrial engine or special sparkplugs; long-life Teflon sparkplug connector;
buffered voltage supply by 24 V battery.
Mixture charging
The exhaust gas turbocharger takes air and gas out of the gas mixer at atmospheric
pressure; subsequent compression of the gas mixture; re-cooling in one-stage mixture
cooler (low-temperature cooling circuit); two throttle valves downstream of mixture cooler
for power control.
Starter
One high-performance 24V electric starter; flanged to the engine casing (to be confirmed
by electrical dept)
Lube oil system
Forced-feed circulatory lubrication by toothed wheel pump, lubricating oil heat exchanger
integrated in the engine cooling circuit; oil filter in the main stream; automatic lubricating
oil refilling into the oil pan through controlled inflow; automatic pre-lubrication by electric
pump; oil discharge by the same pump at the unit.
Alternator
Three-phase synchronous generator, brushless, self-excited, self-regulated, with

dampening cage for 30% inclined load and parallel operation, artificial star point, minimum
protection type IP 23, with tropical atmosphere and humidity protection insulation & with
anti condensation heater, degree of radio shielding "N", voltage target value setting ± 5%,
electronic type voltage regulator and power factor regulator, and three thermistors for
winding temperature monitoring. Alternator shall be connected with flexible power cable
for power evacuation.
Brushless, Self-Excited, Self-Regulated, Double Bearing, Synchronous Alternator with

electronic AVR, 415 V, 1 Power Factor, 50 Hz, complete with standard accessories.

Produced electric power shall be supplied to main power line to run the Plant.
Assembled engine and generator shall be operated under the following condition;
• The system should be suitable for continuous/ base load operation.
• Momentary speed variation shall not exceed at 10 % in no time.
• Normal speed variation shall be not exceeded at 5 %.
• Recovery time shall be within ten seconds.
• Location to be operated shall be in Delhi in India.
The Assembled Engine shall be manufactured with necessary in-built safety features in
comply with relevant applicable Indian/international standard.
Each Engine shall be provided with following components but not limited to the following:
• Engine body with spark ignition system
• Starting system (Batteries)
• Fuel supply system
• Carburettor
• Distributor
• Speed adjusting device (electronic speed Governor), throttle valve
• Ignition system
• Silencer (pollution control device)
• Cooling system
• Lubricating oil system
• Pressure relief and safety valves.
• Pressure gauges, Level gauges
• Rotating meters, Thermometers and Flow meters.
• Air and oil filters and strainers
• Noise protection, and
• Expansion joints, valves. pipe line for gas and water.
• Tools (Special and maintenance with a tool box), firefighting equipment and safety
gears (helmets, ear muffs, earplug, safety goggles etc)
• Portable rotating meter, Potable noise meter, Potable vibration gauge, Potable
thermometer
• Integral robust fabricated steel base frame with anti-vibration mounting pads.
• Anchor bolts
• Back-up cooling system
o Dry cooler – For emergency cooling
o Three way valve – To control engine water temperature
Engine Body
a) Fine finished Liner of cylinders shall be manufactured with abrasion resistance made
by special metal.
b) Common bed shall provide with shock prevention device and its stoppers.
c) Total vibration value at common base on duty shall not be exceeded at 0.3mm
measured by axial and horizontal direction respectively.
d) Crankshaft and propeller shaft shall be made by grade AA forged steel.
e) Combustion system shall provide air filter, gas carburetor and spark plugs, air
compressor.
f) Speed adjusting device shall provide with perceptive action.

Lubrication
The engine shall have a forced lubricating system throughout using an integral gear-driven
pump with required strainer on the suction side. The lubrication oil gear pump will supply
oil at a requisite pressure before engine is actually started. A full-flow filter having a
pressure-operated by-pass valve shall be provided on the delivery side.
The engine lubricating oil dipstick shall be easily accessible and minimum and maximum
levels shall be clearly marked. The engine sump shall have an easily-accessible drain
point or drain pipe, fitted with a BSP plug. The engine shall be suitable for uninterrupted
running over prolonged period and the lubrication system shall be controlled by the Engine
Management System.
Cooling
The engine shall have a high temperature cooling circuit for jacket cooling water and for
this complete required arrangement i.e. flame proof electric motor driven water pumps for
HT and LT circuits, pipe work, valves and fittings etc. are to be provided.
In case the temperature exceeds the pre-set maximum temperature, the engine shall be
protected by Engine Management System.
Drive Belts
Drive belts shall be of the multiple endless V-type which shall be resistant to fuel and
lubricating oils. The number of belts fitted to each drive shall be one more than is
necessary to transmit the maximum power requirement. An accessible belt-tensioning
device shall be fitted to each drive and it shall be possible to change the belt(s) without
major dismantling and re-assembly.
Safety Guards
All exposed hot or moving parts and in particular, fans, belt drives, couplings and flywheels,
shall be guarded in accordance with PD 5304:2000 and to ensure safe operation. To
permit the adjustment and inspection of drives, apertures with secured cover plates shall
be provided in the guards at appropriate points.
OR
Bio gas engine shall be linked to power generator by flexible joint or hydraulic coupling.
Turbocharging
A high performance exhaust turbocharger system, driven with exhaust gas from the
manifold of each cylinder bank, shall be provided. Exhaust turbocharger shall draw in
mixture from venturi gas-air mixer after being regulated through throttle system.
Two stage cooling of the compressed mixture shall be done in the two stage mixture
cooler. The first stage of the mixture cooler shall be integrated in the jacket water circuit
and the energy of the second stage shall be dissipated through separate circuit

Wiring
Engine-mounted wiring shall be insulated with heat resistant insulation to CENELEC

Harmonisation Documents HD 21.1 S4:2002 and HD 22.1 S4:2002 and associated parts
thereof for use at temperatures of up to 85°C. Conductors shall be multi-stranded copper
of minimum cross-sectional area 1.5mm² excepting special types such as screened
cables. All wiring, excluding starter cables, shall be connected to an enclosed metal clad
terminal box or terminal boxes mounted on the base frame. Starter cables may be directly
connected.
Pipe work
Fuel pipe work shall be produced from seamless steel tubing with welded or compression-
type steel fittings. All other pipe work shall be either seamless copper tubing with brazed
or compression-type gunmetal fittings, or seamless steel tubing with welded or
compression-type steel fittings. Flexible sections of pipe work shall be synthetic rubber
with stainless steel braided sheaths. Flexible fuel and lubricating oil connections shall
additionally have flame resistant sleeves. All pipe flanges shall comply with BS 4504-
3.3:1989 and screwed connections with BS 21:1985.
Exhaust System
Engine shall be provided with a complete exhaust system comprising structurally

supported chimney, rigid and flexible duct / pipe work, stainless steel bellows, silencer(s)
and all necessary brackets, hangers, wall sleeves and plates and sundries for a complete
installation. Duct / Pipe wall thickness shall not be less than 3mm.
Unless otherwise specified, silencers shall be of the residential type. The first section of
exhaust from the engine manifold shall include a flexible bellows unit. The next section of
pipe shall be supported to allow movement without imposing forces on the manifold.
Exhaust support brackets shall be designed to allow for duct / pipe expansion and
contraction movement. Bends in the exhaust pipe work shall be kept to a minimum and
shall be of the long radius type.
Where the exhaust pipe passes through a wall, a wall sleeve and plates shall be fitted.
The annular space between the pipe and sleeve shall not be less than 25mm. The space
between the pipe and sleeve shall be filled with heat-resistant material. Exhaust
terminations shall not be located in close proximity to air inlet grills or opening windows
were exhaust gas can re-circulate into the building. The exhaust outlet shall be arranged
to prevent the ingress of water.
For long exhaust runs, a water drain point or condensation trap shall be fitted near to the
engine. Exhaust silencers and pipes, flanges, clips and fixings shall be sprayed with
metallic aluminium paint in accordance with BS 2569-2:1965 Process ‘D’. Exhaust Piping
along with Insulation and Cladding from the engine manifold to the Stack. Internal sections
of the exhaust system shall be effectively lagged. The lagging shall be clad with aluminium
sheet secured by stainless steel band clips. Where it is not practical to lag any part of the
internal section of the exhaust system with which personnel can come into contact, guards
shall be fitted. Complete support structure for the exhaust piping shall be provided.
The exhaust system of the engine should also have necessary arrangement to produce
enough hot water for heating the sludge from the digesters.

Starting Systems
Engine starting shall be electric system as specified and shall comply with the following:-
The starting battery shall be of the nickel-cadmium or lead-acid type and unless otherwise
specified, installed on an engine bed plate mounted non-corrodible tray or rack and shall
have a cover of insulating material. The battery shall have sufficient capacity for three
consecutive start attempts each of 10 seconds duration. In addition, the battery shall have
sufficient capacity after the three start attempts to supply the maximum demand of the
control panel for a minimum period of 24 hours.
The battery charger shall be of the solid-state design and shall incorporate ‘float’ and
‘boost’ charging facilities. In the ‘float’ charge mode, the charger shall automatically
maintain the battery in a fully-charged condition whilst supplying standing loads. In the
‘boost’ charge mode, the charger shall be capable of fully charging the battery from a fully-
discharged condition in a period not exceeding 7 hours.
Fuel System
It shall consist of basically fuel gas pipe work along with necessary supports, from the main
gas valves within the Power house building, Gas pressure control unit and Pre-pressure
regulator unit flexible gas pipe.
Bio Gas Gen-set operating cum monitoring panel shall have colour screen with graphic
display. The operating cum monitoring panel shall be placed in a cubicle within engine
room.
The PLC based control panel shall have:

• 24VDC Battery type
• External supply of control power from starter and control batteries.
• The control panel shall have TFT colour graphic display with function and numeric
keys.
• Control panel shall have Protection IP 65 front.
• Display shall show as a minimum - excitation voltage, oil pressure, oil temperature,
cooling water pressure and temperature, exhaust gas temperature, controller
positions, number of starts, active power demand, reactive power demand, operating
hours, service hours, and operational log book, diagnostic data.
• Should have alarm and diagnostic instrumentation with all active fault messages
together with time records.
• Engine control shall have speed control in no-load and island operation.
• Control system shall be capable of efficient knocking control.
• Control system shall have alternator parameters measurement facility for – power
factor, frequency, active power, reactive power, voltage phase-to-phase and phase-to-
neutral, neutral conductor current, phase current.
• Control panel shall show below shut-down functions with display, but not limited to the
following:
o Low lube oil pressure
o Low lube oil level
o High lube oil level
o High lube oil temperature
o Low jacket water pressure
• High jacket water pressure
• High jacket water temperature
• Over speed

• Emergency stop/safety loop

• Gas train failure
• Start failure
• Shutdown failure
• Engine start/ operation blocked
• Misfiring
• High mixture temperature
• Measuring signal failure
• Overload/output signal failure
• Generator overload/short circuit
• Generator over/under voltage
• Generator over/under frequency
• Generator asymmetric voltage
• Generator unbalanced load
• Generator reverse power
• High generator winding temperature
• Synchronizing failure
• Knocking failure
The air intake and outlet system shall have weather protection, bird screen.
Engine Management System
The engine shall be provided with an Engine Management System, in one electronic unit,
to control and supervise all relevant functions of the gas engine, engine auxiliary drives
and alternator winding temperature supervision. Operating conditions of the engine shall
be picked up as prevailing analogue signals and be checked against programmed limits.
The intelligent handling of these functions by Engine Management System shall enable
safe running of the set at all operating conditions, incorporating operator computer for each
set with full graphic LCD colour display.
The control cabinet module is to be placed at a suitable place near the generating set. The
cabinet of Engine Management System shall be specially designed for optimized wiring to
the central plant switchboard.
The Engine Management System shall generally include display and processing of the
following analogue values of the generating set:
• Inlet water inlet
• Outlet water outlet
• throttle position
• Combustion chamber temperature for each cylinder
• Water temperature after mixture cooler
• final power demand (with 4-20 mA signal)
• Generator windings temperatures
• Generator set output display (external signal 4-20 mA)
• Engine speed
• Gas mixer control position
• Oil pressure after filter
• Lube oil level
• Crankcase pressure
• Exhaust temperature after engine
• History display (long and short history) as curves

Following messages shall also be shown:

• Operation hours
• Start number
All shut downs resulting from the analogue values shall be shown in the display and
transmitted via serial interface. The data of the Engine Management System shall be
transmitted through the interface to other control systems or computers. The Engine
Management System standard interfaces to plant control system are:
• Serial interface
• 4-20 mA signals for power demand,
• receipt of start,
• power and stop commands (potential volt free contact)
Electrical Requirements for Gas Engine Generators
It is proposed to operate all the 3 nos. generators in parallel. The supplier of the equipment,
therefore, shall consider following aspects in the power generation and distribution system:
Design of Power Generation and Distribution System
The generators shall be suitable for parallel operation. Problems associated with parallel
operation such as circulating 3rd harmonic current shall be taken care of in design of
generators.
Fault level and Sub-Transient Reactance (Xd”):- The supplier shall carry out short circuit
study with the design value of Xd” and establish and confirm that with 2 nos. generators
operating in parallel, the 415 V system fault level does not exceed 50 kA (r.m.s.).
Nature of loads:- Substantial load will be non-linear type mostly Variable Frequency
Drives(VFDs). The VFDs are known to generate 5th & 7th harmonics prominently and are
likely to affect performance of the generators. The supplier of the generators shall highlight
in his offer the measures taken by him to filter out these harmonics.
Control of the Generation:- Load on the gas generators is likely to vary considerably,
depending upon the factors such as:
• Availability of electrical loads in STP project.
• Availability of facility for evacuation of excess power to existing STP and their load
demand.
• Availability of grid supply.
• Availability of gases required for generation also is not guaranteed and constant.
• Generation by the gensets and power evacuation has to be balanced continuously to
avoid over-speeding/under-speeding of the generators.
Load sharing:- Generator operating in isolation shall operate in “Automatic Frequency

Control “ mode. Generators operating in parallel shall operate in “Automatic Power
Control” mode. The running generators shall share kW and kVAr equally. The controls
shall also provide for automatic & manual control of switching On & Off of the generators
where the generation-load balance requires so, to avoid running of engines & generators
at very low loads/ overloads.
Synchronization – Both “Automatic” and “Manual” synchronization facilities shall be

provided. The governor and AVR shall be hooked up for this purpose. Irrespective of mode
of synchronization, the actual paralleling shall be supervised by a separate check-

synchronizing relay to prevent incorrect paralleling. Necessary PTs shall be provided at

various locations to assist synchronization operation.
Protections – A minimum of following electrical protections shall be provided to the engine-

generator set:
• Phase overcurrent (voltage controlled) and earth fault protection
• Ground (Neutral) overcurrent protection as a standby earth fault protection.
• Overvoltage and Under voltage protection.
• Over frequency (over speeding) and Under frequency protection with df/dt
measurement.
• Anti-motoring/ Loss of prime mover protection by way of Reverse Power protection.
• Loss of Field protection.
• Negative Phase Sequence Overcurrent protection.
• Bearing & winding temperature – Alarm & Trip.
All the above mentioned protections can be with discrete static/ numerical relays or can
be built into engine-generator protection software. In case of discrete relays, one complete
set of protective relays shall be provided as spare. For software based protections,
software and programming devices for the system shall be provided free-of-cost to the
Purchaser.
Room for Engine/ Generator

a) Engine and generator shall be coupled and mounted on steel base frame with inserted
ant-vibration elements. Transmission of the vibration shall be minimal. There shall not
be any anti-vibration concrete blocks and foundation shall be sufficiently strong to take
care of static load.
b) Gas leakage detectors shall provide in the Engine room along with alarm annunciation.
c) Requirement for engine room floor:
d) Dust free concrete or pavement
e) Ventilation of engine room:
f) Engine room should be well ventilated by forced ventilators with minimum three times
per hour air change rate.
g) Minimal air change quantity technically required corresponds to the heat lost from
cogeneration unit and inlet air to be burned by engine.
h) Other safety requirements for air change shall be solved according to locally valid
safety rules and standards to the satisfaction of Engineer.
i) Oil tank shall be located on the cantilever on the wall in the engine room.
j) The electrical switchboard with base frame shall be located in individual room adjacent
to Co-Generation unit.
k) Venting (degassing)
l) Piping above the roof with min. distance 3 m from possible source of the fire
m) Exhaust piping
i) Independent exhaust piping of appropriate sizing leaded over engine room.
ii) Piping shall be made of stainless steel SS 304.
iii) Leaded into chimney – overpressure system required.
n) EOT of suitable capacity shall be provided in the Engine Room to facilitate Installation
and maintenance of the Engine.
o) Installation space
i) Minimal free space from unit base frame on side of the unit 2000 mm (for both
side).
ii) Minimal free space in front of electrical switchboard 1500 mm.
iii) Minimal free space from side where piping connection 1500 mm.

14.21 Digesters Sludge Heating System
For sludge heating, sludge will be withdrawn from digesters and will be pumped through
concentric tube type heat exchangers, where heating will be done by flue gas generated
from biogas engine.
Complete sludge heating system, consisting of heat exchangers, sludge recycling pumps,
motors, switchgears, piping etc. required for efficient heating of the sludge along with
recovery & transferring of heat from the exhaust system of biogas engine shall be provided.
Heat Recovery System
Heat recovery system to utilize waste heat from running engine shall be provided to heat
up 100% of inlet thickened sludge in primary sludge digest at 35 to 39 degree Celsius.
Generated gas shall also supply to heat exhaust exchange and gas boiler unit so called
“waste heat recovery boiler” as backup system to keep sending hot water to sludge heat
exchanger to warm up digestion tank as required in case engine is not service.
Hot water control valves and water temperature meter shall be provided to control hot
water flow in case of not to use heat exhaust heat exchange or heat from gas boiler is
required.
It is absolutely necessary to keep monitoring water flow through Digester heating circuit
when Engine is in operation since there is danger of exhaust Heat Exchanger severe
damage.
The work shall include but not necessarily be limited to the following;
i) Jacket heat exchanger.
ii) Exhaust heat exchange and gas boiler unit.
iii) Cooling water pumps
iv) Cooling towers
v) Heating water pumps
vi) Hot water control valves
vii) Hot/Low water tank
viii) Safety valve – heating water circuit
ix) Safety valve – cooling water circuit
x) Jacket water supply unit
14.22 Digestion Sludge Heat Exchange
Concentrated sludge from thickener to digestion tank shall be warmed up by hot water
supplied from the Heat recovery equipment. At the same time, the sludge in the digestion
tank shall be fed to the heat exchanger by the sludge circulation pumps.
All components of the Heat Exchanger that come in contact with the sludge shall be of
stainless steel (SS304) construction.
i) Hot water-sludge heat exchanger.
ii) Sludge and hot water circulation pumps
iii) Sludge temperature
iv) Safety valve

Drip Traps
• The drip traps shall be leak proof to the required pressure.

• The drip trap shall be of suitable size to fit in gas pipe lines.
• All the flanges should be properly machined and should have finished smooth surface
so that leakage is avoided.
• Double layer of welding is to be done after cleaning the surface.
• Drip traps are to be painted with two coats of epoxy primer and two coats of epoxy
paint from inside. The outer body is to be painted with two coats of synthetic paint.
• After painting, the top flange is to be fitted by suitable nuts & bolts and gasket -after
applying hold-title-compound. The sealed unit shall be again tested for leakages.
• Gasket should be steam gasket of best quality and required thickness.
• Each drip trap shall have two baffle sheets. The holes in the baffle sheets shall be
staggered i.e. the holes in one baffle sheet shall not be in line with the holes in the
other baffle sheet. Baffle sheet shall be made out of mild steel sheet of required
thickness.
• Drip traps shall be provided at a suitable height above ground level to facilitate easy
draining.
Flare System
The flare unit shall be designed for biogas flow generated during average flow conditions.
It shall be fabricated of suitable materials (carbon steel with epoxy coating except for top
portion which shall be in SS316 including the wind shield). The design of flare unit will be
such that it shall be conveniently mounted on the steel supporting structure.
The Modular Flare structure consisting of 10 meters (minimum) Height with MS epoxy
coated structural members, ladder with safeguard, Platform with railing, mounting
arrangement for burner piping, and control panel and riser pipe with necessary isolation
valves and check valve.
The velocity of biogas through the flare unit should be minimal keeping in mind 100-150
mm Water column pressure of biogas at flare inlet. The design of flare unit should allow
maximum possible turndown ratio.
The flare work shall include but not necessarily be limited to the following;
i) Electric ignition(Automatic) and flame control equipment
ii) Gas burners
iii) Flame arrester and trapping.
iv) Water Trap.
v) Gas Flow meter.
vi) Gas compressor
vii) Lightning protection.
A suitable spark ignition system aforesaid should be provided at a convenient location.

Biogas shall be used as a pilot fuel. The pilot flame generated with the help of spark ignition
systems shall propagated through the flare unit to ignite main biogas. The control system
involving control panel, ignition transformer, etc. shall be provided for the said purpose.
Control panel shall have audio-visual alarms for flow monitoring and push button ignition
system.
H.T. cable shall be provided from the secondary terminal of ignition transformer up to spark
ignition system. Necessary ignition electrode shall also be provided.

Adequate number of gas burners (minimum 2 Nos.) shall be provided to burn the biogas
with 100% standby. Fencing shall be provided for gas burner area.
The Gas pipe connecting the Flare to the Gas plant must contain the following devices: an
isolation device operated manually, an emergency shutdown device which interrupts the
biogas feed automatically, a flame trap as a safety device.
Moisture Traps
The moisture trap shall be designed to effectively separate out moisture in the biogas such
that moisture free biogas is made available at the outlet of a trap. It shall be of suitable
materials of construction and be provided with suitable drain connection.
Flame Traps
The flame trap shall be of suitable size for biogas application. It shall be used primarily in
pipe lines to prevent flash back during explosions. This device shall be installed in
horizontal or vertical pipe line and hence it should be bi-directional. It shall be of suitable
materials of construction.
The flame arresting element shall be designed such that it results in minimal pressure loss
under normal operating condition but to ensure maximum security in the event of
explosion, the end connection shall be flanged. It should be designed as per British
Standard 7244:1990
14.23 Digesters Mixing Equipment
14.23.1 Gas Mixing and Scum Breaker Equipment
a) Direct gas insert pipes shall be installed at top of digestion tank Digestion tank to
mixing sludge effectively.
b) The mixing of digester contents shall be done by injecting compressed gas drawn from
the gas holder. The gas flow shall be 0.135 Nm3/m3 Digester/hr.
c) The mixing gas shall be supplied from Gas bell pipe line through gas blowers.
d) Scum breaker and antifoaming water sprinkling shall provide to eliminate forming scum
layer on the surface of sludge digestion tank or scum will be loss digestion system as
well as it may be to creative obstruction of gas pipeline.
i) Gas supply line and valves.
ii) Pressure relief valves with flame arrestor.
iii) Flame arrester and trapping assembly.
iv) Gas filter.
v) Water trap.
vi) Gas flow meter
vii) Pressure meter.
viii) Pressure switch for gas – low/high pressure indication
ix) Mist separators
x) Gas compressors.
xi) Water sprinkler
xii) Scum breaker
The mixing systems shall be designed to explosion-proof, no high vibrations which cause
structural damage and should give efficient mixing of the sludge contents. In case of

stoppage/breakdown of the sludge system, the mixing process should be able work
against stagnant sludge inside the tank and to start instantly.
14.23.2 Mechanical Mixer
a) Digester mechanical mixer shall be vertical screw mixer with draft tube type or dry pit
horizontal inline screw mixer with draft tube and mixing pipes.
b) Screw mixer shall consist of screw with shaft, speed reducer, and motor, and shall be
normal and reverse rotation.
c) Mixing number of times in digester shall be not less than ten times per day.
d) The mixer shall have a self-cleaning screw optimised for effective mixing and vibration-
free running.
e) The mixer shall be driven by a high effective 3 phase explosion protection motor. Motor
shaft and rotor shall be dynamically balanced
f) The vertical type mixer shall be provided the suitable mounting and sealing device for
floor mounting.
g) All wetted materials shall be constructed from stainless steel SS304 grade.
h) The mixing systems should be designed to explosion-proof, no high vibrations which
cause structural damage and should give efficient mixing of the sludge contents. In
case of stoppage/breakdown of the sludge system, the mixing process should be able
work against stagnant sludge inside the tank and to start instantly.
14.23.3 Electrical Equipment
The work shall include but not necessarily be limited to the following
i) Control and power part (control system)
ii) Circuit breaker
iii) Power switches and measuring units
iv) Modular control system
v) Power part (circuit breaker, power switches)
14.24 Hot Water Boiler for Digesters heating system
14.24.1 Codes and Standards
The design, materials, construction, manufacture, inspection, testing and performance of

boilers and accessories shall comply with all currently applicable statutes, regulations and
safety codes in the locality where the equipment is to be installed. The equipment shall
also conform to the latest applicable Indian or equivalent standards. Other international
standards are also acceptable, if these are established to be equal, or superior to the listed
standards. Nothing in this specification shall be construed to relieve the Contractor of this
responsibility. The materials, design, construction and testing of the boilers and
accessories shall be in conformity with the applicable sections of the latest edition of the
Indian Boiler Regulations (if applicable) and all amendments thereof. It shall be the
Contractor’s responsibility to satisfy the Indian Boiler Authorities that all the stipulations of
these regulations have been met, before fabrication of the boilers and accessories is
started.
14.24.2 Construction Features
The hot water boiler shall be fire tube vacuum evaporate type

Boiler Supporting Base
The complete boiler including all auxiliaries and accessories shall be shop assembled and
shall be supported on a welded steel structural base, which shall form a part of the unit
and require only a flat reinforced concrete slab foundation. Suitable lifting lugs shall be
provided on the unit to facilitate handling. Foundation bolts for fixing the steel structural
base on to the foundations shall also be supplied.
Platforms and Ladders
The boiler shall be provided with suitable platforms and ladders for gaining access to boiler
top for operation and maintenance of valves, for reaching instruments and manholes etc.
Platforms and ladders shall be provided with suitable hand railings.
Piping, Valves, Specialities and Instruments
All necessary piping, valves, specialties and instruments shall be in line with enclosed
Piping and Instrumentation (P&I) diagram, piping material specifications and as required
for safe, reliable and satisfactory operation and proper maintenance of the boiler. Layout
of integral piping boilers shall ensure that all valves, instruments and specialties are
located at maximum 1.5 M height as to be conveniently accessible for operation and
maintenance.
14.24.3 Boiler Controls-Oil/Gas Firing
Combustion Control
The combustion system shall be fully automatic, either modulating type or HIGH/LOW/OFF
firing type, with a minimum turndown ratio of 4:1. In either type of control, the boiler shall
be ON/OFF control, below 25% of the boiler load. The fuel input to the furnace shall be
regulated from boiler hot water outlet temperature using temperature controller or
temperature switches and Forced Draft (FD) fan discharge damper or burner register
damper which shall also be simultaneously regulated directly from fuel oil/gas control valve
position so as to maintain correct air fuel ratio. Provision shall be made for locking the
control at base load. A bypass selector switch shall be provided for manual control in
emergency. The combustion control system shall be furnished complete with all actuating
and operating devices, necessary control and bypass switches, relays, timers, solenoids
and other control hardware.
Boiler Feed Water Control
Feed water supply to the boiler shell shall be automatically controlled to maintain flow at
all loads.
Expansion Vessel
For closed circuit hot water system or where the system is pressurized, an expansion
vessel shall be provided which shall act as system surge suppresser and main venting
point of the system. The expansion vessel shall be installed at the highest point in the
system and connected to the suction side of the pumps. The vessel shall be fitted with a
sight glass to cover the full operating range and level switches for alarm and interlock for
high and low levels. If the system requires to be kept pressurized from NPSH consideration
of boiler feed water pumps, nitrogen under pressure shall be supplied to the expansion
vessel through control valves to maintain the desired pressure. Safety relief valves shall

be provided on the expansion vessel to prevent against nitrogen pressure increase above
the maximum operating pressure, due to any malfunctioning of the system.
A mixing tank shall be provided as per process requirement.
Boiler Safety System
To protect the boiler from possible damage due to unsafe boiler operating conditions, the
fuel feed to the burner shall be instantly cut-off on occurrence of such unsafe operating
conditions. The following conditions are considered unsafe for boiler operation:
i) Burner flame failure
ii) Fuel oil/gas pressure low
iii) Fuel oil/gas temperature low
iv) Feed water supply failure
v) Hot water temperature high
vi) Failure of FD fan/motor
vii) Water level low in expansion vessel
For proving the burner flame, burner windbox shall be provided with a suitably located,
reliable and fool-proof flame sensor of photo-resistance type.
The boiler safety system shall be complete with all sensing devices such as flame sensor,
pressure switches, temperature switches, level switches, all relays, timers, auxiliary
switches and other hardware etc.
An alarm shall also be provided to alert the operator on occurrence of burner lockout. Also,
indicating lamps to indicate each of the above causes of burner lockout shall be provided
on the boiler control panel. A push button on boiler control panel for manually shutting off
the boiler in emergency shall also be provided.
For gas firing, dual automatic safety shut-off valves in main burner gas line with vent valve
on the line between the shut-off valves shall be provided. The discharge of vent valve shall
be piped to an area outdoors to a height above building roof where the gas may be safely
dispersed.
Also Gas leak detectors (2 no.s per Boiler) shall be provided as a part of built-in safety
feature for the Hot water Boilers.
Programming Control
A programming control system shall be provided for safe and automatic starting, stopping
and emergency shut-down of the boiler. The programming control system shall on start-
up, initiate FD fan, purge the furnace and gas passes for a set period prior to the initiation
of burner lighting up, initiate lighting up only if all the pre-conditions such as fuel oil
pressure “normal” and fuel oil temperature “normal” are satisfied, initiate lighting up of the
pilot torch if adequate gas pressure exists, automatically light up the pilot torch and then
light-up the main burner. The system shall automatically shut down the boiler on the
occurrence of unsafe operating conditions as described above. The system provided shall
be complete with necessary hardware.
Boiler Control Panel
The control gear and starting gear for all auxiliaries shall be furnished by the Contractor
and shall be centrally located on a control panel on the steel structural base. In addition,
indicating lamps for indicating availability of supply, voltage, indicating operating conditions

of each auxiliaries, indicating burner lockout causes shall also be provided on the boiler
control panel. The panel shall be factory piped and wired and completely enclosed with
access door for maintenance. Motor starters shall be direct-on-line type.
Painting
Two coats of primer shall be applied to all steel and iron surfaces. In addition finish paint
shall be applied to exposed surfaces, as required, to prevent corrosion.
14.24.4 Room for Boiler
a) Boiler shall be coupled and mounted on steel base frame.

b) Gas leakage detectors shall provide in the Boiler room along with alarm annunciation.
c) Requirement for Boiler room floor:
d) Dust free concrete or pavement
e) Ventilation of Boiler room:
f) Boiler room should be well ventilated by forced ventilators with minimum three time per
hour air change rate.
g) Minimal air change quantity technically required corresponds to the heat lost from
cogeneration unit and inlet air to be burned by boiler.
h) Other safety requirements for air change shall be solved according to locally valid
safety rules and standards to the satisfaction of Engineer.
i) Oil tank shall be located on the cantilever on the wall in the boiler room.
j) The electrical switchboard with base frame shall be located in adjacent to boiler.
k) Venting (degassing) Piping above the roof with min. distance 3 m from possible source
of fire or the exhaust piping
i) Independent exhaust piping of appropriate sizing leaded over boiler room.
ii) Piping shall be made of stainless steel SS 304.
iii) Leaded into chimney – overpressure system required.
l) Installation space
i) Minimal free space from unit base frame on side of the unit 2000 mm (for both
side).
ii) Minimal free space in front of electrical switchboard 1500 mm.
iii) Minimal free space from side where piping connection 1500 mm.
14.25 Flare
The flare unit shall be designed for biogas flow generated during average flow conditions.
It shall be fabricated of suitable materials (carbon steel with epoxy coating except for top
portion which shall be in SS316 including the wind shield). The design of flare unit will be
such that it shall be conveniently mounted on the steel supporting structure.
The Modular Flare structure consisting of 10 meters (minimum) Height with MS epoxy
coated structural members, ladder with safeguard, Platform with railing, mounting
arrangement for burner piping, and control panel and riser pipe with necessary isolation
valves and check valve.
a) The velocity of biogas through the flare unit should be minimal keeping in mind 100-
150 mm water column pressure of biogas at flare inlet. The design of flare unit should
allow maximum possible turndown ratio.
b) The flare work shall include but not necessarily be limited to the following;
i) Electric ignition(Automatic) and flame control equipment
ii) Gas burners
iii) Flame arrester and trapping.
iv) Water Trap.
v) Gas Flow meter.

vi) Gas compressor

vii) Lightning protection.
c) A suitable spark ignition system aforesaid should be provided at a convenient location.
d) Biogas/ LPG shall be used as a pilot fuel.
e) The pilot flame generated with the help of spark Ignition systems shall propagated
through the flare unit to ignite main biogas.
f) The control System involving control panel, ignition transformer, etc. shall be provided
for the said purpose. Control panel shall have audio-visual alarms for flow monitoring
and push button ignition system.
g) H.T. cable shall be provided from the secondary terminal of ignition transformer up to
the spark ignition system. Necessary ignition electrode shall also be provided.
h) Adequate number of gas burners (minimum 2 Nos.) shall be provided to burn the
biogas with 100% standby.
i) Fencing shall be provided for the gas burner area.
j) The Gas pipe connecting the Flare to the Gas plant must contain the following devices:
an isolation device operated manually, an emergency shutdown device which
interrupts the biogas feed automatically, a flame trap as a safety device.
14.26 Ventilation and Odour Control
General
Due to the nature and combination of processes and activities likely to be employed at the
waste water treatment works it is important not to treat odour control and ventilation.
Ventilation
Mechanical Ventilation system to be provided all pumps house, chemical handling

building, Centrifuge building, Air blower room MCC room, Bio gas engine Building Diesel
generator room,
Mobile ventilation system to be provided to access wet well of sewage pumping station.
Effective and suitable provision must be made to ensure that every enclosed workplace is
ventilated by a sufficient of fresh or purified air.
Due to the variety of operational workspaces on the works, it is likely that no single solution
will be possible and the Contractor shall be responsible for selecting the most suitable
methods.
The function of the building or enclosure shall determine the level of comfort which is
required. Comfort depends on the inter-relationship of the following factors: -
• Air temperature
• Relative humidity
• Mean radiant temperature of the enclosing space
• Ventilation rates
The Contractor shall determine the air temperature and relative humidity for each enclosed
space. Generally, humidity will depend on the operational requirements of the equipment
and activities undertaken within the enclosed space. Where close control is required de-
humidifiers may be required.
The mean radiant temperature of the enclosed space will be determined by the selection
of material and form of construction of the enclosure.

Ventilation rates shall be determined by the following factors: -

• Occupancy levels
• Requirement to control the temperature or remove excessive heat
• Requirement to avoid contamination with foul air migrating from other area
• Requirement to pressurise a particular workspace (Positively or negatively)
• Opening in the enclosing space and frequency of operation
• Infiltration
Ventilation can be by natural draught or forced ventilation provided by mechanical means.

Where mechanical ventilation is employed, standby system shall be used with audible and
/or visible warnings when abnormal conditions exist.
Prior to discharge to the atmosphere, the exhaust stack shall be designed to ensure that
noise shall be below 65dBA at 1 meter from the unit.
Fans and Ductwork
General :
Fans shall be sized to provide the required air volume at the point of use. The contractor
shall be responsible for determining the fan performance requirements. Prior to delivery to
site, fans shall be tested in accordance with BS 848 (Part 1& 3)
Belt driven fans shall be capable fitted with V-belt drives complying with BS3790 of
transmitting the rated motor output with provision for adjustment of belt tension
Guards shall be provided for all unprotected inlets and outlets to fans and fan drives.
Guards shall be galvanised steel wire mesh with apertures not greater than 12 mm
attached to a rigid galvanised frame. Belt guards shall be galvanised steel sheet and
designed for easy removal for belt replacement. Access holes shall be provided to allow
tachometer readings to be taken from the fan and motor shaft and for belt tension to be
checked.
Where protection coating are specified for use with corrosive gases, the coating shall
cover all contact surfaces of the fan, motor and shaft.
Flame proof enclosures shall comply with the requirements of BS EN60079
Centrifugal Fans
Small centrifugal circulating fans shall comply with the requirements of BS 5060. Fans
larger than 7.5Kw output shall be the backward bladed type having a total fan efficiency of
not less than 78%
Fan casings shall be constructed from steel sheet with angle stiffeners to ensure freedom
from drumming and to withstand the maximum differential pressure of the system. Casings
shall allow fan impellers to be withdrawn, their outlets shall be flanged and a drain plug
shall be fitted at their lowest point.
Impeller shall be fabricated mild steel or Aluminium with robust hubs and shall be capable
of running at 10% above normal operating speed.
Shaft bearing of single inlet fans shall be mounted on a common pedestal. Bearings shall
be the ball or roller type. Pedestal bearing shall be insulated from the fan casing.

Axial and Propeller Fans
Axial flow fans shall be single stage or multistage with each impeller mounted on an
independent motor to suit the duty requirements.
Propeller fans may ring mounted, diaphragm mounted or mounted in casing.
Casing shall be rigidly constructed from mild steel stiffened and braced to obviate
drumming and vibration. Mounting feet shall be provided for bolting to the base or supports.
Inlet and outlet ducts shall terminate in flanged rings for easy removal. An inspection door
shall be provided.
The length of the duct casing shall be greater than the length of fan and motor(s) to
facilitate removal from ductwork. Electrical connection to the motors shall be through an
external terminal box secured to the casing.
Impeller shall be steel or aluminium with the hub keyed to the drive shaft and the assembly
statically balanced. Blades shall be of aerofoil section. Shafts shall be carried in ball or
roller bearings. Lubrication points shall be extended to the outside of the casing.
Ductwork
The design, manufacture and erection of ductwork shall be in accordance with following
building and Engineering services Association (formerly the Heating and ventilation
Contractor’s Association) codes of Practice.:
• DW/142 Galvanised and Stainless sheet steel ductwork (Low pressure class A)
• DW/154 Un-plasticised polyvinylchloride and polypropylene ductwork
• DW/191 Resin-bonded Glass fibre ductwork
The contractor shall base their design on theses codes as a minimum requirement
a) The mean air velocity in any section of ductwork shall not exceed 10m/s and maximum
static pressure (Positive or negative 0 shall not exceed 500N/m2)
b) Where flexible ductwork is required the internal diameter of the flexible duct shall be
equal to the external diameter of the adjoining ducts. Flexible ducts shall consist of a
liner and cover of tough tear resistant fabric. It shall be reinforced with a bonded
galvanised spring steel wire helix between the liner and cover.
c) An outer helix of glass fibre cord shall ensure regular convolutions. Non-metallic
materials shall comply with BS 476 for fire resistance.
Odour Control
If active odour control is specified for the plant, or if otherwise determined to be required
for operational or environmental reasons, the odour control plant shall be in accordance.
Notwithstanding the above, the plant layout and design will take into account the possibility
of odour production and shall be arranged to minimize nuisance as a consequence.
Waste water treatment works are perceived by the public to be a source of odours.
However, odour are not considered to be a health risk but are considered to be a nuisance.
To ensure that unpleasant odour can be controlled in the most efficient and cost effective
manner, the design and layout of the sewage treatment works should take account of all
opportunities to minimize the problem at an early stage of the design. The methodology
which should be adopted when designing the waste water treatment works is to:-
• Consider systems which minimise the production of unpleasant odours

• Maximise the distance between the vented sources of any unpleasant odours and the
site boundary.
• Restrict the release of unpleasant odour to atmosphere by contaminant and, if
specified appropriate treatment.
All odour measurements shall be made by using dynamic olfactometry.
The factors to be determined when designing an odour control system will include:-
• The odour threshold (dilutions) at the inlet
• The total flow rate
• The total mass of the contaminants
• The odour threshold (dilution) at the outlet
Several factors which can have an effect on odour production include

• Nature of Sewage
• Increase retention time of the sewage
• Increased saline content
• Increased septicity
• Increased ambient temperature
A well-designed odour control system shall be capable of accepting a large variation in the
contaminant loads and still maintain the designed odour threshold at the outlet.
Odour control systems shall be based on the following technology: -

• Chemical oxidation
• Biological oxidation
• Adsorption onto solids
Odour masking, incineration, ozone and ultraviolet scrubber systems hall not be
considered.
It should be noted that due to the possible changes in the characteristics of the sewage
with time, any system which is supplied must be flexible enough to allow expansion without
total re-design of the odour control system, including the collection systems.
Where combined technologies are proposed to remove the odour in two or more stages,
the first stage would be expected to remove the majority of the contaminants by oxidation
methods and the second stage would polish the remaining low level of contaminants by
adsorption onto solids.
Any odour control system shall be available for use at all times and therefore should be
designed in a duty/standby mode. An allowance shall be made for 10% standby capacity
in the extraction fan sets, recirculation pump sets and adsorption onto solids chambers. In
the event of duty pumps or fans failure, the standby set shall start automatically.
Each flow stream shall be fitted with variable control dampers, non-return valves and
isolation valves. Components which may be exposed to corrosive environments shall be
manufactured from austenitic stainless steel.
The inlet ducts shall be fitted with mesh screen and disposable dust filters.
To ensure sufficient mechanical strength the ductwork shall be coated with GRP (300g/2).
The system should be designed to avoid static electrical charges being built up;

Where polishing filters are proposed, a de-humidifier controlled by a relative humidistat

shall be required to ensure that the relative humidity of the air stream is limited to 70-80%
before delivery to the polishing filter.
The use of final effluent as a recirculating fluid in the bio-scrubbers shall not be permitted.
The distribution nozzles shall be enclosed and dispersal of aerosols into the atmosphere
shall be minimized
The system shall be fully automated and monitored by continuous gas monitoring
equipment to control the airflow and establish efficiency.
The treated air shall be exhausted through a purposes-built exhaust stack. The factors to
be considered when designing an exhaust stack will include.
• Capacity
• Material
• Noise and vibration
• Shape
• Visible impact of stack and plume
• Temperature
• Access for maintenance
• Sampling
• Lightning protection
The noise shall be below 65dBA at 1.0 meter from the unit.
Apart from nuisance at the boundary, high concentrations of odours gases may give rise
to problems within the workplace and may need control. The Occupational Exposure Limit
(OEL) of H2S is 10ppm. This is the level at which it is deemed not to be harmful to operators
exposed for 8 hours a day,40 hours a week, over a 40 year working life.
14.27 Chemical Waste Tanks and Special Drainage System
A HAZOP study shall be carried out on the chemical dosing system including the drainage
to identify the risk of chemical interaction and the need for nay or multiple chemical waste
tanks and special drainage systems.
Where required, a chemical waste tank shall be constructed with minimum capacity of
110% of the maximum single delivery volume. The chemical waste tank shall accept
drainage from:
i) Drainage from the chemical reception area during chemical delivery
ii) Any other contaminated liquid stream identified as applicable under the HAZOP study.
Where required, a valued drain shall be provided to discharge residual chemical from the
delivery pipe to a container appropriate for the most likely chemical and discharge
volumes. Where rain or other surface water cannot be prevented from entering this drain,
then a key interlocked changeover system shall be provided, interlocking to the tanker
connection, which shall allow the drain to be sent to the chemical tank during offloading
and to the surface water drainage at all the fill point control panel may be considered.
The level of the content of the chemical waste tank shall be displayed locally and at the
control center. A high level alarm shall be enunciated both locally and at the control center.

Safety
The contractor shall provide two sets of all the necessary specialist protective clothing and
equipment required for use with the chemical to be used in the works.
Where leakage of hazardous liquid presents a risk to personnel, due consideration shall
be given to secondary protective measure such as screening and pipework containment.
Where pipe runs are contained, then these shall drain to catch pots fitted with alarm
The requirement for frost protection and water heating shall be considered in HAZOP
studies and must be provided where environmental factors and first and treatment requires
warm water.
Emergency showers and eyebaths shall be provided at locations directed by plant layout
and risk assessments. They shall be accessible from the chemical reception areas,
chemical storage areas and any other area where there is a risk identified. Where identified
during the HAZOP study, operation of an emergency shower or eyebath shall raise an
alarm via telemetry.
Safety Shower and Eyewash
Safety showers shall be hand and treadle operated and shall continue until the valve is
manually closed The Water shall be heated by trace tape or an immersion heater to
between 25 Deg. C and 35 Deg. C
Under normal ambient conditions. The shower shall supply 90 to 140 l/min through a 60
Deg. C spray angle at a minimum supply pressure of 2.2 bar. A header tank shall be
provided where insufficient supply pressure is available.
Shower pipe work shall be gal vanished carbon steel insulated with polyurethane.
Eyebaths shall be mounted adjacent to or the rear of the standpipe with IS 10592, Din
12899 part 3, ANSI Z 358.1, DIN 12899 part 3.
Alight shall be mounted on the shower controlled by a timer or light intensity switch to
illuminate the shower when dark. Signs and operating instruction shall be prominently
displayed in the vicinity of the shower.
14.28 Emergency Equipment (General)
Fire Extinguishers
The Bidder shall also provide required no. of dry powder type CO 2 fire extinguishers (10
kg) with ISI mark of Approved make and Buckets filled with dry clean sand for the pumping
station and switchyards at the following locations after consultation with the Engineer in
Charge:
• Outdoor switchyard
• Indoor electrical room
• Pump house (maintenance bay)
• Centrifuge building
• Chemical handling area (chemical house)
• Control room
• GAS handling area

Besides above, Ionization smoke, optical smoke & heat detectors shall be provided in
control room with fire alarm panel having appropriate battery back-up. Fire alarm detectors
shall be provided both below & above false ceiling, if any Fire alarm system and public-
address system shall be provided at the Plant.
All the smoke and heat sensors shall be wired up to nearest JB and interfaced to respective
PLC/DDC for alarm annunciations.
All buildings shall be provided with manual fire alarm system connected with main control
panel. The alarm system shall be with pillboxes and hooters. The layout of the fire alarm
system shall be in accordance with the relevant ISI.
Fire Protection Water System
The contractor shall design and construct suitable firefighting system along with pump
sets, fire hydrant shall be provided in the firefighting pump house. The system shall be
complete with motor and diesel driven fire pump including Jockey pumps and other
accessories for meeting the firefighting requirement of buildings located in the plant area.
Final treated effluent shall be the source of water supply for firefighting purposes which
shall be conveyed to the firefighting pump house in which all pumping machinery shall be
installed. Delivery head for the pump should be sufficient to supply the water to all
structures and to meet the firefighting requirement. Fire hydrant shall be provided near all
the units of buildings/ pump houses/ panel rooms conforming to the directions of Engineer.
All firefighting network shall be of pressurized HDPE pipes class PN-12 and material
classification PE-100 conforming to IS:4984., a fire fighting water store of adequate
capacity using treated wastewater as water for firefighting.
The pump house shall be suitable for installation of pumps. The sump shall be constructed
in RCC M30 as liquid retaining structure.
This shall be RCC framed structure with outer brick walls of 230 mm thick over the sump.
The minimum plan area shall be 120 sqm. Height of the roof / ceiling up to the soffit of the
beam shall be minimum 4500 mm. This structure shall house panels and other electrical /
mechanical fittings.
Pumps:
Pumps shall be exclusive for firefighting purpose and be of the following type:
• Electric motor driven centrifugal pumps
• Compression ignition engine driven centrifugal pumps.
Pumps shall be direct-coupled.
The diameter of the suction pipe/header shall be based upon a velocity of flow not
exceeding 2 m/s. The pumping arrangement shall incorporate jockey pumps to ensure the
system remains under the correct pressure. The capacity of the jockey pumps shall be not
more than 5% or less than 3% of the installed pumping capacity, subjected to a minimum
capacity of 3 l/s.
Where pumps operate automatically, they shall be connected to an audible alarm located
prominently outside the pump house.

Each pump shall be provided with a non-return valve and isolation valve on the delivery
side. A pressure gauge shall be provided between the pump and non-return valve. The
size of the non-return valve and cut off valve shall be not less than the size of the initial
delivery pipe and not less than the delivery outlet of the pump. Butterfly valves shall not
be used.
Mains:
The pipework shall be constructed from buried ductile iron or polyethylene. Pipes shall be
run at least 2 m away from the face of the buildings and open storage areas. Mains shall
not be laid under open storage areas.
The system shall be capable of withstanding a pressure equivalent to 150% of the

maximum working pressure.
The fire main shall not have any dead ends and its shall be not less than the internal
diameter of the delivery outlet of the pump.
Hydrants:
The maximum distance between hydrants shall be 80. The minimum diameter of the main
shall be 75mm. Before final inspection, the hydrant system shall be flushed thoroughly.
Except where impracticable, all hydrant outlets shall be situated 1m. above ground level.
The stand posts shall be 80mm diameter for single headed hydrant, 100mm for double-
headed hydrants and monitors of 63mm or 75mm size and 150mm for monitor of 100mm
size. Stand posts shall be painted fire red (IS:5, shade no.536) and numbered for easy
identification.
Hydrants shall be oblique type confirming to IS:5290 Type A with outlets angled towards
ground. The hydrant coupling shall be gunmetal or stainless steel of the instantaneous
spring-lock (Female) type, 63 mm diameter and the valve shall be of the screw down type.
Hydrant shall be easily accessible. Where hydrants are situated in remote locations, they
shall be approachable by means of paved pathways.
Hydrant located in situations where they are likely to be damaged by vehicular traffic shall
be suitably protected on all sides against possible damage.
Hydrants shall be located according to the attendant fire hazards at the different locations
to be protected to give the most effective service. Hydrant shall be distributed to provide
protection for all sides of the buildings and need not necessarily be equally spaced.
Hydrants shall be positioned not less than 2 m from buildings or edge of any storage plot
to be protected, except in the case of high hazard occupancies wherein the hydrant heads
shall be located not less than 7.5m from the face of the building, edge of the storage plot
or from the plant battery limits.
In case where, owing to the size or layout of the building, or the building being divided by
internal walls, any point within the building is at a distance of more than 45m form an
external fire hydrant, an internal hydrant system shall be provided so that no portion of the
floor is more than 45 m from an external hydrant or from 30 m from an internal hydrant.

A hydrant shall be provided on every floor landing which shall not be less than 1.5m x 1
m. The mains feeding the landing hydrant shall be provided with a cut-off valve at ground
level.
Alternate hydrants for the protection of loading bays shall be replaced by water/foam
monitors.
Fire hose:
In case of yard hydrants, hose pipes and nozzles shall be installed near each hydrant in
glass fronted hose boxes of an approved design.
In the case of hydrants on upper floors or internal hydrants, hosepipes and nozzles shall
necessarily be installed near each hydrant in glass fronted hose boxes of an approved
design.
If hoses are kept in hose boxes alongside hydrants, each box shall contain two lengths of
the 15m each. All hoses shall be of 63 mm diameter of one of the following types.
• Unlined flax canvas comply with Indian Standard IS:4927
• Rubber lined woven-jacketed complying with Type A of Indian standard IS:636.
• Controlled Percolation type complying with Indian standards IS:8423.
All couplings shall be of the instantaneous spring-lock type and the nozzles shall be of not
less than 16 mm in diameter, nor more than 25 mm in diameter except in the case of high
hazards occupancies where the maximum nozzle diameter may be 31 mm, subject to
approval. All couplings, branch pipes and nozzles be of gun metals or stainless steel and
shall comply with IS:903.
Spares hoses to the extent of 10 percent of the above requirement, with minimum quantity
of 30 m shall be provide. Such spare hose shall be in 15 m lengths and complete with
couplings.
Nozzles
The number of nozzles to be provided shall be equivalent to half the number of hose pipes
installed on the premises.
In location where a jet of water directed from a normal type nozzle is likely to cause excess
damage or where a gentle spray of water is essential for the extinguishing of a fire, a fog
or spray type of nozzle complying with IS:2871 shall be used.
Spares nozzles to the extent of 10% of the above requirements, with a minimum of two,
shall be provided.
Marking
Each appliance incorporating and air gap shall be clearly and permanently marked (Air
gaps are non-mechanical backflow preventers to be used where either back siphon age
or backpressure conditions may exist.)
Marking shall indicate:

• Manufacturer’s brand or logo
• Air gap type
• Nominal diameter

• Reference to the relevant standard

• Model or type reference
• Serial number
14.29 Standard Specification
This section covers standard equipment and accessories used in the supply and
installation of mechanical equipment, as well as standard working practices and
procedures concerned with manufacture and fabrication which will assure the minimum
standards of workmanship and comprehensive installation of specialist equipment are
achieved in the delivery of this Mechanical Specification.
14.29.1 Welding and Flame Cutting
A high standard of finish, defined as "Waterworks finish" is required for all work carried-
out on Plant.
A smooth neat finish, by careful grinding if necessary is required on all exterior welding
and flame cutting. All plates and bars used in fabrication shall have smooth surfaces with
no pitting or deep slag inclusions.
14.29.1.1 General Welding Requirements
Inspection and quality of surveillance shall not be limited to the examination of finished
welds. All aspects of materials, fabrication procedures and examination procedures shall
be subject to the approval of the Engineer-in-Charge. The equipment used shall be
suitable for the quality of work specified. The techniques employed shall be based on
methods which are known to produce good results and which have been verified at Site
by actual demonstration.
Haphazard striking of the electrodes for establishing arc shall not be permitted. The arc
shall be struck either on the joint or on a starting tag. The starting tag shall be of the same
material or a material compatible with the base metal being welded. In case of any
inadvertent strike on place other than the welding, the area affected shall be ground
flushed and examined by liquid penetration method.
Generally, a stringer bead technique shall be used with a slight oscillation if necessary to
avoid slag and to minimize the number of beads needed to fill the joint. However, the width
of the deposited pass shall not exceed 3 times the wire diameter. Vertical welds shall be
made in upward direction. For all pipes above 300 mm dia., welding shall be done
whenever possible, by 2 welders working simultaneously along both sides of the pipe.
All joint fit ups shall comply with the tolerances specified on the manufacturing drawings.
The root pass shall have less than 1.5-mm internal reinforcement. Defects like icicles, burn
through and excessive “suck back” etc. shall be cause for rejection of welds.
Final welds shall be suitable for appropriate fabrication of the non-destructive examination
of the weld. If grinding is necessary, the weld shall be blended into the parent metal without
gouging or thinning of the parent metal in any way. Uneven and excessive grinding may
be a cause for rejection. Fillet weld shall preferably be convex and free from undercutting
and overlap at the toe of weld. Convexity and concavity shall not exceed 1.5 mm.
The leg lengths shall not exceed the specified size by more than 1.5 mm.

