Volume 2 - PK 5 - Bhairoba STP To Biddders-Min PDF

ŽŶƐƚƌƵĐƟŽŶŽĨ75D>Bhairoba^dWŽŶKĂƐŝƐ
/ŶĐůƵĚŝŶŐZĞŚĂďŝůŝƚĂƟŽŶŽĨKalyani Nagar IPS

sŽůƵŵĞ͗ϮͲŵƉůŽǇĞƌΖƐZĞƋƵŝƌĞŵĞŶƚƐ
(Section -VI A)
WƌŽũĞĐƚ͗ ŵƉůŽǇĞƌ͗
WŽůůƵƟŽŶďĂƚĞŵĞŶƚŽĨ dŚĞDƵŶŝĐŝƉĂůŽŵŵŝƐƐŝŽŶĞƌ͕
ZŝǀĞƌDƵůĂDƵƚŚĂĂƚWƵŶĞ WƵŶĞDƵŶŝĐŝƉĂůŽƌƉŽƌĂƟŽŶ
ǆĞĐƵƟŶŐŐĞŶĐǇ͗ /ŵƉůĞŵĞŶƟŶŐŐĞŶĐǇ͗
EĂƟŽŶĂůZŝǀĞƌŽŶƐĞƌǀĂƟŽŶŝƌĞĐƚŽƌĂƚĞ͕ WƵŶĞDƵŶŝĐŝƉĂůŽƌƉŽƌĂƟŽŶ
DŽ&Θ
WƌŽũĞĐƚDĂŶĂŐĞŵĞŶƚŽŶƐƵůƚĂŶƚ͗
3 H O O ) U L V F K P D Q Q ) 3 3 U R M H F W 0 D Q D J H P H Q W
& R Q V X O W L Q J ( Q J L Q H H U V )RUPHUO\ )ULVFKPDQQ 3UDEKX ,QGLD 3ULYDWH /LPLWHG 1-6(QJLQHHUV
,QGLD 3YW /WG
DecHPEHU
3)7'3$005<D
Project for Pollution Abatement of River Mula-Mutha Volume – 2 - Employer‘s Requirements
Construction of 75 MLD Bhairoba STP on DBO Basis, Including Rehabilitation of Kalyaninagar
Intermediate Pumping Stations (IPS)
Table of Contents
1 Project Requirements ......................................................................................................... 1

1.1 Background to the Project ............................................................................................. 1
1.2 Funding Agency ............................................................................................................ 2
1.3 Description of Scope of Work ........................................................................................ 3
1.4 Scope of Work .............................................................................................................. 3
1.5 Sustainability................................................................................................................. 4
1.6 Provision of Utilities....................................................................................................... 4
1.7 Independent Compliance Auditing ................................................................................ 5
2 The Site ................................................................................................................................ 7
2.1 Location of the Site ....................................................................................................... 7
2.2 Access to the Sites ....................................................................................................... 7
2.3 Site Constraints ............................................................................................................ 8
2.4 Demolition of Existing Structures at Site ....................................................................... 8
2.5 Maintenance of the Site .............................................................................................. 10
2.6 Road Works ................................................................................................................ 10
2.7 Clearance of the Site .................................................................................................. 11
2.8 Areas outside the Site ................................................................................................. 11
2.9 Environmental Mitigation during Construction ............................................................. 11
2.10 Safety and Security on Site ......................................................................................... 13
2.11 Site Working Hours ..................................................................................................... 18
2.12 Protection from Weather and Storage ......................................................................... 19
2.13 Archaeology ................................................................................................................ 19
2.14 Survey and Geotechnical Data.................................................................................... 19
2.15 Benchmark ................................................................................................................. 20
2.16 Contract Signboards / logos ........................................................................................ 20
2.17 Advertising .................................................................................................................. 20
2.18 Method Statements ..................................................................................................... 21
2.19 Smoking...................................................................................................................... 21
2.20 Blasting and the use of Explosives .............................................................................. 21
2.21 Vehicles for the Employer‘s Representative ................................................................ 21
2.22 Site and Laboratory Testing ........................................................................................ 21
2.23 Delivery to Site............................................................................................................ 21
2.24 Daily Records ............................................................................................................. 22
3 General Requirements ...................................................................................................... 23
3.1 Introduction ................................................................................................................. 23
Section VI-A: Employer‘s Requirement i Bid Document

3.2 General Design ........................................................................................................... 23

3.3 Precedence of Employer‘s Requirements ................................................................... 28
3.4 Key Programme Requirements and Staffing ............................................................... 28
3.5 Contract Management ................................................................................................ 31
3.6 Site Meetings .............................................................................................................. 32
3.7 Site Photographs and Video Recording ...................................................................... 32
3.8 Camp Facility .............................................................................................................. 32
3.9 Assistance to the Engineer ......................................................................................... 35
3.10 Instruments to be provided.......................................................................................... 35
3.11 Erection of Plant ......................................................................................................... 36
3.12 Site Labour and Supervision ....................................................................................... 36
3.13 Sub-letting .................................................................................................................. 36
3.14 Temporary Works ....................................................................................................... 37
3.15 Languages .................................................................................................................. 37
3.16 Drawings and Information to be provided .................................................................... 37
3.17 Notice of Call for Inspection ........................................................................................ 42
3.18 Quality Management System ...................................................................................... 42
3.19 Licences and Consents ............................................................................................... 51
4 Process Requirements ..................................................................................................... 52
4.1 General Requirements ................................................................................................ 52
4.2 Process Requirements ................................................................................................ 52
4.3 Influent Wastewater Characteristics ............................................................................ 54
4.4 Effluent Quality Requirements .................................................................................... 55
4.5 Dewatered Sludge Quality Requirements ................................................................... 55
4.6 Treatment Process...................................................................................................... 55
4.7 General Design Requirements .................................................................................... 56
4.8 Demolition of or Interfaces and Tie-Ins with Existing Facilities .................................... 58
4.9 Process and Facilities Description .............................................................................. 59
4.10 Flow Measurement, Sampling and Monitoring ............................................................ 78
4.11 Hydraulic Design ......................................................................................................... 79
5 Particular Civil & Structural Requirements ..................................................................... 82
5.1 Design Submissions ................................................................................................... 82
5.2 Design Standards ....................................................................................................... 82
5.3 Design Life .................................................................................................................. 83
5.4 Design Loadings ......................................................................................................... 83
5.5 Joints .......................................................................................................................... 85
Section VI-A: Employer‘s Requirement ii Bid Document

5.6 Design Criteria for Underground or Partly Underground Liquid Retaining Structures .. 85
5.7 Foundations ................................................................................................................ 87
5.8 Design Requirements ................................................................................................. 87
5.9 Materials in General .................................................................................................... 90
5.10 Samples and Tests of Materials .................................................................................. 90
5.11 Standards ................................................................................................................... 90
5.12 General Arrangement of Plant .................................................................................... 94
5.13 Orientation .................................................................................................................. 95
5.14 Buildings and Structures ............................................................................................. 95
5.15 Roadways, Pathways & Hard standings.................................................................... 100
5.16 Site Drainage ............................................................................................................ 100
5.17 Cable and Pipe Work Trenches ................................................................................ 100
5.18 Pipes and Ducts........................................................................................................ 101
5.19 Main Gate ................................................................................................................. 101
5.20 Landscaping ............................................................................................................. 101
5.21 Specification for Anti-Corrosive Internal Lining protection of Concrete Surfaces ....... 101
5.22 Hydraulic Testing of Liquid Retaining Structures ....................................................... 109
5.23 Non-Destructive Testing of RCC Structures .............................................................. 110
5.24 General Painting and Protection Requirements ........................................................ 110
5.25 General ..................................................................................................................... 110
6 Particular Mechanical Requirements ............................................................................. 118
6.1 General Requirements .............................................................................................. 118
6.2 Mechanical Requirements......................................................................................... 118
6.3 Criteria for the selection of Aeration Blowers............................................................. 120
6.4 Bio-gas System and power generation...................................................................... 120
7 Particular Electrical Requirements ................................................................................ 121
7.1 Introduction ............................................................................................................... 121
7.2 Scope ....................................................................................................................... 121
7.3 Basis of Design ......................................................................................................... 124
7.4 Document and Calculation ........................................................................................ 124
7.5 Emergency Stop Equipment and Local Isolation ....................................................... 124
7.6 Emergency Power Supply ......................................................................................... 125
7.7 Electrical Power Supply Design ................................................................................ 125
7.8 Power System Studies and Selective Coordination ................................................... 126
7.9 Power Factor Correction and Harmonic Mitigation .................................................... 127
7.10 Switchgear and Controlgear...................................................................................... 127
Section VI-A: Employer‘s Requirement iii Bid Document

7.11 High Voltage (HV) Switchgear and Controlgear Assembly ........................................ 127
7.12 Measurement of Electricity Usage............................................................................. 129
7.13 Cabling ..................................................................................................................... 129
7.14 Earthing .................................................................................................................... 131
7.15 Lightning Protection .................................................................................................. 131
7.16 Building and Site Services ........................................................................................ 132
7.17 Miscellaneous Materials and Accessories ................................................................. 138
8 Particular Instrumentation & Control Requirements .................................................... 163
8.1 Introduction ............................................................................................................... 163
8.2 Reference Standards ................................................................................................ 163
8.3 Project Requirements ............................................................................................... 166
8.4 Qualification Criteria for Instrumentation vendor, Integrator and Automation vendor,
Integrator, and Lab equipment Vendor .............................................................................. 168
8.5 Submissions to be made by the contractor during the contract period:...................... 169
8.6 Design Requirements for Instrumentation, Control & Automation system ................. 172
8.7 General Technical Requirements .............................................................................. 173
8.8 Metering Bases And Chart Units ............................................................................... 179
8.9 Process Connection & Instrument Hook Up .............................................................. 180
8.10 Process Instrumentation ........................................................................................... 208
8.11 Installation Requirements for Instruments ................................................................. 215
8.12 Control & Automation ................................................................................................ 217
8.13 Closed Circuit Television System .............................................................................. 221
9 Inspection, Testing and Commissioning Requirements .............................................. 226
9.1 Inspection and Testing During Manufacture .............................................................. 226
9.2 Field test ................................................................................................................... 237
9.3 Reinforced Cement Concrete Pipes .......................................................................... 238
9.4 Steel Cylinders Pipes and Specials ........................................................................... 239
9.5 Cast Iron / Ductile Iron Pipes .................................................................................... 240
9.6 Chlorination and Gas Pipeline System ...................................................................... 240
9.7 Bio Gas Engine and Power Generator (for contracts that include power generation) 241
9.8 Mechanical Equipment .............................................................................................. 243
9.9 Tests at Site .............................................................................................................. 243
9.10 Pumps, Piping and Valves ........................................................................................ 244
9.11 Motors....................................................................................................................... 244
9.12 Cranes ...................................................................................................................... 244
9.13 Screens .................................................................................................................... 244
Section VI-A: Employer‘s Requirement iv Bid Document

9.14 Gates ........................................................................................................................ 244

9.15 Reinforced Cement Concrete Pipes .......................................................................... 244
9.16 Steel Cylinder Pipes and Specials ............................................................................ 245
9.17 Cast Iron, Ductile Iron Pipes and Fittings .................................................................. 246
9.18 Manufacturer's Works Acceptance Tests on Electrical Equipment ............................ 247
9.19 Manufacturer's Works Acceptance Tests on Instrumentation, PLC, SCADA and
Associated Equipment....................................................................................................... 247
9.20 Manufacturer's Works Acceptance Tests on Uninterruptible Power Supplies ............ 253
9.21 Inspection at Site ...................................................................................................... 254
9.22 Plant Protection on Site ............................................................................................ 254
9.23 Erection staff ............................................................................................................. 254
9.24 Erection and Building-in ............................................................................................ 255
9.25 Civil Inspection (Water Leakage Test)....................................................................... 257
9.26 Site Acceptance Test Document ............................................................................... 258
9.27 Tests on Completion ................................................................................................. 258
9.28 Dry Test Requirements ............................................................................................. 261
9.29 Process Plant Item / Equipment ................................................................................ 263
9.30 Hydraulic Wet Test Requirements............................................................................. 263
9.31 Safety Audit .............................................................................................................. 263
9.32 Process Wet Tests (with Raw Sewage) .................................................................... 264
9.33 Effluent Quality Criteria for Passing the Tests on Completion ................................... 265
9.34 Co-operation with other Contractors in the Execution of their Tests .......................... 265
9.35 Tests After Completion ............................................................................................. 265
9.36 Performance Certificate ............................................................................................ 268
10 Training Requirements ................................................................................................... 269
10.1 General ..................................................................................................................... 269
10.2 Off the Job Training .................................................................................................. 269
10.3 On The Job Training ................................................................................................. 270
10.4 Training Programme ................................................................................................. 272
10.5 Training Personnel .................................................................................................... 273
10.6 Instrumentation, Control & Automation Training requirements .................................. 273
10.7 Training Assessment ................................................................................................ 274
11 Operation and Maintenance ........................................................................................... 275
11.1 Operation Service Performance Requirements ......................................................... 275
11.2 Operation Management Requirements ..................................................................... 280
11.3 Operation and Maintenance Plan .............................................................................. 291
Section VI-A: Employer‘s Requirement v Bid Document