Qualified welders in accordance with the design details and materials specifications shall
also do all attachments such as lugs, brackets and other non-pressure parts. Temporary
attachments shall be removed in a manner that will not damage the parent metal. Areas
of temporary attachment shall be dressed smooth and examined by ultrasonic or liquid
penetration methods.
All tack welds shall be made using qualified procedure and welders, the number of size of
tack welds shall be kept as small as to consist of adequate strength and joint alignments.
All tack welds shall be examined visually for defects and if found defective shall be
completely removed. As welding proceeds, tack welds shall be either removal completely
or shall be properly prepared by grinding or filling their starting ends so that they may be
satisfactorily incorporated in the welds. Grinding machine or chipping or gouging shall
remove unacceptable defects. Flame gouging may be permitted provided gouged surface
is ground at least by 1.0 mm below the deepest indentation.
All weld repairs shall be carried out using the approved welding procedures and welders.
Preparation of weld repair shall have the prior approval of the Engineer-in-Charge. Re-
welded areas shall be re-examined by the methods specified for the original welds and
repair procedures shall be duly qualified by the Engineer-in-Charge.
14.29.1.2 Design Approval of Welding
Welding shall comply with the latest revision of the BS 5135 code. In all welded
fabrications, the Contractor shall submit to the Engineer-in-Charge before fabrication
commences detailed drawings of fabrication with sizes of weld and weld preparation
together with the details of the application codes. The Engineer-in-Charge shall carry out
no welding before approval of the details. No alternations shall be made to any previously
approved details of weld preparation or size without prior approval of the Engineer-in-
Charge.
14.29.1.3 Qualification of Welders and Procedures
Welders shall be qualified in accordance with the requirement of the appropriate section
of BS 4871 part 1. The Engineer shall have the right to call for further qualification from
time to time from any welder who in the opinion of the Engineer does not produce weld in
accordance with the qualification. Each welder shall be assigned a number and letter.
Each weld shall clearly be identified as to its welder marking the welder’s code adjacent
to the welds. A record chart shall be maintained for each welder showing the procedures
for which he has qualified, the date of such qualification, the type of defects produced and
their frequency. The Engineer-in-Charge shall disqualify the welder whose work requires
a disproportionate amount of repairs. All procedures where required shall be qualified as
per BS 4870 Part 1.
14.29.1.4 Pre-heating and post-heat treatment
Pre-heating and post heating treatment shall conform to the relevant application codes.
Pre-heating not exceeding 121-Degree Celsius for all carbon steel construction above 25-
mm thickness would be mandatory. Such pre-heating would be maintained during flame
cutting, flame or arc gouging, welding and repairs and may be done by gas heating by gas
torches/gas rings with neutral flame. The temperature shall be checked by temperature
indicating crayons. However, such pre-heating will not be necessary for welds less than 6-
mm size. In large diameter pipe fabricated out of plate materials, production control test
plates in accordance with the BS 4870 Part I Table 6 to represent 30% of the long seams
and each welder’s performance would be mandatory.

14.29.1.5 Electrodes
The makes and type of electrodes to be used shall be submitted for approval of the
Engineer. All electrodes shall be stored in their original sealed containers under dry
conditions. Electrodes shall remain identified until consumed. All electrodes shall be dried
before use. Drying ovens shall be provided in work areas for drying purposes. Electrodes
withdrawn from oven shall be promptly used and excess unused electrodes shall be
promptly returned to oven.
14.29.1.6 Examination/NDT/Radiography
The various stages of examination and types shall be a stipulated in the respective
fabrication codes. Radiographic examination shall be carried out as per provision of BS
2600 or BS 2910: Ultrasonic tests where called for shall be carried out as per provision of
BS 3923; magnetic particle tests shall be carried out as per BS 6072. Liquid penetration
tests shall be carried out as per BS 6443.
14.29.1.7 Stainless steel welding
All wires consumable such as electrodes, fillers wires, argon gas for shielding and purging
shall be of high quality and the proposed brand shall be furnished for approval of the
Engineer. Weld deposits shall have similar or higher physical properties and similar
chemical composition to the members joined.
All electrodes shall be purchased in sealed containers only and stored in their packing
intact. The packets opened shall be consumed as early as possible. The electrodes
removed from the containers shall be kept in holding ovens at temperature recommended
by electrodes manufacturer. Special care shall be taken in avoiding mixing of electrodes
in the oven.
The electrodes and filling wires shall be free from rust, oil, grease, earth and other foreign
matter.
Argon gas with purity 99.5% shall be used for shielding and purging. The gas
manufacturers shall certify the purity of gas.
Non-destructive examination of these welds shall be carried out to ensure quality of weld.
The electric current for welding shall be direct current, straight polarity (electrode
negative). The welding current shall be kept minimum possible to ensure minimum heat
affected zone in the parent material. Other side of the weld joint shall be periodically
flushed with argon gas.
14.29.2 Castings
Casting surfaces shall be smooth and free from surface blowholes. Stock castings shall
be specially selected with this in mind. All castings shall be shot blasted before machining.
Cast iron shall be of standard grey close - grained quality. The structure of the castings
shall be homogenous and free from non-metallic inclusions and other injurious defects. All
surfaces of castings, which are not machined, shall be smooth and shall be carefully fettled
to remove all foundry irregularities.
Minor defects in depth not exceeding 12.5 percent of total metal thickness and which will
not ultimately affect the strength and serviceability of the casting may be repaired by

approved welding techniques. The Engineer-in-Charge shall be notified of large defects

and no repair welding of such defects shall be carried out without prior approval of the
Engineer-in-Charge. If the removal of metal for repair should reduce the stress resisting
across section of the casting by more than 25 percent, or to such an extent that the
computed stress in the remaining metal exceeds the allowable stress by more than 25
percent, then that casting shall be rejected. Test coupons cast simultaneously with the
main casting shall be identified by the Engineer-in-Charge to check physical, chemical
analysis of casting.
Major defects on casting are not acceptable. Castings repaired by welding for minor
defects shall be stress-relieved after such welding. Castings subject to hydraulic pressure
shall be pressure tested to 1 ½ times the rated pressure or, twice the working pressure,
whichever is higher and certified copies of test reports shall be forwarded to the Engineer-
in-Charge as soon as each test has been completed. Non-destructive tests as directed by
the Engineer-in-Charge will be required for any casting containing defects whose extent
cannot otherwise be judged, or to determine where repair welds have been properly made.
Unless otherwise specified casting shall be produced to the following standards or equal:
Sr. Component Grade

(a) Grey Iron BS 1452 Grade 220 /IS3005 Part 1 to 4
(b) Carbon Steel BS 3100 Steel Alloy /IS 1030:1998
(c) Stainless Steel BS 3100 Steel 316 C16 / IS 3038:2006
(d) Copper & Copper Alloy BS 1400 /3288:1986PART 1 TO 8
Group A Grade LG2
Group B Grade CT1, AB2
Group C Grade G1
14.29.3 Forgings
All major stress - bearing forging shall be made to a standard specification. Forging shall
be subjected to magnetic particle testing or dye penetration test at the areas of fillets and
change in section. The testing shall be conducted after rough machining (10 microns). Any
defect which will not machine out during the final machining, will be gouged out fully,
inspected by dye penetration or magnetic particle inspection to ensure that the defect is
fully removed and repaired using an approved repair procedure. Any indication, which
proves to penetrate deeper than 2.5% of the finished thickness of the component, shall be
reported to the Engineer giving the details like location, length, width and depth. For the
magnetic particle inspection the choice of wet or dry particles shall be at the Contractor’s
discretion. All forging shall be demagnetized after test and shall be heat-treated for the
relief of residual stresses. The name of the maker and particulars of the heat treatment
proposed for each such forging shall be submitted to the Engineer-in-Charge. The
Engineer-in-Charge or the Inspector may inspect such forging and identify test coupons to
check physical and chemical analysis and witness such tests at the place of manufacture
with a representative of the Contractor.

14.30 Pipes, Specials and Fittings
14.30.1 General
The term pipe work shall include all necessary supports, saddles, slings, fixing bolts and
foundation bolts required to support the pipes and associated equipment. The pipe work
shall be laid out and designed to facilitate the erection, painting in situ and dismantling of
any section for maintenance and to give a constant and uniform flow of working fluid with
a minimum of head loss. Where steel pipe work is used, the number of flanges shall be
kept to a minimum and the size of each length of pipe work shall be determined by the
ease of handling, installation and general appearance of the completed pipe system.
Positions of flanges shall take account of any concrete pipe supports or thrust blocks
needed. Flexible joints shall be provided where needed to facilitate removal of equipment
or to allow for differential settlement of the building. Wherever practical, flexible joints shall
be provided with tie-bolts or other approved means to transfer thrust or tension axially
along the pipe work.
Where steel and cast flanges are to be bolted together, the steel flange shall be machined
over its full face after welding to its pipe is completed. Flanges shall be finished truly square
with the pipe axis. Wherever possible, standard fittings shall be used in preference to
special fittings. Pipe work layout within pumping stations shall be prepared to meet the
requirement of the pump manufacturer. Valves, strainers and other devices mounted in
the pipe work shall be supported independently of the pipes to which they connect. Flanges
shall be drilled in accordance with the appropriate pressure rating. Where a pipe passes
through a wall, a retaining wall, or is subject to end thrust, it shall incorporate a puddle
flange. Puddle flanges shall be undrilled. All small-bore pipes shall be blown through with
compressed air before connection is made to instruments and other equipment.
All underground-buried mild steel piping unless found otherwise necessary, shall be
protected by the application of hot coal tar enamel and fiberglass wrapping. The coating
shall consist of one coal` tar primer one coat, wrapping of fiber glass one more coat of
enamel and the final wrap of enamel impregnated fiber glass. However, all water supply
plumbing pipelines shall be of UPVC class 4 thick-walled inside the premises and GI class
B in external locations and either anchored externally with SS AISI fasteners or
appropriately buried below the ground with a sand cushion of 20 cm all round. All sanitary
piping shall be of UPVC class 4 suitably buried below the ground with a sand cushion of
20 cm all round. Changes in direction on the ground shall be achieved with inspection
chambers of 45 cm x 45 cm and heavy-duty CI/Steel reinforced fiberglass chamber covers.
14.30.2 Design Basis:- Piping Material, Pipe Sizing etc.
Unless otherwise specified, the water velocity in the suction branches of a pump shall not
exceed 1.5m/s and in the discharge branch shall not exceed 2.1 m/s when the pump is
operating within its specified working range. There shall be no discernible noise due to
hydraulic turbulence or cavitation within the pump or its associated pipe work and valves.
The piping and valves will be sized on the following basis for sizing:-
Service / Flow Basis MOC

Velocity between 0.7 to 1.0
Gravity Lines for Sewage,
m/s & designed as pipe line DI Class K 9
Water & Waste Water flowing full

Service / Flow Basis MOC

Pressure/pumping line for DI Class K 9 / MS Cement
Velocity between 1.2 to 2
Sewage, Water & Waste Mortar lined for sizes above
m/sec
Water 1200mm.
Gravity: Velocity 1 m/sec
(max)
Sludge line Pumping: Velocity 1.5 DI Class K 9
m/sec (max) with min
pipe size 200 mm
Air (Pressurized Lines) for
Aeration Tank, Grit Chamber, At velocities between 8 –
SS – 316 conforming to
Gas Mixing System etc. 10 m/sec (desirable) with
schedule 10 S confirming to
except common header pipe a maximum of 15 m/sec
ASTM A312
line from Air Blower to in small sections
Aeration tank.
schedule 10 S conforming to
ASTM A312) with suitable
Air (Pressurized Lines)
At velocities between 8 – type of Insulation for below
Common header pipe line
10 m/sec (desirable) with water level pipeline and
from Air Blower to Aeration
a maximum of 15 m/sec. Galvanised iron (GI) for
tank
above water level pipeline
with suitable thermal
insulation
At velocities between 3.5
Gas Mixing System complete schedule 10 S confirming to
to 4.5 m/sec
ASTM A312)
At velocities between 3.5
Bio Gas Piping schedule 10 S confirming to
to 4.5 m/sec
ASTM A312)
Velocity between 1.4 to
Service Water GI Class B
2.0 m/sec
Velocity between 0.6 to Polypropylene/CPVC/HDPE
Chemical Feed Lines
1.5 m/sec or suitable
14.30.3 Cast Iron Pipes
The cast iron pipes shall generally conform to IS:1537/IS:1536 and pipe fittings shall
conform to IS: 1538. All pipes and fittings above the ground level and inside pumping
station shall be flanged.
The material for cast iron pipes and fittings shall be of grey cast iron conforming to IS: 210,
Gr FG 260/Higher grade
The pipes shall be of uniform bore and straight in axis. Length of the straight double
flanged pipes shall be within a tolerance of + 3 mm.
The flanges of the straight pipes shall be square to the axis of the pipe. The face of the
flanges shall be parallel. The bolt hole circle shall be concentric with the bore and bolt
holes equally spaced. In straight pipes the bolt holes in one flange shall be located in line
with those in the other flange.

The faces of the flanges of the fittings shall be square to the directional axes. The holes
shall be located symmetrically off the centre line. The intersecting axes of the tees shall
be perpendicular to each other.
The bolt holes on flanged pipes and fittings shall be drilled with the help of drilling jig. The
blank flanges are to be machined and drilled.
14.30.4 Ductile Iron Pipes
The DI Pipes conform to IS 8329 /ISO 2531/BS EN 545 & Fitting conform to IS 9523/BS
EN:545. These pipes can also be offered with standard thickness for smooth flow and
corrosion resistance.
All the pipes, valves, specials and other pipe appurtenances shall be designed to withstand
the maximum pressures to which it may be subjected to during the operation.
The pipes shall be such that they could be cut, drilled or machined.
In case of flanged pipes, the flanges shall be at right angles to the axis of the pipe and
machined on face. The bolt holes shall be drilled as per stipulations given in the relevant
BIS.
14.30.5 DI Specials and Fittings
DI specials shall be manufactured as per IS: 9523 and shall be ISI marked.
In case of flanged joints, the flanges shall be at right angles to the axis of the pipe machined
on the face.
The bolt hole circle shall be concentric with the bore and bolt holes shall be located off the
centre lines as per IS: 9523. Fittings shall be tested as per IS: 9523
Tests on pipes and fittings shall be carried out in accordance with IS 8329 and IS 9523.The
test method shall be submitted for approval of Engineer.
14.30.6 Stainless Steel Pipes
All gas pipes, fittings and other related components inside the digester shall be of stainless
steel SS-316.
14.30.7 Steel Pipes
All steel pipes shall conform to IS:3589.ERW steel pipes (200mm to 2000mm) for gas,
water and sewage and laying should conform to IS:5822.
14.30.8 Un-plasticised Polyvinyl Chloride (UPVC) Pipes / HDPE Pipes
The materials used in the manufacture of uPVC pipes and fittings shall comply with the
physical properties indicated in relevant specification. They shall not contain any matter
which could impart taste, odour, toxicity or be harmful to health or adversely affect the
water conveyed.
CPVC pipe shall be in accordance with ISO 15493

Unless specified otherwise joints shall be of the complying with BS 4346/IS4985 having
an elastomeric sealing ring. Joints shall be made in accordance with the Manufacturer’s
instructions.
Fittings shall be injection-moulded in uPVC to the requirements of BS 4346/IS4985.

Fabricated uPVC fittings or fittings manufactured in other materials will only be permitted
when the material and method of manufacture are approved by the Engineer- in-Charge.
HDPE Pipe shall be as per ISO 4427 and Class rating shall be Minimum PE80
14.30.9 Dismantling Joints
Where dismantling joints, flexible couplings or flange adaptors are used these shall be of
the Viking-Johnson type except where otherwise specified or approved. Pressure ratings
shall match the pressure rating of the pipework in which they are installed, and materials
used and methods of protection shall not be inferior to those used for the pipework. Where
needed, joints and couplings shall be provided with tie bolts to restrain the maximum axial
thrust arising when in service.
The dismantling joints for ductile iron pipes shall be of ductile iron with EPDM seal ring.
All interconnecting piping included in these tenders are of CI except for potable water
supply and chemical piping. The pipe shall be as per the specifications. Use of a tailpiece
will be allowed for adjustment of length.
Piping for water supply shall be GI Class ‘C’. The piping for chemical dosing shall be
HDPE/PVC/PP/SS-316, whichever is best suited. The piping includes joints, gasket and
supports.
The fasteners and washers used shall be of GI
14.31 Valves, Penstocks and Sluice Gates
14.31.1 Valves – General
All sluice gates, isolation valves, air release valves, check valves shall be designed for the
medium carried in the respective pipeline, according to the diameter and the design
working pressure of the pipeline. Manual operation shall always be provided. Electrical
drives shall be provided as per requirement unless otherwise specified.
a) The valves shall be installed between flanges. The dismantling shall be possible by
the use of rigid or flexible dismantling pieces or flange adapters at one side. For this
purpose, suitable flange adapters may be provided. All valves shall be installed in the
pipe work in such a manner that they can easily be removed from the line for
dismantling and maintenance.
b) The non-return valves on the pump delivery branches shall be spring loaded and have
high speed non-slam closing characteristics.
c) All valves shall be designed as per applicable standard as mentioned in respective
specification.
d) Valves used in lines conveying chemical solutions and gases shall be manufactured
of material suitable for the purpose and to withstand the corrosive and aggressive
action of the medium. However for sludge pumps Knife gate valve can be accepted.
e) Valves used on sludge conveyance piping etc. shall be of straight through type and
non-logging. Butterfly/knife edge gate valves may also be used on sludge line.
f) The pressure rating of valves must at least be equal to the maximum expected
pressure at the point of installation.

g) All the valves shall be of standard pressure rating of the relevant standard. Non-
standard pressure rating shall not be accepted.
h) The size of valves must not be less than the size of the respective main (suction,
delivery) pipes.
i) The material of construction of valve shall be as mentioned in respective specification
j) All the valves shall be hydraulically tested open ended. Valves bodies for all valves
shall be tested for either side (except for non-return valves, where it will be one side)
to one and half times the maximum pressure or twice the working pressure, whichever
is higher, for a duration of 10 m, during which there should not be any leakage.
k) All valve shall be tested as per applicable IS/AWWA/Equivalent international standard.
l) All valves shall be provided with handwheel, position indicator, open, close and flow
direction arrow indication
m) Valves buried or installed in underground chamber, where access to a hand wheel
would be impractical, shall be operated by means of extension spindle and/or keys.
Wherever extension spindle is provided, the valve shall also be provided with suitable
headstock.
14.31.2 Sluice Gates
Sluice gate shall be wall thimble mounted type. The construction of Sluice Gates shall be
in accordance specification and generally to IS:13349. The Sluice Gate shall be designed
for Seating & Unseating Head without sacrificing reasonable degree of leak tightness. The
frame of Sluice gate shall be flanged back type and shall be machined on the rear face to
bolt directly to the machined face of the wall thimble. The seating faces shall be made of
solid section strip of Stainless steel. They shall be secure firmly by means of counter sunk
fixing in finished grooves in the frame and slide face in such a way as to ensure that they
will remain permanently in place, free from distortion and loosening during the life of the
Sluice Gate. Sluice Gates shall be equipped with adjustable Side & Top wedging devices
as required to provide contact between the slide and frame facing when the gate is in
closed position. The gates shall be of Rising Spindle Type. They shall be operated through
a suitable operating mechanism. The Lifting mechanism shall incorporate gearing
arrangement, if required to keep the torque requirement within 7 kg-m except electrically
actuated gate. In case of gearing, those to be enclosed grease packed Bevel or Worm
Gear box type. Lifting mechanism shall be provided with suitable position indicator to show
the position of the gate from full open to full close. The indicator to be provided in the head
stock only. Stem Cover to be provided on the top of head stock for the rising spindle. The
cross section of the wall thimble shall have the shape of the English letter ‘F’. The Sluice
gate shall be provided with Flush bottom seal. This is a solid square cornered resilent
rubber seal provided on the bottom facing of the slide. The seal may be secured fastened
to the bottom of the face of the slide by a retainer bar and fasteners. The top surface of
the bottom facing of frame shall be flush with invert of the gate opening. Bottom facing of
the slide shall be accurately machined to make contact with the seal when the slid is
closed. Gates shall be fixed for positive seating. Sluice gates shall be electrically operated
with manual override facility. The Sluice Gates shall be of Class – 2 i.e., suitable for
maximum unbalanced head needs asper calculation / design. The bypass gate shall
automatically open if the flow exceeds the set flow.
The materials of construction of important components of gates will be as follows:
Frame & Shutter : Cast Iron IS: 210 Gr. FG 260

Wall Thimble : Cast Iron IS: 210 Gr. FG 260

Seating Faces & Counter Sunk : Stainless Steel ASTM A276 type 316
Fixing
Wedging Device : Cast Iron IS: 210 Gr. FG 260
Wedge Linings : Stainless Steel ASTM A276 type 316
Stem & Stem Coupling : Stainless Steel ASTM A276 type 316
Stem Nut : Stainless Steel ASTM A743 CF8M
Flush Bottom Rubber Seal : EPDM ASTM D200
Seal retainer bar : Stainless Steel ASTM A276 type 316
Fasteners, Studs Anchor Bolt & : Stainless Steel ASTM A276 type 316
Nuts
Lift Nut : Bronze IS: 318 Type LTB-2
Headstock, Stem Guide : Cast Iron IS: 210 Gr. FG 260m. Hand wheel
Mild Steel IS: 2062
Painting : Ordinary Black Bituminous Paint
Standard Painting
Unless otherwise specified elsewhere provide following standard painting.

• Surface preparation: Blast clean or Ground to near white metal finish
• Priming: 1 coat of red oxide primer before and after shop testing. Total priming
thickness 75 microns.
• Finish painting for gate assembly: 2 coats of black bitumen paint for gate assembly.
Total paint thickness inclusive of priming 200 microns.
• Finish painting for headstock: Grey enamel paint. Total paint thickness inclusive of
priming 150 microns.
Shop Testing Parameters

• Leakage test at operating pressure for gate leakage performance.
• Movement test for checking interference free movement of complete assembly.
• Seat clearance check for checking clearance between mating sealing faces.
• Positive Material Identification test for all material other than cast iron.
14.31.3 Aluminium Gate Sluice Valves
Gates are provided for the control of the flow and for maintenance of the mechanically
raked screens, grit removal system and flow division box. The gates and frame shall be of
Aluminium. The frame shall be suitable for channel mounting. The gates provided are self-
contained type with flush bottom and suitable for channel mounting. The water sealing will
be there at two vertical sides and bottom side of gate frame by means of neoprene rubber
seal mounted on shutter having forced contact with gate opening. The gates shall be
provided with manually operated headstock, which is to be mounted on yoke of the gate
frame.
The gate shall be suitable for operation by one person needing effort less than 20 kg. The
stem/spindle shall be of SS304. The operating/stem nut shall be of leaded tin bronze as
per IS318 grade LTB1 / LTB2. The fasteners and anchor bolts shall be of SS316.
The gates shall be shop tested for smooth operation of complete assembly and the
clearance between, which should be within the tolerance limit of the relevant IS.

The construction of Aluminium open channel gate shall be in accordance with the
specifications mentioned hereunder. The open channel gate shall be capable of
performing the duties set out in this specification without undue wear or deterioration, They
shall be constructed, so that maintenance is kept to a minimum. The open channel gate
shall be rising spindle type.
Details – Aluminium Open Channel gates

• Shape of water way shall be Square or Rectangular.
• Mounting; suitable for mounting between two parallel walls of an open channel.
• Type; self-contained type gate with headstock mounted on the yoke of the gate frame.
• Top water level; 200 mm less than gate height.
• Type of head; seating as well as Unseating.
• Method of operation; manually operated suitable for opening with maximum18 kg force
by a single person with maximum diameter of hand wheel or crank of 750 mm.
• Specific Construction; gate frame shall be manufactured of non-corrosion
• Requirement for gate 6061-T6 high strength extruded aluminium section weighing
minimum of 5 kg/m.
• Frame guides shall be made of UHMWPE to prevent metal to metal rubbing between
frame and shutter.
• The shutter shall be made of same composition as the frame and sufficiently reinforced
to restrict deflection to less than 1/360 of span under the design head. All parts of
shutter shall have minimum thickness of 6mm.
• The complete gate assembly shall be given a coating of suitable epoxy lacquer.
• Stem; rising type unless otherwise specified.
• Type of closure; Flush Bottom closure.
• Sealing; only at two vertical and bottom sides of gate aperture due to open channel
installation.
• Seal seat clearance; with the slide in the closed position shall not exceed 0.10mm.
• Fluid flowing; raw unscreened sewage.
• Polycarbonate (UV resistant) transparent Pipe hood cover to cover the threaded
portion of spindle and with additional mechanical stop nut on threaded stem.
• Indicate number of hand wheel revolutions required to fully open the gate.
Gate frame, shutter/Door : Aluminium Alloy 6061-T6

Side Guides : Ultra High Molecular weight polyethylene
Seating faces : Aluminium
Rubber Seals : EPDM Rubber
Rubber seal retainer bar : Stainless Steel AISI-304
Drive Nut; Leaded Tin Bronze to IS : 318 LTB-2
Assembly bolts, nuts and fasteners : Stainless Steel AISI-304
Stem & connecting pin : Stainless Steel AISI-304
Yoke : Mild Steel to IS: 2062
Headstock : Cast Iron
Pipehood : Transparent Polycarbonate

Painting:
Paint for gate assembly : Epoxy primer and finish paint.

Paint for yoke and headstock : Epoxy primer and finish paint. Minimum coating
thickness to be 250 microns.
Shop Testing
Following shop tests at manufacturer site will be conducted as per procedure mentioned
hereunder.
a) Movement Test : Movement test should be conducted in assembled condition using
stems & headstock. The gate should be operated once from full close to full open and
back to full close condition with a max. force of 135 Newton-meter on the crank or hand
wheel
b) Dimensional Checks: Important Dimensions shall be checked with reference to
approved GA drawing.
c) Seat clearance check: With the gate in closed condition, 0.1 mm thick feeler gauge
should not pass through the sealing faces
d) Material test certificates for important components such as Frame, Side guides,
Shutter, Rubber seals & Fasteners to be furnished at the time of inspection.
14.31.4 Penstocks
SS304 penstock gates to be installed in the plant, as required, shall conform to the
following.
Standard construction hand operated stainless steel penstock gates effective against
desired negative as well as positive pressure and complete with frame, gate, SS 304
spindle with suitable dia. rod coupling, SS 304 guide, brackets etc. The penstocks shall be
fitted with brass strips duly hand scraped for maximum practicable water tightness. The
operation should be easily done through single person manually operated worm geared
head stock with hand wheel from a RCC platform suitably located for convenient operation.
14.31.5 Cast Iron Sluice Valves
The construction of cast iron sluice gate shall be in accordance with the specifications
mentioned here under and as per IS: 13349-The sluice gate shall be capable of performing
the duties set out in this specification without undue wear or deterioration. They shall be
constructed, so that maintenance is kept to a minimum. The sluice gate shall be rising
spindle type.
Frame
The frame shall be of the flange back type and shall be machined on the rear face to bolt
directly to the machined face of the wall thimble.
Seating Faces
Seating faces shall be made of full width, solid section; dove-tail strips of stainless steel.
They shall be secured firmly by means of counter sunk fixings in finished dove-tail grooves
in the frame and slide faces in such a way as to ensure that they will remain permanently
in place, free from distortion and loosening during the life of the sluice gates.

Wedging Devices
Sluice gates shall be equipped with adjustable side, top and bottom wedging devices as
required providing contact between the slide and frame facing when the gate is in closed
position.
Lifting Mechanism
i) Sluice gate shall be operated through suitable lifting mechanism which shall
incorporate suitable gearing if required, to keep the torque requirement within 7 kg.m.
ii) Lifting mechanism shall incorporate a strong locking device suitable for use with a
padlock or padlock and chain.
iii) Lift mechanism shall be provided with a suitable position indicator to show the position
of the gate at all times.
Wall Thimbles
The cross section of the thimble shall have the shape of the letter 'F'.
Lifting Lugs
Lifting lugs shall be provided for all gates.
Flush Bottom Seal
i) When sluice gates are provided with flush bottom seals, the wedging device and facing
along the bottom edge of the slide and frame shall be omitted.
ii) A solid square cornered, resilient rubber seal shall be provided on the bottom facing of
slide. The seal shall be securely fastened to the bottom face of the slide by a retainer
bar and corrosion resistant metal fasteners.
iii) The top surface of the bottom facing of frame shall be flush with invert of the gate
opening. Bottom facing of the slide shall be accurately machined to make contact with
the seal when the slide is closed.
iv) 2 Nos. of Portable type of electric actuator for closing and opening of sluice gates shall
be provided at each STP including TPS and similarly 2 Nos. for each IPS also, so that
the closing and opening operation time shall be maximum of 10 minutes and similarly.
Suitable arrangement shall be made on all the sluice gates or actuators such that the
actuator is capable of operating all sizes of sluice gate, under this contract.
Details of Cast Iron Single Face Thimble Mounted Sluice Gate
Applicable standard : IS:13349- latest version

Shape of water way : Square / Rectangular / Circular
Operating head from surface to water centre line should be given
Design head in meters across seat should be given
Method of operation : Manually geared operated/ motorised.

Length and shape of wall : As per site requirement
Stem : Rising type
Type of closure : Conventional Closure/Flush Bottom closure.

Seating face : The maximum clearance between the

seating surface with the slide in the closed
position hall not exceeds 0.10 mm. The
seating face should be fitted in dove tailed
machined grooves.
Side and Top wedges : Separately adjustable type
Shop Testing
The following shop test at manufacturer site will be conducted as per procedure mentioned
hereunder :
Movement Test
Movement test should be conducted in horizontal/vertical assembled condition using

stems & headstock. The gate should be operated once from full close to full open and back
to full close condition with a max. force of 135 Newton-meter on the crank of hand wheel.
Shop Leakage Test
Shop leakage test by applying unseating hydraulic pressure will be conducted at

manufacturer’s shop. A hydrostatic pressure equal to maximum seating/unseating head
shall be applied to gate at centre line of gate opening from the back, i.e. Unseating face of
the gate in closed position, through pump. The suitable sealed calibrated pressure gauge
put on the unseating face of the gate shall indicate constant reading equal to unseating
pressure head. The pressure gauge shall be placed at centreline of the gate and should
indicate the actual pressure being encountered by the gate. It will not be allowed to put
pressure on any other location like delivery line of pump set, etc.
Water leakage through the gate under above condition shall be collected in a collection
pan and measured. The leakage so measured should not exceed the limit of 2.5, 3.5 and
4.5 liters per minute per meter sealing perimeter for class-I, class II and class III sluice
gates as stated in the IS: 13349-.
No alternate testing arrangement will be permitted in place of above method.
Hydrostatic Body Test
After the leakage test hydrostatic body test will be conducted as manufacturer’s shop A
hydrostatic pressure equal to 1.5 times the maximum operating head should be applied
on the gate for 5 minutes continuously. No permanent deformation in casting should be
observed.
Torque Test at Operating Head
Torque test at operating head would be head conducted at applicable head at

manufacturer’s shop for gates up to 2000 x 2000mm size
Dimensional Check
Important Dimensions shall be checked with reference to approved GA drawing.

Seat Clearance Check
With the gate in closed condition, 0.1 mm thick feeler gauge should not pass through
between seat facings
Indicator on C.I. headstock to be provided for gate travel with transparent / galvanized pipe
hood and full scale and with additional mechanical top nut on threaded stem.
Indicate number of hand wheel revolutions required to fully open the gate.
Wall guide brackets, bearing and coupling with housing shall be provided as per site
requirement and/or as per I.S. 13349
Part Material
Gate frame, shutter, wall thimble, : Cast Iron IS-210 Grade FG-260,
headstock stem guide bracket, wedging
device, stop nut, lifting mechanism,
pedestal gear house and nuts
Flush bottom seal retainer bar, anchor : Stainless Steel AISI-410
bolts and buts
Wedge, wedge facings seating face/seat : Naval Brass IS – 291 Grade 1, Grade 2
facings
Flush bottom seal (if required) : EPDM Rubber
Stem Nut & Lift Nut : Leaded Tin Bronze IS– 318 Grade LTB-2
All Fasteners & bolts : Stainless Steel AISI-304
Stem & stem extension stem coupling : Stainless Steel AISI-410
Painting
Painting of gate assemblies and stem guide brackets shall be with Black Bituminous Paint.
Head stock pillars shall be painted in Grey enamel
14.31.6 Sluice valve (Sewage Water Applications)
General
Sluice valve shall be conforming to IS: 14846: 2000 and with ISI marking. Additionally they
should meet the specific requirement given here under.
Sluice valve must be from ISO-9001 certified company towards Quality Management
System.
The valves shall be double flanged machined and drilled to IS-1538 Part 4 & 6. The back
side of the drill holes to be spot faced for proper seating of bolts & nuts. Reasonable
clearance behind the rear face of the flange on body and bonnet to be kept to provide free
access to use spanners for assembling & dismantling. No tap hole is acceptable.
The valves should close with clockwise rotation of hand wheel. The direction of closing
shall be cast on hand wheel.

Nominal size, PN rating & Brand name should cast on the body.
Design Requirements
The valve should be of PN 1.0 rating / based on working pressure in the pipeline.
The valves shall be of Non-rising Spindle type.
The valves shall be with back seat bushing arrangement for replacement of packing
without leakage.
The valve size 350 mm & above shall be provided with renewable Shoe & Channel
arrangement to reduce the clearance between body and wedge lugs.
The valve size 350 mm & above should be supplied with 2 nos. Single trust deep groove
Ball bearing on both end of spindle collar to reduce operating torque and vertical trust on
spindle.
The valve size 450 mm & above should be supplied with enclosed grease packed
bevel/worm gear box of suitable rating to ensure that the valve shall be operated with effort
not more than 7 KgM at the pinion shaft.
The valves shall be provided with position indicator for indication from full open to full close.
The valves shall be provided with cast iron cleaning door at the bottom of Sluice valve
body.
The clearance between wedge nut housing lugs on the wedge and the inside surface of
the valve body shall be adequate to insert the wedge nut into the wedge lug recess either
in the direction of water flow or in perpendicular direction when the wedge is in closed
position.
The valve shall be provided with air release plug arrangement on the top of the bonnet.
The valves should also be compatible with Actuator system.
Materials of Construction
1 Body : Cast Iron to IS: 210 Gr. FG 260

2 Wedge : Cast Iron to IS: 210 Gr. FG260
3 Spindle : SS to BS 970 Gr 316 S16
4 Seat Rings : SS to BS 970 Gr 304 S16
5 Spindle Nut : High Tensile Brass to IS – 320 HT2
6 Back Seat Bush : SS to CF8
7 Shoe & Channel Lining : SS to BS 970 Gr 304 S16
Shop Testing and Witnessing
1 Seat Leakage Test (2 Minutes) : 10Kg/cm2

2 Body Leakage Test (5 Minutes) : 15Kg/cm2

3 Back Seat Leakage Test (2 Minutes) : 10Kg/cm2
14.31.7 Check Valves
General
Checking valve shall be conforming to IS: 5312 Additionally they should meet the specific
requirement given below:
The valves shall be double flanged machined and drilled to IS-1538 Part 4 & 6. The
backside of the drill holes to be spot faced for proper seating of bolts & nuts. Reasonable
clearance behind the rear face of the flange on body to be kept to provide free access to
use spanners for assembling & dismantling. No tap hole is acceptable.
The valve should be of PN 1.0 rating based on working pressure in the pipeline.
Nominal size, PN rating, Brand name & Direction of Flow should cast on the body.
The Valves shall be of Swing Check type.
The Valve sizes 50 to 600 mm should be of Single door design & above 600 mm should
be Multi door design.
The Check Valves shall be with Non Slam Characteristics. Non Slam Characteristics to be
achieved by combination of hydraulic passage and additional disposition of weight on
doors without any external clamping arrangements or passages. The angle of sealing and
door weight shall be designed to provide the most efficient working with least restriction to
flow.
Valve of diameter greater than 450 mm shall be provided, in addition to others, supporting
feet and jacking screws. Hinge pins / shaft shall preferably be square in section to ensure
positive location of flaps and provide for secure fixing.
If self-closing without slamming cannot be achieved, external mechanisms may be used

to control the closure rate. Details of mechanisms will be subjected to approval. Valves
shall preferably be fitted with resilient faces or seats.
Non return valve used in raw water or sludge systems shall not be installed vertically or
positioned so that water-borne solids can settle against the valve flap when the flap is
closed. Direction of the flow shall be clearly embossed on the valve body. Valve of size
450mm and above shall be provided with supporting foot.
The valves shall be suitable for mounting on a horizontal pipeline and flow direction shall
be clearly embossed on the valve body.
Maximum pressure drop across the valve shall be 0.4 m WG
Maximum allowable leakage rate shall be 7cc/hr/mm diameter or as per applicable

standard whichever is lower.

Body & Cover : Cast Iron IS: 210 Gr. FG 260

Door : Cast Iron IS: 210 Gr. FG 200
Hinge Pin : Stainless steel, IS 6603:1972, 04Cr 17Ni 12MO2
Seat Rings : Stainless steel, IS 6603:1972, 04Cr 17Ni 12MO2
Bearing Bush : Teflon
Fastener : carbon steel
Shop Testing and witnessing
Seat Leakage Test (2 Minutes) : 10Kg/cm2

Body Leakage Test (5 Minutes) : 15Kg/cm2
14.31.8 Kinetic Air Valves
General
Kinetic Air valves shall be conforming to IS: 14845: 2000. Additionally they should meet
the specific requirement given here under.
Kinetic Air valves should be from ISO – 9001 certified company towards Quality
Management System.
The Valves shall be flanged end machined and drilled to IS – 1538 Part 4 & 6
The valves should have an isolating Sluice Valve attached to it.
Nominal size, PN rating, Brand name should cast on the body.
Design Requirement
The valve should be of PN 1.0 rating /based on working pressure in the pipeline.
The Valves should double ball air valve consisting of large orifice (LP) & small orifice.
The large orifice chamber should have built-in Kinetic features to avoid blocking of the
large orifice during filling & emptying of pipeline. It should have a large timber ball covered
with rubber to be seated on a large orifice rubber ring.
The small orifice chamber should have a small timber ball covered with rubber to be seated
on gunmetal orifice plug.
Body, Cover, Cowl : Grey Cast Iron. IS: 210 – 1993 Gr. – 200
Stem : Stainless steel, IS 6603, 04Cr18Ni10
High Pressure Orifice : Stainless steel, IS 6603, 04Cr18Ni10
Low Pressure seal ring and face ring : EPDM

Body Seal Ring : Stainless Steel IS:3444 Gr 1

Float (Low Pressure Orifice) : Seasoned timber ball covered with soft
Vulcanite
Float (High Pressure Orifice) : Stainless Steel IS:3444
Seat of large orifice : Neoprene Rubber
Isolating Gate valve : IS:14846 (GM internals & AISI: 410 Spindle)
Bolt & Nut : Carbon Steel
Shop Testing and witnessing
Seat & Body Leakage Test (2 Minutes) : 10 bar
Painting & Coating
Pre – inspection
1st Step: Surface Preparation : Blast cleaning to near white – SA 2 ½ Gr.

nd
2 step: Application of Primer Coating : One coat of two component epoxy based
after blast cleaning primer
Post – inspection, if applicable
3rd Step: Application of Finish Coat : One coat of two component solvent free amine
cured epoxy coating (Shade)
14.31.9 Butterfly Valves
General
The design standard of butterfly valves shall be latest revision of AWWA C-504 or BS:
EN:593 or equivalent standard of required class/rating.
Unless otherwise specified, valve body and disc shall be of close-grained grey cast iron.
Valves shall be mounted with shafts horizontal. Valves shall be fitted with indicators to
show the position of the disc, clearly marked with ‘open’ and ‘closed’ positions. Valves
shall not contain any brasses containing more than 5% zinc. Gunmetal conforming to BS
1400 Grade LG2, aluminium bronze, or nickel components may be used for internal
components. Resilient-seated valves shall have nitrile rubber seals.
Valve of diameter 450 mm and above shall be provided with enclosed gear arrangement
for ease of operation. The operation gear shall be such that they can be opened and closed
by one man against an unbalanced head 15% in excess of the maximum specified rating.
Valve and any gearing shall be such as to permit manual operation in a reasonable time
and not exceed a required rim pull of 200 N.
The actuator arrangement for Butterfly valves shall be provided as per the Automation
requirement, however valves of diameter 600 mm and above shall be provided with electric
actuator only. All motorised or actuated valve shall be provided manual override (Hand
wheel) as a additional provision.

All hand wheels shall be arranged to turn in a clockwise direction to close the valve, the
direction of rotation for opening and closing being indicated on the hand wheels.
Valves shall be mounted with shafts horizontal. Valves shall be fitted with indicator to show
the position of the disc, clearly marked with ‘open’ and ‘closed’ positions
For valves of 900mm and above, retaining rings shall be provided to enable the sealing
ring to be replaced without the need to remove the valve body from the pipe work. Metal
seated valves of 900mm and above, shall have seat clearances adjustable to obtain as
near a watertight condition as possible, without the need to remove the valve body from
the pipe work.
Percentage Opening - Flow Curve shall be submitted along with data sheet mentioning
area where such valves are subjected for any controlling of the fluid flow.
Proof of design (P.O.D) test certificate shall be furnished by the manufacturer for all
applicable size-range and class of Butterfly valves supplied by them. In the absence of
certificates, actual P.O.D test shall be conducted in the presence of the Employer
representative. All valves that are designed and manufactured as per AWWA C-504 shall
be governed by the relevant clauses of P.O.D test in AWWA C-504. For Butterfly valves
designed and manufactured to EN-593 or Equivalent, the P.O.D test methods and
procedure shall generally follow the guidelines of AWWA C-504 in all respect except that
Body &seat hydro test and disc-strength test shall be conducted at the pressures in EN-
593 or the applicable code. Actuator shall also meet requirement of P.O.D test of AWWA
C-504.
Component Material
Body : Cast Iron, IS:210 Gr FG260

Inner lining : Stainless steel, BS:970 Gr 304
Plate /Disc : Stainless steel, IS 3444 1987 Gr 7
Stem : Stainless steel, IS 6603:1972, 04Cr 17Ni 12MO 2
Seat ring / Boss : Stainless steel, IS 6603:1972, 04Cr 17Ni 12MO 2
Gland housing : Cast Iron, IS:210 Gr FG260
Gland packing : Non-asbestos TEFE or EPDM
Shaft : Stainless steel BS 970 Grade 431 S29
Internal Fasteners : Stainless steel AISI 316
Nuts, bolts & Washers for pipe : High tensile steel hot dip Galvanized
flange
14.31.10Pressure Relief Valves
Pressure-relief valves shall be designed to prevent the pressure in the pipeline upstream
of the valve rising above a pre-set level. The valve shall remain closed at lower pressures.
The pressure at which the valve opens shall be adjustable. A pressure gauge shall be
provided to indicate upstream pressure over the operating range of the valve. Safety
valves shall comply with BS 6759: Part 1.
They shall be designed to open at the specified pressure and re-close and prevent further
release of fluid after normal pressure has been restored. The pressure / temperature rating

shall be in accordance with relevant standards. Flanged ends shall be Class 900, raised-
face type complying with ANSI B16.25 or relevant standards.
Component Material
Body Cast Iron : IS:210 Gr FG260

Inner lining Stainless steel : BS:970 Gr 304
Knife gate/ plate Stainless steel : BS:970 Gr 304
Stem Stainless steel : BS:970 Gr 304
Seat ring / Boss Stainless steel : BS:970 Gr 304
Gland housing Cast Iron : IS:210 Gr FG260
Gland packing Teflon Impregnated with asbestos + Rubber
14.31.11Ball Valves
Ball valves shall conform where applicable to relevant standards or IS: 9890, IS:9884 /
BS-5351 latest version. Multi-piece bodies shall be used where work on the ball and seats
when installed may be needed. If valves need removal for servicing, one-piece bodies may
be used. Seat materials shall be chosen for long life, with erosion and corrosion resistance.
Ball supports shall be of the floating ball or trunnion type. If line pressure is too low to
ensure a positive leak-free seal, built-in seat loading devices, or specially shaped seats
shall be used to ensure sealing.

Gland packing Teflon Impregnated with asbestos + Rubber

Gland packing : Teflon Impregnated with asbestos and rubber
14.31.12 Knife Gate Valves
The valve shall meet standards AWWA C105/A21.5-10, AWWA C520-10, C706-10, C707-
10, C713-10 and D106-10 and testing requirements of MSS SP 81.
Outer body may preferably be provided with inner liner in corrosion resistant stainless steel
which shall extend into the gland. The body shall be devoid of any wedge/ dead pockets
to avoid setting of suspended particles and solids in the service fluid.

The gate / plate shall be precision buffed and the edge contoured to a knife edge. The
gate shall move along / be guided by the seat ring to ensure that it scraps any deposit /
scale enabling smooth uninterrupted movement.
Seat shall be so designed that there is no recess / relieve groove to harbour deposition
that could build-up and swamp the valve. The design should also incorporate bosses that
guide the gate and avoid deflection ensuring positive shut-off. The stem shall have double
start threads cut in order to ensure smooth and speedy operation.
Gland packing shall offer minimal frictional resistance and precludes external lubrication.
As positive sealing elements, the packing shall also include a resilient rubber ring. The
knife edge and seat face in flow path shall be hard faced to a hardness of 400 to 450 BHN
to counter erosion. In such cases, provision shall also be made to ensure the fluid contact
with the seat ring is minimal.
Component Material
Body – Cast Iron : IS:210 Gr FG260

Knife gate/ plate – Stainless steel BS:970 Gr 304 /ASTMA240 Gr.304
Stem – Stainless steel : BS:970 Gr 304
Seat ring / Boss – Stainless steel : BS:970 Gr 304
Gland housing – Cast Iron IS:210 Gr FG260
Gland packing : The seal shall be non-asbestos PTFE
14.31.13Cast Iron Flap Valves
The Flap Valves with circular aperture, single door and double flanges, shall be provided.
The flap valves up to 600mm dia shall have sealing faces in angular section and secured
to the frame and door by a force fit. For sizes above 700 to 2000mm dia the sealing faces
are of rectangular section and are secured to the frame and door using countersunk taper
headed screws in the same material as the sealing face. The flap valve shall be suitable
for mounting on a vertical wall or flange for static seating heads up to 6 meters.
Material of Specification
Frame
Constructed in BS EN 1561 min. 250 cast iron designed for wall, thimble or pipe mounting
applications.
Door
Constructed in BS EN 1561 min. 250 cast iron designed to withstand static seating heads
up to 6 meters.
Sealing Faces
Copper alloy sealing faces to BS EN 1982 : 1999 are supplied as the standard material for
ranges up to 600mm dia and for the ranges 700 to 2000mm dia phosphor bronze to BS
EN 12167 : 1998. Sealing faces are set to 0.1mm feeler gauge non-acceptance to provide
an effective seal.

Hinge Links
Manufactured in Spheroidal Graphite cast iron
Fasteners
Standard fasteners are supplied in stainless steel to BS EN 10088 : 1995 grade 1.4401
(316).
Hinge Pins
Manufactured from stainless steel to BS EN 10088 : 1995 grade 1.4401 (316).
14.31.14Telescopic Valves
The telescopic valve shall be a proprietary item of proven design manufactured in cast iron
and adjustable to cater for variation in level.
The bell mouth height shall be controlled by a hand wheel operated from top of the
chamber.
The bell mouth, pipe work, spindle and headstock shall be robustly constructed with
adequate brackets of cast iron.
The bell mouth shall be connected by swept tees to a cast iron sludge outlet pipe of
suitable diameter.
Bell Mouth : Iron: IS:210 Gr. FG 260

Piping : Iron : IS:210 Gr. FG 260
Spindle : Stainless Steel Gr. 304
Hand wheel : Iron : IS:210 Gr. FG 260
14.31.15Valve Actuators (wherever required)
General
All actuators shall be motorized type and local controls shall be protected by a lockable
cover.
Each actuator shall be adequately sized to suit the application and be continuously rated
to suit the modulating control required. The gearbox shall be oil or grease filled, and
capable of installation in any position. All operating spindles, gears and head stocks shall
be provided with adequate points for lubrication.
The valve actuator shall be capable of producing not less than 1½ times the required valve
torque considering valve spindle jamming and shall be suitable for at least 15 minutes
continuous operations.

The actuator starters shall be integrally housed with the actuator in robustly constructed
and totally enclosed weatherproof housing. The motor starter shall be capable of starting
the motor under the most severe conditions.
The entire electrical system shall be tropicalised.
The starter housing shall be fitted with contacts and terminals for power supply, remote
control and remote positional indication, and shall also be fitted with internal heaters so as
to provide protection against damage due to condensation. Heaters shall be suitable for
single phase operation. The heaters shall be switched “ON” when the starters are “OFF”
and shall be switched “OFF” when the starters are “ON”.
Each actuator shall be equipped as follows:
a) AC electric motor with engage/disengage clutch mechanism of the dry type.

b) Reduction gear unit
c) Torque switch mechanism
d) Limit switch mechanism complete with set of limit switches and additional two spare
sets for suitable intermediate positions.
e) Hand wheel for manual operation of valve.
f) Valve position indicator – open/closed
g) Auto-Manual lever with suitable locking arrangement
h) Valve position transmitter to give 4-20 mA feedback signal.
i) Reversing contactor starter complete with overload relays of suitable range and
adequately rated control fuses
j) Actuator with integral starter shall have selection between local/remote operation
k) Local control switch/push buttons for local operation 415 V/110 V AC control
transformer
l) .
m) A potential free contact shall be provided to annunciate over-load trip/main supply
failure on remote panel
n) Provision for local as well as remote operation
o) Two (2) nos. interposing relays for matching the control voltage of remote commands.
p) The motor shall be specially designed for valve operation, combining low inertia with a
high torque and with linear characteristics.
q) All motor actuators shall be provided with visible local valve position indicators
mounted on the actuator assembly itself. Actuator shall have inbuilt facility to show the
status and fault annunciation locally through LED or LCD for easy diagnosis and
maintenance.
r) The torque switch shall function to stop the motor on closing or opening of the valve,
on actuation by the torque when the valve disc is restricted in its attempt to open or
close. A minimum of two (2) torque switches, one for closing direction and one for
opening direction shall be provided.
s) The non-adjustable limit switches shall stop the motor and give indication when the
disc has attained the fully open or close position. Adjustable limit switches shall be
suitable to set at any intermediate position and give remote indication as applicable.
Provision shall be made for indication of stuck or jammed valve
t) All wiring connections from the various switches shall be brought out on to separate
terminal box mounted on the valve, having liberal space for wiring and making
connection.
u) The terminal box shall be suitable for outdoor use and shall be weather-proof and water
tight to IP 68.