11.4 Operation Management Plan .................................................................................... 295

11.5 Maintenance Management Plan................................................................................ 296
12 Handing Over................................................................................................................... 303
12.1 General ..................................................................................................................... 303
12.2 Residual Life and Planned Asset Replacement at Handback .................................... 303
12.3 Expiry of the Operation Service Period and Joint Inspection ..................................... 304
12.4 Tests Prior to Contract Completion ........................................................................... 304
12.5 Handback of the Works to the Employer ................................................................... 305
12.6 Training of the Employer‘s Operators ........................................................................ 305
12.7 Final Documentation ................................................................................................. 305
APPENDIX 1 – DESIGN STAGE CONTRACTOR’S DOCUMENTS ....................................... 307
APPENDIX 2.1 – DESIGN EFFLUENT QUALITY DURING OPERATION AND
MAINTENANCE ................................................................................................................ 312
APPENDIX 2.2 – PERFORMANCE TESTS DURING PLANT PROVING PERIOD ........... 313
APPENDIX 3 – MONTHLY STATUS REPORT IN OPERATIONS PERIOD ........................... 326
APPENDIX 4 – SAMPLE ASSET HIERARCHY ..................................................................... 332
APPENDIX 5 – TYPICAL PLC INPUT/OUTPUT (I/O) SCHEDULE ........................................ 333
APPENDIX 6 – LIST OF PREFFERED SUPPLIERS .............................................................. 336
APPENDIX 7A – ENVIRONMENTAL MONITORING PLAN ................................................... 361
APPENDIX 7B – ENVIRONMENTAL MANAGEMENT PLAN ................................................ 364
APPENDIX 7C – MONITORING FORM (during Construction Phase) ................................. 369
APPENDIX 7D – MONITORING FORM (during Operation Phase) ...................................... 372
APPENDIX 8 – LOGO FOR THE PUBLIC RELATIONS ........................................................ 375
Section VI-A: Employer‘s Requirement vi Bid Document

1 Project Requirements
1.1 Background to the Project
Pune is the second largest city in the Indian state of Maharashtra after Mumbai and the
ninth most populous city in the country with a population of 3.12 Million (2011 census)
and area of 243.8 km2.
The Rivers Mula Mutha pass through Pune City. The total length of River Mula, River
Mutha, and River Mula Mutha in PMC jurisdiction is 48 km. Discharge of partially treated
or untreated municipal sewage into the water bodies (natural drains, lakes and rivers), is
leading to increased level of pollution. Increasing water use by the growing population as
well as that for economic development has led to increase in sewage volume, ultimately
increasing its discharge into the water bodies.
The total sewage treatment capacity of the existing functional sewage treatment plants
(STPs) is 477 MLD, while generated sewage volume at present is estimated at 728 MLD.
Sewage Generation volume in 2027 is estimated to be 873 MLD in assumptions of a
high annual population growth ratio of 2.5%. Therefore, it is urgent for the Pune
Municipal Corporation (PMC) to provide expansion/ augmentation of the existing
sewerage facilities including sewage collection systems, intermediate pump stations and
sewage treatment plants. River Mula-Mutha catchment in Pune has been identified as a
polluted river by National River Conservation Directorate (NRCD) of Ministry of
Environment, Forests and Climate Change (MoEF&CC), Government of India.
MOEF&CC is supplementing the efforts of the State Governments in abatement of

pollution of identified stretches of various rivers through the National River Conservation
Plan (NRCP) on cost sharing basis between the Central and State Governments. NRCD
has received a Japanese ODA Loan to finance the Project for Pollution Abatement of
River Mula-Mutha in Pune.
The construction works has been divided into 13 Contract Packages (3 packages for
sewer and 7 packages for STP and IPS, one package for community toilet facility,
Central SCADA system, GIS/MIS, and for public participation and capacity building,
each) as follows:
Package 1 : (LCB with Single Stage Two Envelope): Construction of Main/Sub-

main and Branch sewers in Baner area including the crossings of
rivers/bridges and others
Package 2 : (ICB with PQ followed by Single Stage Two Envelope): Construction
of Main sewers in the left bank area of Mutha River and Mula-Mutha
River, and Central area of PMC including the crossings of
rivers/bridges and others using pipe-jacking method
of Main sewers in the right bank area of Mutha River and Mula-
Mutha River including the crossings of rivers/bridges and others
using pipe-jacking method
of 2 STPs at Mastya Beij Kendra and Mundhwa with respective
treatment capacities of 7 MLD and 20 MLD
of STP at Bhairoba Nallah with the treatment capacity of 75 MLD and
Kalyani Nagar Intermediate Pump Station (IPS)
Section VI-A: Employer‘s Requirement 1-1 Bid Document

Part 1: Project Requirements

of STP at Naidu with the treatment capacity of 127 MLD including
New Kasba, Old Kasba and Topkhana IPSs
of 2 STPs at Vadgaon Bk and Warje with respective treatment
capacities of 26 MLD and 28 MLD
of 2 STPs at Tanaji Wadi and Dhanori with respective treatment
capacities of 15 MLD and 33 MLD
of 3 STPs at Botanical Garden, Baner and Kharadi with respective
treatment capacities of 10 MLD, 25 MLD and 30 MLD
Package 10 : (LCB with Single Stage Two Envelope): Construction of Community
Toilet Facilities in Slum areas and fringe villages
Package 11 : (ICB with PQ followed by Single Stage Two Envelope): Installation of
the Central SCADA system
Package 12 : (LCB with PQ followed by Single Stage Two Envelope): Capacity
Development of NRCD & PMC in application of GIS/MIS and Asset
Management for sewers and STPs/IPSs and its implementation
Package 13 : (LCB with Single Stage Two Envelope): Strengthening in Public
awareness/participation and institutional capacity, and facilitation of
implementation of Environmental Management Plan (EMP), and
Environmental Monitoring Plan (EMoP)
The contractors‘ works for Package 4 to Package 9, and Package 11 will include O&M of
STPs for ten years after construction / installation of the facilities.
1.1 Objective of this Package
The main objectives of this package include:

 Demolition and disposal of existing structures on the Site, including site clearance
removal of bushes and trees;
 Construction of a new treatment facility for the design capacity specified that will treat
the Influent and Sludge to the standards required by the Employer.
 Operation and maintenance of the facility for a period of 10 years including 1 year of
defect liability period following the Design-Build Period, including disposal of
screenings, grit and sludge produced;
 Rehabilitation of existing Intermediate Pumping Stations at Kalyani nagar as per
Employer‘s Requirement.
 Hand back of the Works to the Employer in a well maintained and operating condition
at the end of the Contract.
Throughout the construction and operation of the project the requirements of all
approvals and consents and all relevant legislation and environmental regulations must
be complied with.
1.2 Funding Agency
Funds for Contract are being provided by Japan International Cooperation Agency
(JICA) of Japan.

1.3 Description of Scope of Work
The Design Build scope comprises the design, specification, procurement, supply,
construction, commissioning, testing, operation and maintenance of a fully functioning
wastewater treatment facility which is fit-for-purpose including all necessary pumping,
sludge digestion and dewatering plant, with associated power generation from biogas.
The Contract also includes 10 years of operation and maintenance of the fully
functioning wastewater treatment facility, including disposal of grit, screenings and the
final dewatered and stabilized sludge.
The Site is located within an existing defunct pumping, which is to be demolished; the
site is located opposite to an existing 130 MLD STP.
1.4 Scope of Work
1.4.1 Bhairoba Sewage Treatment Works
 Construction of STP at Bhairoba with the treatment capacity of 75 MLD and

Operation and Maintenance for 10 years including Defect liability period.
 Demolition of existing Non-Functional Pumping Station for the proposed 75 MLD STP
Works.
 Total area available for the construction of STP is approximately 2.19 Ha. This area
needs to accommodate the Proposed 75 MLD STP (Year -2027).
 Treated Sewage after Disinfection would be discharged into Mula-Mutha River.
The Works shall be constructed in 2 Stages as follows:
Stage 1
 Emptying the redundant tanks (including desludging where required), demolishing

the structures and utilities within the site area, site clearance,
 Ground preparation and compacting to meet the requirements set out in Civil
Specifications. All equipment will be stored at a place determined by the Contractor
in a safe and approved manner prior to authorise and legal disposal off site.
 Provision of retaining wall to the site boundary exposed to the river and adjacent
Nallah (approximately 300 m).
Stage 2
 Construction of the 75 MLD sewage treatment facilities including preliminary

treatment, biological treatment, sludge treatment and dewatering for the design flows
and loads specified in Part 4.
 Construction of an administrative building-cum-laboratory, a G+1 storey building with
each floor of 150 Sqm built up area shall be provided to accommodate administrative
block for the 75 MLD STP. On the ground floor there shall be parking place and
laboratory and on the first floor there shall be conference room, PLC & SCADA
control room and Engineer‘s rooms.
 Testing and Commissioning
1.4.2 Intermediate Pumping Station (Kalyani Nagar)
 Rehabilitation of Kalyani Nagar Intermediate Pumping Station (IPS) and Operation

and Maintenance for 10 years.

 The Contractor will be responsible for taking over and the Operation and
maintenance of all existing facilities at Kalyaninagar Intermediate Pumping Station.
 Contractor shall survey and submit structural stability report of existing structure at
Kalyaninagar and accordingly carry out any repairs if required in consultation with
Employer and will be paid under provisional sums for this purpose.
 Prior to Commissioning, the Contractor in addition to particular requirement specified
in this volume shall carry out repairs or replacement, if required to the station and site
so that all equipment will be in good operating condition and suitable for
commissioning and complying with all Operation and Maintenance requirements. The
scope of work to the station and site prior to commissioning will be agreed between
the Contractor and Employer and paid for under a Provisional Sum for this purpose.
 During the Operation and Maintenance period any required plant replacement of the
existing facilities will be agreed with the Employer and paid for under a Provisional
Sum for this purpose. The Contractor will be otherwise be fully responsible for
Operation and Maintenance of existing facilities in accordance with the requirements
of Contract.
1.5 Sustainability
The Contractor shall design, construct, and operate the Works to ensure that the
infrastructure that is procured through this assignment is sustainable over the long term.
The Contractor shall educate themselves on the role of asset management systems in
achieving this objective. When decisions are to be made by PMC throughout the duration
of the Contract, the Contractor shall provide information to facilitate an informed
decision-making process that is based on the long-term sustainability of the
infrastructure.
1.6 Provision of Utilities
1.6.1 Water Supply at Site
 The Contractor shall make his own arrangements for water supply at the site for the
duration of the Design Build period.
 The Contractor shall ensure the quality of the water remains suitable for the purpose
for which it is intended. The Contractor shall also conduct monthly test for water
quality and comply with the quality requirements.
 Wastewater shall be disposed clear of the Site to the satisfaction of the Engineer so
as to maintain the hygienic condition at the site and no damage or complaint.
1.6.2 Electricity for Contractor's Use on Site
a) During Construction:
The Contractor shall arrange and provide at his own cost electric connection of
suitable capacity from Electricity Supply Agency. All electricity charges during
construction period shall be borne by the Contractor. The Contractor will also keep
ready Generators of adequate capacity as standby arrangement, in case of electricity
failure during construction for running of pump sets, vibrators, mixer, needle sets,
welding sets and other electrically operated construction equipment etc. at his own
cost. Employer will issue a certificate in favour of the Contractor for obtaining a
temporary electric connection from Electricity Supply Agency. The cabling for electric