14.31.16Supports of Pipes, and Valves
All necessary supports, saddles, slings, fixing bolts and foundation bolts shall be supplied
to support the pipe work and its associated equipment in an approved manner. Valves,
meters, strainers and other devices mounted in the pipe work shall be supported
independently of the pipes to which they connect. All brackets or other forms of support,
which can conveniently be so designed, shall be rigidly built up of steel by riveting or
welding in preference to the use of castings. No point of passage of pipes through floor or
walls shall be used as a point of support, except with the approval of the Engineer in
charge.
CI/DI Piping above ground level shall be only flange jointed and adequately provided with
structural/ masonry supports. Stainless steel AISI 304 expansion bellows which can take
radial and axial misalignment of minimum one percent of the valve nominal size and tie
bolts shall be provided. All pipe work shall be adequately supported with purpose-made
fittings. When passing through walls, pipe work shall incorporate a puddle flange. Flange
adapters and union shall be fitted in pipe work runs, wherever necessary, to permit the
simple disconnection of flanges, valves and equipment.
14.32 Hoists and Lifting Equipment
The lifting arrangement shall be of type as mentioned below:
Type : If not specifically mentioned against any unit, type for less than 1 Ton
capacity –HOT (Double Rail) and for more than 1 Ton - EOT (Double
Rail) shall be provided.
Capacity : (a) Pumping Stations –
1.5 x (Total weight of each set of Pump and motor or single any heaviest
equipment to be lifted) whichever is higher.
(b) Air/Gas Blower/compressor Building – 1.5 x (Total weight of each set
of blower and motor or single any heaviest equipment to be lifted)
(c) Chlorinator Room –Minimum 3 ton EOT
(d) Sludge Dewatering System building – 1.5 x (Total weight of each set
of Dewatering machine or any single heaviest equipment to be lifted)
(e) Digester control building - 1.5 x (Total weight of each set of any single
heaviest equipment to be lifted) whichever is higher.
(f) Power Generation Set Building – 1.5 x (Total weight of each set of
Power
Generation set or any single heaviest equipment to be lifted) whichever is
higher.
14.32.1 General
All components of Electrically operated hoist (EOT) / HOT Crane shall be comply the
following applicable Indian standard.
IS : 2266 Specification for steel wire rope for General Engineering purpose
IS : 594 Technical supply conditions for wire ropes and standards
IS : 1835 Specification for Round steel wire for rope
IS : 3938 Specification for electric wire rope hoists
IS : 7847 General Characteristics of lifting hook

IS : 3815 Specification for point hook with shank for general engineering purpose
IS : 242 Calibrated hand chain for long travel & cross travel
IS : 807 Code of practice for design, Manufacture, erection & testing (Structural
portion of crane & hoist)
14.32.2 Electrically Operated Hoist with Travelling Trolley
A monorail beam with an electric driven hoist and trolley unit shall be provided for the
moving of the chlorine tonne cylinders. The monorail beam, hoist and trolley shall conform
to BIS 3177 (Code of Practice for Electric Overhead Travelling Cranes and Gantry Cranes
other than Steel Work Cranes), where applicable.
The trolley shall be of the underhung type supported by the monorail beam. The system’s
load capacity shall be as mentioned above, with a lifting height of at least 5.0 m or as per
requirement of location to be installed whichever is higher. The monorail beam shall be
supported from the roof slab. The equipment manufacturer shall determine the spacing
requirements for the support brackets and/or hangers.
The hoist and trolley shall be a single unit with a single motor. The maximum allowable
distance from the bottom flange of the monorail beam to the hook (headroom) shall be
limited to no more than 500 mm. The main hoisting speed shall be in the range of 2.0 to
3.0 m/min.
The hoist and trolley shall be equipped with the following:
a) Motor: Of the conical rotor type, no larger than 3 kW at 440v/3ph/50 hz, with Class H
insulation and a TEFC enclosure. Stalling torque shall be at least 290% of the full load
torque requirement.
b) Gearbox: Cast iron with alloy steel spur gears and ball bearings. The gearbox shall be
oil lubricated.
c) Rope Drum: Welded steel with roller bearings at each end. A rope guide shall be
attached to the drum and be equipped with a rope tightener.
d) Rope: Steel core 8 x 50 with an ungalvanized steel outer wrapping.
e) Brake: Cast iron disk type which can be maintained without removing any part except
the end cover. The braking torque shall be 100% higher than the motor torque at the
rated load.
f) Micro speed Attachment: Shall reduce the hoisting speed to 10% of the main hoisting
speed.
g) This unit shall have a separate control from the main hoist.
h) Control: A pendant pushbutton station shall be furnished. The electrical supply shall
be 220v/1ph/50Hz.
i) Limit Switches: The hoist shall be furnished with built-in limit switches to control the
top and bottom positions of the hook. Tappets shall be provided to adjust limit switches
to intermediate positions.
A drum-lifting beam shall be furnished with the hoist unit.
The hoist and trolley manufacturer shall be responsible for designing and furnishing the
entire system including the monorail beam and its supports.

14.32.3 Electrically Operated Overhead Travelling Crane
The crane shall be electrically operated, bridge type complete with all accessories
including down shop conductor, crane rails and fixtures, and shall conform to BS 2573,
IS:3177 or relevant internationally approved standards.
The crane bridge shall consist of bridge girders on which a wheeled trolley is to run. The
bridge trucks and trolley frames shall be fabricated from structural steel. Access walkway
with safe hand railing as is required along the full span length of the bridge girder. Steel
shall be tested quality conforming to ASTM A36 except that, plates more than 20 mm thick
shall conform to IS: 2062, BS: 4360 or relevant internationally approved standards. The
bridge shall be designed to carry safely the loads specified in IS: 807, BS: 2573 or relevant
internationally approved standards. All anti-friction bearings for bridge and trolley track
wheels, gear boxes and bottom sheaves on hook shall be lubricated manually by hand
operated grease pump through respective grease nipples.
Wheel base and structural frame of the wheel mounting of the end carriages shall be
designed so as to ensure that the crane remains square and prevent skewness. Bridge
and trolley track wheels shall be of forged steel and shall be double flanged type. The
wheel diameter and rail sizes shall be suitable for the wheel loads. The crane rails shall
be manufactured from wear resistant austenitic manganese steel. Mountings of the wheels
shall be designed to facilitate easy removal for maintenance. Walkways shall be at least
500 mm clear inside width with a 6 mm thick non-skid steel plate surface. Steel rail stops
to prevent rails from creeping and trolley from running off the bridge shall be abutted
against ends of rails and welded to the girders. Bridge and trolley stops to match the wheel
radius shall be provided before the buffer stops.
All exposed couplings, shafts, gear, wheels, pinions and chain drives etc. shall be safely
encased and guarded completely to prevent any hazard to persons working around. All
bearings and gears shall have a design life of 100000 hours. Electro-magnetic and
hydraulic thrust or brake shall be provided for the main hoist. One electro-magnetic brake
shall be provided for each of the cross travel and long travel motions.
Hook shall be solid forged, heat treated alloy or carbon steel suitable for the duty service.
They shall have swivels and operate on ball thrust bearings with hardened races. The
lifting hooks shall comply with the requirements of IS 8610 or BS: 2903 / BS: 3017 or
relevant internationally approved standards and shall have a safety latch to prevent rope
coming off the hook.
Hoist rope shall be extra flexible, improved plough galvanized steel rope with well
lubricated hemp core and having six strands of 37 wires per stand with minimum ultimate
tensile strength of 1.6 X 106 kN/m2 of Right Hand Ordinary (RHO) lay construction. The
ropes shall have a 6:1 safety factor on the specified safe working load, and shall conform
to IS: 2266. Rope drums shall be grooved and shall be either cast iron or cast steel of or
welded steel conforming to IS: 3177, BS: 466 or relevant internationally approved
standards.
Gears shall be cut from solid cast or forged steel blanks or shall be stress relieved welded
steel construction. Pinions shall be of forged carbon or heat treated alloy steel. Strength,
quality of steel, heat treatment, face, pitch of teeth and design shall conform to BS: 436,
IS: 4460 and BS: 721 or relevant internationally approved standards.
Name Plate showing the capacity, year of manufacture and rated capacity of hoist, in
figures not less than 150 mm height, shall be placed on each side of the crane girder.

The maximum deflection under full load shall not exceed 1/900 of the span (as per IS:
3177).
All accessory and auxiliary electrical equipment including drive motors, electrically
operated brakes, controllers, resistors, conductors, insulators, current collectors, pendant
push button station, protective devices, operating devices, cables, conduits, etc.
necessary for the safe and satisfactory operation of the crane shall be provided.
Power to the crane shall be provided by down shop conductors manufactured from high
conductivity hard drawn copper. Conductors shall be completely shrouded such that they
have no exposed current carrying surfaces. Pendant type push button station shall be
sheet steel enclosed and shall comprise the following push buttons and indicating lamps:
i) `Start’ and `Stop’.
ii) Long travel - `Right’ and `Left’.
iii) Cross travel - `To’ and `Fro’.
iv) Hook - `Hoist’ and `Lower’.
v) Red indicating lamp for supply ÒN’ indication.
Pendant type push button shall be supported independently of the electrical cable and
shall be earthed separately, independent of the suspension. Automatic reset type of limit
switches shall be provided to prevent overtravel for each of the following:
• For ÙP’ and `Down’ motions of the hook.
• Long travel motion
• Cross travel motion
Crane structures, motor frames and metal cases of all electrical equipment including metal
conduit and cable guards shall be earthed. All motors, brakes, limit switches, panels, drum
controllers, resistor unit sets shall be provided with two studs for earthing.
All motors shall be of the quick reversing type with electric mechanical brakes suitable for
the duties specified. All movements shall be electrically powered suitable for operating
with the hook loaded. Facilities shall be provided for the accurate location of the hook by
means of ìnching' the cross travel and down shop travel motions.
Sufficient slings, ropes, shackles, lifting beams, etc shall be supplied to handle all items of
plant covered by the crane. They shall be labelled or marked with the Safe Working Load
(SWL) and the purpose for which they are intended.
The crane, and all slings, ropes, shackles and other lifting equipment supplied shall be
tested by the manufacturer at his works. The tests shall be carried out at 125% of Safe
Working Load, and Test Certificates shall be supplied.
The Contractor shall include with the cranes all necessary contactors, control cubicles and
protection equipment necessary to operate the crane and provide adequate electrical
protection against overload, phase and earth fault and fail-safe protection in the event of
an interruption in the power supplies. All access ladders and platforms necessary to carry
out maintenance and repairs shall be provided and installed by the Contractor.
All electrical equipment shall be fully tropicalised.
Site tests shall be carried out by the Contractor who shall supply the necessary materials
for the test load. The test load shall be removed from site by the Contractor after successful
tests have been carried out.

14.32.4 Hand-Operated Overhead Cranes
Cranes shall be designed and manufactured in accordance with BS: 2573 and shall
comply with the requirement of BS: 466 class 2 medium duty. The crane details and
ancillary equipment provided shall conform to applicable parts of the general
requirements specified for electrically-operated overhead cranes, except that the crane
shall be manually operated in all motions by conveniently mounted endless chains,
arranged for operation by one man. The main features shall conform to the followings:
General Requirement
The crane bridge shall consist of a single bridge girder carting two wheels at each end
of the span. Steel used shall be of tested quality steel conforming to IS: 2062. The girder
shall have enough strength to carry the test load without causing undue stress or
deflection.
The long travel bridge wheels shall be rim toughened; treated carbon steel or low alloy
steel or CI tray shall be double flanged type. The wheels shall be machined on their
treads to match the runaway rail section. The bridge shall have a geared shaft and
pulley connecting to opposite wheels of the span, to achieve the long travel motion of
the bridge, by means of a chain. The runway rails of adequate strength and rigidity, rail
clamps and other accessories for mounting the rails and suitable end stops for the bridge
shall be supplied by the Contractor.
Trolley and Chain Pulley Block
The chain pulley block shall be operated on the lower flange of the bridge girder.
The load chain shall be made of alloy steel as per IS: 3109. It shall be heat treated to give
ductility and toughness so that it will stretch before breaking. It shall be of welded
construction with a factor of safety not less than 5.
The hand chains, SS316 for the hoisting and traverse mechanism shall hang well clear of
the hook and both the chains shall be on the same side. The hand chain wheel shall be
made from pressed sheet steel and shall be provided with roller type guard to prevent
snagging and fouling of the chain.
All the gearing shall be totally encased. Proper lubricating arrangements shall be
provided for bearings and pinions. Gears shall be cut from forged steel blanks. Pinions
shall be of heat treated alloy steel. Gears shall as per BS: 436/IS: 4460.
The trolley track shall be rim toughened, heat treated carbon steel or low alloy steel
or CI and shall be single flanged and shall have antifriction ball bearings. The wheels
shall be machined on their treads to match the flanges of the track joints.
The travelling trolley frame shall be made of rolled steel conforming to IS: 2062. The
side plates of trolley frame shall extend beyond wheel flanges, thus providing bumper
protection for the wheels. The two side plates shall be connected by means of an
equalizing pin. Axles and shafts shall be made of carbon steel and shall be accurately
machined and properly supported.
The lifting hooks shall be forged, heat treated alloy or carbon steel of rigged construction.
They shall be of single hook type provided with a standard depressed type safety latch.
They shall swivel and operate on antifriction bearings with hardened races. Locks to
prevent hooks from swivelling shall be provided. Hook shall be as per BS: 2903/IS: 3815.

The brake for the lifting gear shall be automatic and always in action. Is shall be of screw
and friction disc type self-actuating load pressure brake. Brakes shall offer no resistance
during hoisting.

15 Standard Specifications – Electrical
15.1 Codes and Standards
All equipment or systems supplied under this Contract shall conform to the latest editions
of the International Electro-Technical Commission (IEC) Standards or equivalent Indian
Standards (BIS). Standards other than IEC or BIS may be referred e.g. International
Standards BS EN, provided, it shall promise to confirm equal or superior performance. If
standards other than IEC or BIS are referred, then the Contractor shall enclose English
Version of the standard with the bid. Where applicable, the appropriate Indian Standard
(IS) shall take precedence over International (IEC) or British standard (BS EN).
15.2 Regulations
The Contractor shall ensure that the Works comply in all respects with the relevant
statutory and regulatory instruments of India
Where the requirements detailed thereon are less stringent than the relevant British or
International instrument then the latter shall rule.
The relevant Indian statutory and regulatory instruments for electrical installations are as
follows:
• The Factories (Amendment) Act, 2016
• Employee’s Compensation (Amendment) Act, 2017
• Electricity Act, 2003
• Maharashtra Fire Prevention and Life Safety Measures Act, 2006
• Energy Conservation Building Code 2016
• Occupational Health and Safety Management System,2008
Electrical installations covered by the scope of the Central Electricity Authority, 2010, and
designed, installed and tested in accordance with these regulations shall generally satisfy
the requirements of the above-mentioned statutory regulations.
The Contractor shall be responsible for complying with all local bylaws, supply authority
and local authority requirements. It shall be the Contractor’s responsibility to determine the
existence of these requirements and for compliance with them.
In view of sizing an electrical installation and the required equipment, as well as

determining the means required for the protection of life and property, short-circuit currents
must be calculated for every point in the network in accordance with IEC 60909, which is
intended for radial and meshed low-voltage (LV) and high-voltage networks.
15.3 Abbreviations
Wherever the following abbreviations are used they shall have the meanings below:
A Ampere
A.C./a.c. Alternating Current
ACB Air Circuit Breaker
APFC Automatic Power Factor Correction
ASTM American Society for Testing and Material

Part 15: Standard Specifications – Electrical
BS British Standard
CPU Central Processing Unit
CRCA Cold Rolled Closed Annealed
D.C. / d. c. Direct Current
DOL Direct On Line
ECBC Energy Conservation Building Code
ELCB Earth Leakage Circuit Breaker
EMC Electro Magnetic Compatibility
PABX Private Automatic Branch Exchange
FAT Factory Acceptance Test
FSD Full Scale Deflection
GSM Global System for Mobile Communication
GUI Graphical User Interface
HMI Human Machine Interface
HRC High Rupturing Capacity
HV High Voltage
ICA Instrumentation Control and Automation
IEC International Electro technical Commission
IEEE Institute of Electrical and Electronic Engineers
I/O Input /Output
IP Ingress Protection
IS Indian Standard
kA kilo Ampere
kVA Kilo Volt Ampere
kVAr Kilo Volt Ampere reactive
kW Kilo Watt
kWH Kilo Watt Hour
LCD Liquid Crystal Display
LDB Lighting Distribution Board
LED Light Emitting Diode
LPU Lightning Protection Unit
LV Low Voltage
mA milli Ampere
MCB Miniature Circuit Breaker
MCC Motor Control Centre
MCCB Moulded Case Circuit Breaker
MPCB Motor Protection Circuit Breaker
NC Normally Close
NO Normally Open

PCC Power Control Centre

P&ID Process and Instrumentation Diagram
PLC Programmable Logic Controller
PSTN Public Switched Telephone Network
PT Potential Transformer
RCBO Residual Current Breaker with Overload Protection
RCD Residual Current Device
SAT Site Acceptance Test
SCADA Supervisory Control and Data Acquisition
SF6 Sulphur Hexafluoride
SPD Surge Protection Device
TCP/IP Transmission Control Protocol/Internet Protocol
UPS Uninterrupted Power Supply
VCB Vacuum Circuit Breaker
VFD Variable Frequency Drive
15.4 Specification of Electrical Equipments
15.4.1 Distribution Transformers
15.4.1.1 Standards
Transformers and its accessories shall comply with the following International Standards,
including those referred to therein.
IS:2026 Specification for Power Transformers

IS:1180 Outdoor distribution Transformer up to and including 100 kVA
IS:12444 Specification for Copper wire rod

IS:335 Specification for Transformer Oil
IS:5 Specification for colors for ready mixed paints
IS:104 Ready mixed paint, brushing zinc chromate, priming.
IS:2099 Specification for high voltage porcelain bushing
IS:649 Testing for steel sheets and strips and magnetic circuits
IS:4257 Dimensions for clamping arrangements for bushings
IS:7421 Specification for Low Voltage bushings
IS:3347 Specification for Outdoor Bushings
IS:5484 Specification for Al Wire rods
IS:9335 Specification for Insulating Kraft Paper
IS:1576 Specification for Insulating Press Board
IS:6600 Guide for loading of oil Immersed Transformers
IS:2362 Determination of water content in oil for porcelain bushing of transformer
IS:6162 Paper covered aluminium conductor

IS:6160 Rectangular Electrical conductor for electrical machines

IS:5561 Electrical power connector
IS:6103 Testing of specific resistance of electrical insulating liquids
IS:6262 Method of test for power factor and dielectric constant of electrical
insulating liquids
IS:6792 Determination of electrical strength of insulating oil
IS:10028 Installation and maintenance of transformers.
IS:11171 Specification for Dry type Power Transformers
IEC 60076 Power Transformer
IEC 60214 Tap Changers
IEC 60296 Fluids in Electrotechnical applications.
15.4.1.2 Design Features
Transformers shall be suitable for indoor/outdoor duty and shall be installed inside closed
room or in outdoor switchyard as applicable. It shall be rated for satisfactory operation at
500C design ambient temperature. Transformer shall be designed for over- fluxing
withstands capability of 110% continuous at no load, 125% for at least 1 minute and 140%
for 5 seconds as per IEC standard.
a) The individual Transformer kVA rating shall be designed considering maximum 80%
loading on the transformer at full load with a power factor of 0.8. Both the transformers
should be suitable for momentary parallel operation.
b) Voltage regulation of Transformer should be ≤ 5% at starting of largest motor at
0.8power factor.
15.4.1.3 Accessories and Fittings
Each main Distribution transformer shall have the following fittings and accessories as
applicable for Oil Filled and Dry type Transformer including but not limited to:
a) A conservator of sufficient volume with

i. oil level gauge with potential free contacts for initiating alarm for low oil level
ii. weather-proof dehydrating breathers for both compartments with activated alumina
or silica gel as the dehydrating breather
iii. Shut off valves
iv. Filling plug and drain valves
The conservator shall be designed to maintain an oil seal up to a temperature of 1000c
b) Gas and oil actuated Buchholz relay with

i. necessary shut off valves
ii. Test cock with pipe connections for sampling
iii. Potential free contacts for initiation of alarm in case of slow gas formation and trip
in case of fast oil and gas surges
c) Dial type thermometer with

i. maximum temperature indicator and its resetting device
ii. Potential free contacts for initiating alarm on high temperature and trip on very high
temperature

d) Winding temperature indicator with

i. necessary sensing, compensating and calibrating devices
ii. Potential free contacts for initiating alarm on high temperature and trip on very high
temperature
iii. WTI transmitter for remote indication on remote tap changing panel.
e) Detachable type of radiators including but not limited to:

i. Shut-off valves and blanking plates on transformer tank at each point of connection
of inlet and outlet header
ii. Top and bottom shut-off valves and blanking plate on each radiator
iii. Lifting lugs
iv. Top oil filling plug
v. Air release plug at top
vi. Oil drain plug at bottom
vii. Earthing terminals
f) Pressure relief device for transformer tank
g) Weather - proof marshaling box mounted on transformer tank
h) Name plate, rating plate and Diagram plate
i) Valves and plugs as below:

i. Drain valve
ii. Filter valve
iii. Oil sampling valves at top and bottom
iv. Valves between radiators and tank (in case of detachable radiators)
v. Air release plug
vi. Twin outlets (with plug) for applying vacuum with attachments.
j) Earthing pads of copper or non-corrodible material for transformer tank (2 places) and
radiator banks
k) Inspection manholes as required
l) Lifting arrangement for
i. fully assembled transformer
ii. Core and coil
iii. Tank
m) Hauling eyes on each face of the transformer
n) Bi-directional flanged wheels
o) Anti-earthquake clamping devices
p) Jacking pads
Distribution transformers shall be provided with fire extinguishers in compliance with CBIP
guidelines.
Distribution transformers shall be provided with Nitrogen Injection Fire Prevention System
(NIFPS) measures in compliance with CEA (Measures relating to Safety and electric
supply) Regulations 2010 and CBIP guidelines.
15.4.1.4 Windings
The windings shall be of electrical grade copper.

Materials used in insulation and assembly shall be insoluble, non-catalytic and chemically
inactive in the hot transformer oil and shall not soften or otherwise be affected under
operating conditions. Windings and insulation shall be so arranged that free circulation of
oil is possible between coils, between windings, and between winding and core.
Leads from winding to the terminal board and bushings shall be rigidly supported to
prevent injury from vibration. Guide tubes shall be used where practicable.
Windings shall be subjected to shrinking and seasoning processes so that no further

shrinkage occurs during service. Adjustable devices shall be provided to take up possible
shrinkage in service. High voltage end - windings shall be suitably braced to withstand
short circuit stresses.
15.4.1.5 Core
The magnetic circuit shall be constructed from high grade, cold rolled, non-ageing, grain
oriented silicon steel laminations. Each sheet shall have an insulating coating resistant to
the action of hot oil. Each lamination shall be coated with insulation which is unaffected by
the temperature attained by the transformer during service.
The insulation structure for the core to bolts and core to clamp plates shall be such as to
withstand appropriate dielectric test. All steel sections used for supporting the core shall
be thoroughly shot or sand blasted after cutting, drilling and welding. Core laminations
shall be annealed and burrs removed after cutting. Cut edges shall be insulated. The
framework and clamping arrangements of core and coil shall be securely earthed inside
the tank by a copper strap connected to the tank. The core clamping structure shall be
designed to minimize eddy current loss. The core shall be provided with lugs suitable for
lifting the complete core and coil assembly. The framework and clamping arrangements
shall be securely earthed.
The core and coil assembly shall be dried out and impregnated under vacuum.
15.4.1.6 Tank
The transformer tank shall be made from high-grade sheet steel, suitably reinforced by
stiffeners made of structural steel sections. All seams, flanges, lifting lugs, braces, and
other parts attached to the tank shall be welded. The interior of the tank shall be cleaned
by shot blasting and painted with two coats of heat resistant, oil insoluble paint. Adequately
sized manholes shall be provided for ease of inspection and maintenance. Steel bolts and
nuts exposed to atmosphere, shall be galvanized.
Tank together with radiators, conservator, bushings and other fittings shall be designed to
withstand without permanent distortion the following conditions:
a) Full vacuum of 760 mm of Hg for filling with oil under vacuum
b) Internal gas pressure of 0.35 kg/cm² with oil at operating level
Tank shall be provided with a pressure release device, which shall operate at a pressure
below the test pressure for the tank and radiators. The device shall be provided with a
device visible from ground to indicate operation. An equalizer pipe connecting the pressure
relief device to the conservator shall be supplied. The device shall be provided with
potential free contacts for alarm and tripping. Alternatively, a separate pressure relay shall
be provided for this purpose.

The tank cover shall be bolted type and not welded, sealed type. The tank cover shall be
removable and shall be suitably sloped so that it does not retain rainwater.
15.4.1.7 Radiators
Radiators shall be designed to withstand the vacuum pressure conditions specified for the
tank. They shall be so designed as to completely drain oil into the soak pit and to prevent
formation of gas pockets when the tank is being filled.
Transformers of rating above 1500 kVA shall be equipped with detachable or separately
mounted radiator banks. Radiators for the main transformers shall be with bolted and
gasket flange connections. Transformers of rating 1500 kVA and below shall be provided
with fixed type radiators. Fins of the radiators shall not have sharp edges and shall be
rounded in shape.
When transformers are provided with separately mounted radiators, flexible joints shall be
provided on the main oil pipes connecting the transformer tank to the radiator banks, to
reduce vibration and facilitate erection and dismantling. The interconnecting pipes shall be
provided with drain plug and air release vents.
15.4.1.8 Marshalling Box
The marshalling box shall be tank mounted, weather proof, vermin proof, dust proof, sheet
steel (2 mm thick), enclosed and with hinged door having padlock. Door and gland plate
shall be fitted with neoprene gaskets. Bottom shall be at least 600 mm from grade level.
Top surface shall be sloped. The degree of protection shall be IP65.
Contacts / terminals of electrical devices / relays, etc. mounted on the transformer shall be
wired to the marshalling box. Interconnecting wires between the marshalling box and the
accessories / devices shall be either PVC insulated wires in GI conduits or PVC insulated,
armoured cables together with provision of double compression type, brass cable glands
at the marshalling box. The above mentioned cables as well as terminating the cables
shall be the Contractor's responsibility.
All contacts for alarm, trip and indication circuits shall each be electrically free, designed
for the auxiliary DC supply of 110 V /30 V and brought out to separate terminals in the
marshalling box. Terminals shall be rated for 10 A. Disconnecting / shorting type terminal
block shall be used for CT circuits.
In case of main transformers, provision for remote annunciation shall be provided with two
changeover contacts for alarm condition and two changeover contacts for trip condition for
each of the following conditions including but not limited to:
a) Buchholz alarm
b) Buchholz Trip
c) Oil Temperature high
d) Oil Temperature very high
e) Oil level low
f) Pressure relief device operated
g) Winding temperature high
h) Winding temperature very high
i) Conservator oil level low

15.4.1.9 Cable Terminations
Cable boxes shall have sufficient space for segregating the cable cores and for adequate
clearance in air between bare conductors at the terminals. Cable boxes shall be complete
with necessary glands, lugs and armour grips.
Air filled cable boxes shall be of adequate dimensions and designed in such a manner that
they can be opened for inspection without disturbing the gland plate or incoming cable.
Disconnecting chamber shall be provided for disconnecting and moving away the main
transformer, without removing the cables or the cable box. Provision shall be made for
earthing the body of each cable box.
15.4.1.10 Tests
All tests required by the specification including repeated tests and inspection that may be
necessary owing to the failure to meet any tests specified, shall be carried out at the
Contractor's expense.
The following tests shall be carried out on the assembled transformer during inspection at
the manufacturer’s works.
a) Temperature rise test on one transformer
b) Measurement of resistance of windings at principal and extreme taps
c) Ratio at each tap, polarity and phase relationships
d) Measurement of impedance voltage at principal and extreme taps
e) Measurement of no load current and no load losses at rated frequency and at both the
rated voltage and 110 % rated voltage
f) Measurement of efficiency and regulation at ½, ¾ and full load
g) Measurement of insulation resistance
h) Induced over voltage withstand test
i) Separate source voltage withstand test
j) Magnetic balance test
k) Test on OLTC
Type test certificates shall be provided for verification. Whenever two nos. or more identical
transformers are being offered, type tests on one of them shall be carried out, including
heat run test.
All auxiliaries and accessories such as temperature indicators, Buchholz and pressure
relays shall be tested as per the applicable standards and test certificates shall be
furnished to the Employer’s Representative for approval.
15.4.1.11 Rejection
The Employer may reject the transformer if anyone of the following conditions arises during
Factory Acceptance testing:
Any of the quantities / parameters of transformers subject to tolerances are outside the
tolerances given in the applicable standards or such tolerance as guaranteed in the
Contractor's bid.
Voltage ratio at no load not within the limits of tolerance over the guaranteed value.
No Load and Load losses exceeding the guaranteed loss value by more than 15%
Impedance voltage at principal tapping not within the limits of tolerance over the
guaranteed value.

a) Winding and / or top oil temperature rise exceeds the specified / guaranteed value;
and
b) Transformer fails to withstand any of the dielectric tests.
Additional tests shall be conducted to locate the failure and after rectification, all tests shall
be repeated to prove that the rebuilt transformer meets the specification in all respects, all
at the Contractor’s expense.
ENGINEER reserves the right to have the transformer replaced or repaired by the
Contractor within reasonable period to Employer's satisfaction at no extra cost to the
Employer. The Contractor shall also bear the costs, including but not limited to, incurred
by the Employer in re-inspection / re-testing such as travel and incidental expense, etc.
The Contractor shall note that any delay in completion time due to such repair /
replacement shall be subject to liquidated damages as specified in the Conditions of
Contract.
15.4.2 High Voltage Switchgear and Controlgear Assembly
15.4.2.1 General
High voltage switchgear and controlgear assemblies or switchboards shall be of the indoor
type and conform to the latest version of IEC 62271-200, Internal Arc Classified(IAC) -
AFLR-25 kA for 1 second (or as per system short circuit calculation) and Loss of Service
Continuity category -LSC-2B for use on a 22kV/11kV system as applicable. It shall be
internal arc type tested for short circuit capacity on four sides; shall have metal partitions;
and shall conform for loss of service continuity. It shall have porcelain-clad gang operated,
triple pole vacuum circuit breaker/SF6 circuit breaker. Adequate phase clearance and
height shall be provided to meet standard and safety requirements. The circuit breakers
shall be fully draw out type with distinct ‘service’, ‘test’ and ‘isolated’ positions.
Switchboards shall be dust, moisture and vermin proof. The degree of protection of
enclosure shall be IP 4x. Switchboards shall be suitable for 3 phase, earthed A.C. system.
15.4.2.2 Standard
HV indoor VCB switchboard shall comply with the following Standards, including those
referred to therein.
IEC 62271-1 High-voltage switchgear and controlgear - Part 1: Common

specifications for alternating current switchgear and controlgear
IEC 62271-100 high-voltage switchgear and controlgear – part 100: alternating-
current circuit-breakers
IEC 62271-102 Alternating current disconnectors and earthing switches
IEC 62271-103 High voltage switchgear and controlgear: Switches for rated voltage
above 1 kV up to and including 52 kV.
IEC 62271-107 High voltage switchgear and controlgear: Alternating current fused
circuit Switches for rated voltage above 1 kV up to and including 52
kV.
IEC 62271-200 high-voltage switchgear and controlgear - part 200: ac metal-
enclosed switchgear and controlgear for rated voltages above 1 kv
and up to and including 52 kv.
IEC 60282 high voltage fuses

IEC 60529 Degrees of protection provided by enclosures

IEC 60255 Measuring relays and protection equipment
IEC 61211 Insulators of ceramic material or glass for overhead lines with a
nominal voltage greater than 1 000 V - Impulse puncture testing in
air
IS:722 AC electricity meters
IS:2705 Current Transformer
IS:3156 Voltage Transformer
IS 3427 A.C. Metal Enclosed Switchgear and Controlgear for Rated Voltages
Above 1 kV and Up to and Including 52 kV
IS:4237 General requirements for switchgear and controlgear for voltages not
exceeding 1 000 volts ac or 1 200 volts dc
IS 9920 High Voltage Switches, Part 1: Switches for Rated Voltages Above
1 kV and Less Than 52 kV.
IS 9921 Alternating Current Disconnectors (isolators) and Earthing Switches
for Voltages Above 1000 V.
IS 12729 Common High-Voltage Switchgear and Controlgear Standards
IS 10118 Code of Practice for Selection, Installation and Maintenance of
Switchgear and Controlgear.
IS 13118 High-Voltage Alternating Current Circuit Breakers
15.4.2.3 Circuit Breaker
Circuit breakers shall be vacuum type. Circuit breaker along with its operating mechanism
shall be mounted on a wheeled carriage moving on guides, designed to align correctly and
allow easy movement. Plugs and sockets for power circuits shall be silver faced and shall
be insulated with suitable insulating material shrouds. All corresponding components of
circuit breaker cubicles of same rating shall be interchangeable with one another.
There shall be ‘Service’, ‘Test’ ‘Fully withdrawn’ positions for the breakers. In the ‘Test’
position the circuit breaker shall be capable of being tested for operation without energizing
the power circuits, i.e. the control circuits shall remain undisturbed while the power
contacts shall remain disconnected. Separate limit switches, each having a minimum of 2
‘NO’ + 2 ‘NC’ contacts, shall be provided for both ‘Service’ and ‘Test’ positions of the circuit
breakers for SCADA.
Electrical tripping shall be performed by shunt trip coils. “Local / Remote” selector switch
lockable in “Local” position shall be provided on the cubicle door. `Red’ and `Green’
indicating lamps shall be provided on cubicle door to indicate breaker close and open
positions. Breaker “Service” and “Test” positions shall be indicated by separate indicating
lamps on the cubicle door, in case mechanical indication of “Service” and “Test” positions
are not available on the cubicle door.
Connection of the control / interlocking circuits between the fixed portion of the cubicle and
the breaker carriage shall be preferably by means of plug socket arrangement.

15.4.2.4 Operating Mechanism Control
a) Circuit breakers shall be operated by a motor spring charging type of mechanism. The
mechanism shall be complete with motor, opening spring, closing spring and all
accessories to make the mechanism a complete operating unit
b) Operating mechanism shall normally be operated from the breaker cubicle itself.
c) The tripping spring shall be charged by the closing action, to enable quick tripping.
Closing of the circuit breaker shall automatically initiate recharging of the springs to
enable the mechanism to be ready for the next closing stroke. Charging time for the
springs shall not exceed 30 seconds. It shall be possible to manually charge the
springs in an emergency. Transfer from motor to manual charging shall automatically
disconnect the charging motor. All operating mechanisms shall be provided with "ON"
- "OFF" mechanical indication. The charging mechanism shall be provided with
mechanical indicators to show "charged" and "discharged" conditions of the spring.
Failure of any spring, vibration or mechanical shock shall not cause tripping or closing
of the circuit breaker.
d) Only one closing operation of the circuit breaker shall result from each closing impulse
(manual or electrical), even if the breaker trips while the control device (manual or
electrical) is being held in the "close" position.
e) The circuit breaker mechanism shall make one complete closing operation, once the
push button (PB) or control switch has been operated and the first device in the control
scheme has responded, even though the PB or control switch is released before the
closing operation is complete, subject to the condition that there is no counter- impulse
for tripping.
f) Means shall be provided to manually open and close the breakers slowly, when the
operating power is not available, for maintenance and adjustments. A local manual trip
device shall also be provided on the operating mechanism.
g) Circuit breaker control shall be on 110 V DC. Closing coils and other auxiliary devices
shall operate satisfactorily at all voltages between 85-110 % of the control voltage. Trip
coils shall operate satisfactorily between 70 -110 % the rated control voltage.
h) Provision for remote control shall be provided .
15.4.2.5 Safety Interlocks and Features
a) Withdrawal or engagement of a circuit breaker / switch disconnector shall not be

possible unless it is in the open position.
b) Operation of a circuit breaker / switch disconnector shall not be possible unless it is in
service position, withdrawn to test position or fully drawn out. It shall not be possible to
close the circuit breaker electrically in the service position, without completing the
auxiliary circuit between the fixed and moving portions.
c) Circuit breaker / switch disconnector cubicles shall be provided with safety shutters
operated automatically by the movement of the circuit breaker / switch disconnector
carriage to cover the stationary isolated contacts when the breaker / switch
disconnector is withdrawn. Padlocking facilities shall be provided for locking the
shutters positively in the closed position. It shall, however, be possible to open the
shutters intentionally against spring pressure for testing purposes.
d) The circuit breaker / switch disconnector carriage shall be earthed before the circuit
breaker / switch disconnector reaches the test position from fully withdrawn position.
In case of breakers / switch disconnector with automatic disconnecting type of auxiliary
disconnects, the carriage shall be earthed before the auxiliary disconnects are made
and the carriage earthing shall break only after the auxiliary disconnects break.
e) Caution nameplate, “Caution Live Terminals” shall be provided at all points where the
terminals are likely to remain live and isolation is possible only at remote end, i.e.
incomer to the switchboard. Suitable interlock shall be wired for the purpose.

15.4.2.6 Current and Voltage Transformers
CTs and VTs shall have polarity marks indelibly marked on each transformer and at the
associated terminal block. Facility shall be provided for short-circuiting and earthing the
CT secondary at the terminal blocks.
CT shall be able to withstand the thermal and mechanical stresses resulting from the
maximum short circuit current. Core laminations shall be of high grade silicon steel.
VTs shall be of the single phase type and mounted on a draw out trolley. VTs shall be
protected on their primary and secondary sides by current limiting fuses with interrupting
ratings corresponding to breaker rating. It shall be possible to replace the secondary fuses
safely when the switchboard is energized. Alternatively, MCB having auxiliary contact shall
be provided. Primary side fuses shall be replaceable only in the de-energized position.
Secondary winding of voltage transformer (VT) shall be rated for a three phase line to line
voltage of 110 V.
Identification labels giving type, ratio, output and serial numbers shall be provided for CTs
and VTs.
15.4.2.7 Relays
All relays shall conform to the requirement of IS: 3231, IEC 60255, IEC 61000.
Protection relays shall be Numerical (microprocessor based) type. All the numerical relays
shall be equipped with RS-485, Modbus TCP..
All relays shall be enclosed in rectangular shaped, dustproof cases and shall be suitable
for flush mounting.
All relays shall be accessible from the front for setting and resetting. Access to setting
devices shall be possible only after the front covers of the relays are removed.
All protective relays shall be of the draw-out type and shall be provided with operation
indicators visible from the front.
Relays on VFD feeder shall be able to measure and record harmonics apart from Current
and frequency.
Current input should be rated for both 1A & 5A. CT supervision feature shall be available.
15.4.2.8 Over Current / Earth Fault Protection
This relay shall be of the multi-characteristics type which has a flexible mode selection
facility so that it is possible to select one mode for the over current elements and another
for the earth fault element.
Phase current range shall cover at least 50-300% of ‘In’ in steps of not more than 10%
while the earth current range shall cover at least 5-100% of ‘In’ in steps of not more than
5%.
The time setting range of the definite time mode shall not be less than 5 seconds in steps
of 0.1 second each.

The time multiplier setting for the inverse time-current characteristic modes shall have a
range not less than 0.05- 1.6 in steps of 0.05.
Over current and earth fault relays shall have separate timers and operation indicators.
The high set element shall have a range of 2 - 15 times the nominal current in steps of ‘In’
and shall be of low transient overreach, with a tripping time of less than 25 ms and possible
to be selected on "blocked" position. Reset time shall be not more than 50 ms for both
elements.
The relays that are installed on the transformer neutral side shall be of single phase
version, but they shall have the same characteristics as the phase side relays.
15.4.2.9 Restricted Earth Fault Protection
The restricted earth fault relay shall be operated from a completely separate core of line
and neutral current transformers. The dedicated CTs shall be of class PS and have the
same magnetization characteristics with a knee ‘emf’ value higher than the highest
possible setting of the relay. Intermediate CTs for ratio correction are not acceptable. CT
sizing shall be matched with the requirements of the relay.
For this protection, 1-phase high impedance relay shall be provided and all the aspects
regarding stability of the protection, dimensioning of current transformer, considering the
peak short circuit current, etc. and all the auxiliary equipment such as non-linear VDR
resistor for voltage limiting, filter for harmonics and DC component suppression and
variable shunt resistor for sensitivity adjustment, if required, shall be provided. The total
fault clearing time shall not exceed 20 m sec. at 3 x In.
The stability of this protection against out-zone faults shall be confirmed. A calculation to
show the proper selection of the relay up to the maximum short circuit of the switchboard
shall be submitted.
15.4.2.10 Under Voltage Relays
Suitable voltage operated relays for sensing loss of voltage shall be provided. The relay
shall have a drop off to pick up ratio of the order 90%. The relays shall be fast operating
type and shall be fitted with operation indication. The indication shall come on drop off or
loss of voltage.
Additional potential free contacts for all the relay outputs i.e. trip as well as alarm signals
shall be provided for connection to SCADA.
15.4.2.11 Auxiliary Relays and Timers
Following auxiliary relays shall be provided on each breaker cubicle:

i. Trip circuit supervision relay
ii. Anti- pumping relay
Hand reset type lockout (tripping) relays and timers shall be provided as required in
addition to the protection relays given in the single line diagram.
Auxiliary relays and timers shall be rated to operate satisfactorily between 70% and 110%
of the rated voltage.

Voltage operated relays with sufficient contacts to initiate tripping, alarm, annunciation for
various trip functions like Buchholz relay operation. Each relay shall have four (4) pairs of
self-reset contacts except for Buchholz and "PRD" trip which shall have hand-reset
contact. The relays shall have hand-reset operation indicators.
Voltage operated relays with sufficient contacts to initiate alarm and data logging for
various alarm functions for transformers, etc. shall be provided. Each relay shall have four
(4) normally open self-reset contacts. The auxiliary relay for Buchholz alarm shall be
slugged to have delay on drop off at 100 ms. The relays shall have hand reset operation
indicator.
15.4.2.12
15.4.2.13 Constructional Features of Switchboard
Switchboard design shall comprise metal enclosed, fully compartmental and draw out
execution having separate sections for each circuit. Compartments with doors for access
to operating mechanism shall be so arranged as not to expose high Voltage circuits.
Switchboard cubicle shall be provided with hinged door on the front with facility for locking
door handle.
Switchboard shall be dust and vermin-proof and shall have a degree of protection of
enclosure of IP 4X.
All removable covers shall be gasketed all around with neoprene or superior gaskets.
Instruments, relays and control devices shall be flush-mounted on hinged door of the
metering compartment located in the front portion of cubicle. The metering compartment
shall be properly shielded to prevent mal-operation of electronic equipment such as
numerical / static relays due to electro-magnetic fields. Separate signal earth shall be
provided for such devices, if necessary.
Each switchboard cubicle shall be fitted with a label on the front and rear of the cubicle.
Each switchboard shall also be fitted with label indicating the switchboard designation,
rating and duty. Each relay, instrument, switch, fuse and other devices shall be provided
with separate label.
Sheet steel used for fabrication of switchboards, control cabinets, marshalling boxes, etc
shall be cold rolled.
All panels, cabinets, kiosks and boards shall comprise rigid welded structural frames made
of structural steel sections or of pressed and formed cold rolled sheet steel of thickness
not less than 2 mm. The frames shall be enclosed by sheet steel of at least 2 mm thickness.
Stiffeners shall be provided wherever necessary.
All doors, removable covers, gland plates, etc. shall be of at least 2 mm thickness and
shall be gasketed all-round the perimeter.
All doors shall be supported by strong hinges of the disappearing or internal type and
braced in such a manner as to ensure freedom from sagging, bending and general
distortion of panel or hinged parts.
All floor mounted panels / boards shall be provided with a channel base frame.

It shall be possible to extend the switchboard on both sides.
The fully draw-out modules shall have all the circuit components mounted on withdrawable
type steel chassis. All power and control connections shall be of the draw out type. It shall
be possible to withdraw the chassis mounted circuit components without disconnecting
any connections. All draw-out contacts shall be of silver plated copper.
In case of circuit breaker compartments, suitable barriers shall be provided between

breaker and all control, protective and indication circuit equipment including instrument
transformers such that no live parts are accessible. External cable connections shall be
through separate cable compartments for power and control cables.
One metal sheet shall be provided between two adjacent vertical sections running to the
full height of the switchboard except for the horizontal busbar compartment. However,
each shipping section shall have metal sheets at both ends.
After isolation of the power and control connections of a circuit, it shall be possible to carry
out maintenance in a compartment safely, with the bus bars and adjacent circuits alive.
15.4.2.14 Earthing
An Aluminium or Galvanised iron earthing bus shall be provided and extended throughout
the length of the switchboard. It shall be bolted to the framework of each unit and brazed
to each breaker earthing contact bar. It shall be located at the bottom of the board.
The earth bus shall have sufficient cross section to carry the momentary short circuit and
short time fault current for at least 1 second or higher as specified, without exceeding
maximum allowable temperature rise. The earth bus shall be properly supported to
withstand stresses induced by the momentary short circuit current.
Suitable clamp type terminals at each end of the earth bus shall be provided to suit the
size of the earthing conductors.
Bolted joints, slices, tap, etc. to the earth bus shall be made with at least two bolts.
Positive earthing of circuit breaker frame shall be maintained when it is in the connected
position and in all other positions whilst the auxiliary circuits are not totally disconnected.
Hinged doors shall be earthed through flexible earthing braid of adequate cross section.
All non-current carrying metal work of the switchboard shall be effectively bonded to the
earth bus.
Positive connection of the frames of all the equipment mounted in the switchboard to the
earth busbar shall be maintained through insulated conductors of size equal to the earth
busbar or the load current carrying conductor, whichever is smaller.
All instrument and relay cases shall be connected to earth busbar by means of 1100V
grade, green colored, PVC insulated, stranded, tinned copper, 2.5 sq. mm conductor
looped through each of the earth terminals.
15.4.2.15 Circuit / Busbar Earthing Facility
It shall be possible to connect each circuit or set of 3 phase bus bars of the switchboard
to earth through earthing switches.

Earthing switches / earthing devices shall be mechanically interlocked with the associated
breakers / switch disconnector to prevent accidental earthing of live circuit or bus bars.
In case the earthing facility comprises earthing trucks to be inserted in place of circuit
breakers, separate earthing trucks shall be supplied for each type / size of breaker.
The earthing facilities proposed to be provided by the Contractor shall be clearly detailed
in the Bid and shall be subject to ENGINEER or their representative 's approval.
Auxiliary contacts (min. 2 NO + 2 NC) shall be provided on each earth switch / earthing
device and shall be wired to the terminal block for interlocking purpose.
15.4.2.16 Annunciators
Annunciators shall be of facia type with translucent plastic window for each alarm point.
Annunciator facia plates shall be engraved in block lettering with respective alarm
inscriptions. The inscriptions shall be clearly readable and visible when the respective facia
light is lighted.
Each annunciation window shall be provided with two lamps to provide redundancy against
lamp failure. Lamps shall be replaceable from the front. Lamps shall be of clustered LED
type.
All facia annunciator points shall be suitable to accept external contacts of either ‘NO’ or
‘NC’ self or hand reset type for initiating the annunciation sequence. Annunciators shall be
suitable for accepting fleeting faults of duration as less as 15 millisecond.
For static annunciator schemes, special precaution shall be taken by the Contractor to
ensure that spurious alarm conditions do not appear due to influence of external magnetic
fields on the annunciator wiring and switching disturbances from the neighboring circuits
within the panels / desks.
A “Lamp Test” push button shall be provided for each individual panel’s group of
annunciators to limit the sudden drain on the battery.
Provision of testing facilities for flasher and audible alarm circuits of annunciators is
desirable. The Contractor shall give the details of the offered scheme.
Annunciators shall have following features:
Suitable for annunciating subsequent faults immediately after the sound cancel of the
previous fault.
During lamp test, if a fault occurs, the corresponding lamp circuit shall be automatically
disconnected from the “lamp test” circuit and shall start flashing.
Designed to prevent mal-operation of the scheme or sequence when the push buttons are
pressed incorrectly or in the wrong order.
"Alarm Supply Failure” Alarm scheme similar to the normal annunciation sequence, but
shall operate on a different DC supply or on AC auxiliary supply.

15.4.2.17 Instruments
All electrical instruments and meters shall comply with IEC:60051, IEC 61010 and IS :722,
IS:1248.
All indicating and recording instruments shall be flush mounted in dust proof cases
complying with IEC 60068 and dimensions to IEC 61554. All digital instruments shall have
interface facilities to communicate data to SCADA system.
15.4.2.18 Indicating Instruments
Instruments shall have accuracy class of 1.0 or better. The design of the scales shall be
such that it can read to a resolution corresponding to 50% of the accuracy class index.
Instruments shall be electronic / digital type with LCD display. These instruments should
have high performance ratio and can be equipped with digital output (for alarms) or with
interfacing facilities for communication and remote reading of parameters.
15.4.2.19 Metering instruments
All meters and instruments shall be suitable for operation at a frequency of 50 Hz with
current transformers having 5 or 1 ampere secondary circuits and potential transformers
having 110 volt secondaries as applicable.
Watt-hour and Varhour meters shall be of the three phase two element type of accuracy
class 1.0, suitable for measurement of unbalanced loads in three phase three wire circuits.
Multifunction meter with full compliance to IEC 62053-21 for Class 1.0 and Harmonic
parameters as per IEC 61557-12 standards,
Watt-hour and Varhour meters shall be suitable for operation from the secondary of CTs
and VTs. They shall be provided with a separate 3 phase 4 wire type test blocks for the
testing of the meters without disturbing the CT and VT secondary connections.
Meters shall have digital type of registers. They shall read kWh, kVARh or MWh, MVARh
as the case may be without the use of additional multiplying factors. Multiplying factors if
unavoidable shall be multiples of 10 (ten). Number of digits provided shall be adequate to
cover at least 1000 hrs. of operation.
Instruments shall be electronic / digital type with LED or LCD display. These instruments
should have high performance ratio and can be equipped with digital output (for alarms)
or with interfacing facilities for communication and remote reading of parameters.
Resistors, reactors and other devices which may be required to complete the meter
installation shall be furnished.
Each voltmeter and ammeter shall be provided with a selector switch for reading each
phase-value.
All instruments, meters, relay metal cases and parts and miscellaneous metal devices
shall be effectively grounded.
All the incomers, outgoing feeders and motor feeders shall be provided with digital multi-
function meters with RS-485 port, Modbus TCP.

15.4.2.20 Control and Selector Switches
Control and instrument switches shall be rotary type, provided with escutcheon plates
clearly marked to show operating position and suitable for semi-flush mounting with only
the switch front plate and operating handle projecting out. The connections shall be from
the back. The contact assembly at the back of the switch shall be enclosed in dust tight
removable covers.
The control switches shall be 3 position, spring return to neutral type. They shall be
provided with contacts to close in ‘normal after close’ and ‘normal after trip’ position. Each
switch shall have external red and green indicating lamps, (except when discrepancy type
switches are called for). In addition, a semaphore indicator shall be provided for earthing
switch.
Contacts of the switches shall be spring assisted and contact faces shall be of silver / silver
alloy. Springs shall not be used as current carrying parts. Contact rating and configurations
of the switches shall be adequate for the functions desired.
Instrument selector switches shall be of the maintained (stay-put) type. Ammeter selector
switches shall have make-before-break type contacts so as to prevent open circuiting of
CT secondary when changing the position of the switch.
Lockable type switches, which can be locked in a particular position, shall be provided, if
required.
Emergency stop buttons, if any, shall incorporate ‘stay-put’ features with independent reset
facilities.
15.4.2.21 Indicating Lamps / Pilot Lights
Indicating lamp shall be of the double contact, bayonet cap type rated for operation at
either 240 V AC or at the specified DC system voltage as applicable. Lamps shall be
provided with translucent lamp covers.
Clustered LED type lamps shall be provided Lenses shall be glass or plastic in standard
colors, red, green, blue, white and amber, in accordance with IEC 60073.
Bulbs and lenses shall be interchangeable and easily replaceable from the front of the
panel. Tools, if any, which are required for replacing the bulbs and lenses, shall also be
included in the scope of supply.
Miniature pilot lamps may be provided with plastic marking plate contained inside square
(or rectangular) front lens to provide indication of legend or symbols engraved on the
marking plate.
The basis of colors shall be as follows:
Red : Flow of energy.