connection shall be arranged by the Contractor himself at his own cost. The non-
availability /approval of electric connection shall be no excuse for delay in completion
of work.
b) During Commissioning:
No payment on account of electricity charges is admissible to the Contractor.
c) Defect Liability Period, O&M period:
Permanent power connection(s) in the name of the Employer, upon instruction from
the Contractor, will be arranged by the Employer as per the requirement from
Electricity Supply Agency. For permanent connection(s) all the statutory
deposits/fees and associated charges as required by the Electricity Supply Agency
and electrical inspector shall be paid by the Employer directly. However, necessary
approval, follow up and liaison with statutory authorities for the proposed electrical
power distribution system are in the Contractor's scope. Approval of entire electrical
installation including gas engines, etc. shall be obtained by the Contractor at his own
cost from electrical inspector and no cost will be reimbursed by the Employer on this
account.
During the 10 Years of Operation & Maintenance including one year of DLP, PMC
shall pay the electricity charges to the Electricity Supply Agency directly but this shall
be:
i. Lesser of the actual power consumed during the period and the power charges
calculated on the basis of net power consumption guaranteed by the Contractor.
The net power consumption shall be adjusted for the quantity and quality of the
raw sewage treated at the STP, as per Volume 1.
ii. Any additional electricity charges on account of the actual power consumption
exceeding the guaranteed net power consumption are to be borne by the
Contractor and the Employer shall recover such additional amount from
Contractor.
iii. The Employer shall not pay any penalties due to excess power consumption etc.
imposed by the Electricity Supply Agency.
1.7 Independent Compliance Auditing
The STP shall be inspected annually by the Engineer and an Independent Auditing
Body approved and overseen by the Engineer. The purpose of the annual inspection
shall be to verify that the operation and maintenance of the treatment facility is
performed in conformance to the requirements of the Contract. The Contractor shall
develop a compliance auditing plan which shall address:
 Tests to be conducted for each piece of equipment to determine their physical and
operational conditions;
 The physical and operational conditions and general status of repairs of all
equipment, buildings, structures, pavements, grounds, utility lines, spare parts,
inventories, etc.
The Engineer and the Independent Auditing Body shall prepare a detailed report
documenting the findings of the inspection. The report shall include an assessment of
the current conditions of each item or component, its estimated remaining service life,
and whether the current conditions are consistent with the maintenance and general

upkeep requirements of the contract and in accordance with the Contract. A copy of the
report shall be submitted to Employer for review.
In the event that such inspections reveal work not in accordance with the Contract or
lack of repairs or necessary maintenance to the STP or equipment, the Engineer shall
bring to the attention of the Contractor such items and the Contractor shall perform the
repairs and maintenance activities identified by the inspection.
The annual inspection shall also review:

 Laboratory conditions and procedures – All laboratories where tests are conducted
on samples shall be inspected to ensure conformance and compliance with
laboratory procedures and requirements.
 Chemicals - All areas where chemicals are stored or used and hazardous materials
procedures and records shall be inspected to ensure compliance with the O&M
Manual and all applicable regulations and standards.
 Operation Service records - All records kept by the Contractor, including safety and
emergency conditions records shall be reviewed.
 O&M Plan – conformance to approved plan.
 Training and staffing plans – conformance with approved training and staffing plans.
 Health and Safety Plan.

2 The Site
The existing defunct pump house boundary, the Site boundaries, and other relevant
structures or areas are shown on the drawings in Background Information.
The Site is in clear possession of the Employer, and the Contractor shall take
possession of the Site as specified in the Contract Data and shall be responsible for the
Site.
The Site is opposite to the existing 130 MLD STP, and is where the defunct pumping
station is located.
2.1 Location of the Site
The project site is within the Pune Municipal Corporation (PMC) Area.
Location Latitude Longitude

Bhairoba STP 18°32'26.23" N 73°54'8.14" E
Kalyani Nagar IPS 18°32'33.52" N 73°54'15.87" E
2.2 Access to the Sites
2.2.1 General
Contractor shall not have the right to access any areas outside the Site defined as this
may interfere with existing operations. This includes the existing access area to the
facility.
The Contractor shall make reasonable endeavours to minimise the impact on the
Employer‘s activities during the construction of any works on the Employer‘s operational
premises or works which have an impact on access to the Employer‘s premises. The
Contractor shall liaise with the Employer to agree the construction methodology and
access arrangements. Immediately on completion of the work the sites shall be left in a
tidy state and cleared of construction debris.
2.2.2 STP at Bhairoba
Construction of STP at Bhairoba with the treatment capacity of 75 MLD
Sr.
Name of STP Location Total Area in Ha
No.
North Main Road, Existing defunct
Bhairoba-
1 Bhairoba Pump House, Koregaon 2.19
75MLD
Park.
2.2.3 IPS’s for Kalyani nagar
i. Rehabilitation of Kalyani Nagar IPS.

Part 2: The Site
2.2.4 Access for the Employer and Engineer
The Contractor shall permit the Employer and the Engineer and any person authorised
by the Employer or the Engineer including workmen of the Employer, other Contractors
or utility undertakings access for the purposes of the Contract to all areas of the Site and
to any additional accommodation or temporary way leave for the duration of the Contract
period.
2.3 Site Constraints
2.3.1 Access
i. A sites constraint drawing PF-D-PARMM-5-43-400-Y-003 is included for information

to the Contractor. The Contractor will take full account of these constrains in the
preparation and pricing of his tender.
2.3.2 Tree Cutting:
It is a requirement of the Contract that the Contractor obtains consent for removal of any
trees and shall follow the instructions of the consent. The Contractor shall allow an
appropriate amount of time in his programme for liaising with the authority, including
organising a Site visit with the authority, and obtaining the necessary consent. A
tentative number and location of Trees are shown on drawing no PF-D-PARMM-5-43-
400-Y-001 for information to the Contractor; however, the Contractor must verify the
details of trees on site before commencing the work. All the cost and fees related to tree
cutting shall be borne by the Contractor and no reimbursement on account of this will be
made by the Employer.
2.4 Demolition of Existing Structures at Site
2.4.1 General
The Contractor shall obtain written consent from the Employer prior to commencing any
demolition.
The Scope of Demolition shall include the following, but not limited to:
i. Demolition, removal and disposal of existing structures within the site identified on
drawing no. PF-D-PARMM-5-43-400-Y-0001 including all other underground
structures like manholes, pipe works, services etc. which are required to be
demolished to accommodate the new 75 MLD treatment facility.
ii. It shall include the excavation of all underground materials relating to the existing
facility to natural ground and disposal of surplus materials off site to an appropriate
disposal location, leaving the ground in a tidy finished state.
iii. Prior to commencement of the demolition, the Contractor shall carry out all necessary
pre-demolition surveys to ensure that demolition will be carried out correctly and
safely.
iv. The Bidder shall indicate the salvage value of the demolished items. However, prior
to the pre-bid meeting of this package, the Employer may remove any equipment or
materials he so chooses.

Part 2: The Site
2.4.2 Existing Services, Utilities and Structures
i. Where information is provided concerning existing services, this information must be

verified by the Contractor with the relevant service provider or authority as its
accuracy or relevance cannot be guaranteed.
ii. 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 minimise dust-nuisance.
iii. The Contractor shall relocate and protect all existing utilities and underground
services that need to be retained for future works.
iv. The contractor shall dismantle the existing Electrical equipment at Bhairoba Pump
house e.g.11kV cables, high voltage equipment‘s (e.g. Oil circuit breakers etc.),
Transformers, low voltage switchboards, Capacitor banks, APFC panels, Motors,
distribution boards, low voltage cables, Cable trays and its accessories, Battery bank
and battery chargers, earthing material etc. All of these dismantled plant and
machinery will be moved to PMC designated store.
v. The contractor shall dismantle the existing 11kV Express feeder originating from
22/11 kV Koregaon Substation of MSEDCL and terminated to the Air Break (AB)
Switch/Metering kiosk at Bhairoba pumping station. All the cables originating/
terminating from 22/11 kV Koregaon Substation of MSEDCL that are within the
proposed plot area of 75 MLD Bhairoba STP and feeding other than existing defunct
pumping station shall be re-routed or re-laid as per standard engineering practice, in
consultation with Engineer and MSEDCL, as applicable.
vi. Contractor shall ascertain the safety of the 11 kV, 130 MLD Bhairoba STP feeders
and dismantle, reroute, provide straight through joint and terminate this feeder for the
stretch within the proposed plot area of 75 MLD Bhairoba STP, in consultation with
Engineer and MSEDCL, as applicable.
vii. All the dismantled cables pertaining to existing defunct pumping station shall be
recovered after excavation, transported to and stored at PMC‘s designated store.
viii. The contractor shall dismantle the existing Electrical equipment‘s at Kalyaninagar
IPS; e.g. High voltage equipment‘s (e.g. Load Break Switch etc.) as applicable, in
consultation with Engineer and MSEDCL.
ix. In case cables other than MSEDCL cables that are to be retained, are damaged
during construction or Operation and maintenance period then contractor shall
supply, lay, terminate and test all these damaged cables by following standard
engineering practice in consultation with the Engineer, as applicable.
2.4.3 Safety:
Following precautions should be taken by the Contractor before any demolition work is
commenced and during the process of the work:
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.

Part 2: The Site
2.4.4 Demolition and Reinstatement
i. The Contractor shall demolish the required structures in accordance with the detailed
execution plan submitted to the Engineer.
ii. 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.
iii. The Contractor shall either backfill excavated areas and voids due to demolition /
removal of materials or barricade the excavated area immediately for safety purpose.
2.4.5 Removal of Debris
i. The Contractor shall carry out demolition in a prudent manner and shall dispose of
materials according to local statutory procedures. The Contractor shall identify
building materials and take appropriate measures to handle them in a safe manner.
ii. The Contractor shall be responsible for determining the location/land and proper
disposal route for all debris and waste materials arising as a consequence of
demolition including sludge disposed on site if any, and for paying all tipping fees and
other associated costs. The Contractor shall dispose of any hazardous materials off-
site in accordance with existing laws and regulations. All permissions and consents
from respective authorities shall be obtained by the contractor.
iii. 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.
2.4.6 Asbestos Based Materials
i. Asbestos based materials may be present in buildings to be demolished under this

contract.
ii. If any suspected asbestos based materials are discovered during demolition work
this shall be reported immediately to the Engineer.
iii. Removal of asbestos based materials shall be carried out by a specialist, licensed
sub-contractor prior to any other works starting in the location
2.5 Maintenance of the Site
The Contractor shall be responsible for maintaining all the site structures, buildings,
equipment, contract display board and related services until expiration of the Contract
period or until such time as the aforementioned facilities are removed with the Engineer‘s
prior approval, whichever is earlier.
2.6 Road Works
The Contractor shall obtain all permits required for carrying out works such as
excavation on public roads and shall liaise with the appropriate authorities with regard to
the timing and execution of the road works.
The Contractor shall be responsible for establishing and maintaining temporary road
diversions for the duration of the road works. The road shall be kept open at all times
during the road works period, and the work shall be carried out in such a manner as to
minimise the disruption to traffic. The Contractor shall reinstate all the roads to their
original condition to the satisfaction of the Engineer after completion of works.