Green : No flow of energy.
White : Supervision of power available, relay coil healthy, etc.
Amber : Disagreement with original condition, ‘abnormal’ condition or
‘sequence–on’ condition.

15.4.2.22 Push Buttons
Push buttons shall be of momentary contact type with rear terminal connections. The color
of the push button actuator shall be red for ‘OPEN / STOP’ and green for ‘CLOSE / START’
and for other applications shall be as per specified requirements. The push button knob
shall be suitably shrouded to prevent inadvertent operation. The push buttons shall be
provided with integral inscription plates engraved with their designation.
All push buttons shall have independent, potential free, 2NO + 2NC contacts. The contact
faces shall be of silver / silver alloy. The contacts shall be rated 10A and capable of
breaking inductive load of 1A at 110V DC and 5A at 110V AC.
15.4.2.23 Space Heaters
Adequately rated anti-condensation space heaters shall be provided for each switchboard
/ cubicle.
Space heater shall be of the industrial strip continuous duty type, rated for operation on a
240 V, 1 phase, 50 Hz, AC system.
Space heater shall be provided with a single pole MCB with overload and short circuit
release, a neutral link and a thermostat to cut off the heaters at 350 C.
15.4.2.24 Cubicle Lighting / Receptacle
Each cubicle shall be provided with interior lighting by means of 18 W fluorescent tube or
9 W LED lighting fixture. An MCB shall be provided for the lighting circuit. The lighting
fixture shall be suitable for operation from a 240 V, 1 ph, 50 Hz, AC supply.
A 240 V, 1 phase, AC receptacle (socket) plug point shall be provided in the interior of
each panel with an MCB.
15.4.2.25 Power and Control Cable Terminations
Terminals for power connections shall be complete with adequate phase segregating
insulating barriers, shrouds and suitable crimping type of lugs for terminating the cables.
Double compression type glands with armour and bonding clamps for the termination of
all solid dielectric multicore cables shall be provided. They shall be designed to secure the
armour wires to provide electrical continuity between the armour and the threaded fixing
component of the gland and to provide watertight seals between the cable outer sheath
and gland and between the inner sheath and threaded fixing component. The gland shall
preferably project above the gland plate to avoid entry of moisture.
Earthing connectors between cable armour and earth shall be routed outside the cable
gland in an approved manner. Gland insulation shall be capable of withstanding test for
appropriate high Voltage for one minute.
Cable terminations for HV / MV cables shall be heat / cold shrinkable type. Adequately
sized shrouds/ bolts shall be provided at connections to completely cover the terminations.
Where core-balance type current transformers are provided on the feeder cables for earth
fault protection, glands for cables shall be insulated from earth in an approved manner.

15.4.2.26 Wiring for Control and Protective Circuits
All low voltage wiring for control, protection and indication circuits shall be carried out with
1100 V grade, PVC insulated cable with stranded, tinned copper conductor of minimum
1.5 sq. mm size. The size of conductor for CT circuits shall be minimum 2.5 sq. mm.
All wiring shall be run on the sides of panels and shall be neatly bunched and cleated
without affecting access to equipment mounted in the panel.
The wiring shall be bound and supported by clamping, roughing or lacing. Spiral wrapping
will not be accepted. Wire ways shall not be more than 50% full. Adequate slack wire shall
be provided to allow for one re stripping and reconnection at the end of each wire. When
screened cables or wires are necessary, an insulating sheath shall be included.
Wiring and supports shall be of fire resistant low smoke material.
Wiring shall only be jointed or teed at terminals. Terminals of the clamp type shall not have
more than two wires connected.
15.4.2.27 Terminations and Ferrules
Engraved core identification ferrules, marked to correspond with the wiring diagram, shall
be fitted to each wire and each core of multicore cables terminated on the panels.
Moisture and oil resisting insulating material shall be used. The ferrules shall be of the
interlocking type and shall grip the insulation firmly without falling off when the wire is
removed.
All wires forming part of a tripping circuit shall be distinctively marked.
Spare auxiliary contacts of electrical equipment shall be wired to terminal blocks.
15.4.2.28 Control Wiring Terminal Blocks
Terminal blocks shall be of 1000 V grade and stud type. Brass stud of at least 6 mm dia.
with fine threads shall be used and securely locked within the mounting base to prevent
turning. Each terminal shall comprise two threaded studs, with a link between them,
washers, and matching nuts and locknuts for each stud. Connections to the terminals shall
be at the front.
Terminals shall be numbered for identification, grouped according to function. Engraved

‘black on-white’ labels shall be provided on the terminal blocks describing the function of
the circuit.
Terminals for circuits with Voltage exceeding 110 V shall be shrouded. Terminal blocks at
different voltages shall be segregated into groups and distinctively labeled.
Terminals used for connecting current transformer secondary leads shall be ‘disconnecting
and shorting’ type with a facility for earthing the secondary.
Terminal blocks shall be arranged with 100 mm clearance, between any two sets.
Separate terminal stems shall be provided for internal and external wiring respectively.

All wiring shall be terminated on terminal blocks, using crimping type lugs or claw type of
terminations.
15.4.2.29 Electronic Equipment
Electronic equipment shall be capable of withstanding randomly phased transient over

voltages of either polarity on the power supply or interruptions of the power supply without
damage or impairment to the equipment's subsequent performance. In the case of
controls, no mal-operation shall occur.
Where manufacturers require that electronic equipment supplied under this Contract
should not be subjected to insulation resistance tests ('Meggering'), suitable warning
notices shall be provided and installed in appropriate locations. When specified by
manufacturers, separate shield / signal earthing shall be provided.
It shall be possible to remove / replace cards from / to electronic equipment without

damage and without interfering with the operation of the rest of the equipment or system.
If necessary, consideration should be given to switching off the supplies locally to a card
to prevent inadvertent interference to the equipment or system during removing / replacing
a card.
Electronic equipment shall not use local internal batteries unless the approval of the
Engineer has been obtained. Where approval is given, batteries used inside equipment
shall be of the totally sealed, leak proof type.
15.4.2.30 Interference
a) Self-Generated Interference
Equipment shall not generate any type of interference at a level, which could be
detrimental to the performance of any other equipment / component or which could
cause annoyance or discomfort to personnel.
The earthing and cabling arrangements shall be such that detrimental interference is
not generated.
b) External Interference
In the presence of interference expected in substation environments, the design of the

equipment shall be such that no damage occurs and performance is maintained to the
requirements of the individual specifications.
c) Spark Quenching
Spark quenching devices shall be fitted wherever necessary to ensure continued

satisfactory operation of contacts and prevent mal-operation of electronic devices.
d) Noise and Vibration
The acoustical noise levels and / or vibration produced by the equipment in operation
shall be as low as is reasonably practicable for the type of equipment concerned and
shall be agreed with the Engineer.

15.4.2.31 Setting-Up and Maintenance Facilities
All equipment shall be provided with sufficient easily accessible test points to facilitate
setting-up and fault location together with maintenance aids such as extension boards,
jumper leads and special maintenance tools.
Pin or terminal numbering of all cards in all crates shall be consistently uniform throughout.
Power supplies shall use the same pin positions on all cards in an equipment or system.
15.4.2.32 Loose Equipment
Special connecting leads, extension boards and any special item required for calibration
or maintenance purposes, together with the mating half of all necessary connectors shall
be supplied.
15.4.2.33 Printed Circuit Boards
Printed circuit boards shall be epoxy glass fabric boards to comply with IEC - 60194
suitable for use in hot humid climates. Printed circuit boards may be single-sided, double-
sided or multi-layer.
Printed boards shall, in general, comply with IEC 60721.
They shall not bow perceptibly when they are mounted in their shelves or racks. Means
shall be provided to prevent boards being plugged into the wrong sockets and the plugging
in / out action shall be arranged in a positive manner.
An approved protective coat shall be applied to the printed circuit side of the board to
protect against tracking, tarnishing and general deterioration due to moisture and
deposition of dust. The coating shall not have any adverse reaction with any other material
or components used and shall be suitable for use under tropical conditions. When boards
are repaired in the field it shall be possible to apply (or 'touch up') such a finish by simple
convenient means.
15.4.2.34 Component Identification
a) A component reference number shall be marked adjacent to each component. Where

this is impossible, components shall be identifiable from the layout drawings provided.
b) The following shall be marked in all instances:
i. Fuses
The rating and the circuit identification of each fuse shall be marked adjacent to
the fuse base.
ii. Control, Protection and Indication Devices
The function of each control, protection and indication device shall be marked. The
caption and its arrangement shall be subject to the approval of the ENGINEER or
their representative’s Representative.

iii. Preset Controls
The circuit reference and if possible, the function shall be marked adjacent to each
preset control in a position where it will be clearly visible while the adjustment is
being made.
iv. Connectors
The diagram reference number shall be marked on or adjacent to each connector.
c) Test points shall be individually marked with the diagram reference number.
d) The polarity of any polarized devices (e.g. diodes) shall be marked.
15.4.2.35 Test Terminal Blocks
Test terminal blocks, if any, shall be provided for secondary injection and testing of relays.
A suitable metering block shall be provided where specified for the connection of a portable
precision instrument to be operated when required for specific plant testing purposes.
15.4.2.36 Tests
The following routine tests shall be carried out on the assembled switchboard / panel
during inspection at the manufacturer’s works in addition to other tests as per applicable
standards.
i. Primary injection tests to ensure correct ratios and polarity of current and voltage
transformers and of the current operated protection relays and direct acting coils, over
their full range of settings.
ii. Balance earth fault stability test by primary current injection. Care must be taken to
reproduce accurately the burdens of interconnecting cables. A further test to ensure
correct polarity must be made after assembly.
iii. Tests on auxiliary relays at normal operating voltages by operation of associated
remote relays.
iv. Correct operation of sequencing and control circuits at normal operating voltages by
operation of local control switches, and simulation of operation from remote control
positions.
v. Carry out functionality tests, check interfacing status contacts and instrumentation.
vi. Checking of Differential protection relay.
vii. One minute power-frequency voltage dry withstand tests on the main circuits
viii. One minute power-frequency voltage dry withstand tests on auxiliary circuits
ix. Insulation resistance tests
x. All circuit breakers shall be subject to the following tests:
a) Routine tests including HV pressure test, millivolt drop tests and mechanical tests.
b) To ensure the operation of the dc closing coil and satisfactory closing of the circuit
breaker with the voltage of the coil down to 80% of its rated voltage, and that mal-
operation does not occur with a voltage on the coil of 120% of its rated voltage.
c) Interchangeability of withdraw able identically equipped circuit breakers, and
checking of all mechanical and electrical interlocks.
Type test figures for heat test runs performed on identical panel types shall be made available.
Following minimum type test reports shall be submitted for the evaluation.

All short circuit duties from test duty 1 to test duty 5 including single phase and double line
to ground as per IEC62271-100.
• Short time rating of 25kA for 3 seconds as per IEC 62271-100,62271-200.
• Temperature rise test as per IEC 62271-200.
• Cable charging 25 A test as per IEC 62271-100 For test duties 1 to 4.
• Degree of protection test as per IEC 62271-200.
• Upto 600/1000 mm cubicle and upto 630A tested for IP-4X
• Lightning impulse voltage test as per IEC 62271-100, 62271-200
• Internal arc test in all the three high voltage compartments 25 kA 1 sec as per IEC
62271-200
15.4.3 Low Voltage Switchgear and Controlgear assembly
15.4.3.1 General
LV indoor switchgear and controlgear assembly or switchboard and its components shall
comply with the following National and International Standards, including those referred to
therein.
15.4.3.2 Standard
IEC 61439 : Low-voltage switchgear and controlgear assemblies

IEC 61641 : Enclosed low-voltage switchgear and controlgear assemblies - Guide
for testing under conditions of arcing due to internal fault.
IEC 60947 : Low Voltage switchgear and controlgear
IEC 60529 : Degrees of protection provided by enclosures
IS 4237 : General requirements for switchgear and controlgear for voltages not
exceeding 1000 volts ac or 1200 volts dc
IS:1248 : Direct Acting Indicating Analogue Electrical Measuring Instruments
and their Accessories
IS:722 : AC Electricity meters
IS:2705 : Current Transformers
IS:3156 : VOLTAGE TRANSFORMERS
IS:10118 : Code of Practice for Selection, Installation and Maintenance of
Switchgear and Control gear
IS:11353 : Guide for Uniform System of Marking and Identification of Conductors
and Apparatus Terminals.
IS/IEC 60947 : Low voltage switchgear and controlgear
These cover the main switchboard and distribution boards. The distribution board shall be
of floor / wall mounting type. Entry for incoming and outgoing cables shall be from bottom.
Bus bars shall be of aluminium . Degree of protection of the panel shall be IP 5X.
The board shall be provided with circuits as required, ammeter with ammeter selector
switch and voltmeter with Voltmeter selector switch. Contractor shall furnish proposed
single line diagram of the board along with the Bid.
Incoming and outgoing circuit shall be protected by suitably rated ACBs/MCCBs.

The switchboard and its components shall be subjected to tests as per the applicable
standards.
Deviation from this requirement shall be subject to the approval of the ENGINEER or their
representative’s Representative.
Intelligent Motor Management device
The motor management device shall confirm to IEC 60947-4-1, 60947-5-5 & 60947-8 for
overload and thermistor protections. The device shall be suitable for operation at 50
Degree Celsius. The components in the main circuit (i.e. Current / Voltage measuring
devices) shall have rated operation voltage of up to 690V.
The device shall offer comprehensive motor management functions including Protection,
Monitoring, Control and Diagnostics functions.
The motor management & control device shall be modular in construction The device shall
have integrated communication port for direct link to higher level, with open protocol bus
system e.g. profibus preferably, without any routers or gateways in between. The
protection system shall be independent/autonomous of the automation system. i. e. Motor
protection & control shall continue to be available even in the event of a communication or
automation system failure.
The device shall have a control voltage of either 24V DC or a wide band control voltage
from 110 to 240 V AC, as applicable.
The basic unit shall have the following minimum status display
Device Readiness
Status of control supply
Feeder fault indication
Status of communication with PLC
The device shall have facility to test/reset as standard. It shall be possible to select
between manual reset (at the device) or remote reset (through PLC/SCADA from control
room)
The device shall have following minimum no. of Digital Inputs & Outputs as standard which
should be freely assignable.
4 Digital Inputs
2 Digital outputs (Potential free)
Optionally, It shall be possible to expand the no. of digital inputs / outputs if required
additionally using add-on modules
Functional Requirements
Protection Functions
The device shall incorporate the following protection function as standard

Overload protection with trip class adjustable from 5 to 30

The device should have an in-built Thermal Motor Model (Thermal Memory)
It shall be possible to adjust the reset time after an overload
Provision for connecting thermistor inputs
Phase failure protection
Unbalance protection with adjustable time delay
Stall protection with adjustable time delay
Monitoring Functions
The device shall incorporate the following monitoring function as standard
Over current monitoring with adjustable time delay

Under current monitoring with adjustable time delay
Earth fault Monitoring with adjustable time delay
When threshold value of above settings exceeds, it shall be possible to set the type of
response (Warning, Tripping, Signalling and Disable)
Motor Operating Hours monitoring

Motor Stop time monitoring
No. of starts monitoring
When threshold value of above protection setting exceeds, it shall be possible to set the
type of response (Warning, Signalling and Disable)
Additionally, the following monitoring functions shall be possible as an option and should
be provided for feeders wherever specifically asked for.
Under voltage monitoring

Power factor monitoring
Active Power Monitoring
Phase sequence monitoring
Temperature monitoring via PT100 / PT 1000, NTC, KTY 83/84 inputs
Recording the curves of measured values like current, voltage, power etc.
Monitoring of analogue values using Analog I/O modules
Control Functions
In order to minimize the wiring & interlocks, the device shall have built-in software logics
to achieve the various control functions like
Direct on line starter (DOL)

Reversing DOL (RDOL)
Automatic star delta starter
Configuring & Communication
The Contractor shall offer standard software for configuring the device. It shall be possible
to configure a device either individually or over a communication network. For this purpose,
provision for connecting a laptop should be available at the motor management device.

15.4.3.3 Bus Bars
The phase and neutral bus bars shall be of rating indicated in the corresponding single
line diagram. Bus bars shall be of aluminium as per standard IS:5082 and shall be provided
with minimum clearances as per standards.
All bus bars and bus taps shall be insulated with close fitting sleeve of hard, smooth, dust
and dirt free, heat shrunk PVC insulation of high dielectric strength, to provide a permanent
non-ageing and non-tracking protection, impervious to water, tropical conditions and fungi.
The insulation shall be non-inflammable and self-extinguishing type and in fast colors to
indicate phases. The dielectric strength and properties shall hold good for the temperature
range of 0 to 95 degree centigrade. If the insulating sleeve is not colored, bus bars shall
be color coded with colored PVC tape at suitable intervals.
Bus bar joints, if any, shall be of the bolted type with minimum 4 bolts. Spring washers
shall be provided to ensure good contact at the joints. Bus bars shall be thoroughly cleaned
at the joints and suitable contact grease shall be applied just before making a joint.
Direct access to, or accidental contact with bus bars and primary connections shall not be
possible. All apertures and slots shall be protected by baffles to prevent accidental shorting
of bus bars due to insertion of maintenance tools.
Sequence of red, yellow and blue phases and neutral for four-pole equipment shall be left
to right and top to bottom, for horizontal and vertical layouts respectively.
15.4.3.4 Air Circuit Breaker(ACB)
15.4.3.4.1 General
Air Circuit Breaker shall comply with latest IS/IEC 60947-2.
The circuit breaker shall have rated service voltage of 415 V AC and rated insulation
voltage of 1000 V AC.
Breaking Capacity of Breaker in Power and Motor Control Centre (PMCC) or Power
Control Centre(PCC) shall not be less than Ics = 100% Icu = 50kA unless otherwise
specified. Icw shall not be less than 50kA for 1 second, as applicable.
The circuit-breakers shall have a rated impulse withstand voltage of 12 kV;

The circuit breaker shall comply with the isolating function requirements of IEC60947-2 to
facilitate safety of person in use.
15.4.3.4.2 Accessories
The accessories like shunt trip, closing trip coils should be continuously rated to avoid the
burning due to sustained command. The Accessories shall be accessible from the front
and should not need removing of the breaker from its panel for the replacement.
ACBs shall have : -
Necessary circuit breaker carriage with 3 positions (Isolate, Test, Service) draw-
out mechanism with positive auto-locking feature at each position.
Necessary isolating plugs and sockets.

Necessary mechanism interlock and automatic safe shutters gear with arrangement for
pad locking.
full rated current carrying capacity at 50 Degrees Celsius without derating – Manufacturer
shall furnish Deration Charts for the same. Necessary independent manual spring
mechanism with mechanical On/Off indication as well as electrical On/Off indication,
Necessary bus bars with bolted type neutral links.
ACB shall be provided with microprocessor based releases having built in over
load, short circuit & earth fault protection. Microprocessor release shall be
EMI (Electromagnetic Induction) / EMC (Electromagnetic Compatible) certified. Necessary
set of auxiliary switches.
Necessary set of CTs with ratios as specified.
Necessary identification, metering requirements as specified including ON/OFF indication

lamps, selector switches, fuses, ammeter, voltmeter etc.
In case of 4 pole breaker neutral shall be fully rated with adjustable settings from 50% to
100% of ln.
ACB terminals shall be suitable/suitably brought out for direct aluminum termination as per
IS/IEC 60947 Part II.
‘red’, ‘green’ and ‘amber’ indicating lamps to indicate ‘closed’ ‘open’ and ‘auto-trip’
conditions of the circuit breaker when breaker operation is controlled by a control switch.
All indicating lamps shall be clustered LED type, with in-built short circuit, surge protections
etc. Adequate number of contacts shall be provided to have remote annunciation of the
breaker feeders:
• Breaker 'ON'
• Breaker 'OFF'
• Breaker 'TRIP'
• Breaker 'Service'
• Breaker 'Test'
• Trip Circuit Healthy(TCH)
• Operating Mechanism
The operating mechanism shall be of the Open/Closed/Open stored-energy type. The

closing springs shall be able to be manually charged by operating the front lever
The ACB shall provide as a standard feature the following mechanical or electrical indicator
on the front panel:-
• Contact position indicator (ON / OFF)
• Stored energy status indicator
• Connected / Test / Disconnected position. (DO version)
• Trip indication on fault and fault differentiation (type of fault) i.e. Overload, short circuit
or earth fault.
All circuit breakers should be provided with “Integrated safety mechanism” contact which
internally checks following conditions before closing the circuit breaker to enhance the
safety and reliability of the circuit.
1) ACB is in ‘OFF’ position

2) Spring is Charged
3) Shunt not Energised
4) U/V Energised
5) Fault trip signal is not present
6) Local/Remote trip signal is not present
7) Device is completely racked in
8) Device is not locked on ‘OFF’ position
The circuit breaker shall be of trip free type and shall be provided with built-in mechanical
Anti Pumping feature. Closing coil and other auxiliary devices shall be available in
sufficient number for the purpose of indication, alarms, annunciations on switch boards as
well as on respective remote control panel in control room & for the purpose of interlocking
scheme shall be provided
There shall be three distinct & separate position of the circuit breakers on the cradle as –
Service / Test / Isolated. All position shall be positively achieved only through the racking
motion of draw out mechanism and not by trial & error. There shall be indicator clearly
showing the above 3 conditions.
In case, Electrical Draw Out(EDO) mechanism fails Circuit breaker shall have provision of
manual charging of closing spring.
15.4.3.4.3 Protection Function :
All ACBs shall have Microprocessor based releases capable of sensing true RMS value
of current based on digital technology.
Protection unit shall offer following as standard in all breakers.
Long time overload protection with adjustable time delay.
Short circuit protection with time delay. The short circuit setting (Isd) should necessarily
be the function of the nominal current (In) of the ACB. The instantaneous protection shall
have the option of OFF position in case of certain conditions of discrimination.
Earth fault protection with adjustable current settings in absolute values of the fault current.
The time delay setting for tripping on earth fault shall be adjustable. There should be
provision to disable the Earth Fault Protection, if required.
Separate adjustable setting for instantaneous short circuit protection.
Neutral Protection with a provision of Setting range off – 50% - 100%
All the adjustments (settings) of protection release should be on line and the circuit breaker
need not be switched off while adjusting the settings.
Trip indicators shall be provided to display the exact nature of fault (i.e. Overload, Short
Circuit, and Earth Fault) that caused tripping of circuit breakers. The circuit breaker will
have to be necessarily with mechanical re-closing lockout. The trip indication shall need
no external power supply for display. The control unit shall have thermal memory for
repetitive over current faults for protecting the cables and loads.
All ACBs shall be equipped with an integral self powered microprocessor based current &
voltage release which works on true R.M.S values for ensuring accurate protection and

integral LCD display which should show atleast current and voltage parameters and bar
graph display for % loading of the phases.
Integral Test facility to test healthiness of release and the trip circuitry shall be provided on
the release.
The microprocessor based release shall be capable of providing last trip history on LCD
display of release.
All 4 poles of the ACBs shal have equal current handling capacity.
15.4.3.4.4 Advanced Protection Functions:
Thermal memory for functions L shall be available;
Start-up function shall be available: this function allows a different setting of protections S,
I and G during the “start-up” phase of motors or transformers;
Protection against unbalanced current or unbalanced voltage shall be provided by the

protection release
Embedded additional protections, based on voltage/frequency measurement shall be

available as applicable :
• Under voltage protection (UV)
• Over voltage protection (OV)
• Under frequency protection (UF)
• Over frequency protection (OF)
• Protection against reversal of active power (RP)
User interface and HMI

• The basic release shall allow selection of the pick-up thresholds and timing by means
of dip switches;
• Warning LEDs for functions L, S, I, G shall be activated without the need for auxiliary
power supply or battery;
• A watchdog LED shall be available,
• The advanced release shall allow parameterization by means of an interactive high
resolution display;
• For the advanced releases, in the event of CB tripped, the type of function that tripped
shall be shown on the display. Each alarm or warning shall be clearly shown on the
display, when it is active.
• it shall be possible to set as default page of the display one of the following pages:
current, for each phase, active, reactive and apparent power for each phase, line to
line voltage.
• A remote display to be mounted separately shall be available
15.4.3.4.5 Communication
Release Feature:
All the Breakers shall be able to -
Communicate and display current, voltage values, switching states, reasons for tripping.

LCD Display to display all parameters of release.
I2t characteristic curve for overload protection
Rating Plug option to reduce the Nominal current for optimum adaptation to the system
shall be provided wherever required
The Breakers Shall be compatible for integration with SCADA System on industrial
communication protocol, PROFIBUS or MODBUS TCP IP.
The ACB shall be able to communicate the following via an integral Device / Release
• Spring charge and readiness to close depending on the status of the various internal
auxiliary releases and interlocks to the upper level network.
• Remote status monitoring
• Service & Test Position
Release shall have self-diagnostic feature with indication
Release shall have Neutral and earth fault protection as an inbuilt feature.
The data shall continue to be stored and displayed even after opening the circuit breaker.
15.4.3.5 Moulded Case Circuit Breaker (MCCB)
The MCCB’s shall comply with Indian Standard IS/IEC 60947 and International Standards
as per IEC60947-1 and IEC60947-2.
Moulded Case Circuit Breaker (MCCB) shall be a circuit breaking device which can make,
withstand and break current whose intensity is at most equal to its nominal current and
protection device which can automatically break over current which may occurs as a result
of fault in the system.
The terminals and connections between all current carrying parts shall be designed to
assure permanently low resistance connections.
MCCB shall have rated operational voltage of 415V, 50Hz power supply system.
MCCB shall have minimum fixed symmetrical interrupting capacity i.e. ICS = 100% ICU
and variable overload capacity.
MCCB shall have auxiliary contacts as required.
MCCB shall have minimum power loss as defined by the standard IS/IEC 60947.
MCCB shall be current limiting type with let through energy limit as specified in IS/IEC
60947.
MCCB housing shall be heat resistant and having high impact strength.
All MCCB 400A and above, fixed as incomer, shall be microprocessor based with
adjustable overload (40% to 100%), short circuit (2 to 10 In) and earth fault protection (10
to 50%). All MCCB at incomer shall be provided with rotary handle and shall have under
voltage release feature. All other MCCBs will be thermal magnetic type with earth fault
protection.

MCCB terminals shall be protected against finger contact to IP 2X degree of Ingress

Protection to provide total safety to the operating personnel.
Considering MCC panels, where specified:

• ‘3Pole + Neutral’ MCCBs shall be used on mains incomers,
• 3Pole MCCBs shall be used on the outgoing ways for each motor load.
• ‘3Pole + Neutral’ MCCB/MCB will be used as incomers for lighting distribution boards.
• MCCB Operating mechanism shall be quick- make, quick-break and trip-free type. The
‘ON’, ‘OFF’ and ‘TRIP’ positions of the MCCB shall be clearly indicated and visible to
the operator when mounted as in service.
MCCBs shall be capable of withstanding the thermal stresses caused by overloads and
locked rotor currents of values associated with protective relays settings of the motor
starting equipment and the mechanical stress caused by the peak short-circuit current of
value associated with the switchgear rating. The maximum tripping time under short circuit
shall not exceed 20 milliseconds.
MCCB terminals shall be suitable for accepting spreader links to receive cable lugs for
cable sizes relevant to circuit ratings. Phase barriers shall be provided for isolation of the
poles.
Clearly-labelled isolating circuit breakers shall be provided for each incoming power
supply. Switches shall be spring-loaded contacts that close fully without requiring full
operation of the handle. The handle and cover shall be interlocked so that the handle
cannot be operated when the cover is open and the cover cannot be opened unless the
switch is in the ‘off’ position. The ‘on’ and ‘off’ positions of each switch shall be indicated
clearly.
Motor protection circuit breaker (MPCB) shall be used for motor feeder instead of MCCBs.
15.4.3.6 Miniature Circuit Breaker (MCB)
Miniature circuit breakers shall be of the thermal and magnetic tripping type, and comply
with IEC 60898 and IEC 60947-2 and IS:8828.
The rated voltage for single pole and three pole (with or without neutral) shall be 240 V &
415 V, 50 Hz frequency respectively.
MCB shall be hand operated, air break, quick make, quick break type.
Operating mechanisms shall be mechanically trip-free from the operating knob to prevent
the contacts being held closed under overload or short-circuit conditions.
Each pole shall be fitted with a bi-metallic element for overload protection and a magnetic
element for short-circuit protection. Multiple pole MCBs shall be mechanically linked such
that tripping of one pole simultaneously trips all the other poles. For motor feeders, MCB
shall have type C characteristics.
The short circuit rating shall be not less than that of the system to which they are connected
with a minimum of 10 kA.
Incorporate, if specified, residual earth current detection in combination with the over
current protection.

The ‘current limiting’ MCB (RCBO) shall be either of the 30 mA or 100 mA tripping variety.
RCCBs shall be double pole or four-pole current-operated, housed in a totally enclosed

moulded case, manufactured and tested in compliance with IEC 61008 for RCCB and IEC
61009 for RCBOs. RCBBs shall have clear indication of ‘Tripping on fault’ on front facia.
15.4.3.7 Contactors and Starters
The power contactors used in the switchboard shall be of air break, single throw, triple
pole, and electromagnetic type. Contactors shall be suitable for uninterrupted duty and
rated for Class AC3, AC-4, AC-6 duty as applicable, in accordance with IEC 60947-4.
Operating coils of all contactors shall be suitable for operation on 240 V, single phase, 50
Hz supply.
Contactors shall be provided with at least two pairs of NO and NC auxiliary contacts.
Contactors shall not drop out at voltages down to 70 % of coil rated voltage. All motor
contactors and their associated apparatus must be designed to operate for a period of not
less than 5 minutes at a voltage of 20% below the nominal value and at normal frequency
without injurious overheating.
Contactors shall be provided with a three element, positive acting, ambient temperature
compensated, time lagged, hand reset type thermal overload relay with adjustable
settings. The hand reset button shall be flush with the front door of the control module, and
shall be suitable for resetting the overload relay with the module door closed. Relays shall
be either direct connected or CT operated. Overload relay and reset button shall be
independent of the "Start" and "Stop" push buttons. All contactors shall all be provided with
single phasing preventer (SPP).
Motor starters shall be complete with auxiliary relays, timers and necessary indications.
Starters shall be of the electrically held-in type with integral “start” and “stop” push buttons
mounted externally on the door, with integral interlocked isolators. Where required,
auxiliary switches shall be included for the operation of “red” and “green” indicating lights
in remote instrument panels.
For details of other equipment/ accessories of LV switchboard (e.g., relay, constructional

features of switchboard, earthing, annunciator, control and selector switch, indicating
lamp, push button, space heater, cubicle lighting/ receptacles, control cable termination,
wiring, terminal blocks, etc), refer specification of HV switchboard.
15.4.3.8 Metering Instruments
All meters and instruments shall be suitable for operation at a frequency of 50 Hz with
current transformers having 5 or 1 ampere secondary circuits and potential transformers
having 110 volt secondaries as applicable.
Watt-hour and Var-hour meters shall be of accuracy class 1.0 unless and until specified,
suitable for measurement of unbalanced loads in three phases three wire circuits.
Multifunction meter with full compliance to IEC 62053-21 for Class 1.0 and Harmonic
parameters as per IEC 61557-12 standards,

Watt-hour and Var-hour meters shall be suitable for operation from the secondary of CTs
and VTs. They shall be provided with a separate 3 phase 4 wire type test blocks for the
testing of the meters without disturbing the CT and VT secondary connections.
Meters shall have digital type of registers. It shall read kWh, kVARh or MWh, MVARh, as
the case may be, without the use of additional multiplying factors. Multiplying factors if
unavoidable shall be multiples of 10 (ten). Number of digits provided shall be adequate to
cover at least 1000 hrs. of operation.
Instruments shall be electronic / digital type with LED or LCD display. These instruments
should have high performance ratio and can be equipped with digital output (for alarms)
or with interfacing facilities for communication and remote reading of parameters.
Resistors, reactors and other devices which may be required to complete the meter
installation shall be furnished.
Each voltmeter and ammeter shall be provided with a selector switch for reading each
phase- value.
All instruments, meters, relay metal cases and parts and miscellaneous metal devices
shall be effectively grounded.
All the incomers, outgoing feeders and motor feeders above 22 kW shall be provided with
digital multi-function meters with RS-485 port, Modbus TCP..
15.4.3.9 Tests
The main distribution boards and the components as applicable shall be type tested in
accordance with the IEC standards from a recognised and approved test laboratory and
certified by a competent authority.
The following type tests as specified in IEC 61439-1/2 standards shall be carried out at
recognized test laboratories and certificates from recognised and approved test witness
authority shall be provided for each type test:
• Short Circuit withstand test for main Busbar and neutral Busbar
• Strength of material and parts
• Degree of protection
• Temperature rise test
• Internal electrical connections
• Dielectric Properties
• Effectiveness of Protective Circuit
• Incorporating of switching devices and components
• Clearance & Creepage Distances
• Impulse withstand voltage stage
• Terminals of external conductors
• Electromagnetic Compatibility
• Mechanical Operation
The panel assembler shall perform the routine test and provide the test certificates as
defined in IEC standards. The routine test shall include but not limited to the following:
• Inspection of the assembly including inspection of wiring and electrical operational test;
• Dielectric test & Insulation resistance test;

• Checking of protective measures and of the electrical continuity of the protective

circuits;
• Functional test as per the approved test procedure.
All circuit breakers shall be subject to the following tests:

i. Routine tests including HV pressure test, millivolt drop tests and mechanical tests.
ii. To ensure the operation of the dc closing coil and satisfactory closing of the circuit
breaker with the voltage of the coil down to 80% of its rated voltage, and that mal-
operation does not occur with a voltage on the coil of 120% of its rated voltage.
iii. Interchangeability of withdrawable identically equipped circuit breakers, and checking
of all mechanical and electrical interlocks.
15.4.4 Soft Starters
The soft starters shall comply with the requirements of Bureau of Indian Standard (BIS)
and International Electro Technical Commission(IEC) standards as follows…
IEC 60034 : Rotating Electrical machines
IEC 60947 : Low voltage switchgear and controlgear
IS 325 : Three phase Induction motors
Digital Soft starter or Digital motor controller shall be suitable for mains voltage 415 V, +/-
10 % and 50 Hz +/- 5 % System.
It shall be suitable for continuous operation with derating up to operating temperature of

50ºC and altitude up to 1000 m. Derating chart shall be made available.
The soft starter shall be three-phase controlling type Digital soft starter using reverse or
anti-parallel SCR pairs in each phase of the main power circuit.
Semiconductor fuses shall be utilized for type 2 co-ordination. It shall have minimum fault
withstand rating of 50 kA RMS symmetrical, unless otherwise specified.
It shall be suitable for continuous operation of 110% of the rated current.
The supply voltage shall be 110V AC or 240V AC and control voltage shall be 24V DC /
48V DC.
The selection of the soft starter shall be optimum with minimum 4 starts and stops per
hour.
The soft starter shall be modular in design and construction.
The soft starter shall be suitable for soft starting and soft stopping of three phase
asynchronous motors
Soft starter shall be of current limiting type and suitable for heavy duty start.
The digital reduced voltage soft starter’ shall be installed in the MCC panel complete with
all accessories and indicating lights.
15.4.4.1 Standard Features
The SCR’s shall have a minimum PIV rating of 1400 V for units rated up to 690V AC.

The soft starter bypass contactor utilization category shall be AC 53b.

Soft start and stop mode of operation with adjustable motor acceleration and
deacceleration periods from 2 to 30 seconds
Current limit starting mode to limit motor starting currents, adjustable from 150 to 400% of
full load amps;
Minimum starter efficiency shall be 90%.
It shall have built in transient protection.
It shall have contactor to bypass the SCR’s in the drive once the motor is at rated voltage
and current. Shorting contactor should be connected upstream of internal solid state motor
overload protection.
It shall have Full voltage starting mode to provide across-the-line motor starting;
It shall have Self-calibrating control adjusting for variations in line voltage, frequency and
current level at or below the maximum continuous rating of the controller;
It shall have Pump control options to provide proper torque-speed characteristics to

minimize hydraulic surges.
The soft starter shall provide means to test operation of all control circuitry and protection
mechanisms, without connection to mains voltage.
The soft starter shall provide a means of automatically starting and stopping the motor at
a predetermined time or after a predetermined period of operation.
15.4.4.2 Constructional and Performance Features
Motor soft starters shall be switched or electronic type.
Soft starter panel shall be indoor, metal clad with separate metal enclosed compartments
for
a) Control, metering and current transformers for differential protection, if specified
b) DOL bypass arrangement
c) Bus bars
d) Power cable terminations
e) Push buttons with indicating lamps.
Soft starter shall achieve smooth starting by torque control for gradual acceleration of the
drive thus preventing jerks and extending the life of equipment.
Starting current shall be limited to 2.5 to 3 times the rated current of the motor. The soft
starter manufacturer shall co-ordinate with motor manufacturer for this purpose.
Separate removable gland plates shall be provided for power and control cables.
Each cubicle shall be fitted with a label in the front and rear of the cubicle, indicating the
panel designation, rating and duty. Each relay, instrument, switch, fuse and other devices
shall be provided with separate labels.

Necessary wiring diagram shall be provided considering starting interlock, trip circuit,
starting and running mode signal.
It shall be possible to manually start the motor locally from the starter panel or in Auto
mode through PLC.
15.4.4.3 Main Bus Bars
Bus bars shall be fully insulated by encapsulation in epoxy resin /shrinkable PVC Sleeve,
with moulded caps protecting all joints. Bus bars shall be supported on insulators capable
of withstanding dynamic stresses due to short circuit. Bus bars shall be of Aluminium
conductor (Copper is not recommended in sewage corrosive atmosphere as it oxidized.)
15.4.4.4 Earthing
A Aluminium earthing bus shall be provided at the bottom and extended throughout the
length of the panel. It shall be bolted / welded to the framework. All non-current carrying
metal work of the panel shall be effectively bonded to the earth bus. Hinged doors shall be
earthed through flexible earthing braid.
15.4.4.5 Panel Accessories and Wiring
Panel shall be supplied completely wired internally up to equipment and terminal blocks
and ready for the external cable connections at the terminal blocks. Inter panel wiring
between compartment of the same panel shall be provided.
All auxiliary wiring shall be carried out with 1100 volts grade, single core, stranded copper
conductor with PVC insulation. The sizes of wire shall be not less than 1.5 sq. mm.
Terminal blocks shall be of stud type, 10 A rated, complete with insulated barriers.
Terminal blocks for CTs shall be provided with test links and isolating facilities.
All spare contacts and terminals of cubicle mounted equipment and devices shall be wired
to terminal blocks.
Accuracy class for indicating instruments shall be 1.0 or better. Instruments shall be 110
mm square, 240° scale for flush mounting with only flanges projecting.
Push buttons shall be provided with inscription plates engraved with their functions.
Indicating lamps shall be of clustered LED type.
Space heaters of adequate capacity shall be provided inside each panel. They shall be
suitable for 240 V, 1 phase, 50 Hz supply. They shall be complete with MCB and
thermostat.
Each panel shall be provided with 240 Volts, 1 phase, 50 Hz, 5 A, 3 pin receptacles with
MCB located in a convenient position. An interior illuminating lamp together with the
operating door switch and protective MCBs shall be provided.
The DC and AC auxiliary supply shall be distributed inside the panel with necessary
isolating arrangements at the point of entry and with sub-circuit MCBs as required.

15.4.4.6 Tests
Each unit of soft starter shall be tested at the manufacturer’s work. Test result must satisfy
all the characteristics during starting and acceleration against their quoted values during
bidding.
15.4.5 Variable Frequency Drives (VFD)
15.4.5.1 Standards
AC induction motor shall be coupled with a Frequency drive of rating commensurate with
the rated motor in compliance with following standards.
IEC 61800: Adjustable speed electrical power drive systems
IEC 60068: Basic Environmental testing
IEC 62529: Degrees of protection provided by enclosures (IP Code)
IEC 60721: Classification of environmental conditions.
The Frequency drives shall be of Voltage Source Inverter Pulse Width Modulated
(CSIPWM) with latest version, which performs precise speed and torque control of
standard squirrel cage motors with optimum efficiency. Each VFD shall employ Insulated
Gate Bipolar Transistors (IGBTs) on both the rectifier and frequency convertor.
Each drive must have a soft starting feature and a bypass arrangement for DOL starting
of motors. All frequency dives shall be suitable for data connectivity with PLC/SCADA
system and shall have suitable for data connectivity with PLC/SCADA system and shall
have communication port and protocol compatible to PLC. The drives must be easily
programmable. The drives shall be provided with surge protection, programmable lockable
code. The Frequency drive shall have following characteristics:
• Accurate open loop torque control
• Torque step rise time typically less than 10 ms
• Speed control inaccuracy typically 0.1% to 0.5% of nominal speed
• 150% overload capacity for 60 second
Total Harmonic distortion shall comply with the provisions of IEEE 519. Necessary
metering, self-diagnostic arrangement (including display and alarm facilities) shall be
provided for local/ remote monitoring.
Variable Frequency Drive shall comply with EMC
15.4.5.2 Environment limits
Ambient temperature : 0 to 50 degree Centigrade.
15.4.5.3 General Standard Control Connections or as per Process Requirement
• 3 programmable differential analogue inputs (1 voltage signal, 2 current signals)

• 7 programmable digital inputs
• 2 programmables analogues outputs (current signal)

• 3 programmable digital outputs (from C relays)

• Optional analogue and digital extension modules can be added as well as a wide range
of field bus adapters.
15.4.5.4 Protection
• Over current
• Short circuit at start-up
• Input phase loss
• Output phase loss
• Motor overload
• Earth fault
• Overvoltage
• Under voltage
• Over temperature
• Motor stall
15.4.5.5 Application Macros
The features a selection of built-in, pre-programmed application macros for configuration

of inputs, outputs, signal processing and other parameters. It shall have interfacing
facilities to communicate data to SCADA system. These include:
• FACTORY SETTING for basic industrial applications
• HAND/AUTO CONTROL for local and remote operation
• PID CONTROL for closed loop processes
• TORQUE CONTROL for process where torque control is required.
• SEQUENTIAL CONTROL for processes where torque control is required.
• USER MACRO 1 and 2 for user’s own parameter setting
• Comprehensive testing and diagnostic function
15.4.5.6 Tests
Each unit of Variable frequency drive shall be tested at the manufacturer’s work. Test result
must satisfy the efficiencies on various loads and at different frequency levels against their
quoted values during bidding.
15.4.6 Non-Segregated Phase Bus Duct
1) This specification covers the requirements of 3 phase,4 Wire, 415 V, 50 Hz, 65 kA/50
kA continuous rated, Aluminium TPN bus with enclosure suitable for indoor / outdoor
type, as applicable. The bus – duct shall be designed for continuous current ratings
and for a maximum temperature rise of 40°Cover an ambient temperature of 50°C.
2) The bus – bars shall be of hard drawn high conductivity electrolytic grade aluminium
flats of electrical grade 63401-WP as per IS: 5082. The bus- bars shall be of uniform
cross section along its entire length. No tapering of the bus bars’ cross-section is
allowed.
3) The enclosure of bus – duct shall be of 14 SWG sheet steel of minimum thickness of
2 mm bolted on to an angle iron / structural steel framework. The bus duct shall be
painted after suitable pretreatment of all structural steel and plates with anti-corrosive
epoxy base primer paint & two coats of anti-corrosive epoxy base paint externally with
a colour of pebble gray shade RAL7032and dried in an oven. The enclosure shall
conform to IP: 55 for outdoor and IP: 54 for indoor, as per Indian Standards. Inner
surface of the bus – duct shall be coated in the rubber paint.

4) The bare bus-bars shall be provided with a coat of Matt finish.

5) The joints in the bus-bars shall be of the bolted type and it shall be ensured that the
following precautions are observed.
i. The contact pressure must be ample and this shall be maintained during the time
the panel is in service.
ii. The surfaces of the conductors must be clean.
iii. With flat conductors, the overlap should be equal to or greater than the width of the
bars or ten times the thickness of the bar whichever is greater.
iv. The joints shall be treated by the application of joint compound to render the joint
moisture-proof.
v. For the joints use of bolts of cadmium plated high-tension MS bolts having
expansion characteristics due to temperature change similar to the conductor may
be used with steel nuts.
vi. Smearing the surfaces with oxide inhibiting grease just prior to making the joint in
order to preserve the efficiency of the joints. Minimum phase and earth clearance
required shall be maintained at joints. The joints shall be thoroughly shrouded.
6) The bus bar arrangement shall generally conform to IS:13947, IS:8623, IS: 5578 and
IS: 11353. The bus – duct shall be also supplied with suitable earth bus running all
along the length of the bus – duct made of GS strips. Current density at any part shall
not exceed prescribed limits. Two GS flats of same phase shall be stacked together or
the spacing between them shall be maximum of the thickness of one conductor.
7) The bus bars shall be phase identified by colour, at intervals. Colour code shall be
RED, YELLOW and BLUE for phase and BLACK for the neutral bus – bar.
8) Bus – bars shall be supported on tough, non-hygroscopic, resin bonded self-
extinguishing fire retardant insulators preferably of SMC / DMC with ribbed
construction to prevent tracking due to dust paths. Bus-bars and supports shall
withstand the maximum stresses that are induced in the event of. The short-circuit
currents being as specified. The bus-bar support shall be at a minimum interval of
500mm.
9) The bus- bars shall be supplied with flexible expansion joints at both the ends and also
at bends. The supports and expansion arrangement shall be so chosen to avoid undue
stress to the bus – bars, supports and end connections.
10) Dust excluding gaskets of neoprene shall be used for enclosures to ensure water and
dust tightness. The duct shall be suitable for outdoor/indoor installation, as applicable.
Minimum two numbers of space heater switch thermostats shall be provided to prevent
moisture condensation and maintain cubicle temperature 5 Deg. C above the ambient.
11) The clearance between the individual bare phase power bus-bars and between the
phase and earth bus –bars in air shall be not less than 25 mm and 19 mm respectively.
12) Drain points shall be provided at the bottom of the bus – duct, at suitable locations.
The bus-duct shall be provided with silica gel breathers, in all sections.
13) Bus duct joints shall be covered with encapsulated PVC sleeves. Phase cross over
shall be provided wherever required.
14) Fire proof sealing shall be provided wherever bus ducts enter/exit the wall of substation
building.
15) Joints of bus ducts shall be covered with pvc caps.
16) Phase cross over shall be considered wherever required in the route length of bus
ducts.

15.4.7 Reactive Power Compensation and Harmonic mitigation
15.4.7.1 Standards
Unless specified otherwise, the reactive power compensation shall conform in design,
material, construction and performance to the latest editions of the IS Standards, IEC
standards, their corresponding British European /(BS EN) standards and in particular to
the following publications :
IS:13340 : Shunt power capacitors of the self-healing type for ac systems

having a rated voltage up to and including 1000 V.
IS:13341 : Requirement for ageing test, Self-healing test and destruction test
on shunt capacitors of the self-healing type for ac power systems
having rated voltage up to and including 650V.
IEC 61921 : Power capacitors – Low voltage power factor correction banks.
IEC 60831-1 & 2 : Shunt power capacitors of the self-healing type for A.C. systems
having a rated voltage up to and including 1000 V.
IEC 60076-6 : Power transformers - Part 6: Reactors
IEC 60085-1 : Electrical insulation – Thermal evaluation and designation.
IEC 60664 : Insulation coordination for equipment within low-voltage systems.
IEC 61439-1 : Low-Voltage Switchgear and Controlgear Assemblies
Part 1: General Rules
IEC 60947-1 : Low-voltage Switchgear and Controlgear - Part 1: General Rules
IEC 60947-2 : Low-voltage Switchgear and Controlgear - Part 2: Circuit-
Breakers.
IEC 60947-4-1 : Low-voltage Switchgear and Controlgear – Part 4-1: Contactors
and Motor- starters.
IEC 62208 : Empty enclosures for low-voltage switchgear and controlgear
assemblies – General requirements
IEC 60529 : Degree of protection provided enclosures (IP code)
IEC 62262 : Degrees of protection provided by enclosures for electrical
equipment against external mechanical impacts (IK code)
IEC 61000 : Electromagnetic compatibility
IEEE 519 : IEEE Recommended Practices and Requirements for Harmonic
Control in Electric Power Systems.
In addition to the above listed standards, the Rules and Regulations for electrical
installations issued by CEA regulation shall also be adhered to.
15.4.7.2 Marking
The following minimum information shall be given by the manufacturer in an instruction

sheet and on a rating plate to be fixed on the automatic power factor correction assembly.
1) Manufacturer’s name or trademark.
2) Serial number.
3) Date of manufacture
4) Rated reactive power, QN in kilovars (kVar).
5) Rated voltage, UN in volts (V).
6) Rated frequency, fN in hertz (Hz).

7) Minimum and maximum ambient temperatures in degrees Celsius (°C).

8) Degree of protection.
9) Short-circuit withstand strength, in amperes (A)
10) Number of stages
11) Step Size
The technical parameters of capacitors shall be as given below:
15.4.7.3 LV Capacitors and Control Panel
LV capacitors shall be provided for connection across LV motor terminals as applicable

while LV capacitors with APFC relay and a panel shall be provided for connection to LV
switchboard bus, where specified.
15.4.7.4 Design Criteria
The capacitors shall be designed for industrial application providing, high performance,
high longevity, loss power loss, good harmonic capabilities technology. The technology
shall be capable of giving the longest life, highest over load limits and the highest operating
ambient temperature. Capacitor rating across motor shall be such that capacitor current is
less than 90% of the magnetizing current of the motor or for improvement of rated motor
power factor to 0.98, whichever is lesser.
Capacitors rated for improvement of overall power factor on LV side to 0.996 Lag
15.4.7.5 General
The capacitor bank shall be complete with all parts that are necessary or essential for
efficient operation. Such parts shall be deemed to be within the scope of supply whether
specifically mentioned or not. It shall be complete with the required capacitors along with
the supporting post insulators, steel rack assembly, Copper bus bars, connecting strips,
foundation channels, fuses, fuse clips, etc. The steel rack assembly shall be hot dip
galvanized. The bus bar section of power factor assemblies shall withstand, as a minimum,
the fault current of the system at the point where it is intended to be connected
The capacitor bank shall comprise of suitable number of single phase units in series
parallel combination. However, the number of parallel units in each of the series racks
shall be such that failure of one unit shall not create an over voltage on the units in parallel
with it, which will result in the failure of the parallel units. The assembly of the banks shall
be such that it provides sufficient ventilation for each unit.
Each capacitor case and the cubicle shall be earthed to a separate earth bus.
Capacitors shall be of polypropylene type. Each unit shall satisfactorily operate at 135%
of rated kVAR including factors of over voltage, harmonic currents and manufacturing
tolerance. The units shall be capable of continuously withstanding satisfactorily any over
voltage up to a maximum of 10 % above the rated voltage, excluding transients.
Each capacitor unit / bank shall be fitted with a directly connected, continuously rated, low
loss discharge device, if required, to discharge the capacitors to reduce the voltage to 50
volts within one minute upon disconnection. The total losses including discharge resistors
to be less than 0.5 Watt/KVAR.

15.4.7.6 Protection
Each capacitor unit shall be individually protected by a HRC fuse suitably rated for load
current and interrupting capacity, so that only the faulty capacitor unit will be disconnected
without causing the bank to be disconnected. An operated fuse shall give visual indication
so that it may be detected during periodic inspection. The fuse breaking time shall co-
ordinate with the pressure built up within the unit to avoid explosion. Mounting of the
individual fuse should be internal to the capacitor case.
A 3 phase pressure switch disconnector for protection against internal faults, over
pressure, etc. should be available. The pressure switch disconnector must isolate all the
three phases simultaneously in the event of fault.
Each stage of the capacitor bank shall also have a suitably rated MCCB with an electronic
over-current relay for overload protection. The electronic over-current relay shall be
adjusted to trip if the RMS current of the stage exceeds the overload setting.
15.4.7.7 Detuned Reactor
The detuning reactor shall be manufactured in full compliance with and tested to the
requirements of IEC 60076-6 Reactors
Capacitors with detuned filtering technique shall be employed to correct power factor while
avoiding the risk of resonance condition.
The de-tuning reactors shall be connected in series with each capacitor stage and shall
be of iron cored type.
The Detuned Reactor Should be equipped with Thermal Switch inside the Winding which
should cut-off the respective contactor in case of Over-temperature.
The capacitors used in conjunction with reactors shall be suitably de-rated to deliver the
designed output at 415V.
The reactor insulation shall be Class “F” or above. Tolerance of reactors shall not exceed
+/-3% of rated value.
15.4.7.8 Electromagnetic Contactor:
The contactors shall be three poles, specially designed for switching capacitors and shall
be able to make against large transient current peaks at a high frequency of several kHz
that can occur on capacitor switching.
The contactors shall isolate all the three supply phases to the capacitor on switch off.
Contactors along with damping resistors (AC 6b) shall be used where there is a possibility
of high inrush peak current to reduce it. The capacitor contactors shall be weld resistant
up to a possible peak inrush current of 200 * IR.
In case capacitor banks are supplied with Harmonic Blocking Reactors, contactors for
capacitor switching shall be without damping resistors (AC3), because the peak current
limitation is provided by Reactor impedance.

The contactors shall conform to IEC 60947-4-1/ IEC 60947-5-1. Contactor should have a
current rating of not less than 1.3 times the rated three phase capacitor unit current. They
shall be tested as per IEC 60269 with a test voltage 1.1x UN.
15.4.7.9 Capacitor (APFC) Control Panel for LV Application
APFC microprocessor based relay shall automatically switch ON / OFF the capacitor
banks to attain the value of ‘pf’ close to the set value. Switching shall follow first in first out
(FIFO) method to ensure uniform use of all capacitor banks. At least eight steps shall be
provided for switching..
Capacitor and capacitor control shall be housed in a metal enclosed cubicle. Capacitor
shall be housed in the lower compartment and capacitor control unit at the top
compartment, the two compartments being segregated.
The cubicle shall be fabricated out of 2 mm thick cold rolled sheet steel and shall of a
degree of protection of IP 42. The panel shall be of indoor type and shall consist of:
• Isolating MCCB
• Contactors with overload element
• Relays responsive to current / voltage / kVAR / pf for automatic switching
• Sequencing devices, timers and auxiliary relays for automatic sequential switching of
capacitor units in and out of circuit
• Auto-manual selector switch
• Microprocessor based Automatic Power Factor Correction (APFC) Relay
• Push button for opening and closing the power circuit
• Red and Green lamps for capacitors ON / OFF indication
• Protective relays to protect the healthy capacitor units when one unit fails in a series
connection
• Space heater and cubicle lighting
15.4.7.10 Tests and Test Reports
Capacitors shall be subjected to routine tests as per IS: 13340, IS:13341, IEC 60831. Test
for capacitor losses shall also be carried out on one capacitor bank of each type ordered.
In addition to the above, the capacitor units shall be subjected to the following tests:
1) Load test at 110% rated voltage at an ambient of 45 to 50⁰ C for a period of 8 hours or
more.
2) Leak proofness test-initially after impregnation and total sealing, each unenergized
capacitor shall be heated up to the temperature as defined in IS:13340. After the load
test, each capacitor unit shall be carefully inspected for leakage.
Type tests shall be carried out as per IS:13340, IS:13341, IEC 60831 on capacitors having
a rated voltage up to and including 1000V rating of identical design. Certificates of type
tests carried out in the last three years for similar capacitor units shall be furnished.
All type tests shall be carried out in accordance with the International Electro-technical
Commission (IEC) IEC 61921 and IEC 61439-1,61439-2 on complete Capacitor banks
equipped with detuned reactors. The following type tests shall include:
Verification of Temperature Rise limits at 130% of nominal current (with allowable

temperature rise values considering 50 Degrees Celsius as the base ambient temperature)
• Verification of dielectric properties
• Verification of the short-circuit withstand strength
• Verification of the effectiveness of the protective circuit

• Verification of clearances and creepage distances

• Verification of mechanical operation
• Verification of the degree of protection
15.4.7.11 Harmonic Mitigation
The arrangement of the electrical system shall be such that any harmonics generated by
the electrical system do not:
1. exceed the limits permitted at the point of common coupling with the electricity supply
company’s electricity distribution system
2. cause malfunction of any electrical plant or of any electrical system
3. lead to overheating of any electrical plant, materials or of any electrical system.
To limit the harmonics generated by electrical plant, every rectifier rated in excess of 3
kVA shall be of the 6, 12, 18 or 24 pulse type as required.
When designing a system utilising variable frequency drives (VFDs), provision shall be
made to minimise the introduction of additional harmonics into the power grid as per
standard IEEE 519.
15.4.8 DC Equipment
DC equipment shall comply with IS:10918, IEC 60623 including those standards referred
to therein.
15.4.8.1 Requirements
Following items shall be covered in the Contract:

a) One set of 110 V Nickel Cadmium type Battery
b) Two sets of Float-cum-boost chargers for 110 V batteries
c) DC distribution board.
All connections between battery, battery chargers and DC distribution board shall be
designed for effective segregation between positive and negative leads.
15.4.8.2 110 V Battery
Battery offered shall be Nickel Cadmium (Ni-Cd) type. Nickel hydroxide and Cadmium
hydroxide shall be used for positive and negative electrode respectively. Aqueous solution
of Potassium hydroxide with small quantities of lithium hydroxide shall be used as
electrolyte. It shall be used only for ion transfer and shall not chemically change during
charging/ discharging.
The containers shall be transparent and preferably be made of toughened glass or plastic
and provided with acid level indicator.
The battery shall be rated on 5-hour basis and for the specified ambient temperature. The
battery shall have maximum recharge time of 8 hours. The batteries shall be sized for a
backup of 2 hours, in case of power failure. The ampere-hour capacity shall be selected
to cater to all the emergency loads, operation of control gear, indication lamps,
annunciation panels, emergency lighting, incoming breaker(s) spring charging currents,
short time loads etc. A margin of about 25% shall be taken to cater to the contingencies.
Terminal posts shall be designed to accommodate external bolted connection conveniently

and positively. Each terminal post shall have two bolt holes of the same diameter,
preferably at right angles to each other. The bottom hole shall be used to terminate the

inter-cell connection. The top hole shall be left for external terminal connections. Bolts,
heads and nuts, except seal nuts, shall be hexagonal and shall be lead covered. The
junction between terminal posts and cover, and between cover and container shall be so
sealed as to prevent any seepage of electrolyte.
Required quantity of electrolyte for first filling with 10% extra shall be supplied in non-
returnable containers.
Each battery shall be complete with following accessories, as applicable, that include, but
are not limited to:
a) Battery racks
b) Porcelain insulators, rubber pads, etc.
c) Set of inter-cell, inter-tier and inter-bank connectors as required for the complete
installation.
d) Electrolyte for first filling + 10% extra.
Accessories for testing and maintenance

ONE - -3, 0, +3 volts DC voltmeter with built-in discharging resistor and suitable
leads for measuring cell voltage.
One - Filler hole thermometer fitted with plug and cap and having specific gravity
correction scale
Three - Pocket thermometers
Two - Cell lifting straps
One set - Terminals and cable boxes with glands for connecting cable as required.
Each of Spare connectors
Spare vent plugs
Spare nuts and bolts
Suitable set of spanners
Each battery shall be mounted in a manner that permits easy accessibility to any cell. The
racks shall be suitable for fixing on flat concrete floor. The complete racks shall be suitable
for bolting end to end.
It shall be the responsibility of the Contractor to provide batteries of adequate capacities

to meet specified requirements pertaining to control, indication, annunciation, etc. and
emergency lighting. For computing battery capacity, it shall be assumed that the battery is
fully charged at the beginning of loading cycle and is discharged to a voltage of 1.2 volts
per cell at the end of the loading cycle.
Emergency lighting load shall be considered as 10 % of total lighting load of the plant
including internal & external lighting. Emergency lighting shall be applicable for all vital
locations like substation, Administrative building, Control room, Pump Houses, Laboratory,
Gas engine room etc. For external lighting/Road lighting /Area lighting emergency lighting
fixtures shall also be considered to overcome the interruption in movement of persons and
vehicles.
The battery shall have minimal difference (approx. 0.3 V per cell) between float and boost
charging voltages.
15.4.8.3 Battery Charger (110 V)
The float-cum-boost type battery charger shall comprise silicon controlled rectifiers (SCRs)
connected in a full wave bridge circuit.

Each battery charger shall be suitable for float charging the battery under normal
conditions and boost charging the battery when it has discharged during service
conditions. The changeover from float to boost mode and vice versa shall be automatic.
The rectifier transformer shall be dry type and double wound with required number of taps.
The DC output voltage during float charging shall be stabilized within + 1% of the set DC
bus voltage for AC input voltage variation of +10%, frequency variation of + 5% and DC
load variation from 0 - 100%. The voltage regulation shall be achieved by a constant
voltage regulator having fast response SCR control. The ripple content shall be within 1%
of DC output nominal voltage with battery disconnected and shall be designed to have
voltage regulation of 1%. Also in any mode of operation, the maximum harmonics in the
charger output shall not exceed 5%.The setting of the output DC bus voltage shall be
adjustable between + 10% of nominal rated voltage. There shall be provision for manual
control if auto mode fails. Line surge suppressers shall be provided.
For boost charging the discharged battery after a mains failure, the rectifier shall charge
the battery at high rate limited to the maximum boost charging voltage. The boost charging
shall come on only when selected for boost mode manually. In auto control, the DC output
current shall be stabilized within +2% for AC input voltage and frequency variation of +
10% and + 5% respectively. There shall be provision for manual control if auto-mode fails.
Boost charging time for charging the battery to full capacity from fully discharged condition
shall not exceed 8 hours.
In the float charging mode, the charger shall be designed for supplying:
a) The DC loads of control, indication and annunciation circuits that remain energized
during normal operation and the momentary closing and trip coil loads of circuit
breakers, vacuum contactors; and
b) The float charging current of the battery.
c) 25% margin over the above load
Battery charging equipment complete with all accessories shall be housed in a free
standing sheet steel cubicle having degree of protection of IP 4X. Sheet steel used for
construction shall be 1.6 or 2 mm thick. The units shall be wired using 1100 V grade,
PVC insulated, stranded copper conductor cables.
Each battery charger shall be provided with accessories that include, but not limited to the
following:
a) Silicon controlled rectifiers connected in full wave bridge circuit with ripple control
devices and transient suppression network.
b) Double wound dry type transformer with taps
c) Automatic voltage regulator unit with manual / auto control switch
d) Coarse and fine control potentiometers for manual control
e) Selector switch for mode of charging i.e. float charging / boost charging
f) Off-load tap changing switch for changing the taps of the transformer
g) DC voltmeter with fuses and a three position selector switch
h) DC ammeter with shunt
i) AC ammeter with selector switch for incoming AC power
j) AC voltmeter with selector switch for incoming AC power
k) MCB for incoming AC supply along with surge suppressers
l) Switch-fuse / MCB on DC output side with kick fuses and alarm contacts
m) Voltage dropping diodes in load circuit during boost charging mode
n) DC under voltage relay and earth fault relay

o) AC / DC switching relays for alarm and indication circuits including buzzer

p) Cubicle space heater suitable for 240 V AC, 1 ph, 50 Hz supply, with MCB and
thermostat
q) 240 V AC compact fluorescent lamp fixture for internal lighting with MCB
Each battery charger shall be provided with the following alarms / indications:
a) AC and DC supply 'ON'
b) AC and DC supply fail
c) Modes of charging
d) Over voltage
e) Under voltage on DC side
f) Earth fault on DC side
g) AC / DC MCB trip
The Contractor shall include in the bid, detailed AC and DC scheme for battery charger
offered.
15.4.8.4 110 V DC Distribution Board (DB)
The distribution board shall be of floor mounting design. Entry for incoming and outgoing
cables shall be from the bottom. Bus bars shall be of aluminum or copper.
Incomers, bus coupler and outgoing circuits shall be controlled by suitably rated double
pole MCBs type suitable for DC application. Contractor shall furnish proposed single line
diagram of the board along with the Bid.
Constructional features, pre-treatment, painting and other aspects shall comply with the
specifications for LV switchboard. DCDB shall have 10% spare feeder for owner use in
future.
Aluminium earth busbar of suitable size shall be provided along the length of the DB at
the bottom. Two nos. earthing terminals shall be provided on the external face of the board
for connection to the earthing grid.
15.4.8.5 Tests
The batteries, chargers and distribution boards and their components shall be subjected
to routine/ acceptance tests as per the applicable standards. For battery, following tests
are also to be carried out:
• Capacity test
• Test for voltage charging and discharging
• Ampere-hour and watt-hour efficiency test
Certificates of type tests carried out on similar equipment shall be furnished.
15.4.9 Motors
15.4.9.1 Standards
All motors shall be of premium efficiency as per IS 12615motors and also comply with
following Indian and International Standards.
IS:5 : Colours for ready mixed paints and enamels

IS:325 : Three Phase Induction Motors

IS:900 : Code of practice for installation and maintenance of induction motors.

IS:1231 : Dimensions of three phase foot mounted induction motors.
IS:1271 : Thermal evaluation and classification of electrical insulation.
IS:1885 : Electro technical vocabulary: Part 35 Rotating machines
IS:2148 : Flame proof enclosures of electrical apparatus.
IS:2223 : Dimensions of flange mounted AC Induction motors.
IS:2253 : Designation for type of construction and mounting arrangement of
rotating electrical machines.
IS:2254 : Dimensions of vertical shaft motors for pumps.
IS:2968 : Dimensions of slide rails for electric motors.
IS:4029 : Guide for Testing of Three Phase Induction Motors
IS:4691 : Degree of Protection Provided by Enclosures for Rotating Electrical
Machinery
IS:4722 : Rotating Electrical Machines
IS:4728 : Terminal Markings and Direction of Rotation for Rotating Electrical
Machines.
IS:4889 : Method of determination of efficiency of rotating electrical machines.
IS:5571 : Guide for Selection Electrical Equipment for Hazardous Areas
IS:6362 : Designation of Methods of Cooling Rotating Electrical Machines
IS:6381 : Construction and testing of electric apparatus with type of protection ‘e’.
IS:7389 : Pressurized enclosure of electrical equipment for use in hazardous
area.
IS:7816 : Guide for testing insulation resistance of rotating machines.
IS:8223 : Dimensions and output series for rotating electrical machines.
IS:8289 : Electrical equipment with type of protection ‘n’.
IS:8789 : Values of performance characteristics for three phase induction motors.
IS:9283 : Motors for submersible pump sets.
IS:9628 : Three phase induction motors with type of protection ‘n’.
IS:12065 : Permissible limits of noise level for rotating electrical machines.
IS:12075 : Mechanical vibration of rotating Electrical Machines with shaft heights
56 mm and higher - measurement, evaluation and limits of vibration
severity.
IS:12615 : Energy efficient induction motors-three phase squirrel cage.
IS:12802 : Temperature rise measurement of rotating electrical machines.
IS:12824 : Type of duty and classes of rating assigned to rotating electrical
machines.
IS:13529 : Guide on effects of unbalanced voltages on the performance of three
phase cage induction motors.
IS:13555 : Guide for selection and application of three phase induction motors for
different types of driven equipment.
IS:14568 : Dimensions and output series for rotating electrical machines, frame
numbers 355 to 1000 and flange numbers 1180 to 2360
IEC 60034 : Rotating Electrical Machines

IEC 60072 : Dimensions and output series for Rotating Electrical Machines.
The LV motors shall be of the totally enclosed fan cooled type, with degree of protection
for enclosure of IP 55 and shall be suitable for continuous operation and direct-on-line
starting, unless otherwise specified.
They shall be suitable in all respects for service in extreme climatic conditions. Main
conductor and slot insulation shall be non-hygroscopic and in accordance with Class F
with temperature rise ‘B’ of IEC 60085.
Motors shall be capable of operating continuously at rated output at any frequency

between 47.5 and 52.5 Hz and at any terminal voltage within + 10% of the nominal value.
Motors shall be designed to be operated for a period of not less than five minutes at a
voltage of 20% below the nominal value and at normal frequency without injurious
overheating.
The starting current at rated voltage when started direct-on-line shall not exceed 6 times
the rated full load current. When started with soft starter it should be 2.5 to 3 times the
rated full load current. The motor characteristics shall be coordinated with soft starter
manufacturer.
All bearings shall be fitted with oil or grease lubricators. Vertical shaft motors shall have
thrust bearings.
All terminals shall be of the stud type of adequate size for the particular duty, marked in
accordance with an approved standard and enclosed in a weatherproof box.
All terminal boxes shall be fitted with an approved sealing chamber, conduit entry or
adapter plate, as required, together with the necessary fittings to suit the type of cable
specified.
The power rating of the motors shall be larger of the following:
115% of the power input to the pump at duty point at a speed corresponding to a frequency
of 50 Hz.
110% of the maximum power absorbed by pump during entire range of operation/.
Motors shall be capable of starting and accelerating the load with the applicable method
of starting, without exceeding permissible winding temperatures, when the supply voltage
is 80% of the rated voltage.
Motors shall be capable of satisfactory operation at a supply voltage of 80% of the rated
voltage for 5 minutes, commencing from hot condition.
The locked rotor withstand time under hot conditions at 110% rated voltage shall be more
than the starting time at minimum permissible voltage by at least two seconds or 15% of
the accelerating time, whichever is greater. The locked rotor current of motors shall not
exceed 600% of full load current of motor, which is inclusive of 20% tolerance.
Motors when started with the drive imposing its full starting torque under the specified
supply voltage variations shall be capable of withstanding at least two successive starts
from cold conditions and one start from hot condition without injurious heating of windings.
The motors shall also be suitable for three equally spread starts per hour under the above
referred supply conditions.

In case of motors started by soft starters, the three phases shall be segregated by metal
barriers within both line and neutral side terminal boxes. The two terminal boxes shall be
on opposite sides.
The earthing pad shall be of non-corrodible metal, welded / brazed at two locations on
opposite sides..
Motors rated 110 kW and above shall have space heaters suitable for 240 V, single phase
50 Hz AC supply. These shall be placed in easily accessible positions in the lower part of
motor frame. Provision shall be made to measure temperature of bearing by temperature
measuring device for rating above 110kW. Thermistors shall be provided for Flame proof
motor.
Motors shall have drain plugs so located that they will drain water, resulting from
condensation or other causes from all pockets in the motor casing.
Pockets shall be provided in the motor bearing housings for insertion of portable instrument
probes for measuring bearing temperature. One portable hand held instrument per
pumping station shall be provided for measuring motor bearing temperature. The same
instrument shall also be used to measure the pump bearing temperature.
Motors for use in hazardous areas (Zone-1 or Zone-2) shall have type of protection Ex d
or Ex e or Ex n, as applicable and shall meet the requirements of applicable Indian
standards.
15.4.9.2 Motor Protection
15.4.9.2.1 Over-temperature Protection
The protective over-temperature devices shall be in close thermal contact with each phase
of the stator windings and the upper and lower bearings. These shall be provided for every
motor which satisfies any of the following criteria:
• It is operated as a variable speed drive.
• It is subject to onerous operating conditions such as a high maximum number of starts
per hour or a long run-up time.
• It is installed in a potentially hazardous area.
• It has a motor rating equal to or greater than 22 kW.
Other over temperature protective devices may be of the P100 (positive temperature
resistance) type and some are commonly known under the ‘Klixon’ and ‘Minicas’ brand
names.
15.4.9.2.2 Overload Protection
Electric motors having a rating equal to or greater than 0.37 kW shall be provided with
control equipment incorporating overload protection of the motor.
Wherever ‘low power’ or ‘low current’ protection is provided, the motor starter circuit shall
be arranged so that the ‘low power’ and/or ‘low current protection’ is overridden:
For a suitable time after starting the motor to prevent spurious tripping of the drive before
it has achieved its steady state operating condition

Whenever the ‘Test’ mode has been selected at the motor starter
In the starter for each drive, an over-torque protection relay, type tested by the
manufacturer of the protection relay shall be provided to prevent damage to the equipment.
15.4.9.2.3 Additional Protection
Where specified, recommended by the driven equipment manufacturer or where otherwise

appropriate, other forms of drive protection such as ‘low power’, ‘low current’ or ‘over-
torque’ based on the measurement of electrical parameters shall be provided. Each type
of such protection device shall be of a type tested by the equipment manufacturer.
In addition to the over temperature and overload protection described above, the following
shall be provided for motors:
• Short Circuit Protection
• Under voltage protection
• Earth Fault Protection
• Phase Unbalance/ Failure Protection
• Locked Rotor/ Stall Protection
• Warning Before Fault Occurrence
• Thermistor Protection (if applicable)
15.4.9.3 Insulation
Any joints in the motor insulation such as at coil connections or between slot and winding
sections, shall have strength equivalent to that of slot sections of the coil. The insulation
shall be given tropical and fungicidal treatment for successful operation of the motor in
extreme climate. The motors shall be provided with class F insulation with temperature
rise limited to that of class B insulation.
15.4.9.4 Constructional Features
The motor construction shall be suitable for easy disassembly and re-assembly. The
enclosure shall be sturdy and shall permit easy removal of any part of the motor for
inspection and repair.
Motors weighing more than 25 kg shall be provided with eyebolts, lugs or other means to
facilitate safe lifting.
15.4.9.5 Terminal Box
Terminal boxes shall be of weather proof construction designed for outdoor service. To
eliminate entry of dust and water, gaskets of neoprene or equivalent approved shall be
provided at cover joints and between box and motor frame. It shall be suitable for bottom
entry of cables. It shall be suitable of being turned through 3600 in steps of 900.
The terminals shall be of stud type with necessary plain washers, spring washers and
check nuts. They shall be designed for rated current carrying capacity and shall ensure
ample phase to phase and phase to earth clearances. Suitable cable glands and lugs shall
be supplied to match specified cables.

15.4.9.6 Accessories
Two independent earthing points shall be provided on opposite sides of the motor for
bolted connections. These earthing points shall be in addition to earthing stud provided in
the terminal box.
15.4.9.7 Tests
Motors shall be subject to routine tests which shall also include the following:
• Insulation resistance test
• Measurement of winding resistance of stator and wound rotor
• High voltage test
• No load / full load tests to determine efficiency, power-factor and slip
• Locked rotor reading of voltage, current and power input at a reduced voltage.
• Reduced voltage running up test
Type test certificates for test runs performed on identical motors (below 11 kW rating) shall
be made available. Whenever two nos. or more identical motors (above 11 kW rating) are
being offered, type tests on one of them shall be carried out, as follows.
• Momentary overload test
• Test for noise levels of motor
• Test for vibration severity of motor
• Overspeed test
• Temperature rise test
15.4.10 HV and LV Cables
15.4.10.1 Standards
HV and LV Cables shall comply with the following Indian and International Standards,
including those referred to therein.
IEC 60228 : Conductors for insulated cables.

IEC 60183 : Guidance for the selection of high-voltage A.C. cable systems
IEC 60227 : Polyvinyl chloride insulated cables of rated voltages up to and
including 450/750 V.
IEC 60502 : Power cables with extruded insulation and their accessories for
rated voltages from 1 kV (Um = 1,2 kV) up to 30 kV (Um = 36 kV)
IEC 60885 : Electrical test methods for electric cables.
IEC 60332 : Tests of Electric cables under fire conditions
IEC 60287 : Electrical cables
IS 7098 : Specification for cross linked polyethylene insulated PVC sheathed
cables
IS:5831 : Specification for PVC insulation sheath and electric cables.
IS:8130 : Conductors for insulated electric cables and flexible cords
IS:1554 : PVC insulated (heavy duty) electric cables
IS:10810 : Methods of test for cables

15.4.10.2 Voltage Drops
Selection of Short Circuit Protective Device(SCPD) shall be done to optimize the cable
sizing. The maximum voltage drops in various sections of the electrical system under
steady state conditions at full load shall be within the limits stated in the following table:
The maximum voltage drop at various buses during start-up of large motor and / or motor
reacceleration conditions shall be within the limits stated below:
The voltage available at the motor terminals during start-up must be sufficient to ensure
positive starting or reacceleration of the motor (even with the motor fully loaded, if
required), without causing any damage to the motor.
15.4.10.3 Installation
a) In on racks in air or laying direct in ground or drawing in ducts or laying on racks inside
cable tunnel
b) Depth of laying in ground 1000 mm for directly buried HV cables and 750 mm for LV
cables
c) In conduit: space factor not more than 40 % (ratio of total cable area to internal conduit
area)
d) In trays: single layer with spacing of one diameter for HV and main LV cables and
touching for small LV cables
Control cables shall be 2C, 4C, 7C, 12C and 19C type. Minimum size of conductor for
control cables shall be 2.5 sq.mm. copper.
All power cables shall be sized based on continuous current capacity, maximum
permissible voltage drop of 2.5% and rated short circuit current withstand. In addition,
rating factors for variation in ground/air temperature, grouping of cables, depth of laying,
number of racks, etc. shall be considered for cable sizing.
15.4.10.4 Tests
All HV, and LV cables shall be subject to routine tests in accordance with the relevant
Indian Standard Specifications.
Test certificates shall be provided against each drum and/or cable length.
The tests carried out on every cable length and / or drum at manufacturer's premises shall
include following tests as applicable but not limited to:
• Annealing test (for Copper)
• Tensile test (for Aluminum)
• Wrapping test (for Aluminum)
• Tensile strength test
• Hot set test for insulation
• High Voltage dc insulation pressure test, between cores, each core to earth, metallic
sheath or armour as applicable;
• Insulation resistance test;
• Core continuity and identification;
• Conductor resistance test
• Elongation test
The following shall constitute additional type tests for cable length with improved fire
performance as per the categories given in Appendix A of IS:7098, as applicable:

Category C2:
a) Oxygen index test
b) Flame retardance test on single cable
c) Test for specific optical density of smoke
d) Test for halogen acid gas evolution'
15.4.11 Field Push Button Station
15.4.11.1 General
The design, manufacture and performance of the equipment to be supplied under the
scope of this specification shall comply with latest revisions of relevant Indian Standards
and rules.
The design and workmanship shall be in accordance with best engineering practices as
applicable to industrial electrical enclosure.
15.4.11.2 Construction
Industrial Local Control Station (LCS)or Push button station (PBS) enclosure shall be Cast
Aluminium LM6 alloy or Polycarbonate/ Polystyrene enclosure having minimum 3 mm
thickness.
The enclosure shall be weather proof, IP-65 suitable for outdoor installation. Local control
stations for use in hazardous areas shall be Ex-d protection, suitable for gases such as
methane (CH4), CO, CO2 and H2S and shall be suitable for zone-1 application, as
applicable. These shall be Petroleum and Explosives Safety Organization (PESO)/Chief
Controller of Explosives (CCoE) certified. All mating surfaces of industrial LCS shall be
with continuous non-deteriorating type special rubber gasket/neoprene gaskets. An
additional 2mm thick Aluminium canopy shall be provided to give adequate protection
against weather.
15.4.11.3 Cable Entries
Two threaded entries shall be provided on each Local Control Stations at the bottom for
fixing the cable glands. Metallic/rubber plug shall be provided for sealing one of the cable
entry.
15.4.11.4 Earthing
The enclosure shall be provided with two (2) nos. of external earthing terminals and one
(1) no. internal earthing terminal each of 2.5 mm diameter complete with nut, spring
washers for termination.
15.4.11.5 Wiring
All internal wiring up to the terminal block in the Local Control Station shall be carried out
with 1.5 sq.mm stranded copper conductors. Wires shall be PVC insulated type 650/1100V
grade. The wire shall be terminated with crimping type lugs only and shall be provided with
ferrules at both the ends.

15.4.11.6 Painting
The Local Control Stations shall be treated with two coats of epoxy primer after thorough
cleaning and treating of the surfaces and shall be finally provided with two coats of epoxy
paint. Shade of final paint shall be RAL-7032.
15.4.11.7 Name Plate
Each LCS shall be provided with name plate. Name Plate shall be made from rear
engraved, acrylic with letters of size minimum 6 mm on black backgrounds. All name plates
shall be identical in size and shall be fixed with screws on the cover.
15.4.11.8 Component Specifications
15.4.11.8.1 Push button
Each push button shall be provided with 1NO+1NC contacts, each rated to carry, make
and break 10A at 240 V AC.
Colour of the actuators of “STOP” push button shall be RED and that of “START” push
button shall be GREEN. Stop push button actuator shall be mushroom head type and shall
have stay-put feature i.e. once the STOP push button is pressed, it remains in pressed
position until its actuator is turned in either direction. START push button shall be totally
shrouded type to prevent accidental start of the motor.
15.4.11.8.2 Terminal Block
Voltage grade of terminal block shall be 660V. Current rating, their size and make shall be
as per the requirement specified. Two nos. spare terminals shall be provided in each local
control station.
15.4.12 Junction Boxes / Marshalling Boxes
Junction boxes / marshalling boxes shall be hot-dip galvanized, weather proof with IP 55
degree of protection and shall be provided with cable glands for incoming and outgoing
cables. The boxes shall be fabricated from 1.6 mm thick sheet steel and galvanized. The
boxes shall be suitable for mounting on walls / columns / steel structures, etc. and shall be
supplied with mounting accessories. The front covers of the boxes shall be removable and
provided with gaskets. All the terminals shall be complete with insulated barriers, terminal
studs, washers, nuts, etc. The boxes shall be effectively earthed.
15.5 Solar Power Generation System
It is envisaged that the solar energy in the form of sunlight falling on each solar module
shall be converted into electricity based on the photo voltaic principle. All the components
and parts used in the solar lighting systems shall conform to the latest BIS or IEC
specifications, wherever such specifications are available and applicable.
a) The generation of electricity by solar module is dependent on the location and it may
vary from place to place. The Contractor shall study the solar radiation profile of the
Pune region from Indian Metrological Department and shall submit the design of solar
power system for approval to Engineer.
b) The generation of electricity shall be highest when the solar radiation is at its peak
value. Generated Electricity shall not be stored..
c) Contractor shall arrange for the requisite numbers of solar module in series or parallel
configuration connected through junction boxes so as to achieve the desired capacity.

d) The Maximum Power Point Tracking (MPPT) controller shall be intelligent enough to
extract maximum energy from the array of solar modules.
Inter connecting cables shall be laid to interconnect the solar modules, junction boxes,
converter and the alternating current distribution board, through suitable conduits.
e) The inverter shall indicate the following: ON Charge, Main Output, Output Voltage etc.
• When solar energy is available :
o Through solar energy, the lights, ceiling fan, exhaust fan, water cooler, etc.
shall operate during day time only.
o During daylight period, the available solar energy shall be utilised to the
maximum permissible limit as specified by the Solar array manufacturer.
• When solar energy is not available :
o The lights shall be fed through utility supply until Solar Inverter terminal voltage
reaches the minimum permissible limit as specified by the Solar manufacturer.
f) Maximum use of solar energy (priority of solar energy over mains):
g) In case the operation philosophy of solar system differs from above, the contractor
shall submit the operation philosophy for approval to the Engineer. The overall
objective of operation philosophy shall be the maximum utilisation of solar energy.
h) Solar system shall have following components:
• Solar photo voltaic modules as per IEC 61215 and IEC 61730.
• Mounting structure with an arrangement to change angle of inclination for solar
photo voltaic modules with anti-corrosive coating.
• Junction boxes with anti-corrosive coating
• Inverter shall be as per IEC 62116, IEC 61727, IEC 62109 with adequate protection
against ‘Short circuit’ Output overvoltage, Output overcurrent, Insulation resistance
monitoring, Residual current detection, Surge protection, Grid monitoring, Islanding
protection, Temperature protection, DC reverse polarity.
• AC distribution board
• Changeover facility from mains to solar power system and vice-versa.
• Installation kit
• Interconnecting cables
• Indication lamps for charging status
15.6 Lighting System
15.6.1.1 Standards
Lighting system shall comply with the following International Standards, including those
referred to therein
IEC 60364-5-52 : Electrical installations of buildings.
IEC 60598 : Luminaries
IEC 60947 : Low-voltage switchgear and controlgear
IEC 60083 : Plugs and socket-outlets for domestic and similar general use,
IEC 60669 : Switches for household and similar fixed-electrical installations
IEC 60884 : Plugs and socket-outlets for household and similar purposes
IEC 60906 : IEC system of plugs and socket-outlets for household and similar
purposes
All of indoor lighting shall be solar based as per specifications given below:

15.6.1.2 General Requirements
Lighting system equipment shall cover lighting distribution boards, lighting fixtures,
switches, receptacles with switches, for outdoor lighting - lighting masts, street lighting
poles, etc.
Galvanized conduits shall be used for all outdoor wiring and UnPlasticised Polyvinyl
Chloride (uPVC) conduit shall be used for internal wiring. Minimum size of conduit shall be
20 mm / 25mm for exposed / concealed conduits respectively. Wiring inside the pump
house, switchboard room and other areas shall be concealed type.
Wires used for conduit wiring of lighting fixtures / ceiling fans and receptacles shall be 240
/415 V grade, PVC insulated, single core, stranded copper conductor wires of sizes not
less than 2.5 sq. mm and 4 sq. mm respectively. Wires shall conform to IS standards.
Three individual wires with proper color coding (P-N-E) shall be used for wiring and no
joint in wires between conduit is allowed. 3 core x 2.5 sq. mm. copper cables shall be used
for circuiting of peripheral lighting.
15.6.1.3 Lighting Distribution Boards
Lighting distribution boards shall be of wall mounting type and fabricated out of 1.6 mm.
thick cold rolled sheet steel. lncomer circuit shall be controlled by a switch disconnector
with a link in the neutral circuit. Outgoing circuits shall be controlled by single pole MCBs
of minimum 10A rating and a link in the neutral circuit. TPN MCB shall be provided for
street lighting/ area lighting purposes. Breaking capacity of MCBs shall not be less than
10 kA. Residual circuit breakers (RCCBs) shall be used on all lighting and receptacle
circuits.
Lighting distribution board shall have facility to receive power from utility and that from
solar power generation system. Necessary interlocks shall be provided giving priority for
the power received from solar energy source.
It shall be possible to terminate incoming and outgoing circuits from top and bottom.
Knock-out for cable / conduit entries for all the circuits shall be provided. Separate circuits
shall be provided for control of lighting fixtures and receptacles. Each phase shall have at
least one spare circuit.
The distribution board shall be provided with 3 phase and neutral Aluminium busbar
adequately rated to cater to the requirement of all the outgoing circuits. Two earthing
terminals shall be provided external to the distribution boards for terminating the external
earthing conductor.
The distribution board shall be internally wired using color coded, stranded copper
conductor, PVC insulated wires of 1100 V grade.
The distribution board shall have hinged door, gasketed all round and provided with handle
lock. Operation of incomer switch or MCBs shall be possible without opening the door.
Detailed specification of lighting distribution board and its accessories (e.g. busbar, MCB,
indicating instrument, indicating lamp, etc.) are described at LV switchboard.
15.6.1.4 Emergency lighting system
Normal and emergency lighting for indoor and outdoor areas shall be provided.

Contractor shall provide maintained or non-maintained self contained emergency lighting

system under this Contract. The Contractor shall provide emergency lighting in the vital
installation including pump house, switchboard room, office building, administration areas,
etc. Minimum 10% of the total normal lighting fixtures shall be emergency type.
15.1.1.1 Lighting Fixtures and its Accessories
Lighting fixtures for illumination of outdoor and indoor areas shall be supplied. Fixtures for
outdoor installation shall be of weatherproof design with degree of protection of IP65. The
fixtures shall be suitable for operation on a nominal supply of 240 V, single phase, 50 Hz,
AC with a voltage variation of + 10 %.
Fixtures shall be complete with internal wiring, lamp, capacitor, starter, holder, ballast,
reflector, louvres / perspex, etc. as required for their satisfactory operation. Fixtures shall
be energy efficient and ballast shall be electronic low loss type. All indoor lighting fixture
for office and control room shall be decorative type and for remaining areas it shall be
industrial type.
Lamp holders shall be low contact resistance,, resistant to wear and suitable for operation
at the specified temperature, without deterioration in insulation value, contact resistance
or lamp holding quality. Contractor shall use high power LED lamp in suitable fixtures at
all location of the plant.
Lighting fixture reflectors shall generally be manufactured from steel or aluminum sheet of
not less than 20 SWG thicknesses. Each fixture shall be complete with a four way terminal
block for connection and looping of incoming and outgoing cables. Each terminal shall be
able to accept two 2.5 mm2 copper stranded conductors. Each lighting fixture shall be
provided with an earthing terminal suitable for connecting 16 SWG copper stranded
conductor. All metal or metal enclosed parts of the housing shall be bonded and connected
to the earth terminal to ensure satisfactory earthing continuity throughout the fixture. All
reflectors and louvers shall be finished to the same standard as the fixture housing.
The enamel finish shall have a minimum thickness of 2 mils for outside surface and 1.5
mils for inside surfaces. The finish shall be non-porous and free from blemishes, blisters,
and fading.
Size of wire chosen shall be such as to limit the voltage drop to within 3 %. Minimum area
of conductor shall be 1.5 sq mm stranded copper for lighting and 2.5 sq mm / 4 sq mm for
6A / 16A receptacle circuits respectively, and current density shall not exceed 2.5 A/sq
mm. Generally, not more than 8 to 10 lighting points shall be wired in one circuit. For
calculating connected loads of various circuits, a multiplying factor of 1.25 shall be
assumed on the rated lamp wattage for sodium vapour and fluorescent lamp fixtures to
take into account the losses in the ballast. A loading of 100 watts and 500 watts shall be
assumed for each, single-phase 6 amps and 16amps receptacles respectively. Wires
belonging to different phases shall not be run in the same conduit. However, more than
one circuit on the same phase can be run in the same conduit. For every phase wire, a
separate neutral wire shall be run. Neutral wire for different phases shall not be looped.
1200 mm sweep ceiling fans shall be provided in areas such as offices, etc. as per design
requirement. Adequate ventilation arrangements shall be made for enclosed areas where
ceiling fans are not proposed to be installed or cannot be provided. Power supply for the
ceiling fans shall be derived from lighting circuits. Ceiling fans shall be complete with all
accessories. Regulators shall be electronic (triac) type.

The work shall comprise wiring in heavy duty (minimum 16 SWG) uPVC conduits, fixed
and supported at intervals of 300 mm on walls, ceiling etc.; installation of light control
switches and receptacles; earthing with 16 SWG copper wire run along the conduit and
clamped to it at every 300 mm; and termination of cables/wires at lighting distribution
boards, light control switches, receptacles, lighting fixtures etc., as required. The minimum
size of conduit shall be 20 mm. Space factor (ratio of total wire area to internal conduit
area) shall be 40 %. Concealed conducting shall be provided to all building / office areas.
For pump house area, the Contractor shall adopt surface conducting also.
The following types of fixtures shall be considered for various areas. The construction
features are indicative.
15.6.1.5 Indoor Areas
High power LED Light fixtures shall be used. These fixtures shall be used in switchboard
room offices and pump houses and other areas. Where false ceiling is provided, fixtures
shall be suitable for recessed mounting. For non-false ceiling office areas, decorative type
fixtures shall be used.
15.6.1.6 Outdoor Areas
Suitable type of fixtures with high power LED lamps shall be considered.
15.6.1.6.1 Flood lighting fixtures
Energy saving, environmental friendly, long life, exclusive innovative die-cast aluminium
IP-65 flood light with high power LEDs as light source with high power LED fixtures.
15.6.1.6.2 High Mast Lighting
High Mast Lights with suitably rated High power LED lighting fixtures, as applicable.
15.6.1.6.3 Gate post lights
Post top lantern fitting with high power LED lighting fixtures shall be used.
15.6.1.6.4 Street Lighting
Energy saving, environmental friendly, long life, exclusive innovative die-cast aluminium
IP-65 street light fixture with high power LEDs as light source. Suitable high power and
efficient LED Street light with 30W/45W/60W/80W LED fixtures shall be used.
15.6.1.6.5 Octogonal Poles for high mast
The Octagonal Poles shall be designed to withstand the maximum wind speed as per IS
875 BS: 5649. Octagonal Poles HT Steel Conforming to grade S355JO. Base Plate Fe
410 conforming to IS 226 / IS 2062. Foundation Bolts EN.8 grade.
The pole shaft shall have octagonal cross section and shall be continuously tapered with
single longitudinal welding. There shall not be any circumferential welding. The welding of
pole shaft shall be done by Submerged Arc Welding (SAW) process. All octagonal pole
shafts shall be provided with the rigid flange plate of suitable thickness with provision for
fixing 4 foundation bolts. This base plate shall be fillet welded to the pole shaft at two
locations i.e. from inside and outside.

The poles shall be hot dip galvanized as per IS 2629 / IS 2633 / IS 4759 standards with
average coating thickness of 70 micron.
The brackets shall be made of specified size NB G.I heavy duty pipe approximately 1.4 M
long, bent at the center, with necessary holding brackets, hold fasts etc. with special
reducer at end to accommodate type of street light fitting to be fixed. The bracket shall
have one coat of anti-corrosion paint before dispatch to site and two coats of approved
make and shade of enamel paint.
The octagonal Poles shall have door of approximate 500 mm length at the elevation of 500
mm from the Base plate. The door shall be vandal resistance and shall be weather proof
to ensure safety of inside connections. The door shall be flush with the exterior surface
and shall have suitable locking arrangement. There shall also be suitable arrangement for
the purpose of earthing
Installation of poles shall be done as per design and drawing. Foundation drawing shall be
submitted for Engineer’s approval.
15.6.1.7 Illumination Levels
Lighting system shall be designed to achieve the average maintained levels of illumination
as indicated below. The Contractor shall be required to measure the actual levels and
carry out necessary modifications to accomplish specified levels. It is to be noted that the
values measured after installation will exceed those specified due to inclusion of light loss
factor in the calculation. Measurement shall be carried out after 100 burning hours.
The top loading i.e. area and the weight of fixtures are to be considered to calculate
maximum deflection of the pole and the same shall meet the requirement of
The illumination system shall be so designed that the uniformity factor is of acceptable
level and that the glare is within limits. The ratio of maximum to minimum illumination levels
shall not exceed 20 in outdoor area.
The Contractor shall furnish detailed design calculations, uniformity factors, ratio of
maximum to minimum illumination levels, ratio of average to minimum illumination levels,
glare values, etc. for approval. Detailed characteristics of various types of fixtures including
photometric curves and tables shall also be furnished for review.
15.6.1.8 Receptacles
Adequate number of receptacles of 6A, 16A and 32A rating with MCBs suitable for
operation on 240 V, AC, 1 phase, 50 Hz supply shall be provided as detailed below:
a) Decorative and industrial type shall be proposed in relevant areas.
b) Receptacles proposed for outdoor installation shall be of weatherproof design of
degree of protection IP65.
c) Single phase receptacle shall be provided with a switch / MCB of the same current
rating, housed in the same enclosure. Three phase receptacles shall be associated
with a MCB of the same rating, housed in the same enclosure. The number, type,
rating and location of receptacle shall be subject to approval of the ENGINEER or their
representative’s Representative.

15.6.1.9 Switches
Decorative / industrial type switches of 6A / 16A rating shall be provided for all indoor
areas. Switches shall be provided to control a group of lighting fixtures in various areas.
Switches shall be housed in galvanized steel boxes, as applicable.
15.6.1.10 Water Coolers
Water cooler shall conform to IS 1475 with latest amendment suitable for operation on 240
volts ±10%, 50 Hz, single phase, AC supply. It shall be supplied with hermetically sealed
type suction gas cooled compressor motor with overload protection. It shall have cooling
capacity of 40 liters per hour with storage capacity as 80 liters.
15.6.1.11 Tests
Lighting distribution boards, fixtures, receptacles and other accessories shall be subjected
to routine and acceptance tests as per the applicable standards.
15.7 Cabling System
15.7.1 General
All apparatus, connections and cable work shall be designed and arranged to minimize
risk of fire and any damage, which might be caused in the event of a fire.
Cables shall be laid directly buried in earth or on cable trays or in built-up trenches or in
conduits / pipes along walls / structures / foundations / ceilings, etc. wherever required as
per direction of Engineer. Cables from substation to various MCCs, PDB, and other LT
Panels shall be laid in RCC cable trench on the trays. Trench shall be covered with Fiber
Reinforced Plastic(FRP) or Glass Reinforced Plastic(GRP) cover after finishing the cable
laying work. The Contractor's scope of work includes unloading, excavation, laying,
backfilling, fixing, bending and terminating the cables. The Contractor shall supply the
necessary material and accessories required for installation and termination of the cables
which shall include but not be limited to items such as glands, lugs, terminating
accessories, hardware, consumables, saddles / spacers, GI conduits / pipes, cable
identification tags, protective bricks, civil materials, etc.
15.7.2 Buried Cables
Cable installation in outdoor areas i.e. outdoor area lighting shall be carried out in directly
buried cable trenches. Stabilized thermal backfilling shall be used for directly buried
cables. Cabling from trenches up to junction box / equipment, etc. shall be carried out in
GI conduit / pipes of class B. Provision of GI pipe sleeves in trench wall shall be the
Contractor's responsibility. Where cables cross roads or water / sewage pipes, the
Contractor shall provide 150 mm diameter GI pipes in a concrete block for passage of
cables. Contractor shall also lay minimum 20% spare pipes for future use. Alternatively,
Contractor shall provide concrete cable duct for road crossing. LV cables shall be buried
at a depth of minimum 750 mm while HV cables shall be buried at a depth of minimum
1000 mm. For road crossings, the pipe for the cables shall be buried at not less than one
meter depth.
Directly buried cables shall be laid on a 75 mm thick riddled and compacted earth bed.
The cables shall then be covered on top and at their side with riddled earth to a depth of
about 150mm. This shall then be gently pulled down to a depth of about 100 mm above
the top of uppermost cable to provide bedding for the protective concrete cable covers,

which shall be placed centrally over the cables. The protective cable covers shall be of
reinforced concrete. The RCC covers shall have one hole at each end to tie them to each
other with GI wires arrangement to prevent displacement. The trench should be then
backfilled with the excavated soil and well rammed in successive layers of not more than
300 mm thick, with the trenches being watered to improve consolidation, wherever
necessary. To allow for subsidence, a crown of earth not less than 50 mm in the center
and tapering towards the sides of the trench should be provided.
All cables to be routed along any particular route shall be laid at one time to avoid repeated
excavation, etc. Each cable shall be tagged with numbers. The tag shall be of aluminum
with the number punched on it and securely attached to the cable / conduits by not less
than two turns of 20 SWG GI wire. Cable tags shall be of rectangular shape for power
cables and of circular shape for control cables. Cables tags shall be provided on all cables
at each end, on both sides of wall / floor crossings, on each duct / conduit entry, at each
bend/ corner and at every thirty (30) meters in cables trench / tray racks on straight run.
Where groups of HV, LV and control cables are to be laid along the same route in the
same trench, suitable non-metallic barriers/bricks to segregate them physically shall be
provided. When power cables are laid in the proximity of communication cables, minimum
horizontal and vertical separation of 300 mm shall be maintained. Power and
communication cables shall, as far as possible, should not cross at right angles to each
other.
15.7.3 Cables in Trays
Cables in trays shall be cleated individually or in a group using GI saddles. Interval for
cleating shall not exceed 1500 mm.
In case of laying on cable trays / racks, power and control cables shall be laid in separate
cable trays, the order of laying of various cables being as given below:
a) HV cables on top tiers
b) LV cables on subsequent tiers
c) Control, instrumentation and other service cables in bottom-most cable tier.
Ladder type Hot Dip Galvanised cable trays and painted rack support shall be installed in
cable trenches for power cables. Perforated trays shall be used for control and
instrumentation cables. Embedded flats for fixing cable tray supports shall be provided in
cable trenches to support the cable trays during civil works. Where such flats cannot be
used, the fixing of cable trays shall be done using anchor fasteners. All cable trays shall
be earthed at a regular interval.
The cable trays shall be complete with all necessary coupler plates, elbows, tees, bends,
reducers, stiffeners and other accessories and hardware. Cable trays and accessories
such as tees, elbows, reducer, etc. shall be fabricated out of minimum 2 mm thick sheet
of hot dip galvanized sheet except for trays of width 300 mm and lower for which 16 G GS
sheet is acceptable. Bends, tees, etc. shall be supplied or fabricated at site, as required.
Cable tray supports such as angles, channels, etc. shall be of galvanized steel.
Galvanizing thickness shall be not less than 85 micron.
15.7.4 Cable Pulling
The cables shall be laid in built-up trenches, directly buried in ground, or on cable trays,
vertical raceways, clamped on structures / walls / ceiling, pulled through pipes and
conduits, etc. The scope of cable installation shall include excavation and backfilling (in

case of buried cable trench), laying, pulling of cables, proper dressing of cables on cable
trays, racks, vertical raceways and supply and installation of cable tags, saddles, spacers
and nylon cord for tying as required. The cost of supplying covers for cable route / joint
markers, supply of sand and cover plates are included in the scope of the Contractor.
Standard cable grips and reels shall be utilized for cable pulling. If unduly difficult pulling
occurs, the Contractor shall check the pull required and suspend pulling until further
procedure has been approved by the ENGINEER or their representative’s Representative.
The maximum pull tension shall not exceed the recommended value for the cable
measured by the tension dynamometer. In general, any lubricant that does not injure the
overall covering and does not set up undesirable conditions of electrostatic stress or
electrostatic charge may be used to assist in the pulling of insulated cables in conduit /
pipes and ducts.
After pulling the cable, the Contractor shall record cable identification with date pulled
neatly with waterproof ink in linen tags / aluminum tag and shall securely attach such
identification tags. Identification tags shall be attached to each end of each cable with non-
corrosive wire. The wire must be non-ferrous material on single conductor power cable.
Tags would further be required at intervals on long runs of cables on cable trays and in
pull boxes. Cable and joint markers and RCC warning covers shall be provided wherever
required.
Each cable shall be pulled into the particular conduit / pipe and shall be taken from the
particular reel designated for the run. In hand holes, pull boxes or junction boxes having
any dimension over 1000 mm, all conductors shall be cabled and / or racked in an
approved manner. Care shall be taken to avoid sharp bending or kinking cables, damaging
insulation or stressing cable beyond manufacturer's recommendations in pulling. Cable
shall be protected at all times from mechanical injury and from absorption of moisture at
unprotected ends. The bending radii for various types of cables shall not be less than 12/15
times the overall diameter of the cable for armoured cables and 15/20 times the overall
diameter of the cable for unarmoured cables.
Cables on cable racks and in conduits / pipes shall be formed to avoid bearing against
edges of trays, racks, conduit / pipes or their supports upon entering or leaving racks or
conduit / pipes.
Cables splices shall not be used except where permitted by the ENGINEER or their
representative's Representative. Splices shall be made by Contractor for each type of wire
or cable in accordance with the instructions issued by cable manufacturers and the
ENGINEER or their representative's Representative. Before splicing, insulated cables
shall have conductor insulation stepped and bound or penciled for recommended distance
back from splices to provide a long leakage path. After splicing, insulation equal to that on
the spliced conductors shall be applied at each splice.
At cable terminal points, where the conductor and cable insulation will be terminated,
terminations shall be made in a neat, skillful and approved manner by specially trained
staff. Terminations shall be made by the Contractor for each type of wire or cable in
accordance with instructions issued by cable manufacturers and / or the ENGINEER or
their representative's Representative.
Control cable termination shall be made in accordance with wiring diagrams, using proper
color codes for the various control circuit.