Part 2: The Site
2.7 Clearance of the Site
i. The Contractor shall clear the Site to the extent required by the Engineer for
checking the setting-out.
ii. Clearance of the Site shall also include demolition and removal of all articles, objects
and obstructions which are expressly required to be cleared.
iii. The Contractor shall ensure that the parts of the Site to be occupied by the
Permanent Works are clear and shall maintain the remainder of the Site as may be
required for access and temporary works areas.
iv. The Contractor shall remove the material arising from such clearance and dispose of
it in a manner and at a location that are both in compliance with all applicable laws
and regulations.
v. The Contractor shall backfill with appropriate specified materials and procedures,
those cavities and losses of soil which result from clearing the parts of the Site not
subsequently to be occupied by the Works.
vi. The Contractor shall not clear the Site of any existing structure(s) without the prior
written instruction of the Engineer.
vii. On completion of the Works, the Contractor shall clear any temporary works areas
and temporary access roads and reinstate the areas to their original condition and to
the satisfaction of the Engineer.
2.8 Areas outside the Site
In the event of the Contractor making use of any special or temporary way leave or
accommodation acquired by him or any pit for the disposal of surplus materials, or any
borrow pit or quarry, he shall obtain the written consent of the owner, occupier or
authority having charge of the land in which such way leave, accommodation, or pit is
situated and shall make a written record, acknowledged and signed by the owner, of the
condition of the surface of that land before entering thereon, with liberal use of
photographs.
The Contractor shall permit the Employer and the Engineer and any person authorised
by the Employer access for the purposes of the Contract to any such special or
temporary way leave or additional accommodation.
In the event of the Contractor making use of any special or temporary way leave or
additional accommodation made available to him by the Employer for the purpose of the
Contract, the land in which such way leave or accommodation is situated shall be
deemed to be part of the Site. The Contractor shall restrict his activities to within this
Working Area. On completion of the works in this area, the Contractor shall reinstate the
area to its original condition to the satisfaction of the Engineer. For the purposes of this
Clause, ―accommodation‖ shall be deemed to include housing, offices, workshops,
warehouses, and storage areas.
2.9 Environmental Mitigation during Construction
2.9.1 Protection of Environment
 The Contractor shall take all reasonable steps to protect the environment on and off
the Site and to avoid damage or nuisance to persons or to property of the public or
others resulting from pollution, noise or other causes arising as a consequence of his
methods of construction, operation and for demolishing existing structures.
 During the contract, the Contractor and his Subcontractors shall abide at all times by
all existing enactments on environmental protection and rules made there under,

Part 2: The Site
regulations, notifications and bye-Laws of the state or central government, and any
other Law, bye-Law, regulations that may be passed or notification that may be
issued in this respect in future by the state or central government.
 Principal environmental regulations include but are not limited to:
Table 2-1 Environmental Regulations
Year Environmental Regulations

1974 The Water (Prevention & Control of Pollution Act) Amendments, 1988
1975 The Water (Prevention & Control of Pollution) Rules
1977 The Water (Prevention & Control of Pollution) Cess Act, Amendment 1992
1978 The Water (Prevention & Control of Pollution) Cess Rules
1981 The Air (Prevention & Control of Pollution) Act, Amendments, 1987
1982/ The Air (Prevention & Control of Pollution) Rules
1983
1986 The Environment (Protection) Act, Amendments
(1989, 1990, 1993, 1996, 1997, 1998, 1999, 2000, 2001)
The Environment (Protection) fourth Amendment Rules 2008
1986 The Environmental (Protection) Rules
1992 E (P) Act Notification – ―Environment Statement‖
1994 E (P) Act Notification – ―Environmental Clearance‖ EIA Notification 2009
1997 Amendments in the Environment Clearance, EIA Notification – ―Public Hearing‖
made mandatory
1989 The Hazardous Wastes (Management and Handling) Rules, Amendments,
2000 and 2003
1989 Manufacture, Storage and Import of Hazardous Chemical Rules,
Amendments, 1989, 2000
1991 The Public Liability Insurance Act, 1991
1995 The National Environment Tribunal Act
1997 Prohibition on the Handling of Azodyes
1997 The National Environment Appellate Authority Act
1998 The Bio-Medical Waste (Management &Handling), Rules
1999 Notification for making 100% Utilization of Fly-ash made mandatory,
Amendments 2003
2000 Municipal Solid Waste (Management &Handling) Rules
2000 Ozone Depleting Substance (Regulation &Control) Rules
1999 Regulation on recycling of Waste Oil and Non-ferrous scrape
2000 The Noise Pollution Regulations and Control Rules
2001 Batteries (Management &Handling) Rules

Part 2: The Site
2.10 Safety and Security on Site
 The Contractor shall comply at all times during the Contract with all relevant Indian
health, safety and environmental legislation, and all amendments thereto and also IS
18001:2007 Occupational Health and Safety (OH&S) management system.
 The Contractor shall immediately notify the Engineer or, in his absence, the
Employer, if any accident occurs whether on or off the Site in connection with the
Works which results in any injury to any person whether directly concerned with the
Site or a third party. Such notification may initially be verbal and shall be followed by
a written report within 24 hours of the accident.
a) At all times maintain a safe system of working and shall comply with all
enactments, regulations and working rules relating to safety, security, health and
welfare of all persons who may be affected by his work,
b) Ensure that only persons who are properly trained for their duties are employed,
that the correct tools and procedures are used and that adequate personal
protective equipment is provided to all persons who may be affected by the work;
c) Carry out toolbox talks for all Contractors Personnel at least once per week,
d) Erect suitable warning signs, barriers, etc. as necessary for the activity which is
being carried out – the Contractor shall maintain such signs, barriers, etc. for the
duration of such activities;
e) Submit to the Employer, no later than 28 days before work commences on the
Site, his Health and Safety Plan containing comprehensive proposals relating to
the management of health, safety and welfare of all his personnel on the Site and
all persons who may be affected by his work.
 The Contractor shall be responsible for the safety of all of his personnel and other
persons directly or indirectly employed for the Works and shall take all measures
necessary to ensure their safety. In particular such measures shall include the
following:
i. Provision of proper safety and emergency plans and regulations, fire, gas and
electric shock precautions, stretchers and first aid box together with rescue
facilities generally for each place of working;
ii. Provision of appropriate and effective safety work gear, including certified safety
helmets and certified work boots for all personnel including the Engineer and
each of his staff and any authorized visitors to the Site.
iii. Safe control of the water table, including provision of ample standby generating
and pumping plant to maintain dry conditions;
iv. Provision and maintenance of suitable lighting to provide adequate illumination of
works with appropriate spares and standby equipment;
v. Provision and maintenance of safe, sound mechanical equipment, each item of
plant having an up-to-date testing certificate;
vi. Provision and maintenance of safe, sound ropes, slings, pulleys and other lifting
tackle, each appliance having an up-to-date testing certificate, where appropriate;
vii. Provision of notices on weather-proof boards measuring 1.25m x 1.5m in size,
written in bold letters in English, Marathi and Hindi to be erected on existing
footpaths and at points of access likely to be used by the public, which shall warn
the public of the existence of the Works. These notices shall be in addition to any
statutory requirements demanded of the Contractor;
viii. Suitable scaffolds shall be provided for workmen for all activities that cannot be
safely executed from the ground, or from solid construction except such short
period work as can be done safely from ladders. When a ladder is used, an extra
person shall be engaged for holding the ladder and if the ladder is used for
carrying materials as well, suitable footholds and handholds shall be provided on

Part 2: The Site
the ladder and the ladder shall be given an inclination not steeper than ¼ to 1 (¼
horizontal and 1 vertical);
ix. Scaffolding or staging more than 3.25m above the ground or floor, swung or
suspended from an overhead support, or erected with stationary support, shall
have a guard rail properly attached, bolted, braced and otherwise secured at
least 1 metre above the floor or platform of such scaffolding or staging and
extending along the entire length of the outside and ends thereof with only such
openings as may be necessary for the delivery of materials. Such scaffolding or
staging shall be so fastened as to prevent it from swaying from the building or
structure;
x. Working platforms, gangways and stairways shall be so constructed that they do
not sag unduly or unequally, and if the height of a platform or stairway is more
than 3.25 metres above ground level or floor level, it shall be closely boarded,
have adequate width and be suitably fenced;
xi. Every opening in the floor of a building or in a working platform shall be provided
with suitable means to prevent fall of persons or materials by providing suitable
fencing or railing with a minimum height of 1 metre;
xii. Safe means of access shall be provided to all working platforms and other
working areas. Every ladder shall be securely fixed. No portable single ladder
shall be over 3 metres in length;
xiii. All scaffolds, ladders and other safety devices shall be maintained in a safe
condition and no scaffold, ladder or equipment shall be altered or removed while
it is in use.
xiv. The Contractor shall take adequate precautions to prevent danger from electrical
equipment.
xv. No material on the Site shall be so stacked or placed as to cause danger or
inconvenience to any person or the public;
xvi. Excavation and trenching: All trenches 1.5 metres or more in depth shall be
considered confined spaces and shall at all times be supplied with at least one
ladder every 30 metres, or fraction thereof. Ladders shall be extended from the
bottom of trenches to at least 1 metre above the surface of the ground. Sides of a
trench which is 1.5 metres or more in depth shall be stepped back to give suitable
slope, or securely held by timber bracing, to avoid the danger of sides collapsing.
Excavated material shall not be placed within 1.5 metres of the edge of a trench,
or half of the depth of the trench, whichever is more. Cutting shall be done from
top to bottom. Under no circumstances shall undermining or undercutting be
done.
xvii. All necessary personal safety equipment shall be provided by the Contractor for
use by persons employed on the Site and maintained in a condition suitable for
immediate use, and the Contractor shall take adequate steps to ensure proper
use of equipment by those concerned:
a) Workers employed on mixing asphaltic material, cement and lime mortars /

concrete shall be provided with protective footwear, gloves and goggles;
b) Those engaged in handling any material which is injurious to eyes shall be
provided with protective goggles;
c) Those engaged in welding works shall be provided with welder‘s protective
eye- shields;
d) Stone breakers shall be provided with protective goggles and protective
clothing and seated at sufficiently safe intervals;
e) Those working with loud machinery or near loud activities shall be provided
with appropriate ear protection such as ear muffs;
f) When workers are employed in sewers and manholes, which are in use, the
Contractor shall ensure that manhole covers are opened and manholes are

Part 2: The Site
ventilated by mechanical means for at least one hour before workers are
allowed entry. Gas detection devices shall be used to ensure the atmosphere
inside the sewer or manhole is safe before man entry is allowed. Manholes so
opened shall be cordoned off with suitable railing and provided with warning
signals or boards to prevent accident to public.
g) When work is done near any place where there is a risk of drowning, all
necessary equipment shall be provided by the Contractor and kept ready for
use and all necessary steps taken for prompt rescue of any person in danger
and adequate provision made for prompt first aid treatment of all injuries likely
to be sustained during the course of the work;
h) Use of hoisting machines and tackle including their attachments, anchorage,
and supports shall conform to the following:
i. These shall be of good mechanical construction, sound material and
adequate strength and free from patent defects and the Contractor shall
keep same in good repair and in good working order;
ii. Every rope used in hoisting or lowering materials or as a means of
suspension shall be of durable quality and adequate strength, and free
from patent defects;
iii. Every crane driver or hoisting appliance operator shall be properly
qualified and no person under the age of 21 years shall be in charge of
any hoisting machine including any scaffold winch or give signals to
operator;
iv. In the case of every hoisting machine and of every chain ring hook,
shackle, swivel and pulley block used in hoisting or lowering or as a
means of suspension, safe working load shall be ascertained by the
Contractor by adequate means. Every hoisting machine and all gear
referred to above shall be plainly marked with safe working load by the
Contractor. In case of a hoisting machine having a variable safe working
load, each safe working load and the conditions under which it is
applicable shall be clearly indicated by the Contractor. No part of any
machine or of any gear referred to above in this paragraph shall be
loaded beyond safe working load except for the purpose of testing;
The Contractor shall notify safe working load of each machine to the Engineer whenever
he brings it to Site.
1) Motors, gearing, transmission, electric wiring and other dangerous parts of hoisting
appliances shall be provided with efficient safeguards. Hoisting appliances shall be
provided with such means as will reduce to the minimum risk of accidental descent of
load. Adequate precautions shall be taken to reduce to the minimum risk of any part
of a suspended load becoming accidentally displaced. When workers are employed
on electrical installations which are already energized, insulating mats, wearing
apparel such as gloves, sleeves and boots, as may be necessary, shall be provided.
Workers shall not wear any rings, watches and carry keys or other material which are
good conductors of electricity;
2) Adequate washing facilities shall be provided at or near places of work;
3) These safety provisions shall be brought to the notice of all concerned by display on
a notice board at a prominent place at the work spot. Persons responsible for
ensuring compliance with the safety provisions shall be named therein by the
Contractor;
4) To ensure effective enforcement of the rules and regulations relating to safety
precautions, arrangements made by the Contractor shall be open to inspection by the
Engineer and any safety inspection officer.