When control cables are to be fanned out and corded together with a cord, the Contractor
shall make connections to terminal blocks, and test the equipment for proper operation
before cables are corded together. If there is any doubt about correctness of connection,
the Contractor shall make a temporary connection with sufficient length of cable so that
the cable can be switched to another terminal without splicing. After correct connections
are established, cables shall be cut to their correct lengths, connected to terminals in the
specified manner, and corded together where necessary to hold them in place in a skillful
manner. Jointing of cables shall be in accordance with relevant Standards and
manufacturer's instructions. Materials and tools required for cable jointing work shall be
supplied by the Contractor. Cables shall be firmly clamped on either side of a ‘straight
through joint’ at a distance of not more than 300 mm away from the joints. Identification
tags shall be provided at each joint at all cable terminations.
Where cables pass through floor or wall openings or other partitions, suitable bushes /
pipe sleeves of GI shall be provided by the Contractor. The Contractor shall seal the cables
at the bushes / pipe sleeves using fire resistant material.
Cable seals shall be examined to ascertain if they are intact and that cable ends are not
damaged. If the seals are found to be broken, the cable ends shall not be jointed until after
due examination and testing under supervision of the ENGINEER or their representative's.
Before joining is commenced, insulation resistance of both sections of cables to be jointed
shall be checked by megger.
In case of motor cables, after installation and alignment of motors, the Contractor shall
complete the conduit / pipe installation, including a section of flexible conduit / pipe
between motor terminal box and trench / tray, if necessary. The Contractor shall install and
connect the power, control and heater supply cables as per equipment manufacturer’s
drawings / instructions. The Contractor shall be responsible for correct phasing of the
motor power connection and shall interchange connections at the motor terminal box, if
necessary, after each motor is test run.
Connections to recording instruments float switches, level electrodes, limit switches,

pressure switches, thermocouples, thermostats and other miscellaneous equipment shall
be done as per manufacturer's drawings and instructions.
In each cable run, some extra length shall be kept at a suitable point to enable one or two
straight-through joints to be made, should the cable develop fault at a later date.
15.7.5 Conduits / Pipes
Where cable trench is not available, cables shall be laid in GI conduits / pipes routed along
walls / columns / beams / steel structures or buried in concrete slabs, etc. to suit site
conditions. GI conduits shall be Class C type. Supply and installation of GI conduits / pipes,
their accessories such as bends, tees, couplers, etc., saddles, spacers, junction /
marshalling boxes and GI hardware required for installation shall be included in the
Contractor's scope. Interval between supports shall not exceed 500mm. For multiple
cables, maximum utilization factor (ratio of total wire area to internal conduit area) shall be
50% of the conduit area.
Non-metallic conduits / pipes shall be used for single core cables of a 3 phase circuits.

15.8 Cable Sealing System
15.8.1 General
Cable sealing system shall be provided and shall consist of
a) Fire-stops / fire-seals for sealing of cable / cable tray and conduit / pipe penetrations,
both horizontal and vertical, through brick or RCC walls / floors, of substation, PCC
and MCC rooms to prevent the spread of fire from one area to other areas by fire-
resistant barriers.
The fire proof sealing system shall also include all the necessary accessories and
equipment required for supporting, holding in position, fixing and installation of the fire-
stop.
The fire proof sealing system shall comply in all respects with the requirements of the
codes and standards mentioned relevant International Electrotechnical Commission (IEC)
standard.
The fire proof sealing system adopted for cables or cable trays penetrating through walls
and floor openings, or cables passing through embedded conduits / pipes / pipe-sleeves,
constitutes a `fire stop / seal', which is meant to prevent spreading of fire between areas
separated by fire-resistant barriers.
15.8.2 Performance Requirements of Fire Stops
i. The material, design and construction of the fire stops shall be such as to provide a
fire-rating of 120 minutes for a fire on any side and meet all requirements listed in this
specification and the relevant codes and standards.
ii. The materials used in the fire stops shall be non-hygroscopic, compatible with the type
of cables.
The fire stops shall be suitable for retrofitting of cables through the penetration seal without
disturbing the sealing of the cables already existing.
15.8.3 Application of Fire Proof Sealing System
Fire stops shall be provided for cable penetration openings listed below
i. The passage of cables / cable trays pipe sleeves / embedded conduits through walls /
floors.
ii. Vertical raceways, if any, which carry cables between successive floors, through
openings provided in the RCC floor slab, shall be sealed by fire stops at each floor
level.
iii. Cable entry through openings in floor slabs.
Contractor shall furnish the test certificates for the fire stops after award of Contract for
ENGINEER or their representative for review. If the certificates are not satisfactory, all the
tests shall be conducted free of cost. The offered system i.e. fire stops and fire breaks
shall be identical (or better) with the system which is successfully type tested for the
specified rating i.e. the composition density of the material, thickness of coating in case of
fire breaks and any other properties of the material / system offered shall be identical or
better than the tested system and shall be subject to ENGINEER or their representative
approval.

15.8.4 Performance Tests:
a) The fire stops shall be subjected to the following type tests:

i. Fire Rating Test
ii. Hose Stream Test
Type tests shall be conducted on different fire stop test specimens described above
as per IEEE-634/UL/ASTM. The sizes of the fire stop test specimens shall be similar
to the largest of the sizes being used in the plant.
b) Preconditioning of fire stop test specimens
Before conducting the Fire Rating and Hose Stream tests, each test specimen shall be
preconditioned for thermal ageing, water immersion and vibration.
c) Test on Fire Stops
During the Fire Rating test, the transmission of heat through the cable penetration fire
stop shall not raise the temperature on its unexposed surface above the self-ignition
temperature of the outer cable covering, the cable penetration fire stop material, or
material in contact with the cable penetration fire stop, with a maximum temperature
limit on the unexposed surface of 2000C.
15.9 Earthing and Lightning Protection System
15.9.1 Earthing
Earthing and lightning protection system shall comply with the following National and
International standards.
IS:3043 : Code of practice for earthing
IEEE:80 : Guide for safety in AC Substation grounding
The scope includes measurement of electrical soil resistivity (during dry season) at site,
supply of earthing conductors, earth electrode pits, lightning protection system and their
installation including associated civil work as per the specifications and approved
drawings, to the satisfaction of the Engineer or their representative’s. The scope of works
shall also comprise designing the earthing and lightning protection systems as per the
applicable standards and specific design basis listed below:
Average value of soil resistivity as measured for different electrode spacing, at site. (from
2 to 10 Meter or more in steps of 0.5,1.5,3,4.5,7.5, 10 Meter. At least 20 nos. readings
shall be taken over the plant area, each in two different directions)
Permissible values of step and touch potentials based on weight of human being as 70 kg
and Earth fault current of 50/65 kA for 1 seconds, as applicable.
Depth of burial of earth conductors of 600 mm below ground level
Ground resistance of earthing grid inclusive of earth electrode of maximum 1 ohm
Corrosion allowance of at least 15 %
Earthing electrode conductor material shall be minimum 38 mm diameter and 3 m long for
GI Pipe material.

Earthing system design and calculations shall be subject to ENGINEER or their

representative’s approval.
Earthing and lightning protection system shall be provided to ensure equipment safety,
personnel safety and to facilitate designed operation of protective devices during earth
fault conditions in the associated system.
The Contractor shall install bare earth conductors as required for the system and individual
equipment earthing. All the work such as cutting, bending, supporting, drilling, brazing /
soldering/welding, clamping, bolting and connections to structures, equipment frames,
terminals or other devices shall be in the Contractor’s scope. All hardware and
consumables such as fixing cleats / clamps, anchor fasteners, lugs, bolts, nuts, washers,
brazing electrodes, flux, bituminous compound, anti-corrosive paint, etc. as required for
the complete work shall be included by the Contractor.
Tap connections (earthing leads) of more than 500 mm long, from main earthing grid to
equipment shall be embedded in the floor by the Contractor together with associated civil
work such as chipping / chieseling, concreting and surfacing, etc. The concrete cover over
the conductor shall not be less than 50 mm.
The scope of installation of earth conductors in outdoor areas, buried in ground shall
include excavation in earth up to 600 mm depth and 400mm width, laying of conductor at
600 mm depth, brazing as required of main grid conductor joints as well as riser’s up to
500 mm above ground at required locations and backfilling. Backfilling material to be
placed over buried conductor shall be free from stones and other mixtures. Backfill shall
be placed in layers of 150 mm, uniformly spread along the trench and compacted. If the
excavated soil is found unsuitable for backfilling, the Contractor shall arrange for suitable
material from outside. Earthing conductors in outdoor areas shall be laid 1500 mm away
from buildings..
Wherever earthing conductor crosses underground service duct and pipes, it shall be laid
300 mm below them. If the distance is less than 300 mm, the earthing conductor shall be
bonded to such service ducts / pipes.
The scope of installation of electrodes shall include installation of electrodes in constructed

earth pits, and connecting to main buried earth grids. The scope of work shall include
excavation, construction of the earth pits including all materials required for treatment (salt,
charcoal, chemicals, etc.), placing the electrode and connecting to main earth grid
conductors.
The work of embedment of earthing conductor in RCC floors / walls along with provision
of earth plate inserts / pads / earth risers shall be done by the Contractor preferably before
the floors / columns / walls are cast. The embedded conductors shall be connected to
reinforcing rods wherever necessary.
The scope of installation of earthing leads to the equipment and risers on steel structures
/ walls shall include laying the conductors, brazing / cleating at specified intervals, brazing
to the main earth grids, risers, bolting at equipment terminals and coating brazed joints by
bituminous paint.
Earthing and lightning protection system conductors along their run on walls / columns,
etc. shall be cleated at an interval of 750 mm.
Main earthing conductor shall be buried below the trench at crossing points.

Metallic frames of all electrical equipment shall be earthed by two separate and distinct
leads and then connected with earthing system.
Neutral of a transformer shall be earthed to two separate copper earth electrode pit by two
separate earth leads.
Crane rails shall be connected to the earthing system.
Metal pipes and cable conduits shall be effectively bonded and earthed by earthing clamps
efficiently fastened to the conduit at both ends.
Neutral connection shall never be used for equipment earthing.
A separate earth electrode shall be provided for each lightning arrester and for each
lightning down conductor or dedicated earth grid shall be laid below the ground at a depth
of 600 mm for respective building/structure.
Cable sheaths and screen shall be bonded to the earthing system.
Armour of multicore cables shall be bonded to earthing system at both ends, while that of
single core cables shall be earthed at source end only. The size of conductor for bonding
shall be appropriate with the system fault current.
All metallic parts such as transformer, motor, cable containment system, fence, gate, etc.
shall be properly earthed.
Wherever earthing conductor passes through walls, galvanized steel pipe sleeves shall be
provided for the passage of earthing conductor. The pipe ends shall be sealed by the
Contractor, by suitable water-proof compound. Water stops shall be provided wherever
earthing conductor enters the building from outside below ground level.
All connections in the main earth conductors buried in earth / concrete shall be brazed
type or as applicable. Connections between main earthing conductor and earth leads shall
also be of brazed type. Connection between earth leads and equipment shall be by two
bolts.
15.9.2 Lightning Protection System
15.9.2.1 Standards
Lightning Protection system shall confirm to the specification laid down in
IS/IEC 62305: -Protection against Lightning: Part 1 to 4.
IS:60364: Low voltage electrical installations.
IEC 61643: Low voltage surge protective devices.
15.9.2.2 System Description
Conductor system protects structures consisting of air terminals on roofs, bonding of

structure and other metal objects, grounding electrodes and interconnecting conductors.
Lightning protection system includes the following minimum components:-

• Air terminals and Interconnecting conductors

• Grounding and equipotential bonding for lightning protection.
• Down conductors
• Joints and bonds
• Testing Joints
• Earth terminations and
• Earth Electrode.
Installation of lightning conductors on the roof of buildings shall include laying, anchoring,
fastening and cleating of horizontal conductors, grouting of vertical rods wherever
necessary, laying, fastening / cleating / brazing of the down comers on the walls / columns
of the building and connection to the test links to be provided above ground level.
Lightning protection system down-conductors shall not be connected to the conductors of

safety earthing system above ground level. No intermediate earthing connection shall be
made to lightning arresters and transformer, who’s earthing leads, shall be directly
connected to electrode pit.
The lightning protection system for the structures shall be installed by forming a grid of
exposed continuous earth conductors and taking down-comers along the walls/supports
of the structure and terminating the same at earth pits. A separate earth electrode shall be
provided for each lightning arrester and for each lightning conductor down comer. The
lightning protection system earth pits shall be inter-connected to form the safety earthing
grid provided for the building / structure. The safety earthing grid shall be connected to the
mains grid of the substation.
The lightning protection air termination rods and / or horizontal air termination conductors
shall be fixed in a firm manner. The necessary accessories such as cleats, clamps, brazing
materials, bolts, nuts, shall be supplied by Contractor.
Air termination systems shall be connected to earthing system by down conductors. There
shall not be any sharp bends, turns and kinks in the down conductors.
All joints in the down conductors shall be of brazed type or as applicable. All metallic
structure within 1 meter of down conductors shall be bonded to lightning protection system.
Every down conductor shall be provided with a ‘test link’ mounted on wall / column at about
1000 mm above ground level housed in a 16 SWG GS enclosure. The test joint shall be
directly connected to the earth electrode.
The lightning protection system shall not be in direct contact with underground metallic
service ducts, cables, cable conduits and metal enclosures of electrical equipment.
However, all metal projections, railings, vents, tanks, etc. above the roof shall be bonded
together to form a part of roof grid.
15.9.2.3 Lightning Protection Unit (LPU)/Surge Protection Device(SPD)
Suitable rating and type of surge diverter shall be provided when earth pits of lightning
system to be connected to main earth grid. Lighting protection unit shall also be connected
to each of HT/ LT Panel to protect the panel and downstream components against lightning
and switching surges.

15.9.2.4 Earth Electrodes and Pit
Treated earth pits shall comprise of treatment material such as highly conductive corrosion
resistant back fill compound. Treatment material placed around the electrode shall be
finely graded, free from stones and other harmful mixtures. Backfill shall be placed
uniformly spread and compacted layers. If excavated soil is found unsuitable for backfilling,
the Contractor shall arrange for a suitable soil from outside.
Earthing pits shall comprise of MS pipe with copper coating of 250+ micron.
The minimum spacing between adjacent electrodes shall be 6 m. Design and
constructional details of electrode pit shall be subject to the ENGINEER or their
representative’s approval.
Electrodes shall, as far as practicable, be embedded below permanent moisture level.
Test pits with concrete covers shall be provided for periodic testing of earth resistance.
Installation of electrodes in test pits shall be suitable for watering. The necessary materials
required for installation of test pits shall be supplied and installed by Contractor. The
installation work shall also include civil works such as excavation / drilling and connection
to main earth grid. Earth electrode pit marker shall be provided.
Treated earth pits shall be treated with suitable treatment material, if average electrical
resistivity of soil is more than 20 ohm meter.
Minimum conductor size for connections to various equipment and sizes of earthing
conductor and nos. of earthing pits shall be selected based on the soil resistivity report of
the site, approved earthing system design:
All paint, scale etc. shall be removed before earthing connections are to be made.
Anchor bolts or fixing bolts shall not be used for earthing connections.
15.10 Public Address System
15.10.1 General
Digital Public address system shall be designed to ensure flexibility, easy configuration,
scalability and sound audio quality for evacuation during emergency situations. The
system shall have the lowest power consumption.
15.10.2 System Controller
The system controller shall be an EN54-16 certified device in a suitable cabinet. The
network device shall contain all controlling and monitoring functions of a voice evacuation
system.
The controller shall manage the supervision of its own operation and that of the connected
devices. It shall control and activate the connected amplifiers and spare amplifier and shall
replace the amplifier routing and channel that has reported a fault. A failsafe mode shall
ensure that emergency calls are passed through to the amplifiers even if the controller
itself fails.
It shall display fault conditions status via LEDs on the front panel.

A single system controller shall be able to manage minimum 2 routers, 2 call stations and
up to 30 loudspeaker circuits.
It shall allow up to 12 controllable local audio inputs.
A built in message manager shall be able to store up to 50 emergency- or business-calls,

with a total storage time up to 60 minutes.
15.10.3 Amplifier
Amplifier shall be Class D, high efficiency type an EN54-16 certified system device in a
suitable cabinet. It shall provide 70/100V loudspeaker output voltages that are galvanically
separated. The amplifier shall be permanently monitored by the system controller.
A special standby mode shall be provided for saving energy during the time the amplifier
is not is use with respect to all economical and supervision aspects.
System control and audio interconnections shall be done via RJ45 connectors.
The amplifier shall be used as a system amplifier, but it shall also be possible to use the
amplifier standalone.
15.10.4 Router
The system Router shall be an EN54-16 certified device in a suitable cabinet. The device
shall extend the number of zones in a system and shall contain all the necessary
controlling and monitoring functions.
The internal supervision system shall monitor the functions and operation of both itself and
the connected devices. It shall be capable of rerouting a spare amplifier channel and shall
replace an amplifier channel that has reported a fault.
Fault conditions shall also be reported to the connected system controller for operational
control and logging purposes. A failsafe mode shall ensure that emergency calls are
passed to the loudspeakers, even if the unit itself fails.
15.10.4.1 Call Station
The call station shall be an EN54-16 certified user interface.
It shall be designed in a modern and robust chassis with a graphical display.
As standard, the call station shall have a gooseneck microphone with pop shield and
permanent monitoring, an illuminated LC-display and an integrated loudspeaker to be
used for system sounds.
The operation status shall be permanently supervised by the system controller.
It shall be possible to modify the call station to suit the user’s requirements by connecting
up to one remote call station extensions, each with appropriate free customizable functions
and selection buttons.
15.10.5 Key Pad
The call station extension shall be EN54-16 Certified. It shall be designed in a robust and
modern chassis. It shall expand the call station by 20 customizable functions keys.

It shall be possible to install a maximum of one call station extensions on one call station,
which shall expand the call station by up to 40 function keys.
It shall be possible to mount the extension on the left or right-side of the call station.
15.10.6 Loudspeaker
15.10.6.1 Ceiling type loudspeaker
A flush-mounting ceiling loudspeaker shall be suitable for both speech and music
reproduction. The speaker assembly consists of a single piece, 6 W loudspeaker and
frame with a 100 V matching transformer mounted on the back. It should be in accordance
with EN 60065.
15.10.6.2 Panel (wall mounting) loudspeaker
Panel (wall mounting) loudspeakers shall be equipped with woofer & tweeter suitable for
excellent speech and music reproduction. The speaker assembly shall consists of a single
piece, 6 W loudspeaker and frame with a 100 V matching transformer mounted on the
back. Speakers shall have provision of flush-mounting in walls, ceilings, or furniture using
Surface-mounting and flush mounting boxes.
Speakers shall be BS 5839-8 Complaint, self-extinguishing, high-impact ABS material

(according to UL 94V0).
15.10.6.3 Horn type loudspeaker
The horn speaker shall be suitable for outdoor applications. The horn loudspeakers
shall provide excellent speech reproduction and sound distribution for a wide scope of
outdoor applications. The rear cover on the horn shall be made from self-extinguishing
ABS (according to class UL 94 V0).
The Horn Speaker shall be Water-and dust protected to IP 65 and shall comply emergency
standards EN 54-24, BS 5839-8 and EN 60849.
15.11 Automatic clean agent fire detection, alarm and suppression system
15.11.1 General
Contractor shall do Supply, Installation, Testing and Commissioning of Automatic Clean

Agent Flooding System complete for electrical panels with fire detection tube, cylinder,
valves, integration with Main Fire Alarm Control Panel for status monitoring etc. The work
shall be executed by authorized and certified agency and shall cover:
i. Providing Direct Panel Gas Flooding System with linear Fire detection tube inside the
panels.
ii. Arrangement of Clean Gas Agent such as 3M Novec 1230 for flooding inside the
panels.
iii. Audio-visual annunciation devices for indicating incidence of fire.
iv. Any other item required to the successful commissioning of the system.
The electrical panel fire suppression system shall be complete with Direct Clean Gas
storage cylinders for required capacities, extinguishing agent as specified, linear fire
detection tubing, filling and end-of-line adaptors, pressure switches, control equipment and
all necessary accessories and push in fittings to form a complete and working installation
to protect the Electrical panel in case of fire.

The panels to be protected shall be determined as per the approval of the engineer.
15.11.2 Regulatory Requirements
All the detecting devices, alarm, indicating devices, containers and other related
equipment shall be UL Listed and/or FM approved and/or LPCB approved.
All installations shall conform to NFPA requirements.
15.11.3 System description
Each Clean Agent extinguishing unit, when installed, shall be a self-contained system,
meaning that it is equipped with its own automatic (non-electric) detection system, which
when actuated, automatically releases the suppression agent into the Electric panel.
The Clean Agent Automatic Direct System shall consists of the following major
components, as a minimum:
• Clean Agent Cylinder/Valve Assembly.
• Cylinder Mounting Bracket.
• Fire Detector, Actuation and Discharge Fire detection Tubing and Fittings (No
Substitute).
• Pressure Switch
The Clean Agent shall be stored in steel containers as a liquefied compressed gas, super-
pressurized with Dry Nitrogen
The container shall be Designed, fabricated, certified and stamped in accordance with the
requirements of NFPA. Containers shall be standard model and size of ease of
replacement and addition. The containers shall be a part of UL listed or FM approved
system.
Each container shall be equipped with a nickel–plated brass valve, a pressure gauge to
monitor container pressure, and a ball valve that interfaces with the Detection Tubing. All
container valves shall be equipped with a pressure relief valve (rupture disc) device in
compliance with safety requirements.
A pressure switch shall be considered at the end of line of the Detection Tubing to monitor
system pressure, system actuation an/or to energize de energize electrically operated
equipment.
15.11.4 Design Requirement
Provide sufficient amount of Clean Agent considering the following when computing
volume to verify suitability and to establish design limitations:
• Volume of hazard area.
• Specific volume of Clean Agent.
• Discharge time and flow rates.
• Design concentration and design factors.
• Detector/discharge tubing placement.
Provide total flooding of Clean Agent concentration by volume as per NFPA-2001.

15.11.5 Installation and Maintenance
Clean Agent container/valve assemblies must be handled, installed, inspected and

serviced only by qualified and trained personnel in accordance with the approved shop
drawings, instructions contained in the operation manual, the container name-place,
NFPA-70, NFPA-2201 and any other regulations and codes, as applicable.
15.12 Safety Equipment’s
15.12.1 Fire Extinguisher:
ABC' Dry chemical powder type, portable Fire extinguishers, of size 5 kg each,
manufactured from CRCA sheets in all welded construction, body coated with glossy
corrosion resistant epoxy powder coating, with inbuilt water proof pressure gauge, with
wall bracket, as per IS 2190 and IS 13849 with latest amendments.
15.12.2 Insulation Mat:
22 kV, C' class, non-skid, high voltage insulation synthetic mat made from elastomeric
polymer material,1000mm wide, 3.0 mm thick, Dielectric strength 65 kV for 1 minute, 33
kV, AC RMS voltage, fire retardant, no adverse effect of transformer oil, diesel, acid, alkali,
High Tensile & Elongation properties, good mechanical strength to withstand load and
movement of breaker trolley, as per IS 15652 with latest amendments
11kV, B' class, non-skid, high voltage insulation synthetic mat made from elastomeric
polymer material,1000 mm wide, 2.5 mm thick, Dielectric strength 45 kV for 1 minute, 11
kV, AC RMS voltage fire retardant, no adverse effect of transformer oil, diesel, acid, alkali,
movement of breaker trolley, as per IS 15652 with latest amendments
415 V, A' class, non-skid, high voltage insulation synthetic mat made from elastomeric
polymer material, 1000mm wide, 2.0 mm thick, Dielectric strength 30 kV for 1 minute, 3.3
kV, AC RMS voltage, fire retardant, no adverse effect of transformer oil, diesel, acid, alkali,
movement of breaker trolley, as per IS 15652 with latest amendments.
15.12.3 Shock Treatment Chart:
Shock treatment chart, duly laminated in Marathi(Local) and English languages
First aid box with all essential medicines including wall mounted bracket.
22000, 11000 V and 415V Alluminium, anodised Danger caution plate in Marathi (local)
and English languages with the sign of skull and bones in signal red colour on front side,
as per IS 2551 with latest amendments
15.12.4 Hand Gloves:
Shock proof, Rubber insulated hand gloves, produced through seamless process for
minimum working voltage of 11000 V. Should be electricity insulated and tested, should
provide dexterity and protection beyond the wrist - length : minimum - 36 cm, white cream
color, soft and flexible quality. With Test Certificate as per IS 4770 with latest amendments.

15.12.5 Helmet:
PVC Safety Helmet with PVC head band, made from HDPE thermoplastic. with fully
adjustable type head band, sweat band and nylon chin strap. colour – YELLOW/WHITE,
with PMC logo. As per IS 2925 with latest amendments.
15.12.6 Safety Goggles:
Safety goggles made of impact resistant polycarbonate, scratch resistant,100% poly

carbonate lens and 100% UV protection, Scratch resistant - vision, curved lenses provides
180 degree vision, good impact resistance and adjustable temples for comfort and fitness
as per EN-166 with latest amendments.
15.12.7 Ear plug:
Reusuable type, Ear plug smooth and dirt resistant surface, protection for high noise
situation upto 105 dBA made from non-irritant soft foam base hypoallegic material - smooth
surface. universal size, tapered shape, smooth surface fits into all Ear canels and gives
comfortable consistent and protection. Should provide measured attenuation of minimum
30 dB confirm to ANSI S319 with latest amendments.
15.12.8 Ear Muff:
Ear muff with wide a headband with padding shall provide firm and comfortable fit, easily
adjustable multi-position [over head/under chin/behind head] headband with / without
elastic crown strap for individual fit. NRR min 24 dB. CE certified /EN 352 approved / ANSI
approval S3.19 / as per IS 6229 with latest amendments.
15.12.9 Sand Fire Bucket:
Galvanised mild steel sand Fire bucket with lid and handle, 9 Litres capacity. Buckets to
be provided with suitable strand with 4 Numbers hooks to hang sand filled buckets, as per
IS 2546 with latest amendments
15.13 Installation
The scope shall cover, in addition to supply, complete installation of plant items and
accessories as indicated in various parts of the specification. Requirements / guidelines /
information / parameters / instructions, etc. specified in this section shall apply to all the
sections.

Installation work pertaining to plant items and systems such as cabling, lighting, earthing
and lightning protection systems, etc. shall comply with the applicable standards, safety
codes, etc.
Installation shall be carried out strictly in accordance with the approved drawings.
Changes, modifications, if any, required to suit site conditions, shall be carried out only
with the prior approval of the ENGINEER or their representative’s Representative. All such
changes shall be incorporated in the "As built" drawings to be furnished by the Contractor.
All tools, brazing equipment, crane, scaffolding, rigging materials, ladders, consumables,
hardware, etc. required for installation shall be provided by the Contractor.
It shall be the responsibility of the Contractor to engage Specialist Engineers from his Sub-
Contractors / Original Equipment Manufacturers to supervise installation work for plant
items such as switchboard, motors, etc. where felt essential. Such services shall be
arranged by the Contractor at no extra cost to the ENGINEER or their representative.
It shall be the responsibility of the Contractor to obtain approval / clearance, if any, from
local statutory authorities, for conducting any work for completed installation.
The Contractor shall ensure that all plant under erection as well as the work area and the
project site are kept clean to the satisfaction of the ENGINEER or their representative. In
case the ENGINEER or their representative is not satisfied about the cleanliness, he will
have the right to carry out the cleaning operations. Expenditure incurred by him in this
regard will be to the Contractor's account. Packing cases and packing material, except for
spares shall be cleared from sites.
In order to avoid hazards to personnel moving around the equipment, which is kept
charged after installation before commissioning, such equipment shall be cordoned off by
suitable barriers to prevent accidental injury.
Switchboard shall be installed on finished surfaces. Proper aligning, joining of various

vertical shipping sections, busbar connections, inter panel wiring, etc. will be the
responsibility of the Contractor.
The Contractor shall take utmost care in handling instruments, relays and other delicate
mechanisms. Wherever the instruments and relays are supplied separately, they shall be
installed only after the erection of switchboards is complete.
15.14 Substation
The sub-stations shall be located in a safe area close to the load center. sub-station and
MCC rooms shall be elevated at least by 1 meter by compacting the soil so that the bottom
of the cable trench within sub-station is above the surrounding grade level.
A separate entry of 3 m x 3 m with rolling shutter shall be provided for drawing in all
equipment for erection. The main entry for operating personnel shall be preferably
provided with double door system. The Sub-station shall also have an emergency door
opening outwards.
For attending sub-station, an operator’s room shall be provided. Sub-station wall adjacent
to the transformer bays shall be 355 mm thick in case of brick construction or 230 mm

thick in case of RCC construction with necessary fire withstand time as per statutory
requirement.
Battery banks shall be located in a separate adequately ventilated room in the sub-station
buildings, along with the necessary exhaust system and water connection with sink. Floor
of the battery room and walls up to 1.0 m height shall have acid / alkaline resistant
protective material coating / tilling. Light fittings in this room shall be chemical resistant
type.
The battery rooms shall be provided with minimum two exhaust fans and louvered opening
in opposite wall/door.
Sub-station shall have firefighting equipment, first aid boxes and other safety equipment
as per statutory requirements. Mats of required voltage rating shall be provided in front of
switchboards. High voltage switchboards, PCC and MCC panels shall be provided with
Automatic Clean Agent Fire detection, Alarm and suppression system.
Oil immersed transformers with oil capacity exceeding 2000 liters shall be provided with a
soak pit of sufficient capacity to take the whole of the oil of the equipment. Fixed fire
extinguishing system shall be provided for all oil-filled transformers having oil content more
than 2000 liters.
One set of accessories consisting of cell testing voltmeter, spanner, face shield, PVC
apron, rubber gloves etc. shall be provided in each battery room.
The substation building shall be sized to take care of present and future needs and to
maintain adequate clearances between equipment for ease of maintenance.
The following minimum clearances around various equipment shall be maintained.
Front clearance for HV switchboard 2500 MM

Front clearance for all other switchboards/panels 2000 MM
Rear clearance for panels having Less than 200mm or
Maintenance access from front only more than 750 mm
Rear clearance for panels requiring Maintenance from rear 1500 mm (HV
SWBDs)
Side clearance between two switchboards or from nearest 1500 mm
obstruction (but not less than twice the width of each panel)
All around clearance for transformers 1500 mm
All around clearance for capacitor bank/ series reactor 1000 mm
Battery rack to wall clearance for single row, single/double tier 100 mm
Double row, single tier 100 mm
Double row, double tier 750 mm
Battery rack-to-rack clearance 750 mm
Head room clearance below bus ducts for any other overhead 2000 mm
equipment
Front clearance for wall mounted equipment 1000 mm
Front clearance for operation station/ annunciation/control panel 2500 mm

Vertical clearance above the top of the highest equipment shall be minimum 1500 mm
measured from bottom of roof slab and minimum 500 mm measured from the bottom of
the lowest roof beam. However for the areas with false ceiling, minimum clearance of 750
mm shall be provided between false ceiling & top of any equipment.
All substations, battery charger/battery rooms shall be provided with at least 25% space
for future expansion.

16 Standard Specification – Instrumentations & Control
16.1 Introduction
This part covers the particular requirements for the design, supply, installation, inspection
and testing of the Instrumentation, Control and Automation and associated plant and
materials.
16.2 General
This section outlines the particular requirements for the instrumentation, control &
automation works. This section shall be referred in conjunction to the general requirements
for instrumentation, control and automation works specified in Part-A of this document.
Unless specified in this section to the contrary, the system provided by the Contractor and
workmanship shall comply with the General Chapters of these Requirements.
The scope of instrumentation, control and automation (ICA) works for Sewage Treatment
Plant under this contract shall comprise of the design, manufacture, supply, programming
and configuration, off site testing, delivery to site, installation and erection, testing,
commissioning, setting to work and provision of documentation for a complete
instrumentation, control and automation system including the interfaces required to
provide monitoring and control for a safe and efficient operation of the plant.
The minimum scope of work for ICA at STP’s shall include but not be limited to:
1) Design, supply, install, test and commission a dual redundant PLC based SCADA
system for STP. The system shall include on a minimum, but not limited to process
controller including its central process units (CPUs in redundant configuration),
redundant communication modules, RIO’s, Simplex input-output (I/O) modules (Hot
swappable), control networks, servers, Historian server and software, operator
workstations, engineering workstation and printers;
2) All servers for SCADA, etc. shall be redundant (Refer control system architecture)
3) Design, supply, install, test and commission field & analytical instrumentation for the
Entire STP;
4) Design, supply, install, test and commission chlorination system including its
instrumentation and chlorination control units and its interface with STP PLC based
SCADA system;
5) Design, supply, install, test and commission individual process systems RIO panels
(SBR/MBR, /other process as applicable, etc..) including its instrumentation and
control system units and its interface with main plant PLC system; The process
systems shall be furnished with individual RIO panels with RIO modules which shall
communicate with the main plant PLC for monitoring and control. No separate PLC
system for monitoring and control of process system shall be accepted.
6) Design, supply, install, test and commission uninterrupted power supply system to
supply the entire PLC based SCADA system including the Remote I/O (RIO) systems
and field and analytical instrumentation;
7) Control room furniture include but not limited to system consoles for placing servers,
workstations and printer compartments, engineering workstation and printer
compartment and ergonomic designed seating systems.
8) The Contractor shall be responsible for the design of each instrumentation and plant
monitoring system, including the selection and design of appropriate transducers,
transmitters, signal conditioning devices, indicators, alarm system programmable
devices, communications, cable system etc. The Contractor shall take account in his
design of all installation and environmental conditions prevailing at the site.

Part 16: Standard Specification – Instrumentations & Control
9) The contractor shall ensure that complete STP plant operational data, all SCADA
mimics inclusive of the Lab analyzed data is made available to the integration panel,
which shall be installed under the centralized SCADA package for onward transmission
to the centralized SCADA center.
10) All necessary required cabling, programming, software and hardware required to make
the data available to the integration panel at all times, is part of the integral scope of
work of the STP contractor. The contractor shall co-ordinate in full and conduct
interoperability tests with the centralized SCADA contractor to ensure data is
compatible with the data format which is required at the integration panel end.
16.3 System Completeness
This section of specifications defines the particular requirements of instrumentation,

control & automation works to be installed at STP.
Irrespective of the detailed specifications of the respective items detailed in the various
chapters of the tender specification, the Contractor shall be required to provide all the
equipment, accessories, cabling, earthing, providing necessary transducers/sensors,
system hardware/software, programming logic, interlocks, cabinets, panels etc. to achieve
the functional requirements described in the Bid Document. The System completeness
shall be the Contractor’s responsibility.
Note: In FAT, all the field instruments shall be tested for functionality as per contract
requirements at the manufacturers work location where the equipment is manufactured.
Quality assurance plan (QAP) shall be submitted along with the datasheets for review and
approval before any inspections call is initiated.
16.4 Field Instrumentation and Control
Each field instrument shall be operable in local mode and have display functions in
SCADA. The Contractor shall be responsible for providing the appropriate signals at the
locations required to provide the specified control and monitoring functions.
The Contractor shall ensure that field measuring systems shall respond quickly to any
changes of the measured process variables.
All field instruments shall, as far as practicable, be mounted in a location that shall be free
of vibration and shall be powered from the instrument control system.
24V dc power wiring for field instruments shall be individually fused and provided with a
means of disconnecting the power without disturbing terminated wiring (e.g. knife-switch-
type terminal blocks). Visual indication of a blown fuse condition shall be provided.
All field instrument components shall be of a proven and reliable design and shall have a
high degree of uniformity and shall, wherever possible, be interchangeable. The design
shall facilitate easy maintenance and repair, taking into account the availability of access
routes through plant and structures generally.
Field Instruments shall perform sensing, indicating, transmitting and controlling. The
devices shall generally interface with the SCADA, either directly or indirectly. The materials
of those parts of the field instruments, including piping material, which are exposed to the
measured media shall be compatible with the conditions of the respective media and of
the ambient fluid and atmospheric conditions.

All field instruments shall be mounted within enclosures that are corrosion proof, dust proof
and waterproof to provide a minimum protection specified in elsewhere in this
Specification. The enclosure shall be rated to minimum IP 65. The enclosure design shall
be submitted along with the instrument datasheet for review and approval before any
design of the same.
All field instruments, including the components, shall be tropicalized and designed for the
ambient conditions detailed elsewhere in this Specification. Lighting protection barriers
shall be used for protecting transmitters and receiving instruments from the surge voltage
due to lighting strike. Lighting protection barriers shall be supplied at both receiving and
sending ends for all signals from outside building and those installed between the
buildings.
16.5 Instrumentation Design Criteria
The design criteria to be applied to instrumentation systems shall be as follows:
1) all instruments shall be suitable for continuous operation;

2) all transmitting instruments shall have a 4 - 20 mA linear output;
3) all digital outputs shall be volt free;
4) all instruments shall be designed for the ambient conditions of temperature and
humidity;
5) all wetted parts of instruments sensors shall be non-corrosive and suitable for use with
sewage;
6) all instrumentation systems for use out of doors shall be protected to IP 65;
7) all analogue displays shall be of the digital type with no moving parts utilising back lit
liquid crystal diode LED technology;
8) instrumentation shall utilise solid state electronic technology and avoid the use where
practical of any moving parts;
9) minimum maintenance requirement;
10) Instrumentation shall resume operation automatically on the application of power
following a power failure.
11) All analytical instruments shall be single channel and have individual analyzer units.
Instrumentation systems shall be provided as detailed in the Employer’s Requirements

and as necessary for the efficient and safe operation of the treatment plant
The Contractor shall provide systems to measure any other parameter required for the
efficient and safe operation of the treatment plant.
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.
All Sensors should be of self-cleaning type.
Instrumentation shall be selected and installed in accordance with the manufacturer’s

instructions. Wherever practical components of similar systems shall be interchangeable,
i.e., open channel flume flow measuring systems and open sump or tank level
measurement and pump control systems shall incorporate identical sensors and converter
units. Instrumentation converter units shall where practical be located in the associated
MCC common control panel well away from any injurious effects of the process.

16.5.1 Flow Measurement and Control
The Contractor shall use electromagnetic flow meters, for all closed pipe liquid flow
measurement as the standard flow meters under this contract. Each flow meter shall be
installed in the pipeline within a suitable access chamber. The access chamber shall be
designed to provide adequate space for personnel access to the chamber and around the
flow meter for maintenance. The flow meter system shall provide flow rate and totalized
flow indication.
The pressure rating of the flow meter and flanges shall be equal to or greater than that of
the pipeline within which it is installed. The preferred location for the flow meter
converter/transmitter units is within a building. Where this is not possible, then the
converter shall be installed in a suitable above ground enclosure providing the converter
with suitable mechanical and environmental protection.
The flow signal converters/transmitters shall provide 4-20mA output linearly proportional
to the rate of flow and shall provide a pulse output for flow totalizing. The flow meter
electronic supervisory unit shall display the following on a minimum:
• Flow rate;
• Flow total-totalizer;
• High flow rate alarm;
• Low flow rate alarm.
Signals for the items above shall form inputs to the PLC and SCADA and be utilized within
Operator displays. The integrator used for the second item above shall have at least six
digits.
Each flow meter shall be provided with downstream and upstream isolation valve including
the washout facility.
16.6 Electromagnetic Flow Meter
Full bore bi-directional electromagnetic flow meters shall be designed, manufactured and
calibrated as per ISO/IEC 17025 standard. Meters shall also have actual Flow rate &
Totalized value. The accuracy shall be +/- 0.5% of reading.
The sensors shall be as per ISO standard lengths (ISO 13359), so that inter-changeability
can be carried out for the applicable flow meter sizes. The sensor shall also have built in
grounding and empty pipe detection electrodes of SS316 for detecting partial flow
condition & efficient operation purposes. The liner material shall be Polyurethane (PU).
The sensor & transmitter shall be capable of working in tropical environment.
The sensors shall be rated IP68. The transmitter shall be rated IP67 in line with local
operating conditions. Installations shall be made with cables and /or conduits that
guarantee the integrity of the system under all operational conditions. The transmitter/
converter shall be wall-mounted type with a 2 line display for the indication of Actual Flow
rate & Totalized value. A glass window within the protection enclosure with optical switches
shall be provided for local reading purposes.
The enclosure material shall be non-corrosive and of die cast material. Magnetic flow
meters should be supplied with built in software feature to analyze and continuously
monitor the health of the sensor, display errors in text format. Transmitter should be
capable of performing the verification program on demand or on request without taking
meter off the line.

The transmitter shall be capable of being fully programmable. It shall have a set-up menu
so that all relevant parameters may be user-set from the self-prompting driven menu.
The transmitter shall have totalizer units and shall have one (1) scalable pulse output &
one (1) current i.e.4-20mA HART output. The current output shall be galvanically isolated.
It shall be fitted with switched mode power supply capability 0-250V or 24 DC and 45-65Hz
to cope with power transients without damage. The Totalizer value shall be protected by
EEPROM during power outage, and utilizes an overflow counter.
The transmitter shall be having facility of indicating flow measurement. It shall be possible
to separate the sensor and transmitters up to 200 meters without the need for signal
boosters or amplifiers
Detailed technical specification of Full bore electromagnetic flow meter is as below
General
1 Application (Suitable for) Sewage Water /Effluent Water
2 Op Temperature 0 to 50 Deg C Max
3 Op Pressure Max 6 Bar g
4 Measurement Instantaneous water flow Rate, Totalized Flow
Flow Sensor
5 Type In-Line Full Bore Electromagnetic flow meter.
6 Power supply type Mains operated
7 Sizes (mm) /Qty As per flow sizing calculations
8 Sensor Type Pulsed DC
9 Process Connection Flanged type
10 Weather Protection Class IP68 as per IS 13947
0.2 to 3 m/s, vendor to provide the detailed sizing
11 Full Scale Velocity
calculations based on the process details.
SS 316 L, Total 4 Electrodes system.
Measuring electrodes – 2 Nos.
12 Electrodes
Grounding electrode- 1 No. and Empty pipe
detection electrode -1 No.
Powder-coated die-cast aluminium Anti corrosive
13 Coil Housing grade with IP 68 protection class with minimum 20
meter cable for remote mount transmitter connection
14 Flanges Carbon Steel PN 10 as per EN 1092-1
15 Flow sensor Grounding Grounding rings shall also be acceptable
16 Flow Tube material SS304
17 Flow Tube Liner Polyurethane
Flow Transmitter Unit
Microprocessor based with facility to configure the
1 Type
range
2 -Line LCD display with operation keys (touch
2 Type of Display
control)

Remote Wall Mounted with 5 cable glands,

3 Transmitter Type integrated fixing points for wall mounting, with
sensor interface
4 Units for Display Flow Rate m3/Hr, Totalized Flow ML
5 Input From Flow Tube
6 Accuracy +/- 0.5 % of Measured Value
7 Operation Via local display, Via HART handheld terminal
Output proportional to Current output (4–20 mA HART);
8
Flow rate pulse/frequency/switch output (2); status input
9 Power supply 0-250 VAC, 45-65Hz – Optional - 11 to 40 V DC
Following minimum diagnostic features shall be
10 Self-diagnostic feature provided Empty pipe detection, system diagnostic
features
Transmitter enclosure
11 Non-corrosive, Die Cast Aluminium
material
Suitable for Wired communication with control
12 Communication
system and HART based integrated and service
interface
13 Memory 100% secure data storage
14 Weather Protection Class IP 67 (NEMA 4X) for flow transmitter
Gravimetric Method ISO 4185 / volumetric method
(ISO 8316). All test equipment fully traceable to
14 Calibration Method
national and international standards with 5 point
calibration.
15 Flow calibration rig Duly Accredited according to ISO/IEC 17025
Note-1: The flow meter manufacturer/supplier shall have full ISO 9000 series accreditation
and fully traceable calibration methods. The suppliers shall also have a testing facility in
India so that methodology and procedures can be verified. Each meter shall be wet
calibrated with 5 point calibration to verify performance in accordance with the specification
& submit report for the same. The testing facility shall be duly accredited in accordance
with ISO/IEC 17025 standards.
In the event if the meter manufacturer does not have a testing facility in India, the flow
meter shall be tested & inspected before shipping at the Manufacturers factory works,
where the meter has been manufactured.
Note-2: The flow meter manufacturer shall have local offices in India and full service
capability in the major cities (metro’s) throughout the country. Full contact details for key
personnel, shall be furnished on request. The supplier shall provide evidence of at least
five years involvement in the manufacturing of meters worldwide.
Note-3: The flow meter manufacturer shall provide full data on each meter required,
including optimizing and sizing programs calculation sheet.
16.7 Thermal mass flow meter for gas (air) for continuous measurement of flow
Thermal mass flow meter shall be utilized as mass air flow meters to measure air flow or
bio gas flow as applicable under this contract.

The sensor shall not cause any pressure loss and no pressure and temperature
compensation shall be required. The meter shall be able to measure Mass flow,
temperature, volume flow and energy flow
The degree of protection for the sensor and transmitter shall be rated to IP67.
Measuring Principle Thermal dispersion principle

Sensor features Shall offer high accuracy and repeatability for a wide
range of utility and process gases.
Measuring Task Flow (Mass), Gas temperature, Gas heat flow
Accuracy +/- 1.5%
Sensor, Insertion tube material Stainless steel
Compression fitting seal PEEK
Material process connection Stainless steel
Transmitter housing material, Powder coated die-cast aluminium, powder coating
Coating
Degree of protection IP67 (NEMA 4X) for transmitter and sensor
Max. measured error Gas: 1.5% or (10 to 100% o.f.s.)
Display/Operation LCD/LED: back-lit, Configuration via local display and
operating tools shall be possible
Outputs 4-20mA HART (active/passive selectable), pulse,
frequency, status
Hazardous area approvals Required (As applicable)
Note-1: The flow meter manufacturer/supplier shall have full ISO 9000 series accreditation
and fully traceable calibration methods. The suppliers shall also have a testing facility in
India so that methodology and procedures can be verified. Each meter shall be wet
calibrated with at sufficient flow rates to verify performance in accordance with the
specification & submit report for the same. The testing facility shall be duly accredited in
accordance with ISO/IEC 17025 standards.
In the event if the meter manufacturer does not have a testing facility in India, the flow
meter shall be tested & inspected before shipping at the Manufacturers factory works,
where the meter has been manufactured.
Note-2: The flow meter manufacturer shall have local offices in India and full service
capability in the major cities (metro’s) throughout the country. Full contact details for key
personnel, shall be furnished on request. The supplier shall provide evidence of at least
five years involvement in the manufacturing of meters worldwide.
Note-3: The flow meter manufacturer shall provide full data on each meter required,
including optimizing and sizing programs calculation sheet.
16.7.1 Flow Switches (Load Monitor)
1) The load (kW) monitor shall be suitable for mounting within the appropriate motor
starter section of the motor control centre. The device shall be used primarily to detect
low or no flow situations. However, it may be utilised to detect overload situations
where appropriate.

2) In low or no flow mode the load monitor shall monitor drive power. If the measurement
of the power falls below an adjustable set value (P-min) an output-relay shall be de-
energised to cause the pump set to stop.
3) The monitor shall incorporate the following features:
a) DIN-rail mounting
b) adjustable start-up delay time
c) adjustable reaction time
d) three monitoring measuring ranges, selected externally on unit
e) normally energised, or de-energised mode
f) output signal may be latched, or automatically reset
g) LED indicators for mains on indication and status
h) Relay output; 1 No. changeover contact.
4) The monitor performance specification shall be as follows:

a) Reaction time - 3 to 30 seconds adjustable
b) Start-up delay time - 0.15 for 20 seconds adjustable
c) Switching capability - 1 A (24 V), 0.1-8 A 250 V ac, 1 100 VA)
d) Maximum switching current - 10 A
16.8 Rotameter
Type On-line up to 2”. By-pass above 2”

Metering tube Borosilicate glass
Float AISI 316-SS unless the process fluid demands some other material.
Body MOC AISI 316-SS
Scale Graduated- Engraved black on white background.
Process Flanged
connection
Accuracy  2% of full scale detection or better for on-line type and 4% of full-
scale detection or better for by-pass Type.
Nameplate Tag number, service engraved in stainless steel tag plate
Accessories Slip-on orifice plate of 316-SS and taps of Stainless Steel as per
application requirements. Applicable
SS Isolation valves and SS Range Orifice – for Bypass type rotameters.
16.9 Level Measurement and Control
The following section describes the minimum technical specifications for level
measurement and control under this contract.
Owing to the nature of sewage and sewage sludges, non-contact methods of level
measurement are preferred. Where foaming problems are identified as a local concern,
the level measurement by level transducer shall be considered. Float switches are
reserved as backup to the level indicating transmitters.
Sensing heads shall be mounted on 316 stainless steel brackets and positioned to ensure
an unhindered beam path and ease of access for maintenance.

16.9.1 Radar Microwave Level transmitter:
Transmitter
1 Type Microwave Level measurement
2 Principle Pulse Time of flight
3 Output 4-20 mA HART current
4 Housing Die Cast Aluminum
Electromagnetic Interference Immunity to EN 61326, Annex A (Industrial)
5
compatibility and NAMUR Recommendation NE 21 (EMC)
6 Ingress Protection IP 67
7 Accuracy +/- 3 mm
8 Area Classification Non-Hazardous. Hazardous
9 Display 4 line LCD display. Service: Display of Envelope curve.
10 Configuration Using Keypad on display
Sensor
11 Range Liquids 0 to 5m and 0 -10m depending on Tank size
12 Temperature range -40°C ... +80°C
13 Max Pressure 3 bar abs
14 Materials Sensor: PVDF Seal: EPDM
15 Antenna seal FKM Viton
Threaded or universal flange dependent on model
16 Process connection
selection
17 Degree of protection IP65
16.9.2 Ultrasonic Level transmitter:
Transmitter
1 Type Ultrasonic
2 Principle Pulse Time of flight
4 Housing Die Cast Aluminum
Electromagnetic Interference emission to EN 61326; Equipment class B
5
compatibility Interference immunity to EN 61326; Appendix A (Industrial)
6 Ingress Protection IP67
+/- 2 mm or 4 mm depending on selection or 0.2% of set
7 Accuracy
measuring distance Whichever is greater.
8 Area Classification Non-Hazardous/Hazardous as applicable
4 line LCD display. Menu guided operation Display of
10 Display
Envelope curve.
11 Configuration Using Keypad on display

Sensor
12 Range Liquids 0 to 5m and 0 -10m depending on Tank size
14 Max Pressure 3 bar abs
15 Materials Sensor: PVDF Seal: EPDM
Threaded or universal flange dependent on model
16 Process connection
selection
17 Degree of protection IP68
16.9.3 Float Switches
1) Level switches of the buoyancy type shall consist of a non-mercury switch with
changeover action enclosed in a non-corrodible material. A balance weight shall also
be incorporated in the switch to counteract the buoyancy effect of the specific gravity
of the particular fluid. The connecting cable shall be factory sealed to the switch. The
switches shall be installed in a stiller tube in the wells.
2) Level switches shall be installed with a minimum of 3 m of spare connecting cable
neatly coiled at a supporting bracket. The connecting cable fixing shall facilitate any
alteration in operating level within the limit of the spare cable.
3) The level switches shall act as backup to the level transmitter in the control interlock
sequence.
16.9.4 Sludge Level Detector
1) This device is used to detect the pressure of sludge or a sludge blanket level.
2) The device shall operate on ultrasonic principles employing two sensors acting as
transmitter and receiver. The absorption of the beam by the presence of a sludge or
slurry shall initiate a switching action which may be used for control purposes.
3) The device shall be unaffected by vibration, temperature or viscosity of medium being
detected.
4) The ultrasonic sensor frequency shall be selected with regard to the medium in which
it is to be used.
5) For sludge blanket level detection the sensor shall be suspended/fixed in the tank
concerned at the required level. The sensor shall be secured to a corrosion resistant
pipe in order to ‘steady’ the sensor. It shall be possible to adjust the level of the sensor
and to remove it easily if required for checking and cleaning.
6) Pipe mounted sludge detectors shall be mounted on opposite sides of a pipe section
with the sensor faces flush with the inner pipe surface, in order to promote self-cleaning
of the sensor faces by the flow of sludge. The pipe section shall be lined with an epoxy
lining or other suitable chemical resistant lining material in order to prevent the build-
up of grease in the region of the sensors.
7) The sensors shall operate in conjunction with a converter. The converter shall be
provided with the following features:
a) LED sensor status indicators
b) DPCO relay output
c) Internally selectable time delays (typically 0.5 to 30 seconds).
8) The converter shall be provided with sensitivity control typically providing a range of
1: 20.