Part 2: The Site
Notwithstanding the above provisions, the Contractor is not exempted from the
requirements of any other Laws in force.
 The Contractor shall submit to the Engineer for review detailed proposals under (i)
above in conjunction with detailed construction and installation method statements
for each element of work to be undertaken. When accepted by the Engineer, and
before the work is started, the Contractor shall distribute copies in English or in other
language as appropriate to all his employees and to the Engineer.
 The Contractor shall ensure that all his employees are fully conversant with the plans
and regulations and the Contractor shall enforce the rule that any employee
committing a serious breach of such plans and regulations shall be instantly
dismissed and shall not be re- employed.
Safety Codes
(Reaf-03) Safety and healthy requirements in Electric and gas
818-1968
welding and cutting operations
2750 Specification for steel scaffoldings
3696 (Pt I)-1987 Safety code for scaffolds
3696 (Pt II)-1991 Safety code for ladders
3764-1992 Safety code for Excavation works
4130-1991 Safety code for Demolition of Building
Safety code for construction involving use of hot bituminous
5916-1970
materials
7293-1974 Working with construction machinery- safety code for
National Building Code of India – 2005
Safety Manual, Central Water and Power Commission, Ministry of
Irrigation & Power, Govt. of India.
2.10.1 Compressed Air Use on Site
i. The Contractor shall provide the necessary compressed air plant and equipment
required for construction of the Works.
ii. Electrically driven compressors connected to the site electricity supply shall not be
used. Diesel engine driven compressors shall not be sited within buildings or in a
location that may cause a health hazard to personnel owing to exhaust fumes or
noise.
2.10.2 Refuse Disposal on Site
Refuse and rubbish of every kind shall be removed from the Site and disposed of by the
Contractor at his own expense, frequently and regularly at a minimum period of one
week so as to keep the Site in a wholesome and tidy condition to the satisfaction of the
Engineer.
2.10.3 First Aid and Life-saving Apparatus on Site
i. The Contractor shall provide on the Site such life-saving apparatus as may be
appropriate and shall provide, equip and maintain at the Site of the Works first aid

Part 2: The Site
boxes as directed and shall be subject to approval by the Engineer for the use of his
own as well as Employer‘s Personnel on Site.
ii. In addition, the Contractor shall instruct an adequate number of persons permanently
employed at the Site in the use of the apparatus and equipment, and the Contractor
shall make known the persons so designated to all employees by posting their
names and designations in a prominent position on Site.
iii. The Contractor shall advise the Employer of measures to be taken in the event of a
serious accident.
iv. The Contractor shall post a list of emergency telephone numbers (including
ambulance) at several locations on Site.
2.10.4 Electrical Safety on Site
i. While any electrical equipment is being installed or tested, the Contractor shall
ensure that all necessary precautions are taken to safeguard personnel working on
Site. If necessary, this shall include fencing off areas that are considered to pose a
risk, and erecting warning notices.
ii. The Contractor shall ensure that the installation of electrical equipment is carried out
by suitably trained competent personnel and that the work is carried out in a safe
manner. No electrical cables shall be laid across rebar. No joints or repairs shall be
made to cables except by suitably trained competent personnel using appropriate
protective equipment. All power sockets used on the Site shall be protected by a
residual current device.
iii. The Contractor shall be responsible for the operation on the Site of a ‗permit to work‘
system during the period of electrical equipment installation and testing. This system
shall regulate the installation, the energising and the use of electrical Plant installed
and the method of work adopted
2.10.5 Noise and Vibration
i. The Contractor shall carry out his operations in such a manner as to minimise noise
and vibration nuisance.
ii. The Contractor shall comply with the requirements of The Noise Pollution (Regulation
and Control) Rules 2000 and all latest amendments.
iii. The Contractor shall ensure that all his equipment used in the Contract shall be
designed to be reasonably quiet in operation and shall check the measures taken by
the manufacturers to minimise noise during operation of the equipment. The
Contractor shall ensure that all his equipment and associated platforms and
connections are properly maintained to be in efficient working order and reasonably
quiet in operation for the full duration of the Works. The Contractor shall fit effective
silencers to machine exhausts and adopt such other means as may be necessary to
reduce noise to acceptable levels.
iv. Machines in intermittent use shall be shut down when not in use or throttled back to a
minimum. The Contractor shall remove from the Site any items of Contractor‘s
equipment which are, in the opinion of the Engineer ineffectively silenced.
v. All compressors, pumps and mechanical static plant shall be low noise models fitted
with properly designed acoustic covers, or screens, to reduce noise to acceptable
levels. These covers shall be kept closed whenever the machines are in use. All
ancillary pneumatic percussion tools shall be fitted with mufflers or silencers of the
type recommended by the manufacturer.
vi. The Contractor shall organise his operations with regard to the positioning of plant
and the location of haul routes, etc. to minimise construction noise to adjacent
properties. The Contractor shall also maintain vegetation at construction sites to
reduce air pollution and noise levels.

Part 2: The Site
vii. He shall further employ the best practical means to minimise noise produced by his
activities.
viii. The Contractor shall ensure that the sound levels arising from his activities during
construction do not exceed the following values when measured at the Site
boundary:
Table 2-2 Noise Limits
dB(A) Leq dB(A) Leq

Area Period Day Time Night Time
(06:00 to 22:00) (22:00 to 06:00)
Site area All days of week 75 70
ix. Measurements and analyses shall be carried out in accordance with ISO 1996,
Acoustics – Description and Measurement of Environmental Noise.
x. In addition, noise emitted between 18.00hrs and 09.00hrs shall be free from tonal or
impulse qualities and pile driving or drilling shall not be permitted during these hours.
xi. The Contractor shall carry out the Works in such a manner as to limit vibration at
adjacent properties and at the works, due to his construction activities, to an
acceptable level.
xii. If required by the Engineer the Contractor shall carry out vibration monitoring at
adjacent properties.
xiii. Vibration caused by construction plant to be limited to the recommended values.
Table 2-3 Vibration Limits
Allowable vibration (in terms of peak particle velocity) at the closest part of any
sensitive property to the source of vibration, at a frequency of
Less than 10 Hz 10 to 50 Hz 50 to 100 Hz (and above)
3 mm/s 3 to 8 mm/s 8 to 10 mm/s
2.10.6 Warning and Safety Signs
i. During construction of the Works statutory safety signs shall be adequately provided
throughout the Works, both indoors and outdoors. These safety signs shall cover
mandatory, prohibition, warning, emergency, fire-fighting and general notices. All
signs shall be positioned around the Works at highly visible points. Provision of signs
and the positions of signs shall be subject to the Engineers approval. Special
attention shall be given to areas designated hazardous.
2.11 Site Working Hours
i. Normal working hours shall be as stated in the Contract Data. Working on Site by
personnel outside these hours in special circumstances, excluding any response to
emergency events, may be permitted by the Engineer but this shall be at his
discretion and he shall have no obligation to allow it.
ii. The Contractor shall not extend the working hours without the prior approval of the
Engineer.

Part 2: The Site
2.12 Protection from Weather and Storage
i. The Contractor shall ensure Plant and Materials for incorporation into the Works are
stored in accordance with manufacturer‘s Recommendations and protected from the
weather.
ii. The Contractor shall be responsible for a proper inventory of plant and materials
together with receipts and issues and identification of same.
iii. The Contractor shall not store or deposit any of his equipment on the Site without the
consent of the Engineer.
iv. The Contractor shall ensure that no fuel or oil spillages discharge to the environment.
Temporary fuel and oil storage tanks in the Contractor‘s compound shall be protected
by an impervious containment bund. The Contractor shall carry out daily inspections
for spillage of fuels/oils at the Site.
v. Stacked equipment and materials shall be protected from damage by spacers on
load distributing supports and shall be safely arranged. No metalwork shall be stored
directly on the ground.
vi. Small items shall be held in suitable bins, boxes or racks and be clearly labelled.
vii. Equipment and materials shall be handled and stored so that they are not subjected
to excessive stresses and so that protective coatings are not damaged.
viii. The Contractor shall comply with the manufacturers‘ package and equipment
markings concerning the use and location of lifting slings, chains and hooks.
ix. Equipment and materials shall be stored in a manner that minimises risks to the
environment and will be located away from sensitive receptors such as watercourses
and drains, where there is risk of harm through spillage, leakage or leaching of
harmful materials.
x. The Contractor shall take all necessary precautions to avoid causing any damage to
buildings, structures, roads, lands, properties, trees and other features and, during
the currency of the Contract, shall deal promptly with any complaints by owners or
occupiers. Any damage done to road surfaces outside the Site shall be restored to
the Engineer satisfaction at the Contractor‘s expense. Where any portion of the
Works is close to, across, or under any existing apparatus of public utilities or other
parties, the Contractor shall temporarily support and work around, under or adjacent
to all apparatus to avoid damage, leakage or danger and to ensure uninterrupted
operation.
2.13 Archaeology
Any finds of archaeological interest such as relics of antiquity, coins, fossils or other
articles of value shall be immediately brought to the attention of the Engineer for
appropriate further course of action.
2.14 Survey and Geotechnical Data
Geotechnical and topographical reports of the proposed STP site covered under the
contract are provided in Background Information. These may be used by Contractor as
part of, in addition to, or in lieu of such investigations at his own risk. The Employer
accepts no responsibility whatsoever for, nor guarantee, the accuracy, applicability, or
completeness of the Report or information contained therein.
The Contractor shall carry out independently fresh survey, geotechnical investigation and
all other details necessary for proper planning and detailed design. The Contractor will
be required to provide full details of the survey and geotechnical investigations for each
site for approval of the Employer.

Part 2: The Site
2.15 Benchmark
i. The Contractor shall be responsible for the accurate location of the Works.
ii. Elevation and levels used for the project are linked to the Mean Sea Level (MSL).
iii. The Contractor shall satisfy himself as to the accuracy of the survey details and shall
carry out surveys to verify the same. The results shall be provided to the Engineer
prior to work commencing on Site.
iv. The Contractor shall provide at the commencement of work on the Site, substantial
master temporary benchmarks at convenient positions over the Site, suitably
protected for the duration of the Contract and agree the levels of such works with the
Engineer. Temporary benchmarks at intermediate locations shall be provided by the
Contractor as required and agreed with the Engineer.
v. The Contractor shall establish a permanent master survey station and benchmark at
a convenient point near the Site. All levels shall be referenced to Mean Sea level.
vi. The Contractor shall set out the Works in accordance with the dimensions, lines and
levels shown on his construction drawings.
vii. The contractor shall give the Engineer not less than 48 hours‘ notice of his intention
to set out or give levels of any part of work so that timely arrangements may be made
for checking or issuing instructions.
2.16 Contract Signboards / logos
The Contractor shall supply and erect signboards at locations to be specified by the
Engineer. The layout and dimensions of the signboards and their construction shall be to
the approval of the Engineer and the lettering in Marathi, Hindi and English Languages
shall be black on a white background.
The Contractor shall put logos shown below, on at all assets constructed under JICA‘s
funding in addition to the logo of MOEF&CC along with PMC. The example for the
design of the panels is shown in Appendix 8.
2.17 Advertising
The Contractor shall not use any part of the Site for any form of advertising without the
prior written approval of the Engineer.

Part 2: The Site
2.18 Method Statements
The Contractor shall submit general and detailed method statements.

A general method statement shall be provided 28 days prior to commencement on Site
which shall outline the procedure that the Contractor intends to employ for each element
of the construction, including a comprehensive list of plant that will be used. It shall
include the relevant sections of his environmental management programme, indicating
what measures will be employed to mitigate against environmental impact during
construction.
Detailed method statements shall be provided for each element of the Works. These
shall comprise a step by step schedule of specific operations or activities with
descriptions, dates, times and duration of each step, supported by sketches or other
detail to aid their understanding. They shall include reference to relevant legislation, and
permits and licences that have been or are required to be obtained.
2.19 Smoking
Smoking shall not be permitted at site.
2.20 Blasting and the use of Explosives
The Contractor shall not carry out any blasting activities on site. The Contractor shall not
be permitted to use explosives.
2.21 Vehicles for the Employer’s Representative
The Contractor shall provide and maintain two vehicles for use by the Engineer only
during the Design-Build Period. One vehicle shall be SUV type and one sedan type, and
shall be approved by the Engineer and shall be brand new. Vehicles shall be suitable for
a minimum of four passengers and shall have air conditioning. The vehicles shall have
Tourist permit and shall be available to the Engineer at any time, 7 days per week. The
Contractor shall be responsible for the running and upkeep of the vehicles including
payment of taxes, insurance, licences, permits, fuel, oil, lubricants, repairs and
maintenance and shall also provide competent driver with the vehicle.
2.22 Site and Laboratory Testing
The Contractor shall be responsible for testing of materials at a Nominated Laboratory

and approved by the Employer as per Clause 3.18.7 of Volume 2, and supplying the
results to the Engineer, who shall be afforded access to the testing facilities during
normal working hours.
All testing shall be in accordance with the Contractor‘s quality procedures.
2.23 Delivery to Site
i. The Contractor shall be responsible for the transporting, handling, and delivery to site
of all the Plant and equipment. The proper storage and protection of all Plant and
equipment at the Site shall be the Contractor's responsibility.
ii. The Contractor shall check all items against packing lists immediately on delivery to
the Site and shall also inspect for damage and shortages. Damages and shortages
shall be remedied with the minimum of delay.

Part 2: The Site
iii. The Contractor may, with the prior approval of the Engineer and at no extra cost to
the Employer, make arrangements for any other contractor or agent to take delivery
of, unload and store the Plant on the Site on behalf of the Contractor.
iv. All deliveries shall take place during the Contractor's normal working hours.
2.24 Daily Records
A daily record of the day‘s activities shall be completed by the Contractor and handed to
and certified by the Engineer at the end of each working day. The report shall include, as
a minimum, for work done, all labour utilised, all plant and equipment (used/standing),
weather temperature/conditions, deliveries, visitors, etc.

Part 2: The Site
3 General Requirements
3.1 Introduction
This Part sets out the technical requirements that are general to the Contract.
3.2 General Design
3.2.1 Codes and Standards
The Works shall be designed, manufactured, constructed, tested and operated in

accordance with the following standards and codes of practice. In the event of
differences between the standards or codes of practice the more stringent shall apply. In
the event of any conflict the standards or codes of practice shall be interpreted in the
order of precedence given below:
1) As specified in this Contract including those in the standard specification of this

Volume 2 – Employer‘s Requirements.
2) For each item of Equipment, Plant and Materials they shall comply with those
standards of the country of manufacture which are relevant to the item concerned, in
addition to the standards cited in the general technical specifications;
3) Relevant standards and codes of practice of India.
The Contractor shall also ensure that each item of equipment, Plant and Materials
comply in all respects with the standards cited in the standard technical specifications.
However, the Engineer reserves the right to make the final decision on the matter.
For items which have not been specified in either Indian codes/standards or in this
Contract the Contractor shall ensure the following standards are met:
a) British Standard Specification (hereinafter abbreviated to `B.S.‘) issued by the British
Standards Institution of 2, Park street, London W.I., or to an Indian Standard
Specification (I.S.) issued by the Bureau of Indian Standards, (earlier known as
Indian Standards Institution), Manak Bhavan, 9 Bahadur Shah Zafar Marg, New Delhi
110 002, or
b) American Society for Testing and Materials (ASTM) issued by ASTM 1916 Race
Street, Philadelphia, P.A., 19103, U.S.A. or
c) American National Standards Institute (ANSI) issued by ANSI 1430, Broadway, New
York, N.Y., 10018, U.S.A. or
d) Japanese Industrial Standards (JIS) issued by Japanese Standards Association, 4-1-
24, Akasaka, Minato-Ku, Tokyo 107, Japan or
e) 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 recognised Reference Standard, including Indian Standard
(IS) and Japanese Industrial Standards (JIS).
All details, materials and equipment supplied and workmanship performed shall comply
with these Standards. If the Contractor offers equipment to other Standards, the
equipment/material should be equal or superior to those specified and shall be subject to
approval by the Engineer and full details of the difference shall be supplied by the
Contractor.

Part 3: General Requirements
In referring to the Standard Specifications the following abbreviations are used:
IS : Indian Standard
ANSI : American National Standards Institute
API : American Petroleum Institute
ASME : American Society of Mechanical Engineers
ASTM : American Society of Testing and Materials
AWS : American Welding Society
AWWA : American Water Works Association
ISO : International Organisation for Standardisation
JIS : Japanese Industrial Standard
DIN : Deutsches Institute fur Normung
BS : British Standard
JWWA : Japanese Water Works Association
IEC : International Electrotechnical Commission
IEE : Institution of Electrical Engineers
IEEE : Institute of Electrical and Electronic Engineers
NEMA : National Electrical Manufacturers Association
AGMA : American Gear Manufacturer‘s Association
3.2.2 Design Life
Unless stated otherwise in the Employer‘s Requirements, the Contractor shall design the
Works such that the design life shall be a minimum of:
Table 3-1 Design Life
Minimum Design Life

Item
(Years)
Civil engineering and building works (including underground
50
services and pipes)
External pipework and valves 50
Roads 25
Steel tanks 25
Mechanical - Internal pipework and valves 25
Mechanical – Rotating machinery and complex equipment 13
Electrical – Cables 25
Electrical - HT Electrical Switchgear & Transformers 20
Electrical - LT Electrical, Switchgear 13
Instrumentation 7
All Plant, Materials, and equipment utilised in the Works shall be new. No existing Plant,
Materials, buildings or equipment from the facility, or element of the existing facility shall

be reinstalled or reused in the final Works. The Contractor shall provide the necessary
information to allow the Employer to decide if the asset with a longer useful life should be
used to replace the existing asset based on cost factors such as immediate cost and
future operating/maintenance costs.
3.2.3 Units of Measurement
All correspondence, drawings, data sheets, calculations, labels, nameplates, field

instruments etc shall be expressed in metric SI units where such unit exists.
3.2.4 Drawings
Refer also to Background Information of this Contract. The Contractor shall use ISO
standard size sheets only. All electrical drawings shall include a key legend of symbols
and references used. All drawings issued by the Contractor shall have a common title
block bearing the name of the Employer, Engineer and the Contractor and shall include
the name of the Subcontractor or supplier where appropriate.
Background Information contains the drawings listed below issued for the purposes of
illustrating and clarifying the Works described in the Employer‘s Requirements:
Table 3-2 List of Drawings
Drawing No. Title

PF-D-PARMM-5-43-900-Y-0001 PROPOSED BHAIROBA 75 MLD STP LOCATION
Rev-A PLAN.
PF-D-PARMM-5-43-400-Y-0001 BHAIROBA PUMPING STATION EXISTING
Rev-A LAYOUT PLAN.
PF-D-PARMM-5-43-400-Y-0002 PROPOSED BHAIROBA 75 MLD STP BATTERY
Rev-B LIMIT.
PF-D-PARMM-5-43-400-Y-0003 PROPOSED BHAIROBA 75 MLD STP SITE AREA
Rev-B AND FENCING.
ELECTRICAL POWER DISTRIBUTION SYSTEM
PF-D-PARMM-5-43-113-E-4002
SCHEMATIC DIAGRAM FOR PROPOSED
Rev-B
BHAIROBA 75 MLD STP.
ELECTRICAL POWER DISTRIBUTION SYSTEM
PF-D-PARMM-5-64-113-E-4002
SCHEMATIC DIAGRAM FOR PROPOSED
Rev-B
KALYANINAGAR IPS.
SYSTEM ARCHITECTURE TYPICAL FOR
PF-D-PARMM-5-43-113-E-4012
PROPOSED BHAIROBA 75 MLD STP AND
Rev-B
KALYANINAGAR IPS
3.2.5 Climatic Conditions
The Contractor shall ensure the Works are suitable for continuous operation in all
3.2.5 climatic conditions likely to be encountered at the Site. The Contractor shall ensure all
Plant and Materials located outside are suitable for a temperature range of at least 10ºC
below the minimum to 10ºC above the maximum temperatures recorded in the area by
3.2.5 the meteorological service. As a minimum the Contractor shall ensure that all Plant and
Materials are suitable for the following:
 Temperature: 0ºC to + 50ºC
3.2.5

3.2.5
 Humidity: 100% (including enclosures)
3.2.6 Labels
All signs, notices, on-site instructions, name-plates, monitors, etc. at the Works shall be
in both Marathi and English.
 Rating Plate:
All Plant items shall to be fitted with a rating plate, which contains as a minimum, the
manufacturer‘s name, the type reference, the serial number, the date of manufacture
and the rating of the machine or Plant item.
 Name Plate:
All Plant items are to be fitted with a unique name plate bearing the individual plant
reference for the Plant item, e.g. ―Blower Motor No. 4‖. In the case of removable
Plant items, the name plate shall be fitted alongside the item.
 Asset Number Plate:
In addition, each item of Plant and equipment shall carry an asset number label
which may be electronic to comply with the requirements of the Operation and
Maintenance Plan to be developed.
 Identification Label:
Each switchboard, motor control centre, ICA panel, pump, valve, etc. and any other
item of Plant and equipment shall be fitted with an identification label with letters not
less than 12mm high. Additionally, each individual switch shall have an identification
label at both the back and front of the unit, where applicable. These labels shall carry
the unambiguous switch name and number, in letters not less than 8mm high, which
will denote the service or Plant items which they control. Fuse or MCB sizes and
circuit numbers must be clearly indicated adjacent to each device to facilitate
identification and replacement. Where more than one power supply is connected to a
distribution board or plant item, clear indication of the danger must be given and the
voltage between phases shall be made obvious by the Contractor. All cables shall be
clearly labelled so that their source, destination, and function can be identified.
 Pipe work Labelling:
All pipe work above ground shall be labelled with contents and flow direction. Pipe
work of diameter less than 50mm may have tags or clamped signs unless it is less
than 1.0m in length where labelling shall not be necessary.
 Tank Labelling:
All storage tanks shall be labelled with contents and volume. Letters shall be of a size
suitable for the application but shall not be less than 100mm high. Labels shall be
painted at 90-degree intervals at a suitable elevation.
Note:
a) Name plates and rating plates shall be either trifoliate (black letters on white label) or
316 stainless steel labels stamped with black lettering. The lettering shall be of a size
suitable for the application but shall not in any case be less than 6mm high. All labels
shall be visible from an operator access way.
b) All labelling or types of labelling shall be subject to approval by the Engineer before
installation.
3.2.7 Hazardous Area Classification
As part of the Contractor‘s design, the Contractor shall carry out a risk assessment of the
possibility of the existence of potentially explosive atmospheres during the operation of
the Works by means of a Hazardous Areas Classification.

All zonal classification and Plant and Materials shall be in accordance with BS EN 60079
and IEC Ex 60079 series of standards.
Plant shall be of an approved type and be ―Ex‖ rated according to the Hazardous Areas
Classification as necessary.
Contractor shall consider the overall effects of installation of Electrical Equipment‘s in the
vicinity of Hazardous areas, as well.
3.2.8 HAZOP Studies
The Contractor shall carry out a hazard and operability (HAZOP) study for the Works at
an appropriate stage in the design. Modifications to the Contractor‘s design or
construction that are required as a result of the HAZOP shall be implemented by the
Contractor.
The HAZOP shall be carried out in accordance with the Indian Standard - HAZARD
IDENTIFICATION AND RISK ANALYSIS - CODE OF PRACTICE IS 15656:2006.
The Contractor shall appoint from his staff the chairman and the secretary for the
HAZOP meetings subject to agreement with the Engineer. Other members of the
Contractor‘s staff familiar with the details of the Contractor‘s design shall attend the
HAZOP meetings, as appropriate. These HAZOP meetings shall be held at Site office
and the Engineer shall be given adequate notice to attend the meeting.
The following shall be included in the studies:

 The design, including all process and instrumentation diagrams, all single line
diagrams, plant layout drawings, pipeline drawings, mechanical GA drawings, and
block diagrams for the control system
 An ICA design appraisal including the control philosophy
During the HAZOP study the following topics shall be considered as a minimum:
 Disaster resilience as per the requirements of Disaster Management Act 2005 as
modified.
 The adequacy of the vehicle and personnel access to plant, plant rooms, switch
rooms, control rooms, etc, together with the means of escape – safety aspects such
as confined spaces, areas where high noise levels are expected, etc.
 the facilities for delivering sludge, chemicals, fuel, etc. to the Permanent Works and
for collecting and removing waste materials such as grit and ash
 the facilities for transferring screenings
 the impact of various climatic conditions
 the facilities for removing items of plant for maintenance
 Safety facilities such as safety showers, fire alarms, etc.
 operation of the Permanent Works under normal conditions
 the impact of abnormal conditions such as high or low temperature, pressure or flow
on the operation of the Permanent Works
 the impact of an electricity supply failure, cooling water supply failure, etc on the
operation of the Permanent Works
 Other topics as determined by the HAZOP study team.
The HAZOP meetings shall be conducted in a systematic manner and the outcomes
shall be recorded.