16.9.5 Level Gauge (Float & Tape)
1) Type : Float and Tape

2) Float & Tape MOC : AISI 316
3) Pulley Housing : Aluminum
4) Guide wire : SS 316 Stainless steel
5) Accuracy : +/- 2 mm
6) Indication : On circular or vertical dial
7) Rating : Twice the design pressure
16.9.6 Sight Glass
1) Type : Flap-type
2) End connection : Screwed / Flanged
3) Material
a) Body : SS-304
b) Cover Plate : SS-304
c) Indicator : SS-316
4) Sight Glass : Toughened Borosilicate
5) Gasket : Neoprene
6) Bolts & Nut : High tensile steel
7) Hydraulic Test Pressure : 1.5 times maximum working pressure
8) Accessories : As required
16.10 Pressure Instrumentation
16.10.1 Pressure Gauges, Switches & Indicating Transmitters:
1) Pressure gauges shall comply with BS EN 837- Parts 1, 2 and 3. Pressure Gauges,
Switches & Indicating Transmitters shall have over range protection up to 1.5 times the
maximum anticipated line pressure.
2) Internal parts shall be of stainless steel, bronze or other corrosion resistant material.
3) All Pressure Gauges, Switches & Indicating Transmitters shall be supplied complete
with isolating valves and calibration points to enable calibration or removal without loss
of fluid.
4) Where compensation of more than 2% of the instrument span is needed for the
difference in level between the instrument and the tapping point, the reading shall be
suitably adjusted and the amount of compensation marked upon the dial.
5) Pressure and differential pressure switches shall have contacts with separate ‘cut in’
and ‘cut out’ pressure values.
6) The nominal pressure values at which pressure switches operate shall be fully
adjustable over the whole range of the instrument and the set value(s) shall be clearly
indicated by means of a scale and pointer.
7) Pressure monitoring shall be by a sensor suitable for the medium and pressure/level
range.
8) The sensor shall be selected to provide adequate sensitivity over the working range
and be capable of sustaining a 400% overpressure without damage. The sensor shall
be suitable for either free wire suspension in the medium or fitted remotely and
provided with threaded sockets to permit connection of pressure pipe work.
9) A transmitter shall be provided either integral with the transducer or separately
mounted and converting the signals received from the transducer to a 4 to 20 mA signal
proportional to the range specified.
10) The transmitter shall have provision for span and zero adjustment.

16.10.2 Specifications for Pressure Transmitters:
Pressure measuring system shall consist of pressure transmitter and digital pressure
indicator and any other items required to complete the pressure measuring system.
Pressure transmitter shall be rugged in construction and shall be suitable for continuous
operation. Pressure transmitters shall be designed for operation over 130% of full range.
It should have EEPROM for storing of history data.
Pressure transmitter shall be suitable for field mounting. They shall provide 4-20 mA
Current output proportional to pressure. Transmitter output shall be isolated and shall be
suitable for transmitting over long distance. Pressure transmitters shall have high degree
of weatherproof protection as specified in technical particular. Pressure transmitters shall
have LCD display to indicate pressure.
The Contractor shall mark the exact location of pressure measuring point on the pipe line.
The contractor shall provide all the hardware items including manifolds, nuts, bolts, pipes,
valves, gaskets etc. required for the work.
Sr.
Detailed specifications for Pressure Transmitters
No.
1 Specifications Pressure Range 0 to 10 /20/50/ 100 Kg/cm2 g
Process Temperature
2 -20 to +125 deg.C.
range
4 to 20 mA with superimposed digital communication
3 Output Signal
protocol HART 6.0, 2-wire
4 to 20 mA HART
4 Signal range –
3.8 to 20.5 mA
As per NAMUR NE 43
5 Signal on alarm
• 4 to 20 mA HART
6 Resolution Current output: 1 micro Amp
7 Response time <250 ms
8 Damping required
9 Supply voltage 11.5 to 45 V DC
10 Reference accuracy ± 0.1%
11 Housing Die Cast Alu. Housing
12 Diaphragm Material Ceramic
13 Long Term Stability ± 0.25% URL/year
14 Turn Down 10 : 1
16.10.3 Differential Pressure Transmitter
1 Working Principle Smart

2 Type 2-Wire
3 Output signal Superimposed field bus over 4-20 mA DC.
4 Signal Processing Silicon solid-state electronic circuitry
Unit
5 Measuring Capsule/ Diaphragm
element

6 Element material AISI-316 (Stainless Steel) or better

7 Static Pressure/ Maximum line (or static) pressure on either side without
Overload Pressure permanent deformation or loss of accuracy
8 Turn-down ratio 100 : 1 minimum
9 Span and Zero Locally adjustable, non-interacting
10 Enclosure class IP-65
11 Zero suppression / At least 100% of Span
Elevation
12 Output Indicator LCD type
13 Performance:-
• Accuracy 0.1 % of span or better
• Repeatability  0.05 % of span or better
• Response time 100 m Sec or better
14 Sealing / Isolation Extended diaphragm with 5 meters SS armoured capillary
for viscous fluid applications.
15 Accessories a) Universal mounting bracket suitable for 2” pipe
mounting.
b) High tensile carbon steel U-bolts.
c) Companion flange with nuts, bolts and gaskets.
d) Hand held configurator kit for calibration of Smart
Transmitter.
e) ½” NPT cable gland
f) ½” NPT generally 5-valve stainless steel manifold,
constructed from SS316 bar stock.
16.11 Temperature Instrumentation
Unless otherwise specified, platinum resistance elements shall be used for measuring
spans of up to 200°C and chromel-alumel thermocouples for spans exceeding 200°C.
The accuracy for temperature meters shall be ±0.03% of span. Configuration data shall be
stored in the EEPROM memory.
In critical and important application, the temperature sensors shall be of a dual type
arrangement for easy replacement. Each temperature sensor, unless otherwise specified,
shall have a stainless steel thermo well, or pocket-and-extension assembly, non-corrodible
metal sheath and waterproof terminal head. Pockets for steam, oil and pressurized-water
lines shall be welded; pockets for other duties shall be screwed. The sensor assembly
shall be designed to permit removal of the temperature element without twisting the leads.
Platinum resistance thermometers shall comply with BS 1041 and BS EN 60751 or

equivalent Indian Standards on the approval of the Employer Representative. Sensors
shall have a resistance of 100 ohms at 0°C and shall conform to the European standard
curve (DIN 43720), where Alpha = 0.00385. Each element shall be artificially aged during
manufacture. Terminal heads and amplifiers shall be designed for four-wire connections
between head and amplifier. Platinum resistance elements shall be spring-loaded and fully
encapsulated in ceramic material and the elements and high-temperature-resistant lead

wires shall be hermetically sealed. The associated resistance-to-current converters shall

have zero and span adjustments and input-output circuit isolation.
Thermocouples shall be of the mineral-insulated type and unless otherwise specified shall
be of the chromel-alumel (nickel-chromium v nickel-aluminum) type and shall comply with
BS 1041 and BS EN 60584-1.
Thermocouple junctions shall be welded. Ceramic-insulation material may be used for

base-metal thermocouples but low-silicon insulation material shall be used for noble-metal
thermocouples. Thermocouple systems shall have thermoelectric ice point reference
chambers or receivers or amplifiers with automatic cold junction compensation.
Thermocouple receivers and amplifiers shall also have zero and span adjustment,
common and series mode interference rejection circuits, radio-frequency filters, input-
output circuit isolation and thermocouple break feature whereby the output is driven to
zero or full-scale, as stipulated by the Employer Representative, when the receiver or
amplifier input circuit is broken.
Thermocouple elements shall be electrically isolated from their sheaths but each terminal
head shall have facilities for earthing the thermocouple and for terminating the screen of
the extension or compensation cable.
Amplifier chassis shall have facilities both for being earthed to the instrument case via a
capacitor and for being electrically isolated from the instrument case.
Temperature transmitters shall be of rugged construction microprocessor based

instruments. They shall provide simultaneous digital and analogue outputs and the 4mA
to 20mA dc output shall be linear with temperature.
16.12 Temperature Switches
Temperature switches shall have contacts with differing ‘cut-in’ and ‘cut-out’ values. Their
nominal operating points shall be fully adjustable over the whole range of the instrument
and the set-value shall be clearly indicated by a dial and pointer.
Note: - RTD’s of Winding and Bearing Temperatures of Pumps / Motors shall be monitored
through Temperature Scanner Indicators.
16.13 Strain-gauge Load Cell Weight Indicator and Transmitters
Weight Indicator Transmitter shall comprise of Compression Type Strain Gauge Load
Cells along with Transmitter and Indicator for measurement of Sludge Hopper Weight
Applications in Sewage Treatment Plant. Strain Gauges shall be mounted on the top and
bottom to measure Tension and compression forces.
Measuring Range As per Process Requirement

Temperature Range -30oc to + 80oc
Accuracy +/- 0.5 % of Measured Value
Supply Voltage 24 V DC
Output 4-20mA
Indicator Display Required

16.14 Analytical Instrumentation
Online Analytical Instrumentation shall be used to provide continuous monitoring of

effluent quality to permit the performance of the sewage treatment plant to be assessed
on a continuous basis and to provide early warning of plant malfunction or failure. Where
appropriate, Online analytical instrumentation shall also be used to monitor functions not
related to effluent quality, e.g., digester pH or sludge solids content of sludge for disposal.
The monitors and their associated sensors or cells shall be selected as appropriate to the
particular application.
In all cases, the location and housing of the monitor shall take into account the provision
of a representative sample to the monitor sensor, the pre-conditioning if any, required prior
to the sample’s analysis, operator requirements for access, maintenance, calibration,
repair and replacement of the monitor or its sensors.
All online analytical instruments shall be single channel and shall have individual analyzer
units only.
16.14.1 Grab Samples
Grab (manual) sampling facility shall be available for each analyzer. Grab sample valves
on the panel front shall be furnished to allow grab sample flow to be directed grab sample
nozzles to the sample trough. Approximately 300 mm of flexible tubing shall be furnished
for each sample to allow grab sample collection and prevent splashing. Valve body and
trim shall be of SS-316.A continuous sink for Grab Sample Analysis shall be provided. The
sink shall be made of stainless steel. Sink shall have drain to a header.
Cleaning water connection shall be provided for cleaning of sample containers.
16.14.2 Online Turbidity Measurement:
Online sensor shall be based on Nephelometric measuring principle with 90deg scattering
light method as per ISO 7027.The sensor shall be of plug and play type with digital
communication. The sensor shall be with IP68 rating suitable for measuring range 0 to
9999 FNU /NTU with accuracy of <2% of measured value or 0.1 FNU/NTU.
The sensor shall store on-board all the calibration data and other diagnostic information.
On a minimum, the sensor shall have provision to store at-least 5 user calibration points.
The transmitter shall be suitable for outdoor installation with IP67 rating.
Transmitter
1 Transmitter Type Four wire
3 Supply voltage 100 / 115 / 230 V AC +10 / –15%,
4 Material Field Housing : Polycarbonate
5 Display LC display, two lines, with status indicators
Graphic display : backlit ; transflective display ; user
settable measuring menus ; red display for alarms

6 Electromagnetic interference emission and interference immunity acc.

compatibility to EN 61326-1:1998
7 Protection class of field IP 67
housing
8 Ambient temperature –20 ... +60 °C
9 Self-Diagnostic feature Required
Sensor
10 Type Turbidity
11 Nephelometric measuring principle 90° NIR scattered
Principle light according to ISO 7027 / EN 27027
12 Measuring wavelength and 860+/- 30nm
range 0..9999 FNU, 0.150g/l SS
13 Material Sensor shaft : Stainless Steel 1.4404(AISI 316L)
Optical window- Sapphire
O-ring- EPDM
14 Max Process temperature 50°C
15 Max Process pressure 10bar
16 temperature sensor Integrated NTC temperature sensor
17 Connection Fixed cable connection
18 Ingres protection IP68
19 Additional Certifications Calibration certification
20 Resolution 0.001 FNU, 0.01 ppm, 0.1 g/l, 0.1%
21 Measurement error <2% of meas. value (min. 0.02 FNU)
16.14.3 Online pH Measurement:
The pH online analytical instrumentation sensor shall be based on potentiometric

measurement using glass sensor. The system shall comprise a combination pH sensor
with integral reference electrode and temperature compensation, cabling, sensor mounting
and a converter.
Sensors shall be either dip probe, flow cell or insertion types whichever is appropriate.
Dip probes shall be mounted on a floating or fixed corrosion resistant bracket. Insertion
type sensors shall be removable without the need to drain down or shut down the process.
Mounting of all sensors shall be arranged to prevent fouling and to allow easy access for
removal for maintenance, cleaning and calibration.
Where the sensor is likely to be subject to poisoning, e.g. in an anaerobic situation where
sulphide may occur, the sensor type shall be selected to be resistant to poisoning, e.g. by
the provision of a double junction electrode. The sensor shall function over the pH range
0 to 14.
The system response time shall be not greater than 15 seconds for pH systems used for
control and not greater than three minutes for monitoring only systems for 90% change in
each case.

Overall accuracy shall be ±0.2 pH with a repeatability of ±0.1 pH. The sensor shall have
digital communication based on inductive energy transfer; the sensor shall have inbuilt
memory to store calibration data, and other additional diagnostic information. The
transmitter shall be suitable for outdoor installation with IP67 rating.
Transmitter
1 Transmitter type Four wire
3 Supply voltage 100 / 115 / 230 V AC +10 / –15%,
4 Material Field Housing : ABS Polycarbonate non corrosive
5 Display LC display, two lines, with status indicators
Graphic display : backlit ; transflective display ; user
6 Electromagnetic Interference emission and interference immunity acc. to
compatibility EN 61326: 1997 / A1: 1998
7 Protection class of IP 67
field housing
9 Diagnostic feature Required
Sensor
10 Type Glass electrode
11 Principle Glass electrode Teflon diaphragm
12 Measurement range 0 - 14 pH
13 Material Glass
14 temperature sensor NTC / Pt100
15 Connection Inductive digital connection with Transmitter
17 Resolution 0.01pH, Temp 0.1°C
18 Calibration Sensor to store calibration data, min/max pH range,
Temperature
19 Measurement Error ± 0.5% of Measuring range
16.14.4 Online Redox Measurement
Redox monitors shall comprise a combination redox sensor with integral reference
electrode and temperature compensation, cabling, sensor mounting and a converter.
In all other aspects it shall be similar to the pH monitors except that the display shall
indicate mV over the range -700 mV to +700 mV.
16.14.5 Online Chlorine Measurement:
Online chlorine analyser shall be based on Amperometric/membrane based measurement

of active chlorine converted to free chlorine by means of pH compensation. The sensor
shall have digital communication based on inductive energy transfer which will withstand
moisture, corrosion and ensure reliable data transmission at all times.

The offered transmitter shall be IP67, Interference emission & immunity shall be as per EN
61326-1:2006.
Transmitter
1 Measuring parameter Free Chlorine
2 Transmitter type 4- wire
3 No of channel Two channel (one for chlorine, one for pH)
5 Supply voltage 100 / 115 / 230 V AC +10 / –15%, 48 ... 62 Hz
6 Material Field Housing : ABS / Polycarbonate
LC display, two lines, with status indicators
7 Display Graphic display : backlit ; transflective display ; user
Electromagnetic Interference emission and interference immunity
8
compatibility acc. to ISO EN 61326: 1997 / A1: 1998
Protection class of field
9 IP 67
housing
Sensor
Amperometric measurement of free chlorine with
11 Principle
pH compensation
12 Measurement range 0,01 - 5ppm free chlorine
13 Material Sensor shaft : PVC
Membrane : PTFE
Membrane cap :PBT (GF30); PVDF
14 pH compensation pH sensor for compensation required
15 temperature sensor NTC / Pt100
16 Connection Inductive digital connection with Transmitter
18 Resolution 0.01mg/l
19 Repeatability +/- 1 %
20 Measurement Error 1 % of measured value
21 Mounting Flow assembly
The residual chlorine analyzer shall continually measure the concentration of free chlorine
residual present and, by control of the chlorine dosage rate, shall maintain the
predetermined concentration. The residual analyzer shall have the capability to initiate
high and low alarm locally and to SCADA.
16.14.6 Online Ammonia Measurement:
Online Ammonia analyzer shall be based on Colorimetric principle as per Indophenol Blue
Method as stipulated under ISO 7150-1. The analyzer shall have auto calibration and auto
cleaning facility. The analyzer shall have provision to connect additional sensors on the
same display for other measurements without any need for extra transmitter.

Measuring Principle Colorimetric

Method indophenol blue method acc. to ISO 7150-1;DIN-38406-5
Measurement range 0.5 to 50 mg/L of NH4-N
No. of measuring channel 1 or 2 channel
Response time >=8min., freely programmable
Accuracy +/- 2 % of measured value +0.5mg/l NH4-N
Repeatability +/- 2% of display value +0.05mg/l NH4-N
Calibration Auto calibration
Enclosure IP55
IEC 61010-1 Class I equipment, Interference immunity as
Electrical safety and
per EN61326-1:2013
Electromagnetic
Interference immunity as per EN61326-1:2013
compatibility
Auto cleaning facility Required
16.14.7 Online Dissolved Oxygen Measurement:
The online dissolved oxygen monitor shall comprise a dissolved oxygen sensor, cabling,
sensor mounting and a converter. The sensor shall be provided with a suitable mounting
either floating or fixed to locate the sensor in the required position. The mounting shall be
specially designed to prevent fouling of the sensor and to permit easy access and removal
of the probe for maintenance, cleaning and calibration. Where the sensor is to be sited in
a hazardous area, it shall be certified as suitable for use in that area, according to its
classification.
The system response time shall be not greater than 40 seconds for control applications
and not greater than 3 minutes for monitoring only.
Accuracy shall be 0.01 mg/L or +/- 1% of measured value. This performance shall be
maintained without manual intervention for a period of not less than 30 days. Auto
calibration or auto cleaning techniques may be utilised to meet this requirement.
If auto cleaning is incorporated it shall not affect the accuracy of the instrument for a period
greater than 5 minutes in any hour for a 40 second response system and 15 minutes in
any hour for a 3 minute response system.
The converter shall be mains powered and suitable for wall mounting in a local enclosure
or for door mounting within an MCC common control section. It shall include a digital
display with manual selection of dissolved oxygen as mg/l or % saturation, and
temperature in oC.
The range shall be selected manually. The controller shall include high and low set point
control functions and high and low alarm functions. It shall also provide an output suitable
for PLC system.
Automatic and manual calibration facilities shall be provided.
Measuring principle Optical type

Measuring Range 0-20mg/l ( 0-20ppm)

Temperature compensation Required

Operating temp range –5 to 60 °C (20 to 140 °F)
Accuracy 0.01 mg/L or +/- 1% of measured value
Repeatability +/- 0.5% of measuring range
Sensor shaft : Stainless steel 1.4571 (AISI 316Ti)Cap:
Sensor material
POM.Fluorescence layer : Silicone
Temperature compensation Required, internal
Cable/connector IP rating IP 68
Sensor signal output Digital communication with transmitter
Sensor memory Required to store - calibration data, sensor model, serial
number etc
Power Supply 100 to 230Vac +/- 15%, 50/60 Hz
Measuring signal input Digital input from sensor
Measuring Range To fit sensor range
Display Graphic display : backlit ; transflective display ; user
Enclosure IP rating IP67, NEMA 4X
Enclosure material Polycarbonate
Electromagnetic Interference emission & immunity as per EN 61326-
Compatibility 1:2006, class A for industry
16.14.8 Online Suspended Solids Measurement
The method of measuring turbidity and suspended solids shall be with a dual-beam
infrared/scattered light photometer. Other methods of turbidity and suspended solids
measurement, such as four-beam or surface scatter methods, are not acceptable.
A) Performance Requirements
1) Measurement range
a) Turbidity: 0.001 to 4000 NTU
b) Suspended solids: 0.001 mg/l to 50 g/L
2) 2. Accuracy
a) Turbidity: <1% of reading or ±0.001 NTU, whichever is greater
b) Suspended solids: Less than 5% of reading
3) Repeatability
a) Turbidity: Less than 1% of reading
b) Suspended solids: Less than 3% of reading
4) Detection limit
a) Turbidity: 0.001 NTU
b) Suspended solids: 0.001 mg/L
5) Response time: Initial response 1 second
6) Units of measure:
a) Turbidity: User Selectable NTU, FNU, EBC, FTU and TE/F
b) Suspended Solids: User Selectable g/L, mg/L, ppm, or % solids
B) Operational Criteria
1) Sample flow velocity: 3 m/s maximum
2) Sample pressure: 6 bar maximum

The sensor shall provide sample color-independent measurement. The sensor shall be
equipped with a self-cleaning device to prevent erroneous values and maintenance
problems caused by biological activity, scum build-up, and gas bubbles. The sensor shall
measures turbidity and suspended solids
16.14.9 Online Phosphate Measurement:
Online Phosphate measurement shall be based on Colorimetric principle as Molybdenum

blue method as per DIN EN1189 / Molybdate vanadate method. The analyzer shall have
auto calibration and auto cleaning facility
Measuring Principle Colorimetric

Photometric orthophosphate measurement based on
Method Molybdenum blue method as per DIN EN1189 /
Molybdate vanadate method
Measurement range 0.05 to 2.5 mg/l PO4-P - Molybdenum blue method
0.05 to 10 mg/l PO4-P - Molybdenum blue method
0.5 to 20 mg/l PO4-P – Molybdate yellow method
0.5 to 50 mg/l PO4-P – Molybdate yellow method
No. of measuring channel 1 channel
Accuracy +/- 2 % of full scale
Repeatability +/- 2% of display value +0.01mg/L
Calibration Auto calibration
Power Supply 115 V AC / 230 V AC, 50/60 Hz
Output 2 X 0/4 ... 20 mA
Enclosure IP55
IEC 61010-1 Class I equipment, Interference immunity
Electrical safety and
as per EN61326-1:2013
Electromagnetic compatibility Interference immunity as per EN61326-1:2013
Auto cleaning facility In-built
16.14.10Online Nitrate Measurement:
Online sensor shall be based on organic substance measurement on absorbance

measurement at wavelength at UV254nm.The offered sensor shall not have any sampling
or conditioning system, without any chemical requirements
Sensor output shall be in digital format for reliable and long distance transmission without
loss of signal due to moisture or water
Measuring principle Optical sensor based on UV absorption method;

measurement at 254 nm without any sampling
/conditioning requirements
Sensor type Direct probe type in-situ mounting without any regent 3for
operation

Process temperature 5 - 50°C (41 -120°F)

Absorption wavelength 190-230nm
Reference wavelength 254nm
Process pressure 0.5 to 10 bar (7 to 145 psi) absolute
Ambient temperature -20 to 60°C / -4 - 140°F
Sensor Ingress Protection IP 68
rating
Maximum measured error 2 % of full scale
Measuring range 0.1 to 50mg/L of NO3-N
0.01 to 20mg/L of NO3-N
Repeatability +/- 2 mg/l NO3-N
Drift Less 0.2 % of end of measuring range per week
No. of measuring channels * 1 or 2 channel /Multichannel
Electromagnetic Interference emission & immunity as per EN 61326-
Compatibility 1:2006, class A
16.14.11Online TOC Measurement:
Online sensor shall be based on organic substance measurement on absorbance

measurement at wavelength at UV254nm, using potassium hydrogen phthalate as organic
reference. The offered sensor shall not have any sampling or conditioning system, without
any chemical requirements. Sensor output shall be in digital format for reliable and long
distance transmission without loss of signal due to moisture or water
Measuring principle UV photometric - SAC [Spectral absorption coefficient]

method; measurement at 254 nm without any sampling
/conditioning requirements
Sensor type Direct probe type in-situ mounting without any regent for
operation
Process temperature 5 - 50°C (41 -120°F)
Process pressure 0.5 to 10 bar (7 to 145 psi) absolute
Ambient temperature -20 to 60°C / -4 - 140°F
Sensor Ingress Protection IP 68
rating

Measuring range TOC : 0 to 410mg/L

Maximum measured error 2 % of upper end of measuring range
Repeatability 0.5 % of end of measuring range
Drift Less 0.2 % of end of measuring range per week
Sensor type Digital sensor communication with transmitter
Chemical Chemical free measurement
Automatic cleaning Air cleaning
No. of measuring channels 1 channel
Electromagnetic Compatibility Interference emission & immunity as per EN 61326-
1:2006, class A
16.14.12Online TDS measurement:
Measuring principle Conductivity

Measuring Range 0.01 - 20 mS/cm
Temperature compensation Required
Operating temp range -20 to +135 °C
Pressure range 16bar max
Cable/Cable connector type Plug in head
Cable/connector IP rating IP 68
Cable length 15 mtr minimum
Sensor memory Required to store - calibration data, sensor model, serial
number etc.
Sensor diagnostics required
No. of measuring channels 1 channel
Electromagnetic Compatibility Interference emission & immunity as per EN 61326-
1:2006, class A for industry
16.14.13Auto Samplers
An all-weather refrigerated auto sampler shall be supplied with all required sample
containers, reagents, media (as applicable) for the representative collection of samples to
monitor influent and effluent waters from municipal and industrial facilities, monitor effluent
waters from indirect industrial dischargers. The auto samplers shall be suitable for indoor
or outdoor use. The equipment shall be UL certified.

The method of sample collection shall be via high-speed peristaltic pump for collection of
the sample liquid.
Performance Requirements
1) Sample cooling: maintain sample liquid at 4°C (39°F) in ambient temperature to 50°C
(122°F) maximum; accurate to ±0.8°C (±1.5°F).
2) Sample volume: shall be programmable in 10 mL increments from 10 to 10,000 mL.
3) Sample volume repeatability ±5% of 200 mL sample volume with: 4.6 m (15 ft.) vertical
lift,
4) Sample volume accuracy: ±5% of 200 mL sample volume with: 4.6 m (15 ft.) vertical
lift
Operational Criteria
5) Operating temperature: 0 to 50°C

6) Storage temperature: -30 to 60°C
The auto sampler shall be interfaced with the plant main PLC system for complete
monitoring of the auto sampler system parameters, control & monitoring from the PLC
system.
16.14.14Online ORP Measurement:
Service Measurement of Oxidation Reduction Potential

Repeatability ± 20 mV
Range -2000 – 2000 mV/-1500 to + 1500 mV
Sensor
Type Immersion Type
Mounting Locally
Installation hardware and Integral Required
cable
Probe material Suitable for Sewage application
Operating temperature range Analog Sensor: - 5 to 105 deg C
Digital Sensor - 5 to 70 deg C
Pressure range 0 to 6.9 bar
Type of Ground Electrode Titanium ground electrode to eliminate ground
Loop currents in the measuring electrodes.
Sensitivity =/- 0.5 mV
Stability 2 mVper 24 Hours, non-cumulative
Flow rate 3 m (10feet) per second maximum
Built in temperature element NTC 300 ohm thermistor for analyzer temperature
Readout
Sensor Cable 4 conductor cable with one shield and
polyurethane jacket rated to 105 deg C
Transmitter
Type Microprocessor Based having back Lit LCD
display
Mounting Field

Prefabricated integral cable for Required

connecting sensor and transmitter
Analog outputs 4–20 mA
16.15 Laboratory Instruments
The laboratory shall be equipped with instruments, equipment, chemicals and other
infrastructure that is necessary to perform the routine analysis for the parameters as
detailed in table below.
STP Contractor shall submit the complete list of lab equipment required for full analysis of
parameters to the employer’s representative for approval. Contractor shall include in his
offer supply of chemicals required for analysis along with proposed lab instruments and
associated equipment, including for the O&M period as specified elsewhere in the bid
document.
Minimum list Laboratory equipment to be provided are detailed as below:
Item
Description Unit Quantity
No
1 Comparator test set for residual chlorine or chloroscope No. 1
2 Multimeter (pH and Conductivity Meter) No. 1
Mains operated pH meter completed with one calomel
3 No. 1
electrode and glass electrode
4 Turbidimeter - Bench Model (Nephelometric Type) No. 1
5 Turbidimeter - Hand held (Portable) No. 1
6 Spectrophotometer No. 1
Water bath with 6 to 8 concentric holes and discs, electrically
7 No. 1
heated
8 Soxhlet extraction unit No. 1
9 Kjeldahl digestion unit No. 1
10 Hot plates No. 5
11 Distilled water plant No. 1
12 Demineraliser No. 1
13 Refrigerator (280 litres capacity) double door No. 1
14 B.O.D. incubator No. 1
15 Muffle furnace No. 1
16 Electric oven No. 1
17 Magnetic stirrer No. 1
18 Monopan balance with digital display No. 1
Jar-Test apparatus with RPM controller and simultaneous
19 No. 1
addition of Chemicals in all jars
20 Centrifuge No. 1
21 Gas cylinder if gas supply is not available No. 1
22 Fume cupboard/hood No. 2

Item
Description Unit Quantity
No
23 Field Test kit for cations and anions No. 2
24 Depth sampler No. 2
25 Online Total organic carbon analyzer analytical instrument No. 1
Sieve shaker with standard sieves and Two pan balance,
26 No. 1
weighing up to 200gm samples
27 Weighing Balance (Max. 10 kg) No. 1
28 Durham tubes and Imhoff cones (1 lot) lot 1
29 D.O meter No. 1
Equipment Needed for Bacteriological Examination
30 Hot Air Oven No. 1
31 Autoclave No. 1
32 Incubator 37°C or 44°C (Water/Air-Jacketed) No. 1
33 Binocular microscope No. 1
34 pH Meter No. 1
35 Pipette Box (Stainless Steel) No. 10
36 Wooden Racks/Aluminum Racks No. 5
37 Wire Baskets No. 10
38 Cotton/ Aluminum Foils No. 10
39 Burners (Bunsen) With Pilot Lamp No. 3
40 Suction Flask (1 Litre Cap) No. 2
41 Suction Pump No. 1
42 Sampling Bottles No. 10
Measuring Cylinders (1000 Ml, 500 Ml, 200 Ml, 100 Ml, 50 Ml,
43 Set 3
25 Ml)
44 Vacuum pump No. 1
Bacteriological Media
45 M. Endo Broth (dehydrated) No. 1
46 Lactose or Lauryl Tryptose broth No. 1
47 Mac Conkey broth No. 1
48 Brilliant Green Bile Lactose Broth No. 1
49 Total Plate Count Agar No. 1
50 Peptone/Triyptone Water No. 1
51 Laminar Air Flow Chamber No. 1
The above indicated lab instruments are the minimum to be provided. If as per process
requirements, any additional equipment is required, the contractor shall supply the same
at no additional cost.

The equipment shall be supplied with all the accessories that are necessary to make the
equipment functional for analyzing parameters. Contractor shall include any additional
equipment if necessary under his scope of work.
16.15.1 UV Visible Pre-programmed Spectrophotometer:
UV Visible Pre-programmed Spectrophotometer for measurements of water Quality

parameters and Spectral Analysis Shall be pre-programmed for more than 150 parameters
for common drinking water testing parameters like residual chlorine, Iron, Hardness,
alkalinity, fluoride and sulfate etc. The spectrophotometer instrument shall be a multi-
wavelength, UV-Visible, single beam spectrophotometer designed for Water analysis. The
instrument, depending on the test selection, shall automatically select the wavelength.
Readout modes shall include transmittance, absorbance, concentration, optional

wavelength scan and time course graphs. Spectrophotometer should come along with the
following reagents and accessories: Power supply, Operators manual, one pair 10mm
rectangular path length cells and reagents for common drinking water parameters like
residual free chlorine, Iron, sulfate, silica Low range and Fluoride for 1000 tests.
Technical Specifications:
Wavelength Range 190- 1100 nm

Spectral Band width 4nm
Lamp type xenon flash lamp
Durability 5x 108 fleshes, corresponding to at least 13000 h
permanent operation
Monochromator type Grating Monochromator with step motor
Wavelength calibration Automatic
Max. scan speed Approx. 3300 nm/min.
Light sensor Photodiode
Photometric measuring range ±3.3 A
16.15.2 Spectrophotometer:
The instrument shall be capable of colorimeter tests for more than 90 parameters, from
aluminium to zinc for testing natural waters. The instrument should be designed
specifically for field testing. The instrument shall be water proof, dust proof and should
have a chemical resistant housing. The instrument should have simple, push-button
program selection and step-by-step prompts that guide users through each testing
procedure.
Wavelength Selection Auto select

Photometric Range 0 to 2 A
Operational Modes Concentration, ABS, %T
Concentration Unit ug/L, mg/L, g/L, ABS, %T
External Outputs RS 232 via Data Transfer Adapter (optional)

50 sample readings (each reading includes

date/time, parameter, program number
Datalogging
concentration, absorbance, % transmittance,
sample number, instrument serial number)
User programs Five user-entered programs, 12 data points each
Large liquid-crystal display (LCD) displays results,
Display
parameter name, and units
Power 4 AA alkaline
Storage Temperature Range -40 to 60 deg.C
Operating Temperature Range 0 to 50 deg. C
Meets IP67 standard, dust proof and waterproof to
Environmental one meter for at least 30 minutes
16.15.3 Laboratory pH Meter:
Instrument should able to give quick and easy pH measurements. Instrument should have
large LCD display. Instrument should have RS232 interface with data logging facility.
Range: pH -6.00 to 20.00, mV: -2000 to 2000 mV, Temp: -10.0 to 120.0°C
Resolution: pH 0.01 pH, mV: 1.0 mV, Temp : 0.1°C
Accuracy: pH ±0.01 pH, mV: ±0.05 % full scale ± 1 LSD, Temp: ±0.5°C
16.15.4 Bench top Multi parameter meter:
A multi parameter instrument capable of analysis of pH, ORP, dissolved oxygen,

conductivity, TDS, salinity and temperature shall be provided. The instrument shall be
capable of a quick response and have an intuitive user interface. The instrument shall have
automatic temperature correction/compensation. Downloading and storage of data should
be easy and convenient. It shall provide RS-232 interface and shall have a minimum of
150 points recall feature.
pH : - 2.00 to 19.999
Range ORP: ± 2000 mV
mV: ± 2000 mV
0 to 199.9 µS/cm;
200 to 19,999 µS/cm;
Conductivity
2 to 199.9 mS/cm;
20 to 199.9 mS/cm.
TDS 0 to 50,000 mg/L as NaCl
Salinity 0 to 42 ppt (%)
Dissolved Oxygen 0 to 20.0 mg/L (ppm); 2 to 100% saturation

pH Test: -10 to 110 °C (-50 to 230 °F)

Temperature Cond. Test: -10 to 105 °C
DO Test: 0 to 50 °C
pH : 0.1/0.01/0.001 (selectable)
Resolution ORP : 0.1 mV
mV: 0.1 mV
0.00 to 19.99 µS/cm; 20.0 to 199.9 µS/cm; 200 to 1999 µS/cm; 2.00
Conductivity to 19.99 mS/cm; 20.0 to 199.9 mS/cm; 0.01 µS/cm; 0.1 µS/cm; 1
µS/cm; 0.01 mS/cm; 0.1 mg/L; 1 mg/L; 0.01 g/L; 0.1 g/L
0.00 to 199.9 mg/L; 200 to 1999 mg/L; 2.00 to 19.9 g/L; 20.0 to 50
TDS
g/L; 0.1 mg/L; 1mg/L; 0.01 g/L; 0.1 g/L
Salinity 0.1 ppt
Dissolved Oxygen 0.01 or 0.1 mg/L; 0.1% saturation
Temperature 0.1 °C
Accuracy pH: ± 0.002
ORP: ± 0.2 mV or ± 0.05% of reading, whichever is greater.
mV: ± 0.2 mV or ± 0.05% of reading, whichever is greater.
Accuracy pH: ± 0.002
ORP: ± 0.2 mV or ± 0.05% of reading, whichever is greater.
mV: ± 0.2 mV or ± 0.05% of reading, whichever is greater.
Conductivity ± 0.5% of range
Salinity ± 0.1 ppt (-2 to 35 °C)
TDS ± 0.5% of full scale
Dissolved Oxygen 0.01 or 0.1 mg/L; 0.1% saturation
± 0.3 °C at 0 - 70 °C;
Temperature
± 1.0 °C at 70 - 110 °C
16.15.5 Laboratory Turbidity Meter:
Turbidity meter shall have pre-programmed features for measurement of turbidity with ratio
color correction covering the range from 0 to 10,000 NTU with auto signal averaging.
Turbidity meter should come along with the following accessories: A complete set of
calibration standards (0.02, 10, 100, 1750 NTU), Two measuring corvettes with light shield
caps, operators’ manual, and plug in power adaptor.
Technical specifications:
1 Principal of operation Nephelometric

2 Light Source Infra-red
3 Extended auto ranging up to 10,000 NTU

0 - 2,450 EBC
0 - 10,000 FNU
0 - 10,000 FAU

4 Resolution NTU on lowest range

5 Accuracy ± 2% to ±10% of reading (in 3 ranges)
6 Response time less than 6 seconds
7 Sample size 30 ml
8 Air purge connection for external dry air supply
9 Auto alert calibration prompt.
10 Outputs RS-232 Serial Port
11 Reusable Calibration Standards
12 Certification UL, CSA, CE, ISO7027
Instrument should have option for connecting flow thru cell.
16.15.6 Portable Turbidimeter
The instrument should have microprocessor-control operation and Ratio optics to bring
greater accuracy, sensitivity and reliability to field testing. The instrument shall
compensate for color in the sample, light fluctuation and stray light, allowing analyst to
achieve laboratory-grade performance on a wide range of samples, under a wide range of
conditions.
0 - 1000 NTU in automatic range mode; 0-9.99, 0-99.9 and 0-

Ranges
1000NTU in manual range selection.
Accuracy ±2% of reading or ±1Least significant digit up to 500 NTU
±3% of reading above 500 NTU to 1000 NTU
Repeatability ± 1% of reading or ±0.01NTU, whichever is greater.
Resolution 0.01 NTU on lowest Range
Stray Light < 0.02 NTU
Sample required 15 ml
16.15.7 Dissolved Oxygen Meter:
Meter should be microprocessor based hand held type instrument with rugged & field
proven design and should be easy to operate with less maintenance. Dissolved Oxygen
meter should come along with the following: 12FT cable and probe, Battery Alkaline 4NOS
1.5V EACH, Instruction Manual, Hardware Kit Fitted, Kclsoln, Membrane, O-RING SET
Range : Dissolved Oxygen 0 – 20 mg/L, 0 – 200 %

air Temperature- 5 to 45o C
Accuracy : Dissolved Oxygen 0.3 mg/L,
 2%.
Temperature  0.4o C
Resolution : Dissolved Oxygen 0.01 mg/L, 0.1%
Air Temperature 0.1 o C

Dissolved Oxygen Sensor : Galvanic

Salinity compensation : Required
Altitude compensation : Required
Temperature : Automatic
Compensation
Power : Battery operation
Cables : 12 feet or more
Other features : Backlit Display
Built-in calibration chamber Waterproof, IP 65
16.15.8 Residual Chlorine Meter:
The instrument should be a handy model which should be capable of analyzing three water
quality tests. Instrument should be simple to use and should display error messages as
and when they occur. The instrument should be pre-programmed to conduct the following
tests:
pH 6.8 – 8.6
Chlorine 0 – 5.0 ppm
Alkalinity 0 – 500 ppm
In addition, Instrument should include the following: Intransclam packing with reagents for
100 free chlorine tests, Crushing rod and 2 test cells. The instrument should be provided
with a operations &instructions manual.
16.16 Associated Lab Equipment:
16.16.1 Sterilizer, Autoclave:
Purpose: For sterilization of glassware and culture media for bacteriological analysis.
Double wall construction with inner & outer chamber made of Aluminum. Electrically
heated by means of superior quality emersion heaters with working pressure 15 PSI. Inner
Chamber Size: 550X750mm. Rating: 6.0 KW, Volume: 175litre.
16.16.2 Balance, Analytical (Electronic):
Purpose: For preparation of standard solutions used in chemical analysis.
Specifications: Should be based on E.M.F.C. Technology
Type: Electronic single Pan, Capacity: 200 mg, Resolution: 0.1 mg, Stainless steel
weighing pan; Pan Size: 100 mm Diameter, Display: Sharp, Clear LED Display and
Standard bi-directional RS232C interfaces. Multiple weighing Units: Grams & Carat. It
should have auto calibration facility, Overload protection and auto zero facility. Balance
should come along with Set of certified calibration weights, Voltage stabilizer, Dust proof
cover, Operational manual and necessary tools.
Centrifuge: Purpose: For separation of suspended matter from suspensions.

Specifications:
Max. Speed 20000 RPM, Max. RCF: 34500, Max. Tube size: 100 ml, Max.
Capacity: 400 ml. Width: 450 mm, Depth: 470 mm, Weight: 35 kg
Connected Load 0.75
Rotor Angle Head 8x50 ml
Speed regulation Step less variable speed control.
Digital Speed 1 to 99 minutes digital timer with by-pass switch for infinite time
indicator run.
16.16.3 Incubator Bacteriological:
Purpose: For incubation in bacteriological analysis
Double walled cabinet. Outer wall should be made of mild steel, inner wall of stainless
steel, lagged with a special insulating material. The inside door should be made of glass
panel set in a metal frame fitted with a felt gasket and be fastened by a ball catch.
Temperature range °C above ambient to maximum 60°C.

Accuracy ±2°C
Size 600X600X600cm
Rating 1000Watts.
Purpose For cooling and storage of (standard) solution in a
laboratory
Specifications:
Type Vertical double door
Capacity Approx: 280 litre.
Water Bath, General Purpose:
Purpose: For enhancement of chemical reaction in various analyses and evaporating of

water from samples
Specifications: Doubled walled construction Fitted with imported thermostat of 30 Deg C

to 110 °C Accuracy of +/- 1 Deg C. Working Temp. from 5 Deg C above ambient 80 °C
made of double wall, stainless steel construction, with glass wool
Capacity: 15 Ltrs
12 holes of 75 mm dia, 2000 Watts
16.16.4 Ware Purifier, Distillation Unit (Automatic)
Purpose:
For generation of reagent water type III which is used for washing and quantitative
analysis.
Made of stain less steel, vapor baffle, condensing tube and lid are stainless steel

This is fitted with immersion type element.
The stopcock fitted to the unit.
The still is provided with wall mounting iron bracket to be fixed on the wall which the still
can rest.
Supplied with 3 core wire and plug to work on 220 Volts AC
Capacity: 2 Litre
Load: 2 K.W
Low water cut-off device for 2 liter and 4-litre cap.
16.1.1 Work Tables and Benches
Minimum of 1set of work table and chair per staff shall be provided for the laboratory and
office staff. The furniture and chairs shall be of ergonomic design.
The work tables shall be along the wall and shall be provided with adequate storage
capacity and open glass shelves on the top to provide additional space for storage of
chemicals and stock solutions.
A fume cupboard with ventilation hood shall be provided to prevent spreading of toxic and
irritant fumes and odours into other parts of the laboratory. Forced ventilation with exhaust
fans shall be provided. The wall space and offsets shall be convenient to locate cabinet,
benches, hoods, incubators alongside without any loss of floor space.
16.17 Online Real Time Multi Parameters Continuous Monitoring System for Influent and
Treated Sewage Parameters for the STP’s
The online real time multi parameter continuous monitoring system shall be able to
measure the below indicated parameters on a minimum through extractive method for
ease of operation, calibration & troubleshooting and shall have the capacity for future
expansion.
On a minimum the following parameters shall be measured at the plant inlet and outlet:
COD, BOD, pH, TSS, TOC, Ammonical-Nitrogen, Total Nitrogen, Dissolved Oxygen, Color
& Temperature measurement at the inlet and outlet of the STP
The system shall have capability to accommodate any additional parameters viz. Turbidity,
Conductivity, TDS, Oil in water, etc. as may be required by the end user, from time to time.
The contractor shall provide complete analyzer with the Sample handling system. The
required Pump, Sample Tubing & other necessary accessories shall be in the contractor
scope of work.
The online real time multi parameter continuous monitoring system shall be equipped with
inbuilt automatic cleaning facility. Required mechanism & cleaning solution for automatic
cleaning shall be supplied for the entire duration of the operation and maintenance period.
For the air-pressure cleaning system, Air Compressor of required capacity along with
required air pipe line etc. shall be supplied.

Further, each of the STP shall be equipped with Auto samplers at the inlet and treated
sewage point. Each of the online real time multi parameter continuous monitoring system
shall be integrated with the Auto sampler. The online real time multi parameter continuous
monitoring system is required to communicate with the auto sampler for exceedance
sample so that it can store sample in Auto sampler for Lab analysis. This is to ensure that
the sample taken by the auto sampler and the multi parametric analyzer are of the same
time period.
All required calibration standard chemicals & reagents, are required to be provided for a
complete duration of the operation and maintenance period for all mentioned parameters.
The online real time multi parameter continuous monitoring system shall accept the input
signal from existing outlet Flow meter at the sewage treatment plant for display as well as
Data transmission. Required cabling, any other hardware to achieve the same shall be
under the contractor scope of work under this contract.
USB port for download of stored measurement data along with diagnostic files for easy
troubleshooting. The minimum data storage for all the parameters shall be three months
in the non-volatile memory of the equipment.
suitable communication ports for integration/ provide data to sewage treatment control
system (PLC based SCADA system).
The online real time multi parameter continuous monitoring system shall have multiplexing
facility to add minimum five sample streams to allow connection of additional sample
stream for future requirements.
The contractor shall provide mandatory spares along with the online real time multi
parameter continuous monitoring system for the entire contract which shall include:
1) 1 No of Electronic circuit Boards,
2) 1 No of Display Board,
3) Tubing’s,
4) 1 No of Cleaning Pump,
5) 1 No of Spectroscopic Modules & all other required spares.
Technical requirements:
A) COD (Chemical Oxygen Demand)
UV-VIS Spectroscopy with entire spectrum scanning between

Measuring Principle
180 nm to 800 nm.
Measuring Range 0 –1000 mg/l(Min)
Accuracy ± 2% on standard solution
Repeatability ± 1 mg/l
Response Time < 5 min.
Cleaning Automatic cleaning

B) BOD (Biological Oxygen Demand)

Measuring Principle
180 nm to 800 nm.
Measuring Range 0 – 1000 mg/l(Min)
C) Ammonical Nitrogen (NH4-N)
UV Absorption after gas stripping. Measurement should be in gas

Measuring Principle
phase for completely interference free measurement.
Measuring Range 0 – 100 mg/l (Min)
Repeatability ± 0.2 mg/l
D) Total Nitrogen

Measuring Principle
180 nm to 800 nm.
Measuring Range 0 – 100 mg/l
Repeatability ± 0.1 mg/l
E) Total Suspended Solids (TSS)

Measuring Principle
180 nm to 800 nm.
F) pH
Measuring Principle Electrochemical Method

Measuring Range 0 – 14 pH

Repeatability ± 0.01 pH
G) Dissolved Oxygen
Measuring Principle Optical Method

Accuracy < 1 % of full scale
Resolution < 0.01 mg/L
Precision < 0.02 mg/L
Response time < 1 min
H) Temperature
Measuring Range 0 – 80”C

Accuracy < 0.1 C
Resolution < 0.1 C
Precision < 0.1 C
Response time < 1 min
I) Online real time multi parameter continuous monitoring system
Operating Pressure Contractor to specify

Operating Temperature Sample temperature: 0 ºC to 80 ºC
Operating Flow Contractor to specify
Enclosure protection IP65 minimum
RS232 or RS485 output - USB port required for USB/ pen
Communication
drive connection.
Memory As specified in the technical requirements in this document
Display Color LCD, with LED backlight Resistive touch screen display.
Measuring time/ 1 Min Programmable
Response time
Measuring Cycle Continuous.
Power supply 90- 264 VAC 50/60 Hz
Equipment should have facility to start cleaning cycle
Cleaning method
automatically as per user defined time interval.
Required. Shall have auto zero calibration facility. Equipment
shall have facility to start auto zero calibration as per user
Calibration requirement defined time interval.
Span Calibration: Shall perform as per laboratory
measurement data.

UV Light Source Xenon Flash Lamp

Equipment shall have facility to expand measurement to meet
future compliance requirements (if any).
Equipment shall have capability to add parameters like NO3 &
Conductivity, turbidity at no extra cost.
Equipment shall have capability to add other parameters as
mention below & should be facilitate to upgrade with Minimal
Expandability of cost using same enclosure.
measurement
Oil in Water: Measurement Technique by UV Fluorescence
Chromium, Phosphate. Measurement Technique by
Colorimetric
TDS/Conductivity: Measurement Technique by

Electrochemical.
Additional Features Should have Automatic Zero calibration facility which can be
programmable as per user defined interval.
UV source should be Xenon flash lamp with life more than 10
years.
Equipment should be cabinet type (IP 65 ) for easy operation,
maintenance & troubleshooting. If not the complete instrument
shall be provided with IP-68 enclosure
USB port for downloading stored measurement data.
Should have robust flow cell which allows very high level of
suspended solid without clogging and also suitable for highly
corrosive water Sample.
Should have automatic turbidity compensation facility by a
dual wavelength
USB port is required for recorded measurement download,
screen copy function (easy troubleshooting) & software
update
16.18 Particular Instrumentation, Control & Automation Requirements
16.18.1 General
This part covers the Particular requirements for the design, supply, installation, Inspection
and testing of Programmable Logic Controllers (PLC) and Supervisory Control and Data
Acquisition (SCADA) and associated plant and materials.
Documents to be submitted during Bid Submission for Technical Qualification
Include a complete Table of Conformance to each and every reference standards or part
of the specifications. Use a chart format with specification part identified, indicate whether
each part is in compliance, a deviation or an exception to the specific part. If an exception
or deviation, include a narrative description as to how the deviation or exception can
benefit the end-user of the system over that item specified.
The Bidder must submit evidence that they employ more than 10 technical staff for
instrumentation and more than 10 technical staff for automation, and should have
minimum of ten (10) design engineers in each field (instrumentation and automation). The

Bidder shall submit the qualification and license for a minimum of ten (10) professional
engineers & field technicians in the direct employment of the Bidder, and submit a list of
personnel nominated for the tendered work.
Provide a system configuration diagram of the proposed control system showing all major
components and their interconnections and interrelationships. Label each diagram and
indicate all external power and communications interfaces. Bidder shall ensure that the
proposed block diagram developed by the bidder shall be the proposed system offered by
the bidder and shall not merely submit the block diagram/system configuration
representation as depicted in this tender as his proposed system.
Bidder shall provide a written overview of the proposed control & Instrumentation system
inclusive of SCADA software, Historian, control room architecture, necessary hardware
and software modification, communication equipment and interface, instrumentation
system, describing the principal functions and capabilities of the system’s (servers, PLC’s,
system communications and general system capabilities (maximum number of network
nodes, PLC’s/RTU and I/O points, communication protocols available, etc. EPBAX system
etc.).
Bidder shall list out the spares considered and to be supplied under this contract for each
component Note: This is in addition to the mandatory spares which are listed in this
document.
Bidder shall provide an operating system and software applications list with descriptive
literature for the proposed system. Include all software items, supplier name, quantity, and
model numbers. Indicate whether any proposed software is proprietary and would not be
turned over to the owner.
Note: Proprietary software will not be accepted.
I. Information is also required for the following :

1) Name, version, product brochures, data sheets of the proposed centralized
SCADA software, historian software, PLC software, OPC software (if any) to
achieve integration of data, etc.
2) Name, version, product brochures, data sheets of the proposed PLC system, I/O
modules,16” HMI,20” HMI etc.
3) Name of version of all necessary software that shall be supplied and implemented
under this contract. (All software’s shall be the latest series version).
4) Name & version of the operating system software for operator & engineering work
station, Blade server software, networking software, etc.
5) Name & version of all IT hardware and software that shall be part of system.
6) Name and version of any required communications software, firmware, etc.
7) Name and version of the specified report application software,
8) Describe how system data points are linked from the system database into various
applications such as reporting, web server or maintenance applications.
9) Name and provide a description of any non-resident software required to program,
troubleshoot or diagnose any devices in the system.
10) Provide a construction schedule for completion of the project within the specified
Contract period. Indicate the following activities with milestones: Mobilization,
design submission, submittal review, equipment procurement, equipment
assembly, system configuration and programming, factory testing, system delivery,
system installation, start up, field testing and training, and post acceptance routine
service intervals.

11) Describe the system supplier’s provisions for service, technical assistance and re-
placement parts for the proposed system. Include the system supplier’s 1-800-toll
free number. Identify with resumes, all personnel who will be providing technical
support services for the project after it is accepted.
12) Above documents shall be submitted in proper bounded form and indexed with
page numbering for easy referencing. All catalogs and literature (including sub-
suppliers’ catalogs), datasheets, Instrument list, etc. shall be bounded together in
indexed volumes. The bidder shall submit all the documents with indexing with
page numbering for easy reference.
16.1.2 HMI
The HMI shall be with color screen and with touch screen capabilities.
All Remote I/O panels which are connected to the main plant PLC based SCADA system
shall be equipped with a 15” minimum panel HMI. The HMI shall be suitable for day to day
operation by non-computer literate personnel in the monitoring and operation of the
treatment works.
The HMI shall provide efficient and safe operation of the process plant by detecting alarm
and error conditions, alerting the operator to these conditions both visually and audibly,
monitoring all important system parameters and providing facilities for plant optimization.
The system will allow operators, technicians and Employer Representatives to issue
commands to change system parameters, start and stop equipment, provide configuration
tools and operate diagnostic facilities.
The System shall perform all the necessary functions for the optimum monitoring, control
and operation of the particular system. HMI unit along with software packages shall be
considered, and also those software packages and Hardware shall be compatible with
TCP / IP protocols as well as OPC communication (Open Standard Communication)
a) Design and Construction Requirements
STP PLC shall be provided as a Hot-Standby configuration to perform combinational

and sequential logic functions, status monitoring and reporting functions with counter
and timer facilities.
In particular, the following configuration shall be applicable across the STP.
Main Plant PLC: Hot standby PLC
Individual Process locations: RIO panel with redundant RIO modules and power supply
and communication modules, with simplex I/O modules. The process systems shall be
furnished with individual RIO panels with RIO modules which shall communicate with
the main plant PLC for monitoring and control. No separate PLC and SCADA system
for monitoring and control of process system shall be accepted.
Main PLC system shall comprise of necessary hot standby PLC processors, Simplex
input/output (I/O) modules, communication interface modules and Human-Machine
Interface (HMI) required performing the desired functions.
PLC shall have the following attributes as a Hot Stand-by Controller.