Following the HAZOP meetings, the Contractor shall consider each of the hazards which
have been identified and assign to it:
 a likelihood of occurrence, i.e. high, medium or low; and
 a severity of the consequences when the hazard does arise, i.e. severe, medium or
low.
From these two factors the overall risk associated with each hazard shall be determined
by the Contractor.
Following this risk assessment, the Contractor shall recommend the action which is to be
taken in relation to each hazard. The Contractor shall submit these recommendations to
the Engineer for review.
3.3 Precedence of Employer’s Requirements
The requirements specified in the Particular Requirements parts, shall be in addition to

those specified in the General Requirements parts. In case of conflict between the parts,
the more stringent requirements shall take precedence.
3.4 Key Programme Requirements and Staffing
The Contractor is required to complete each of the following activities, items of work or
stages in the performance of the Contract in full in accordance with the Contract by the
date or within the period specified for each such activity or item or stage in the table
below. Week numbers refer to weeks after the Commencement Date unless otherwise
stated. Other submissions as specified in the Contract shall be required in addition to the
key submissions identified below.
3.4.1 Design-Build
Table 3-3 Key programme requirements during design and build
Date or period by which item is to be

No. Activity/item of work/stage
completed
Submission of programme in
1. accordance with Conditions of As per the Conditions of Contract
Contract
Within 28 days of receipt of Notice of
2. Submission of project execution plan
Commencement Date
Submission of controlled copy of Within 28 days of receipt of Notice of
3.
Quality Management System Commencement Date
Submission of Health and Safety No later than 28 days before
4.
Plan commencement of Works on Site
No later than 28 days before
5. General method statement
commencement of Works on Site
Submission of Quality Plan for
6. By end of week 4
Design-Build
Submission of draft Contractor‘s
7. By end of week 24
design report(s)


completed
Submission of HAZOP
recommendations
Submission of all licenses, consents,
clearances, NoCs, etc. required for
commencement of Construction
Work
Submission of final Contractor‘s
10 By end of week 30
design report(s)
Submission of construction stage
11 documents (excluding method By end of week 36
statement)
Submission of construction and No later than four weeks prior to
12
installation method statements commencement of that element
Submission of plant delivery No later than three weeks prior to
13
documents commencement of that element
Submission of Testing Plan and No later than 6 months prior to
14 Testing Programme in accordance commencement of the Tests on
with the requirements of Section 17 Completion of Design-Build
No later than 3 weeks prior to
As-built documents submission of
15 commencement of the Tests on
asset sheets
Completion of Design-Build
Draft Operation and Maintenance No later than 8 weeks prior to
16 Plan and Asset Management commencement of Tests on Completion
Database of Design-Build
Draft Final Operation and No later than 3 weeks prior to the date for
17 Maintenance Plan and Asset commencement of Tests on Completion
Management Database of Design-Build
No later than 6 months before the
18 Nomination of Plant Manager anticipated date for commencement of
the Commissioning
Commencement of Tests on
No later than 2 months before the date for
19 Completion of Design-Build (Process
completion of the Design-Build
Commissioning)
Commencement of Tests on
20 Completion of Design-Build (Plant
Proving Period) No later than 6 weeks before the date for
completion of the Design-Build
21 Submission of Quality Plan for
Operation Service
22 Final approved as-built documents
No later than the date set out for the
Final Operation and Maintenance commencement of the Plant Proving
23 Plan and Asset Management Period or 28 days after completion of the
Database commencement of the Commissioning
Final Operation and Maintenance whichever is the earlier
24
Manual


completed
As stated in the Particular Conditions
25 Time for Completion of Design-Build
Part A - Contract Data
3.4.2 Design Review by Engineer
The Contractor‘s final detailed design shall be completed within 30 weeks on prorata
basis from the Notice of Commencement. The design review team of the Engineer and
the Project Management Consultant will be available to carry out design review during
this 30 weeks period, and will revert back with comments on each submission within 21
days.
If the Contractor is late in submission of either the draft, final designs for review, or
construction drawings and documents or proposes changes to a reviewed design such
that additional design reviews are required, then the cost of such reviews shall be borne
by the Contractor.
3.4.3 Operation Service
Table 3-4 Programme during Operation Service
Activity / Item of
No. Date or period by which item is to be completed
Work / Stage
1. Full implementation No later than the date set out in the Commissioning
of the O&M Plan Certificate in accordance with General Conditions, or 28
days after Completion of the Tests on Completion of
Design-Build whichever is the earlier
2. Service Delivery Initial review report within one month of the date set out in
Review Report the Commissioning Certificate in accordance with General
Conditions and subsequent reviews every 3 months
thereafter with a complete review annually
3. Update of the O&M At least every 3 months and when required to meet
Plan recommendations of the Service Delivery Review Reports
4. Submission of draft Within 3 months of the date set out in the Commissioning
O&M Manuals Certificate in accordance with General Conditions
5. Submission of final Within 6 months of the date set out in the Commissioning
O&M Manuals Certificate in accordance with General Conditions
6. Update of O&M At intervals of no more than 12 months
Manuals
3.4.4 Key Staff
 Contractor’s Representative
The Contractor‘s Representative shall be experienced in the construction of large
infrastructure projects. He shall meet or exceed the following parameters:
o 15 years‘ relevant experience
o 3 years‘ experience specifically in construction of water or wastewater treatment
plants
o Bachelor Degree in Engineering;
 Design Manager

The Design Manager shall be experienced in the design of wastewater treatment

plants. He shall meet or exceed the following parameters:
o 5 years‘ experience specifically in design of water or wastewater treatment plants
o Bachelor Degree in Engineering;
 Lead Planner
The Lead Planner shall be experienced in the planning of construction projects. He

shall meet or exceed the following parameters:
o 3 years‘ experience in planning of water or wastewater treatment plants
o Bachelor Degree in a relevant field;
3.5 Contract Management
The Contractor shall be responsible for administration of the Contract from award of
Contract through design, manufacture, manufacturer's works testing, and delivery of
Plant to Site, installation, testing and performance testing to final take over. For this
purpose he shall nominate a Contractor‘s Representative in accordance with General
Conditions of Contract who shall be fully responsible for and undertake this
administration.
Specific responsibilities of the Contractor‘s Representative shall be:

a) The sole representation on behalf of the Contractor in all discussion, correspondence
and matters relating to the Works.
b) The co-ordination and monitoring of Contract progress, which shall include the
preparation of the Contract programme, monitoring of progress and submission of
monthly progress reports. At the discretion of the Engineer, regular meetings shall be
called at which the Contractor‘s Representative shall give a full account of the
Contract progress and programme.
c) The co-ordination and checking of designs, drawings and submissions. The
Contractor‘s Representative shall be responsible for co-ordinating the design,
technical information and data between sub-contractors. All calculations, drawings
and information submitted to the Engineer shall be checked by the Contractor‘s
Representative and certified as having been checked before submission.
d) Contract communication between the Engineer and the Contractor. The Contractor‘s
Representative shall attend all meetings involving the Contractor and the Engineer.
e) The co-ordination and programming of manufacturer's works tests and the
submission of test certificates.
f) The co-ordination and programming of Plant delivery.
g) The co-ordination and programming of the installation of Plant on the Site, site tests
and take over trials. The Contractor‘s Representative, although not necessarily based
at the Site, shall be responsible for the various sub-contractors. At the discretion of
the Engineer regular site meetings will be held during which the Contractor‘s
Representative shall give full account of site progress and programme.

h) The Contractor‘s Representative shall also be responsible for producing in advance

of the work being undertaken, detailed method statements of any work, which
involves or affects the performance of existing equipment, processes, or disruption to
existing water supplies.
i) The co-ordination and preparation and submission of As-Built Drawings and
Operation and Maintenance Manuals.
j) Soft copies of all submissions should be in editable form.
k) The preparation and co-ordination of training of Employer‘s Personnel.
l) The submission of applications for payment.
3.6 Site Meetings
From time to time the Engineer will call meetings in his office or at the Contractor's office,
or at the Site, as he deems necessary, to discuss progress and any technical points
requiring settlement.
The Contractor's Representative or responsible representative shall attend such

meetings.
The Contractor shall prepare and submit to the Engineer Minutes of Meeting.
3.7 Site Photographs and Video Recording
The Contractor shall supply photographs in soft copy (JPEG, JPG format) and
unmounted positive colour prints not less than 250mm x 200mm of such portions of the
Works, in progress and completed, as may be directed by the Engineer and specified
herein. The photographs / prints shall not be retouched. The photograph shall be the
property of the Employer and shall be delivered to the Engineer with the prints. No prints
of soft copy shall be supplied to any other person without the written permission of the
Engineer.
Monthly Progress Photographs: The Contractor shall submit Monthly Progress

Photographs to the Engineer at the last day of each Month in both Soft and Colour prints.
At least 20 to 25 no‘s of monthly photographs shall be submitted by the Contractor.
Video Recording: The Contractor shall submit Progress Video Recording quarterly to the
Engineer at the end of each quarter. The Video recording shall be submitted in MPEG 4
or any other format which is suitable to be viewed on Television. The Contractor shall
install at least six (6) internet-enabled video cameras with internet connectivity on high
masts at Site so as to facilitate remote video monitoring of the Site by the Employer,
Employer‘s Representative and the Engineer. The cameras shall comprise 360degree
day night vision, Pan-Tilt-Zoom, minimum 2 mega pixel resolution with IP 65.
3.8 Camp Facility
3.8.1 Labour Camp at Site for Design Build period
i. The Contractor shall construct and maintain to the Engineer‘s satisfaction a camp to
provide living accommodation for all labours and operatives who have no other local
accommodation. The Contractor's camp shall be located at a location approved by
the Engineer.

ii. Responsibility for providing all services to the camp and compliance with all sanitary
laws and other laws and regulations shall be borne by the Contractor. Security and
the fencing of these areas shall be the responsibility of the Contractor.
iii. The Contractor shall be wholly responsible for the maintenance of these facilities
throughout the Design Build period till issue of Taking Over Certificate, and the camp
shall be removed before Taking Over Certificate.
3.8.2 Employer’s Office
A separate office for the sole use of the Engineer, his staff and Consultant shall be
provided by the Contractor at each site. The Contractor shall provide, erect, furnish,
clean, maintain and subsequently transfer the office and associated furniture/items to the
Employer after the completion of works. The carpet area of the office shall not be less
than 100 Sq. Meter.
Before commencing the construction of the office, the Contractor shall submit to the
Engineer for his approval a drawing of the proposed building with all architectural and
finishing details fully shown. The location of the office shall be as directed by the
Engineer.
The Employer‘s office shall be ready in all respects within 90 days after Commencement
date. The Office shall be maintained throughout the Design Build period with office help
staff, power, water, sewerage, and housekeeping. Power, water supply, and sewerage
shall be arranged by the Contractor either with the available resources or from
independent sources (e.g. diesel generator sets, etc.) at his own cost.
The Contractor shall provide 1 No computer operator with experience & proficiency in
computer operation, experience and proficiency in typing using relevant software.
The Contractor shall furnish the rooms as described below and the equipment, furniture,
furnishings, and fittings supplied shall be new items of approved make.
The equipment, furniture, and furnishings shall include for STPs

a) One conference table 10'-0" x 5'-0" with 12 chairs (approved make)
b) 4 Nos. of 5' x 3' table with drawers on both sides (3 on each side)
c) 4 Nos. of 4' x 2 ½' table with drawers on both sides (3 on each side)
d) 2 Nos. of 3' x 2' table with single side three drawers
e) 30 Executive chairs (approved make) excluding chairs for Conference Room
f) 6 Nos. of Steel cupboards (Storewel type or similar approved)
g) 1 No. Drawing Cabinet
h) 4 Nos. of 4-Drawer Filing Cabinet
i) Filing cabinets, steel with locks and 4 drawers with suspended filing system
j) Refrigerator (200 litres capacity) of approved make.
k) 1 No. 55‖ LED Smart TV 4K resolution of Sony/LG/Samsung make
l) 4 Nos. LED Desk Lamp 7 watts
m) 4 Nos. Oscillating Desktop or wall mounted fan 400mm dia.
n) Vertical blinds / Curtains for all windows
o) Water supply / Plumbing / Electrical complete
p) Computer Table and Chair – 1 No.
q) Photocopier (50 to 200% zoom capability) with a paper storage desk – 1 No.
r) Personal Computer (approved Make) - 3 Nos. with following features, plus UPS:
 Intel Core i7-3630QM (3.4 GHz/2.4 GHz)
 ATX Cabinet (optional)
 256 KB external cache