• carry out sequential logic implementation for operations of plant;

• carry out computation and interfacing for data acquisition, data storage and
retrieval;
• it shall accept downloaded program from a programmer;
• it shall have different functional modules to perform the desired functions;
• it shall scan the inputs in time cycles and update the status of its outputs.
The PLC system shall be expandable, OPC Compatible and shall be modular in
construction, so as to be capable of future expansion without hardware modifications.
PLC s shall be microprocessor based. PLC s shall use standard known protocols and
structures for communication outside the system.
In case of system failure or power supply failure the outputs shall attain a
predetermined fail safe condition (this shall normally be ‘off’). The PLC used shall have
a proven record in the type of application concerned and in the prevailing
environmental conditions.
All PLC Systems should be housed in air conditioned environment. The contractor shall
submit the sizing calculations for the air conditioning system for review and approval.
The contractor shall refer the approved vendor list for the PLC system and hardware,
elsewhere in this document.
Remote input/output modules (RIO)/Panels
The PLC system shall consist of field remote input/output modules (RIO) and panels.
Each RIO panel shall consist of redundant communication modules, power supply
modules, minimum 15” color panel mounted HMI with touch screen functionality. It
shall be possible to view and acknowledge the alarms and view set points for the
particular process from the HMI etc.
I/O Modules:
Standard rack mounted plug in I/O modules shall be provided. I/O Modules should be
of the same series as the PLC CPU. Refer the approved vendor list for the PLC system
and hardware, elsewhere in this document.
Field wiring shall be terminated in screwed terminal blocks and interconnected to the
processor I/O system with prefabricated cables and plug in card type connectors. I/O
Modules should be hot swappable.20% extra modules of installed capacity for each
type of module shall be provided as spare. In addition to the above, provision shall be
made for future expansion of additional 20% extra I/O modules of the installed capacity
in the panel. The panel drawings shall reflect the same.
I/O modules shall be as follows:

a) inputs shall be opto isolated.;
b) filters shall be provided for noise rejection;
c) output status shall be indicated by an LED;
d) all outputs shall be fuse protected and have fuse failure indication the fuses may
be mounted externally from the output module;
e) all the modules shall be of addressable type.
f) Ethernet I/O modules shall be connected to the PLC by on board Ethernet 10/100
Base T connection port. Ethernet I/O modules shall support multiple
communications including TCP/IP and Modbus ASCII and RTU allowing

connection to any device supporting these protocols over standard Ethernet

backplane.
Each PLC shall have memory protected built in historical archiving/data logging of
system alarms & events and process variables. Data logger shall be able to log data
based on time or an event. PLC shall have enough memory allocated to allow 200,000
time and data stamped discrete and /or analog values to be archived. The historical
archive shall allow the oldest data to roll off the system as memory is used keeping the
200,000 most current data points available. Process point time stamping frequency
shall be selectable within the configuration software. It shall be possible for the
archived data to be exported in CSV format allowing use with standard spreadsheet
and data software applications
The PLC system shall be expandable, OPC Compatible (OPC should be a built in
feature of the software and hardware. No external software patch or hardware module
is allowed) and shall be modular in construction, so as to be capable of future
expansion without hardware modifications.
b) Dual Redundant Processors (CPU)
The master station shall be provided with two identical central processors configured
such that they operate in Hot-Standby mode.
Redundant system with hot back up redundancy feature should be built in the CPU.
Software engineered hot backup systems are not acceptable. CPU should have the
memory expansion capability up to 7 MB.
SCADA connectivity with the CPU will be on dual Ethernet network (10/100 Mbps with
open Modbus TCP/IP protocol). On the event of hardware failure in primary system the
standby system will provide dual connectivity with the SCADA.
Redundancy of switch for SCADA (industrial grade managed switch) connectivity is to

be provided. PLC CPU and I/O modules shall be of the same logic family.
The system shall be designed and implemented such that when the Main processor
fails, the Standby one shall automatically take over. The changeover shall be
seamless, smooth and without any time delay and shall not cause any disruption to
the overall distributed control system and to the ongoing processes.
The PLC system shall be expandable (OPC Compatible) and shall be modular in
construction, so as to capable of future expansion without hardware modifications.
The system hardware, application software and database shall be sized to

accommodate a total of 50% increase in signal capacity and up to 100% increase in
an individual zone.
PLC s shall be microprocessor based. PLC s shall use standard known protocols and
structures for communication outside the system. In case of system failure or power
supply failure the outputs shall attain a predetermined fail safe condition (this shall
normally be ‘off’). The PLC used shall have a proven record in the type of application
concerned and in the prevailing environmental conditions.
Application logic programs shall be fully compliant with all five logic development
methods detailed in IEC 61131-3. The PLC shall be powered by two independent

sources provided by the UPS system and all internal operating supplies shall be
derived from the UPS.
The power supplies, I/O modules, CPU and communication modules shall be
monitored by the PLC and shall be available by report. The same shall be monitored
on the SCADA screen.
During the times of the battery discharge, the PLC shall initiate an orderly self-
shutdown and automatically restart on the main power restoration without the need for
reloading or initiation of any kind. The PLC shall comply with the specification specified
elsewhere in this specification.
c) Central Processing Units
The central processing units (CPU) shall be a high performance processor with
modular configuration suitable for real time process applications. The following
additional features shall be provided:
Redundant system with hot back up redundancy feature should be built in the CPU.
Software engineered hot backup system will not be not acceptable. CPU should have
the memory expansion capability of minimum 7 MB.
SCADA connectivity with the CPU will be on dual Ethernet network (10/100 Mbps with
open Modbus TCP/IP protocol). On the event of hardware failure in primary system the
standby system will provide dual connectivity with the SCADA.
Redundancy of switch for SCADA (industrial grade managed switch) connectivity

should be provided. Communication between CPU and peripherals shall be by an I/O
bus. The individual device, interfaces shall be capable of being plugged into the I/O
bus. On resumption of power following a power failure the PLC shall automatically
restart its controlling function.
CPU shall have a real time clock capability to accept a time synchronization pulse and
adjust its internal clock with the pulse. CPU shall have extensive self-diagnostic
facilities and watch dog timers to identify faults at card levels
d) Memory Unit
Memory unit shall comprise of highly reliable memory chips which are industry
standard, proven design with fast random access and suitable for operation in process
environments. Main memory shall be modular and facility shall be provided for the
upgrading and expansion of memory to meet future demands.
Not less than 50 % spare program memory and data memory space shall be provided.
System initialization and application software shall be stored in EEPROM or EPROM.
Operating data shall be stored in a RAM fitted with an internal battery backup.
e) I/O Modules
Standard rack mounted plug in I/O modules shall be provided. I/O Modules should be
of the same series as the PLC CPU. Field wiring shall be terminated in screwed
terminal blocks and interconnected to the processor I/O system with prefabricated
cables and plug in card type connectors. I/O Modules should be hot swappable.

20% extra modules of installed capacity for each type of module shall be provided as
spare.
I/O modules shall be as follows:

• inputs shall be opto isolated.;
• filters shall be provided for noise rejection;
• output status shall be indicated by an LED;
• all outputs shall be fuse protected and have fuse failure indication the fuses may
be mounted externally from the output module;
• all the modules shall be of addressable type.
• Ethernet I/O modules shall be connected to the PLC by on board Ethernet 10/100
BaseT connection port. Ethernet I/O modules shall support multiple
communications including TCP/IP and Modbus ASCII and RTU allowing
connection to any device supporting these protocols over standard Ethernet
backplane.
f) Analogue Input Modules

They shall consist of an input isolation unit, signal conditioning unit and an analogue
to digital converter (ADC). In addition, the following features shall be provided.
• cross talk attenuation
• provision for monitoring of the ADC for overflow detection
• gain amplifier with high common mode rejection ratio
• accuracy for analogue signals shall be 0.5%
g) Digital Input Modules
The following design features shall be provided.

• contact bounce protection;
• choice of type of contacts.
h) Digital Output Modules
The digital output module shall provide contact closure output by driving relays. The
features to be provided are as follows:
• contact bounce protection shall be provided
• relay output shall be provided to operate pump motors and motorised valve
actuators
• fail safe position in case of output module failure and fault indication
PLC’s provided under this specification shall be capable of performing the necessary logic
to control the system as previously defined. These capabilities shall include, but not be
limited to the following:
1) Discrete input/output 10) Latch/unlatch relays

2) Analog input 11) Counters
3) Analog output 12) Comparators
4) Timers 13) Ladder logic
5) Pump Controller 14) Flow Totalization/ Integration
6) Pump Alternation 15) Intrusion Detection
7) Mathematical Function Blocks 16) Time of Day Control w/Lockout

8) Stage Blocks 17) Ramp Blocks

9) Trending 18) Data Logging
i) PLC Programming
PLC programming shall be carried using functional block diagrams (FBD). The logic
shall be prepared using proprietary programming software and shall be
comprehensively annotated with subroutine and rung comments to assist further
development and maintenance.
The system shall support a simple programming of the application software comply
with IEC 61131-3.
The system shall support a structured, modular programming. At least the following
standard operations shall be applicable:
1) Logic functions (such as AND/OR/AND NOT etc.);
2) Timer functions (externally adjustable);
3) Counter functions;
4) Skip functions;
5) Comparison functions;
6) Limit value functions;
7) Arithmetic functions;
8) Physical unit functions;
9) Closed-loop functions such as P/PI/PID/etc.
The Contractor shall submit the logic diagrams for review. The Contractor shall include
the as-built logic in the final submission.
j) Programming Unit
The programming unit shall be of the portable type, industrial model designed to be
used during commissioning on site. A functional keyboard which supports different type
of programming methods shall be included, as well as a LCD display
On a minimum, the following functions shall be included:

i) On-line programming
ii) Off-line programming
iii) Flexible corrections during input
iv) Full screen editing functions
v) Absolute and symbolic programming
vi) Input of comments and title blocks for complete documentation
vii) Complete application software documentation functions. Printouts of application
viii) Software logic functions shall preferably be in Ladder logic diagrams.
ix) Load and transfer functions
The portable programming unit with minimum 16” screen shall be provided complete
with proprietary PLC programming and SCADA software complete with plant mimics
and documentation software. Communications cables required to interact with the
PLC, (E.g.: Modbus Cable) would be supplied by the contractor.
The software shall provide facilities for:

• carrying out program revision management;
• insertion of comprehensive program subroutine and rung comments;

• search and find and search and replace ‘contacts’ and ‘coils’;
• simulation functions and testing of the program by changing the status of contacts
and monitoring the outputs;
• preparation of coil and contact list and their locations and memory maps;
• make system backup copies while the system is online;
• upload and down load programs to the PLC on line;
• Carry out on line maintenance and fault finding on the PLC.
k) Ethernet Switches
The contractor shall only provide managed industrial grade Ethernet switches under
this contract. All switches shall be in redundant configuration.
16.19 Approved Vendor/Manufacturer/Make List-Instrumentation
The naming of a manufacturer in this specification is not intended to eliminate competition

or prohibit qualified manufacturers from offering equipment. Rather, the intent is to
establish a standard of excellence for the material used, and to indicate a principle of
operation desired.
i) List of Makes for Instruments:
Sr.
Description Vendor/Manufacturer/Make
No.
1 Level Indicator Transmitter M/s ABB,
M/s Global Water
M/s Endress+Hauser
M/s Yokogawa
M/s Siemens
2 Flow meters /Flow Indicator/ Transmitter M/s Emerson
(Electromagnetic, Thermal, Ultrasonic) M/s Yokogawa
M/s Endress+Hauser
M/s Forbes Marshall
3 Level/Float Switches M/s ABB
M/s Endress+Hauser,
M/s Krohne GmbH Germany
4 Pressure Gauges/Pressure Switches M/S ABB,
M/s Wika
M/s Switzer
M/s Danfoss
M/s Krohne GmbH Germany
5 Pressure Indicator Transmitter M/s Emerson
M/s ABB,
M/s Endress+Hauser
M/s Siemens
6 Online Residual Chlorine Analyzer Tethys Instruments-France
M/s Endress+Hauser
M/s DKK -Japan
M/s Process Instruments -UK
7 Temperature Indicator Transmitters M/s Endress+Hauser
M/s ABB

M/s Hayashi Denko (Japan)

M/s Yokogawa (Japan)
8 Analytical Online Instruments (DO, ORP, M/s In situ
MLSS, p H, etc.) M/s Endress+Hauser
M/s Process Instruments U.K
M/s DKK (Japan)
9 Strain Gauge Load Cell M/s Jenco
M/s ABB
M/s SWAN
10 Auto samplers M/s Endress +Hauser
M/s DKK (Japan)
M/s Watersam
11 Real time Inlet & Effluent monitoring system Tethys Instruments-France
M/s Process Instruments U.K
M/s DKK (Japan)
12 Laboratory Equipment M/s Machery –Nagel
M/s DKK (Japan)
M/s Savant
M/s Idexx
M/s In-Situ
M/s Shimadzu (Japan)
ii) List of Makes for UPS & Batteries:
a) List of Makes for UPS
Sr. No. Manufacturer / Make

1 M/s APC
2 M/s DB & ELECTRONICS
3 M/s HI-REL
4 M/s NUMERIC POWER SYSTEMS
5 M/s Aplab
b) List of Makes for Batteries

1 M/s AMAR RAJA
2 M/s HBL NIFE
3 M/s AMCO
4 M/s EXIDE
iii) List of Makes for Cables

1 M/s Universal Cables
2 M/s Havell’s
3 M/s CCI
4 M/s Finolex

5 M/s NICCO
6 M/s Delton Cables Limited
iv) List of Makes for Enclosures/ Panels

1 M/s Rittal
2 M/s ECIL
Note: In order to achieve standardization for appearance, operation, maintenance, spare

parts and manufacturer's service, like items of equipment provided hereunder shall be the
end products of one (1) manufacturer.
In order to achieve standardization for operation, maintenance, spare parts and

manufacturer's service
In the event that the contractor wishes to propose alternate makes for the equipment
mentioned above, he shall submit the following during detailed engineering:
1) Demonstrate that the proposed makes are “Superior / Equivalent” to the approved
makes.
2) Manufacturer involved in manufacture of specified equipment for at least 10 years
before bid date
3) Submit documentation from the vendors in the table above that the proposed make of
equipment & software is not available anymore.
4) At least 10 successful installations commissioned in last 5 years.
5) Manufacturer to provide full contact information for each reference as part of technical
bid.
16.20 Approved Vendor/Manufacturer/Make List-Automation
The naming of a manufacturer in this specification is not intended to eliminate competition

or prohibit qualified manufacturers from offering equipment. Rather, the intent is to
establish a standard of excellence for the material used, and to indicate a principle of
operation desired.
Sr.
Description Manufactures/Makes
No.
1 Workstations, Servers, Laptop Dell
(17”) HP
IBM
2 Programmable Logic Controllers & Make CPU Series IO Series
IO Modules Schneider Quantum Quantum 140
Electric Series Series
Siemens S7-400H ET-200M
Series
Allen Bradley Control Logix Control Logix
1756 Series 1756 Series
Mitsubishi Q 25PRH Q Series
Omron CS1D CS1D
3 SCADA Programming Software WIN CC, RS View, Telvent SCADA, MC
Works, CX-Supervisor
Note: All software’s shall be of the latest series
version and shall include both runtime and
developer versions.

4 Historian Software M/s Schneider Electric- Wonderware Historian

M/s Mitsubishi Electric- MC Historian
M/s Siemens – SIMATIC Process Historian
M/s Allen Bradley-Factory Talk Historian SE
M/s Progea- Movicon
Note: In order to achieve standardization for appearance, operation, maintenance, spare

parts and manufacturer's service, like items of equipment provided hereunder shall be the
end products of one (1) manufacturer.
In order to achieve standardization for operation, maintenance, spare parts and

manufacturer's service
In the event that the contractor wishes to propose alternate makes for the equipment
mentioned above, he shall submit the following during detailed engineering:
1) Demonstrate that the proposed makes are “Superior / Equivalent” to the approved
makes.
2) Manufacturer involved in manufacture of specified equipment for at least 10 years
before bid date
3) At least 10 successful installations of similar size as per this contract, commissioned
in last 5 years before bid date and satisfactorily operating for at least five years before
bid date.
4) Manufacturer to provide full contact information for each reference as part of technical
bid.
16.21 Supervisory Control and Data Acquisition System (SCADA)
The SCADA shall be a fully integrated microprocessor based control and data acquisition
system which will monitor, control, display, record and trend all assigned plant inputs and
outputs. The SCADA shall be a fully dual redundant microprocessor based computer
system such that reliable and automatic plant control can be achieved.
The main process monitoring and control shall be by means of VDU based process
operator workstations that shall be located in the central control room.
SCADA system would be dual redundant server system. The system shall be designed
and implemented such that the failure of a central processor or HMI console does not
inhibit continuous automatic control of the plant.
Failure of a single outstation or communications to that outstation shall not effect control
or operation of any other outstation, unless the failed outstation provides essential data to
another outstation, in which case the non-failed outstations shall revert to a fail-safe mode.
An alarm shall be generated whenever a communications system failure occurs.
The SCADA system shall provide a complete monitoring & control of the entire STP facility
via the redundant PLC based control system and RIO system.
The SCADA system shall comprise on a minimum the following:

a) Dual redundant SCADA servers with SCADA software with minimum fifty thousand
tags license and web servers.
b) Historian system inclusive of the software to match the tag database of the SCADA
software, i.e. fifty thousand tags.

c) Engineering & Operator work stations loaded with SCADA software and with latest
Windows Operating system, minimum 1TB storage, latest processor, etc.
d) One number of Sixty five -65” LED screen connected over LAN to the SCADA system
to display the process screens, alarms & reports.
e) Redundant industrial managed Ethernet switches
f) Licensed Antivirus software to be loaded on each system
g) Industrial grade control system console to house the entire PLC based SCADA system
and other equipment as indicated in the system configuration diagram.
h) All required software and hardware to implement the system as indicated in the
specifications and system configuration drawings.
The SCADA system shall follow the International Standards Organization (ISO), Open
Systems Interconnect (OSI), reference model guidelines. All central system hardware and
software devices shall be interconnected using a bus topology data highway. The
communications protocol used shall generally meet the requirements of the ISO.
The system shall provide efficient and safe operation of the complete plant by detecting
alarm and error conditions, alerting the operator to these conditions both visually and
audibly, monitoring all system parameters and providing complete facilities for plant
operation and optimization.
The System shall perform all the necessary functions for the optimum monitoring, control
and operation of the entire system. For each abnormal condition, Plant failure, Plant
unavailable or failure to respond to a command within a given period, the system shall
provide the appropriate alarm.
Printed and archived alarms shall be time and date stamped for occurrence and
acceptance. Alarms, logs and reports shall be output to separate printers. Alarms shall be
in red. The ability to generate alarms within the system software based upon digital and /
or analogue events and set points shall be provided.
An alarm horn with silence button shall be provided to alert the operator of an alarm
condition. Specific alarm, monitoring and control input / output requirements shall be
determined from the particular control specifications and the Project Drawings.
SCADA Software Functions
General:
1) The Contractor shall be responsible for supplying complete software packages to

enable the equipment to operate as stated in this specification. Provision must be
made for the adding of further software tasks as and when required. All software
functions shall be user friendly, with instruction and messages to aid the operator. The
Contractor shall make available all standard software functions, even if not specifically
detailed in the specification.
2) The computers shall utilize a real time multi-tasking and networked operating system
with a proven track record in real time control applications.
3) The Operating System shall be latest Windows operating system, loaded with MS-
Office latest licensed version suitable for interconnection with external networks in a
Wide Area Network (WAN) configuration, where specified.
4) The Application Software shall provide communication with other industrial standard
open networks. The Software shall support Object Linked Embedding for Process
Control (OPC). OPC should be a in-built feature of the software.

5) The System shall support a fully distributed 64 bit Client/Server architecture. The
System shall include Visual Basic for Applications (VBA) as a built-in programming
language. Facility shall be available for building custom objects using VBA. Object
oriented graphics and tools to easily build reusable control strategies. ODBC
Application Program Interface (API) capable of collecting and writing secure real-time
electronic records to one or more relational database.
6) The software shall support OPC standards as both a client and a server for fast and
reliable communications with a wide variety of hardware devices. Provide Active-X
controls with selection of third-party Active-X controls for ready-made solutions without
VBA programming. The SCADA software shall use SQL server as the integral
database.
7) A standard software package, such as Crystal Report shall be provided to facilitate
generation of free format, intuitive and presentation quality reports.
8) The engineering Workstation shall be provided with simulation tools to support off-line
testing of the control logics.
9) The Server shall provide the master clock for the SCADA time synchronization.
10) The system software shall be from the SCADA manufacturer as indicated in the
approved vendor list elsewhere in this specification. Third party software is not
acceptable. It is a requirement that the system be supported by on line configuration
and editing of all VDU mimic displays and database and to create new displays and
additional database.
11) Operational mimics and other graphics shall be presented in an industry standard
graphical user interface (GUI) format. A minimum of two active windows shall be
displayable concurrently and not more than three windows. Both text and graphics
shall resize automatically to accommodate changes made to the size of a window. The
system shall be designed to minimize the operator’s use of the keyboard. All major
functions shall be accessible on-screen through use of the mouse or track ball.
12) Operator system entry, for each area will be password coded with different levels of
entry depending on the level of authority of the operator. Development and systems
level entry passwords will be provided for engineering workstations. Each action taken
by any operator at any level of entry, or at any operator terminal, shall be log file
recorded and time and date stamped. Log in and out time and dates will be printed on
the control room event logging printer.
13) All requests and commands shall be via icons, whether menu linked or linked to
equipment control actions. A permanent dynamic alarm banner shall be displayed at
the bottom or top of each operator screen. Each control action will be routed through
a series of confirmation routines.
14) The reports shall be available for printing in graph or tabular format. Dynamic trend
displays shall also be available for all analogue flow, level and pressure values.
Custom, as well as preconfigured reports and trends shall be available to a higher level
of entry. A colour, A4/A3 size, screen dump printer shall be provided for graph and
trend prints.
15) An operator help utility shall be provided, offering help linked to the particular action
being carried out by the operator at that time. At least one help screen per screen page
shall be available. This facility shall be preconfigured with an option for updating by
operators, via a password entry.
16) The Application Server software shall be configurable to provide for the monitoring and
control of all points, loops, and systems through graphic display screens and hard copy
reports. These shall include:
• Parameter Displays for signal control
• Control Loop Status Displays
• Real Time and Historical Data Trend Displays
• Event Displays and Log Reports
• Alarm Displays and Log Reports

• Equipment Diagnostic Displays and Reports.

17) The system shall provide on-line diagnostics that display the current status and
operation of the local area network and its nodes. The diagnostic display shall include
the LAN adapter status for the machine showing the display, as well as the current
number of messages, errors and retries.
18) The system shall conform to and take advantage of industry standards. These shall
include, but not be limited to:
• ODBC
• OLE
• ActiveX
• COM/DCOM
• DDE and Advance DDE
• C programming language
• Visual Basic
• Microsoft Windows XP or the most current Operating System
• TCP/IP
• OPC
• XML
19) Display Facilities and screen/mimic refresh: The displays shall be user configurable,
with the user being able to construct any desired symbol for display. Any display shall
appear (excluding historical recall) within 1 seconds to 2 seconds of selection and the
displayed data shall be updated from the database. Alarms shall typically appear within
3 seconds to 5 seconds of occurrence and within 1 second of being received into the
central system database. Plant mimics shall display dynamic color details of flow rates
and pressures, pump status, well levels, alarms, electrical power supplies and other
general equipment status conditions. The plants mimics shall include animation to
depict plant process operation, pump running station, media flow within the plant,
levels in the tank, etc. The animation shall be designed such that the screen refresh
rate shall not effected. The SCADA servers and workstations (engineering & operator)
shall be suitably chosen to meet this requirement.
20) The Contractor shall configure all display pages as fully as possible. However, facility
must be incorporated to permit easy construction and modification of the display
pages, by using a standard library of shapes and symbols. The library shall be added
to and modified by the user as required. The configuration shall be object orientated
for ease of use.
21) The initial application software shall provide for the display pages listed below and any
pages necessary for the system to function as a complete entity.
a) Mimic displays
b) Graphic displays.
c) Trend displays.
d) Alarm summary tables with date and time.
e) Event logs of past 72 hours with date and time.
f) Tabular display of data.
g) Inset windows showing an analogue trends may be mixed with mimic displays. In
such a display the main mimic and inset trend shall all be live with automatic display
updates.
h) Indexing of information and menus shall be presented in the form of active windows
on the screen, while the mimics etc. are still available for view.
i) No display or function shall effect the logging/monitoring of data. It shall be possible
for the master station terminal and auxiliary terminals to perform simultaneously,
different tasks within the display.

Monitoring and Alarms
1) The operator shall be able to monitor all of the information at the workstation. He shall
be able to view active equipment information by use of graphical and tabular displays.
2) In the event of an equipment alarm, the following shall occur at the master station:
a) Alarm message displayed in the alarm message area of the screen.
b) The audible alarm shall sound.
c) The appropriate Section of the display page shall change color and flash.
d) A full message shall be written on the alarm page.
e) The full alarm message shall be printed on the alarm printer.
f) The full alarm message shall be recorded, stored on disk and automatically
archived.
3) The operator should be able to acknowledge the alarm by pressing an accept alarm
key or icon. This action shall stop flashing of all associated alarm messages and
displays. However the display shall remain in the alarm state fixed color to indicate an
accepted alarm. When all outstanding alarms have been acknowledged the audible
alarm shall be silenced.
4) Once the alarm has cleared, the messages and displays shall return to normal. The
alarm message shall stay recorded on the event/alarm log and an alarm cleared
message shall also be recorded.
5) If the alarm clears before being acknowledged the sequence of events shall continue
as above except the message shall change to indicate a cleared alarm.
6) An audible alarm silence function shall be provided to enable an operator to silence
the audible alarm without acknowledging all alarms. On occurrence of any subsequent
alarm, the audible alarm shall sound.
7) Each signal within the configured system shall be capable of being assigned an alarm
based on the following:
a) Four levels per analogue (Lo Lo, Hi Hi, Lo and Hi).
b) Rate of change.
c) Deviation from set point or other control parameter.
8) Alarms shall be time tagged to 1 second resolution at the I/O’s.
9) A minimum of four alarm priorities shall be provided so that those requiring immediate
attention may be separated from alarms of lower priority. An audible alarm shall sound
for alarms requiring operator action.
10) Typical alarm assignments are as follows:
a) critical alarm - an alarm that requires immediate operator action
b) non critical alarm - an alarm that requires operator action but not
necessarily immediate action
c) operator guide alarm - an alarm that provides information to the operator
d) event - a low priority condition which is recorded.
Data Archiving
Continuous process (analogue) data, digital event states, alarms and operator actions
shall be archived to a removable media system. The archive media shall be sized to store
logged analogue data, at a maximum sample rate of 15 minutes for a period of three
months locally. Data recording shall be on dual media. The archive system shall generate
an alarm when a file is 60% full.
Analogues will be stored at a rate selected by the operator in the range 1 second to 1 hour.
The operator shall have the facility to select the way in which an analogue is stored.
The system will provide any combination of the following:

• Instantaneous value.

• Average value.
• Maximum value.
• Minimum value.
• Not stored.
Maximum, minimum and average values shall be calculated over a period set by the
operator in the range 15 minutes to 24 hours, the default shall be 1 hour.
The logging of new data and reception of alarms must be carried out at the same time as
the operator is viewing archived data. Any alarms received must be displayed as an
overlay on the visual display unit.
The contractor shall submit the data archiving policy to be adopted as part of functional
design specifications for review and approval. The same shall be demonstrated during the
factory acceptance test and site acceptance test.
SCADA Screens/Mimics
The Contractor shall configure all the mimics to provide total detailed coverage of the
monitoring and control of equipment as detailed in this specification. It is expected that
display modifications will be required in the future and therefore the ability to change the
displays without programming skills is essential.
Instrumentation shall be displayed using ISO standard symbols. For mimic configuration,
it shall be possible to call up a library of standard symbols representing items (e.g. pumps,
valves) and add new symbols to the library. Building mimics shall be simple and be
achieved by using a mouse or tracker ball pointing device.
The mimic displays shall consist of the following pages on a minimum but not limited to:
a) A general diagram covering the entire sewage treatment plant any associated systems
on a single screen with key data being displayed. The same shall be constituted as
plant overview screen. The same shall be programmed with complete animation to
depict the normal process operation and process media flow within the treatment
system.
b) A general block diagram for each site or area of Site showing the equipment displayed
on a series of single screens with key data
c) Mimic of the equipment and instrumentation connected to each IO module displayed
on as many screens as necessary.
d) Individual process screens
e) PLC network monitoring screen
f) Individual vendor packaged PLC monitoring screen
g) Login screens, reports screen, security screen, overall STP screen, etc.. Shall be
configured.
The SCADA software shall have the ability to limit the number of displays being opened
simultaneously at any given point of time. The software shall be able to display at least
three process screens/pop up screens simultaneously and shall be active screens
16.21.1 Trend Displays
It shall be possible to plot dynamically updated real time data and archived data on a line
graph, to represent analogue or digital information. Each graph shall be capable of
displaying 8 plots overlaid on a graph of different colors and line texture. Next to the graph,
there shall be a key relating each color to its function.

The horizontal axis shall be time based and user selectable in minutes, hours, days,
weeks, for example, together with a start time.
The vertical axis shall be scaled as a percentage of range and be displayed in the colour
of the selected reading. To avoid cluttering, the vertical axis scale shall be changed by
selecting the individual display. The vertical axis shall be automatically scaled for each
selected point, between limits entered by the user.
Actual values in engineering units shall be displayed by positioning a cursor at the desired
point of the trend graph. The display of the data shall also be available in tabular form.
a) Manual Data Entry:
The system shall be provided with facility for entering data manually via the keyboard.
This data will fall into two types:
a) Constants which will be changed infrequently. This data may have time and date
associated with it.
b) Maintenance related comments.
b) Manually Corrected Data:
The system shall allow a person with authorized access to correct manually, erroneous
data via the keyboard.
16.21.2 Reports
There shall be a real time spreadsheet facility supplied and installed by the Contractor.
The users shall be able to transfer data from either the archive system or live data to the
spreadsheet.
The user shall be able to produce daily, weekly, monthly and annual reports using any
data and a mixture of formats (tables, graphs, summaries, spreadsheets). It shall be
possible to generate reports, either automatically at predetermined intervals, or manually
on demand by the Operator.
Typical reports on a minimum would be:

• Inlet and treated flow
• Process parameters
• Laboratory analysis and shall be transferred to centralized SCADA system
• Real time data monitoring system report for both inlet & treated flow
• Failures of equipment.
• Analytical instrumentation parameters.
• Wet well and tank levels.
• Discharge pressures.
• Maintenance schedules.
• Power consumption
• Chemical consumption
• Process alarm conditions.
• Status of vendor control packages

16.21.3 Profiling
From an average, typical or manually entered plot, it shall be possible to set an exception
profile whereby readings within an upper and lower level are acceptable. Profiles shall be
set graphically via OW.
The user may select for the system to alarm if the reading is outside the profile and
highlight such exceptions as part of a report, thereby reducing the need to examine all
data, to ensure acceptability. The number of exceptions shall be logged.
16.21.4 Data Manipulation:
It shall be possible to perform simple mathematical functions on any data, including the
following functions:
• Addition
• Subtraction
• Multiplication
• Division
• Square root
It shall be possible to log, display or use in a control loop, the resultant data.
16.21.5 Database Query Facilities:
The system shall support the use of database relationships and wild card characters to
provide database query facilities. It shall be possible for applications integration to
configure queries easily and save them for future use.
Support of Dynamic Data Exchange (DDE) or Structured Query Language (SQL), to permit
data exchange between the SCADA and external applications, including spread sheets
and databases.
Data shall be presented in tabular format and contain any combination of fields from the
main system database. It shall be possible to manipulate the data by specifying search
and sort criteria to define data range limits.
Once a query table has been created, it shall be possible to store the configuration and
initiate successive look-ups, using a point and shoot technique.
16.21.6 Downloading IO Configuration:
It shall be possible to download configuration to the IO’s from the engineering work station
and the Portable Programming Unit (Laptop).
16.21.7 Diagnostics:
The system shall have on-line diagnostic facilities to report system faults as they occur. A
set of off-line diagnostic routines shall be supplied for more extensive fault diagnosis.
16.21.8 Security Access Levels:
The functions available on the system shall be fully flexible so as to allow users access
levels to be customized by the system operator, to suit individual user requirements.

Access to management and engineer levels shall be restricted by user selectable

passwords or key switch. The security systems shall be based on a set of privileges, which
may be granted or denied to individual uses by the system operator.
Windows functionality of CNTRL+ALT+DEL shall be disabled. On SCADA startup, the

system shall load and directly enter in the SCADA welcome home page. The design shall
ensure that SCADA software development page shall not be accessed during the startup
and only on appropriate login access, the same shall be accessible.
The security/access levels would be divided between Engineers, supervisors and

operators.
The system shall be protected from un-authorized changes to the operating system and
application programs.
The system shall prevent un-authorized users from re-booting the system or aborting or
suspending system-related programs.
The system shall provide three levels of operator access to the system as a minimum, with
the first level permitting access to viewing selected plant conditions as described below
and the highest level intended for the system manager.
A mechanism shall be provided which prevents users operating at a lower level from
accessing functions assigned to a higher level.
The system shall provide a password-protected, user log-on facility for definition of the
user access level.
Passwords entered during the log-on process shall not be printed or displayed.
The software shall monitor the actions of the user currently logged on at each node and
shall log the current user off after a definable extended period of no operator interaction
with the system and produce a printed log-off message.
Logging off of the user shall not shut down the system or the SCADA mimic shall not log
out. When the operator has logged off, the current SCADA mimic shall be visible for
monitoring, but no action shall be possible until the operator has logged in back to the
system.
System-generated log messages relating to operator actions, such as alarm

acknowledgements or set-point changes, shall include the identification of the current
logged-on user.
The Contractor shall provide the following defined user access levels as a minimum and
additional levels as instructed by the Employer Representative:
1) Default Level:
The default level shall permit users to view all displays except those specifically
assigned to a higher level of access.
2) Operator level:
The operator level shall permit authorized users to access default level activities in
addition to the following:
a) Perform control actions;

b) Acknowledge alarms;
c) Enter or modify manually entered data for inclusion into reports.
3) System manager level:
The system manager level shall permit authorised users to access default level and
operator level activities in addition to the following:
a) Modify alarm and control set points, dead bands and time delays;
b) Enter or modify historical data;
c) Add, delete or modify individual I/O points or point attributes;
d) Add, delete or modify field device configurations;
e) Create, delete or modify control algorithms;
f) Create, delete or modify graphic displays;
g) Create, delete or modify system reports;
h) Configure trend displays;
i) Access the operating system;
j) Assign access levels and user passwords;
k) Perform any other system maintenance function
16.1.3 Programming:
The method of programming will depend upon the Manufacturers system requirements.
However, the following standards shall be followed:
a) All programs shall be written such that they lend themselves easily to alterations and
additions.
b) Good programming practice shall be followed using structured programming
techniques. All programs shall be tidy in format and logical to follow. Programs should
be extensively annotated with comments and be self-documenting.
c) The system shall be supplied with programs that use a high level language.
16.1.4 Programme – Documentation:
As part of the requirements of this specification full documentation is required as below on

a minimum:
a) Software user manuals
b) Database point allocation table
c) Complete program listing, flow charts for all sequences and control routines
d) Application software source code (applicable even for packaged control systems)
e) End user license agreements.
16.1.5 SCADA Hardware
The system shall support hardware and software interconnectivity to other networks
generally in accordance with the ISO Open System Interconnect 7 layer reference model.
16.1.6 Computers (Workstations):
1) The computer hardware shall be of current technology at the time of installation.

Standard server stations, Standard PC technology with modern hardware, latest
Windows operating system and data transmission over Industrial Ethernet must be
used for the engineering workstations. It must be possible to install more than one
engineering station in a system. Minimum 2 Tb capacity systems shall be supplied.
The engineering system must be an open system that, for example, permits the
importing of project data from Microsoft Excel, SQL or from CAD/CAE programs. It

must be possible to import/export messages to/from Excel and Access for simple
processing. Removable memory media must also be provided for each workstation.
It must be possible to back up all database and configuration data both on removable
media and on non-removable storage media without the system being offline.
Provision of redundant storage media must be possible for the configuration database.
The specs for computer hardware shown are indicative only and minimum requirement
to be supplied by the contractor.
2) All workstations, servers, communications equipment and peripherals shall be from

reputed manufacturers, suitable for continuous operation and shall be the most
currently available models at the time of construction, subject to approval. Adequate
spare capacity shall be included to meet the specified requirements and future
expansions. All workstations shall not be loaded more than 60% of their capacity. An
alarm shall be generated when this capacity is exceeded.
3) The system shall support hardware and software interconnectivity to external

Programmable Logic Controllers (PLC’s) over an RS-232/RS-485 serial data link using
Profibus / Modbus, Ethernet or similar protocol, subject to the approval of the Employer
Representative.
16.1.7 Visual Display Unit (VDU)
1) Visual Display Units (VDU’s) shall be color monitor screens, capable of displaying
information in alphanumeric, bar histogram, graphical and mimic diagram formats.
Monitors shall simultaneously display a minimum of 256 colors, non-interlaced, low
radiation, flat screen with no discernible flicker. Display of characters shall be legible
and stable on a shadow mask tube, having a resolution of not less, so that 1024 by
768 pixels and a refresh rate of not less than 70 Hz. The units shall include all the
necessary picture controls to adjust the sharpness, contrast and position of the image.
LED VDUs shall be flat screen, minimum requirements: brightness 250 cd/m2, 500:1
contrast ratio, 1600 x 1200 pixels,
2) VDU’s shall be 32 inch LED Screens on a minimum.
3) VDU’s shall be fitted with a power management system to reduce consumption upon
detection of a stand-by signal from the PC.
16.1.8 Printer
16.1.8.1 Colour Multifunction Printer:
Color Multifunction printer shall be used for the production of color screen dumps and
reports and shall have a sufficiently sized buffer memory such that system performance
will not be degraded when the color printer is operational and comply with the following:
Printer Specification:
All-in-one functions Print, copy, scan, fax, standalone scan-to email, photo card
slots
Multitasking capability Yes.
Paper Size A3, A4
Print speed, black (normal quality Up to 21 ppm
mode)

Print speed, color (normal quality Up to 21 ppm

mode)
Print speed footnote Exact speed varies depending on the system configuration,
software program, and document complexity.
First page out (color) As fast as 17.9 sec
Monthly duty cycle Up to 40,000 pages
Footnote for duty cycle Duty cycle is defined as the maximum number of pages per
month of imaged output. This value provides a comparison of
product robustness in relation to other LaserJet or Color
LaserJet devices, and enables appropriate deployment of
printers and MFPs to satisfy the demands of connected
individuals or groups.
Paper Heading:
Paper handling standard input 50 sheet multi-purpose tray 1, 250-sheet input trays 2 and 3,
50-sheet ADF
Paper handling standard output 150-sheet face-down output bin
Envelope capacity Up to 30 envelopes
Envelope feeder No
Duplex printing (printing on both Automatic (standard)
sides of paper)
Document finishing Sheetfed
Media sizes, standard Letter, legal, executive, envelopes (No. 10, Monarch)
Media sizes, custom Tray 1: 3 x 5 to 8.5 x 14 in; Tray 2, Tray 3: 3.94 x 5.83 to 8.5
x 14 in
Media types Paper (bond, brochure, colored, glossy, letterhead, photo,
plain, preprinted, prepunched, recycled, rough),
transparencies, labels, envelopes
Media weight Tray 1: 16 to 47 lb (up to 58 lb with Color Laser glossy photo
papers); tray 2, tray 3: 16 to 43 lb (up to 47 lb with postcards,
up to 58 lb with Color Laser glossy photo papers)
Weight 71.2 lb
Processor speed 450 MHz
Memory, standard 160 MB
Memory, maximum 416 MB
Scanner Specification:
Scanner type Flatbed, ADF
Scan resolution, optical Up to 1200 dpi
Bit depth 42-bit
Scan size, maximum (flatbed) 8.5 x 11.7 in
Scan size, maximum (ADF) 8.5 x 14 in
Scan speed (default) Up to 15 ppm
Automatic paper sensor No
Copier Specification:
Copy speed (black, best quality, Up to 20 cpm
A4)
Copy speed black (best, letter) Up to 20 cpm

Copy speed color (best, letter) Up to 20 cpm

Copy resolution, black Up to 600 x 600 dpi
Copy resolution, color Up to 600 x 600 dpi
Copy reduce/enlarge settings 25 to 400%
Maximum number of copies Up to 99 copies
Fax Specification:
Faxing Yes
Fax transmission speed (seconds 3 sec per page
per page)
Fax memory Up to 250 pages
Fax note Based on standard ITU-T test image #1 at standard
resolution. More complicated pages or higher resolution will
take longer and use more memory.
Fax resolution, black (dots per Up to 203 x 196 dpi
inch)
Speed dials, maximum number Up to 120 numbers
Auto redial Yes
Fax delayed sending Yes
Fax broadcast 119
Junk fax barrier Yes
Polling Yes (receive only)
Remote retrieval No
Fax forwarding Yes
16.21.9 Uninterruptible Power Supply (UPS) for Instrumentation, Control & Automation
The UPS shall be floor mounted; self-contained and metal clad and shall be suitable for
supplying a non-linear load. It shall be possible to open the enclosure front door when the
unit is in use without exposing any live contact to touch.
The UPS shall be an on-line type incorporating a six pulse rectifier and pulse width
modulation inverter technology with microprocessor control. It shall incorporate a static
bypass switch which shall operate in the event of UPS failure, overload or manual initiation
in order to transfer the output supply to mains without disturbance to the output supply.
The UPS shall incorporate a dc under voltage trip circuit to electronically trip the UPS
output in order to protect the batteries.
The noise level of the unit shall not exceed 60dB(A) at 1 m from the UPS cabinet.
The output of the inverter shall be a sine wave having less than 2% THD for linear loads
and less than 4% for 50% non-linear load. It shall be suitable for load power factors 0.7
lag to 0.9 lead.
The unit shall have a dynamic response such that a 100% step load causes an output
voltage transient of less than ± 4% with a recovery time of less than 4 ms.
For three phase output units the output voltage shall not vary by more than ± 1% for an
unbalance of 10%.

The load crest factor shall not be less than 3:1.
The efficiency at full load and 0.8 power factor shall be greater than 88%.
Indicators to indicate
• UPS status
• UPS alarm conditions
The UPS shall provide a volt free contact output to indicate:

• warning, i.e. low battery capacity
• fault
• static bypass in use.
The UPS shall have an overload capacity of 150% for 30 seconds and shall be protected
in the event of a short circuit of the output.
The batteries shall be housed, either within the UPS enclosure or within a separate
matching battery cubicle suitable for location adjacent to the UPS. The UPS battery shall
be located in a well ventilated area.
16.1.9 Technical Particulars:
Each UPS shall have the following features:

a) The UPS shall be stand alone, parallel redundant, true on line, based on advanced
IGBT PWM technology with microprocessor based control, monitoring and fault
diagnostics, static by pass switch and front access oriented layout.
b) Main Parameters:
1 Input Voltage 415V +10% -15 % A.C.

Three phase 4 wires with Solidly earthed
Neutral.
2 Symmetrical Short circuit level. 25kA
Frequency 50Hz ± 5%
3 Output Voltage 240 ± 1% A.C, Three Phase 4 wire with
Solidly Earthed Neutral.
4 Frequency 50Hz ± 5%
Wave form True Sine Wave
5 Isolation True on line with complete galvanic
Isolation
6 Total harmonic Distribution < 2% for linear load,
< 3% for non-linear load
7 Over load Capacity 125% for 10min
150% for 10Sec
8 Transient Response Remain within ± 1% and recover to 100%
within ¼ Cycle
9 Crest factor 3:1
10 Duty Continuous
11 Static by pass to be provided
12 Efficiency

Converter > 94%

Inverter > 93%
Overall > 87%
13 Max Ambient Temp and 45°C & 100%
Relative Humidity
14 Cooling Forced air
15 Acoustic Noise Level <60db at 1.5m
16 Battery backup 60min for full load.
c) The UPS shall be complete with Isolation transformer, Converter cum Changer,
inverter, protections, indications, programming, microprocessor based monitoring and
fault diagnostic system, communication facilities, redundant control power supplies,
SMF battery, accessories and interconnecting Cables.
d) Constructional Features: The UPS shall be high quality CRCA sheet steel enclosed
suitable for floor mounting. The sheet steel shall be of 2mm thick. All sheet parts shall
undergo phosphating process to ensure anti rust conditioning and superior finish.
Premier quality powder coating shall be applied. The degree of protection shall be IP
54. The UPS panel shall be provided with two earthing terminals. The final finish shall
be Light Grey Semi Glossy Shade 631 of IS 5.
Converter cum Charger:
When normal AC supply is available, DC power for the inverter is fully supplied by the
converter and the battery is kept under float charge. On main supply failure, the battery
shall be automatically connected to the Inverter without interrupting the output voltage for
critical load. Similarly on normalization of AC power, the DC load shall be transferred to
the converter and battery shall be put on float charge without interruption at output side.
The converter cum charger shall be designed to deliver the full load DC required by the
inverter and charging of the battery. Battery charging shall be with float & boost mode
selection with current limit.
1) Inverter:
The static inverter shall convert the power from the converter/battery into stable AC
power which is supplied to load. The inverter shall be with the latest IGBT PWM
technology with specially designed output transformer.
2) Battery Bank:
Batteries shall be 12V, SMF (sealed maintenance free) type. The Qty & AH of batteries
shall be suitable for backup period of 60 minutes for full load.
The battery shall be rated to provide full load power for required backup time on AC
power failure. After delivering this amount of power, the battery shall be suitable for
recharging through converter cum charger on AC power restoration. The battery shall
be mounted on a separate rack. The battery bank shall be complete with battery stand,
interlinks and UPS to battery interconnecting cable.
3) Other features:
The other features of UPS shall be as follows:

i) Microprocessor based Control, monitoring and fault diagnostics.

ii) Comprehensive LED mimic and LED display with keypad Control to enable the
following:
a) Date-time stamped event recording and logging in a non-volatile memory
b) Programming and Monitoring of various system parameters
c) Status indications and number of LCD digital meters.
iii) 100% Nonlinear local handling Capability with low distortion of less than 5% and
high crest factor of 3:1
iv) RS 232c/ RS 485 interface port.
v) Front access layout.
vi) Inbuilt line chokes for main power supply.
vii) Indications:
• Mains ‘ON’
• Converter ‘ON’
• Inverter ‘ON’
• Battery Low
• Over load
• Inverter Trip
• Charger Trip
• Output ‘ON’
viii) Protections:
• Incomer MCCB with Overload & Short circuit releases
• Outgoing MCCB with Overload & Short circuit releases
• Battery MCCB with Overload & Short circuit releases
• Input under/over voltage
• Converter over voltage
• Battery Low
• Battery charging current limit
• Output under voltage
• Output over voltage
• Output over load
• Output short circuit
• Inverter over temp
• Single phase prevention
Alarm and trip conditions shall be separately enunciated.
The backup period shall be minimum 2 hr on full load.
Testing Requirements
The Contractor shall carry out specified tests as follows in addition to any tests stated or
implied by the foregoing sections of this clause.
The tests shall be carried out on the fully assembled unit utilising the batteries that are to
be supplied with the unit.
The Contractor shall demonstrate the following on a minimum:

• change-over from full load with mains present to full load on battery supply;
• carry out a discharge test on the system at full load and for the specified duty bridging
time period;

• carry out recharge test after operation for the specified duty bridging time at full load.
The UPS shall supply the full load during the recharge cycle.
• Demonstrate the full functioning of the PLC& SCADA system while running on UPS
power.
• All Routine/acceptance tests as per relevant Indian / International standards shall be
carried out in the presence of Employer / his Employer Representative
Quality Assurance/Quality Control (QA/QC)
QA/QVC shall comply with the Contract, with particular requirements specific to the
equipment or service being provided as outlined below for PLC & SCADA systems and
other equipment that shall comprise the instrumentation and automation system under this
contract. The quality assurance/control procedures shall include, but not be limited to the
following:
• Continuity and Wiring tests;
• Insulation and High Potential Testing;
• Complete functional test inclusive of calibration;
• Packaging and Shipping;
• Welding;
• Cleaning and Painting.
The quality assurance/quality control documentation shall include, but not be limited to the
following:
• Material Certifications;
• Shop Test Reports;
• All other documentation required by applicable codes and standards.


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13 Standard Specifications - Civil & Structural Works ....................................................... 1

Section VI-B: Employer’s Requirement ii Bid Document

14.18 Bio Gas Scrubbers (For H2S Gas Removal)........................................................ 299

Section VI-B: Employer’s Requirement iii Bid Document

16.6 Electromagnetic Flow Meter................................................................................ 439

Section VI-B: Employer’s Requirement iv Bid Document

13 Standard Specifications - Civil & Structural Works

13.1.1 Notes to the Standard General Technical Specification

13.1.2 Specification Drawings

13.1.3 Geo-Technical Studies

Section VI-B: Employer’s Requirement 13-1 Bid Document

Materials shall be transported, handled and stored in such a manner as to prevent

13.1.5 Samples and Tests of Materials

13.1.6 List of important Indian Standards

Section VI-B: Employer’s Requirement 13-2 Bid Document

Table 13-1 List of IS

Sr. IS Code No.

Section VI-B: Employer’s Requirement 13-3 Bid Document

Sr. IS Code No.

Section VI-B: Employer’s Requirement 13-4 Bid Document

mm Millimetre CI Cast Iron

13.1.8 Design Standards

Section VI-B: Employer’s Requirement 13-5 Bid Document

13.2.2 Existing Services, Utilities and Structures

13.2.3 Temporary Fencing and Hoarding

13.2.4 Demolition and Reinstatement

Dismantling shall be commenced in a systematic manner. All materials which are to be

13.2.5 Removal of Debris

Section VI-B: Employer’s Requirement 13-6 Bid Document

13.2.8 Asbestos Based Materials

Asbestos based materials may be present in buildings to be demolished under this

13.3 Earthworks and Excavation

13.3.1 Relevant IS Codes

IS: 1200 : Method of Measurement for Building Works

Section VI-B: Employer’s Requirement 13-7 Bid Document

13.3.2 Site Clearance

13.3.3 General Excavation

The excavations shall be carried out systematically. No under-pining or undercutting will

Section VI-B: Employer’s Requirement 13-8 Bid Document

13.3.5 Classification of Earth Works

The earthwork shall be classified under the following main categories:

13.3.5.1 All types of soils, murum, boulders

13.3.5.2 Soft rock

13.3.5.3 Hard Rock

Section VI-B: Employer’s Requirement 13-9 Bid Document

13.3.6 Excavation Side Slopes

13.3.7 Undercutting of Adjacent Works

13.3.8 Storage and Transport

13.3.9 Excess excavation to be made good

13.3.11 Disposing Excavated Material

Section VI-B: Employer’s Requirement 13-10 Bid Document

Pumping arrangements shall be adequate to ensure no delays in construction.

When there is a continuous inflow of water and quantum of water to be handled is

13.3.14 Local Rules and Regulations

Section VI-B: Employer’s Requirement 13-11 Bid Document

13.4 Back-Filling and Filling

Section VI-B: Employer’s Requirement 13-12 Bid Document

Excavated foundations shall be inspected and approved by the Engineer before

13.4.3 Site Grading

13.4.4 Roads and Parking Areas

13.4.5 Rain Water Discharge

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