 8 GB RAM
 500 GB HDD
 DRIVE DVD+RW
 48X speed CD-ROM on EIDE controller
 23‖ SVGA LCD flat panel colour monitor
 8 USB 2.0 ports, with at least 2 of these in the front
 Broadband Internet with 10 MBPS Speed with WiFi router
 Internet key board
 Optical Mouse and Mouse Pad (two sets)
 Pre-loaded with licensed Latest Operating System compatible with all
Engineering Software‘s.
 Comprehensive Security and Management features such as antivirus,
antispyware, and firewall.
 Additional software – MS Office, PDF Editor and AutoCAD (latest version)
 All the necessary consumables including paper, CDs, printer cartridges etc.
s) HP or equivalent Colour LaserJet Printer with scanner (suitable for A4/A3 size paper)
t) Fire Extinguisher – CO2 type (3 Kg) – 3 No.
u) Telephone line with STD facility and intercom facility.
v) Supply, Installation, testing and commissioning of Lighting System covering Lighting
Distribution board, Switchboards, Switch sockets, Power Plug and Sockets,
Luminaries Ceiling Fans Cables Conduits, wires earthing etc, for the Site Office
complete as per Specification.
Peripheral Lighting:
Bracket/Conduit mounted Peripheral Lighting shall be provided on all the corners of the
building.
The Lighting fixture shall have the following features

 Weather Proof Housing made of Powder Coated CRCA Sheet steel.
 Cover made of Opal acrylic.
 Designed for 1x 18/22 W, LED lamps/tubes.
3.8.3 Contractor’s Office
The Contractor shall, before commencing work, erect an office for his own use in a
position and to a standard and layout to be agreed by the Engineer. The office shall be
substantially built, weather-proof, well-lit and suitably furnished. It shall be properly
secure to keep safe the papers, documents and drawings handed to the Contractor by
the Engineer for use in carrying out the Works. The office shall contain a letter box for
the secure receipt of instructions, messages and mail from the Engineer and others. The
Contractor shall obtain the correct postal address and code for the office and notify the
Engineer accordingly. Messages or instructions left at or sent by post to this office shall
be deemed to have been served on the Contractor. The Contractor‘s office shall not be
removed from the Site until the Engineer, by notice in writing, calls upon the Contractor
to do so.
The Contractor shall provide, erect, construct, maintain and subsequently remove all
temporary messing and sanitary arrangements, stores, workshops, compounds, parking
areas, drainage, lighting and the like, necessary for the completion of the Works for the
use of his own staff and work force plus those of his Subcontractors in accordance with
the latest legislation.

The Contractor shall not permit any animals to be brought on to the Site, with the
exception of guard dogs properly trained and controlled by security personnel.
3.8.4 Telephone
 For Employer‘s Use:

The Contractor shall arrange for a telephone line with STD facility at proposed STP
site covered under the contract for sole use by Engineer. The Contractor shall pay for
the installation charges.
 For Contractor‘s use:
The Contractor shall arrange for the installation of a telephone and facsimile system
connected to the terrestrial public telephone system for the use of his own staff and
for those of his Subcontractors. These services shall be located in the Contractor‘s
offices at the STP Site. The Contractor shall be responsible for the task of
establishing, using, maintaining and removing the system. The Contractor‘s
Representative shall be provided with a mobile telephone by the Contractor.
3.8.5 Sanitary Arrangements
Throughout the period of construction of the Works the Contractor shall provide, maintain
and keep clean suitable and sufficient latrines for Employer‘s and Contractor‘s Office
separately. A separate arrangement for Men and Women toilets shall be provided. The
Contractor shall connect the latrines to sealed units suitable for disposal or to the
existing sewer on site subject to agreement from the Engineer.
3.9 Assistance to the Engineer
The Contractor shall provide all necessary assistance to the Engineer and his staff in
carrying out their duties of checking, inspecting, and measuring the Works. The
Contractor shall provide, at no additional cost, chainmen, staff men, office attendants,
and labourers as may be needed from time to time by the Engineer.
The Contractor shall provide for the Engineer and his staff, consultants and their staff
and visitors all required PPE‘s (Personnel Protective Equipment) as may be reasonably
required by them. These articles shall remain the property of the Contractor. No extra
payment shall be made on this account.
3.10 Instruments to be provided
The Contractor shall provide at his own cost for the exclusive use of the staff of the
Engineer all survey equipment and measuring instruments of approved make and of
every kind necessary for the execution of the Works, including
a) One 360 degree circle optic theodolite, accurate to one second, complete with
carrying case and sliding leg tripod.
b) One automatic surveyor‘s levels with horizontal 360 degrees circle, tripod with
carrying case.
c) Two staffs, 4.5 m long, each in 3 sections and with attached bubbles, graduated in
metres and tenth and hundredths of a metre.
d) Two Surveyor‘s steel bands of which one shall be 100 m long and approximately 20
mm wide and one shall be at least 30 m long and approximately 12 mm wide, each
fully divided, complete with tape thermometers and tension handles and wound on an
open plastic cross.
e) An adequate number of ranging rods, steel and linen tapes, string lines, pegs, lines,
spirit levels, survey umbrellas, lights, batteries, stores and tools.

The instruments mentioned above shall be for exclusive use of the Engineer and shall
remain in the custody of the Engineer till the Works are completed.
The Contractor shall be solely responsible for all such instruments and equipment and
shall ensure that they are at all times in good repair and adjustment and shall make good
any loss or damage howsoever caused. No extra payment shall be made on this
account.
3.11 Erection of Plant
Erection of Plant shall be phased in such a manner as not to obstruct the work being
done by other contractors.
Before commencing any erection work, the Contractor shall check the dimensions of
structures where the various items of Plant are to be installed and shall bring any
deviations from the required positions, lines or dimensions to the notice of the Engineer.
Plant shall be erected in a neat and workmanlike manner on the foundations and at the
locations shown on the Approved Drawings. Unless otherwise directed by the Engineer,
the Contractor shall adhere strictly to the aforesaid drawings.
Any damage caused by the Contractor during the course of erection to new or existing
plant or building or any part thereto, the Contractor shall at his own cost, make good,
repair or replace the damage, promptly and effectively as approved by the Engineer and
to the Engineer's satisfaction.
3.12 Site Labour and Supervision
The Contractor shall provide all the skilled and unskilled labour required, and all
necessary tools and equipment, to erect, test and commission the Works within the
period agreed in the programme.
The Contractor shall not remove any supervisory staff or skilled labour from the Site
without the Engineer's prior approval.
3.13 Sub-letting
The Contractor shall not sub-let / assign the whole of the Works. Where any design or
manufacture is sub-let, the Contractor shall not be relieved of his obligation under the
Contract. The Contractor shall be responsible for the acts, defaults and neglect acts in
manufacture or design of any sub-contractor, as if they were his own.
Where the Engineer has consented to supply of Plant or execution of work by

manufacturers or sub-contractors proposed by the Contractor, such manufacturers or
sub-contractors shall not be changed without the prior approval in writing of the
Engineer.
A copy of every sub-order shall be sent to the Engineer at the time the order is placed
each clearly marked with the title of the Contract and the Contract number.

3.14 Temporary Works
Not less than 14 days before commencing any portion of the Works, the Contractor shall
submit to the Engineer for his approval comprehensive drawings and calculations for all
Temporary Works which the Contractor proposes for the construction of that part of the
Works.
Notwithstanding approval by the Engineer of any design for the Temporary Works, the
Contractor shall be entirely responsible for their safety, efficiency, security and
maintenance and for all obligations and risks in regard to such Temporary Works
specified or implied in the Contract.
3.15 Languages
All drawings, instructions, signs, notices, name-plates, etc. for use in the design,
construction, operation and maintenance of the Works shall be in English.
All site sign boards and warning signs shall be in Marathi, Hindi and English Languages.
3.16 Drawings and Information to be provided
3.16.1 Pre-contract Drawings
The Pre-contract Drawings are those issued to Bidders either with the Bidding
Documents as Section VI C Background Information for the purpose of illustrating and
clarifying the Works described in the Employer‘s Requirements or later during the
bidding period as part of an Addendum to the Contract Documents.
Such drawings shall be deemed to have been issued for the guidance of Bidders and
shall, for the purpose of executing the Works, be superseded by the Construction
Documents.
a) Bid Drawings and Details
The Bid Drawings are those furnished by a Bidder with his Bid for the purpose of
illustrating and clarifying his proposals.
The following drawings, details and specific information pertaining to the entire
sewage treatment process / plant / ISPSs shall be furnished by the Bidder for STP /
ISPS in the technical envelope in addition to other information mentioned elsewhere
in the tender.
The lists provided below shall not be considered comprehensive. The bidder shall be
responsible for including any and all drawings and information for any and all works
that may be necessary for full and complete definition or clarification of the design,
regardless of whether or not such drawings, information, or works are explicitly
included in the lists below or elsewhere in these bid documents.
The bid drawings and other technical documents shall be submitted in soft copy
searchable format on CD(s) or DVD(s) as well as in hardcopy paper format.
1) General and Process

i. Narrative Description of the Works
ii. Plant Operation and Control Philosophy

iii. Sizing and Design Calculations covering all Major Unit Processes and
components of the Works
iv. Plan and L-Section Profile of Pumping Main
v. List of all structures (basins, tanks, channels, buildings, etc.) including
dimensions and freeboards
vi. Complete Equipment List
vii. Plant Layout.
viii. Hydraulic Profile.
ix. Process Flow Diagram.
x. Process and Instrumentation Diagrams (P&IDs)
xi. Electrical Load List & Power Consumption Chart.
xii. List of Chemical Consumption on Daily/ Monthly Basis.
2) Mechanical
i. To-scale dimensional layout and/or installation drawings for the following
Equipment, at a minimum:
 Raw Sewage Pump sets
 Process Equipment for primary treatment
 Process equipment for secondary / biological treatment
 Fine Bubble Diffuser Aeration System for the biological treatment
 Process equipment for tertiary treatment (filtration and disinfection)
 Sludge handing system (pumping, thickening and dewatering)
 Anaerobic digester heating and mixing system
ii. Graphs for all major pumps and blowers (including but not limited to Raw
Sewage Pumps, Primary Sludge Pumps, Return Activated Sludge Pumps,
Mixed Liquor Recycle Pumps, Thickened Sludge Pumps, Centrifuge Feed
Pumps, Process Air Blowers, Pump Performance Curves: Q vs H, speed, P,
Efficiency, and NPSH ISO-efficiency curves of the pump model proposed
3) Electrical
i. Summary description of Electrical Design
ii. Motor Control Centre Schedules
iii. Electrical Single Line Diagram.
iv. Details of Bio-Gas power Generation and Synchronisation
v. Sizing Calculations for Transformers.
vi. Specific Energy Consumption
vii. Technical Data Sheets-Volume-I for Electrical Works duly filled in.
4) Instrumentation Control and Automation
viii. System Architecture Drawing and Schedule
ix. Real time communication of Treatment Plant and Pumping Station status.
Historical data and trends to Local Control Centre and compatibility of
communication facility to Central SCADA System. (Central SCADA System
will be implemented in Package 11 of this project)
3.16.2 Contractor’s Documents
3.16.2.1 Format of Documents
i. The Contractor shall submit four paper copies and one copy in electronic format
(unless otherwise stated) of each drawing or document required to be submitted. The
Contractor shall mark incomplete areas of drawings ‗hold‘. Any revisions to drawings
or documents shall be clearly highlighted by the Contractor. The Contractor shall
note drawing amendments in the title box and mark amendments with a triangle
containing the revision number. Amendments to documents shall either be
redlined/struck out or marked in the margin.

ii. Drawings shall all have a similar title block which shall include the name of the
designer, the Contractor and the Employer, the name of the Contract, a unique
description of the content and a unique reference number complying with a
formalised numbering system. The title block shall be such that the whole title block
is visible including space for amendment information when folded to A4 size.
iii. Process and instrumentation diagrams (P&IDs) shall show in symbolic form the
process plant and systems of measurement, control and automation.
iv. Documents shall be in Microsoft Office format or equivalent approved by the
Engineer. Programmes shall be in the latest version of Primavera or MS Project.
Drawings shall be in AutoCAD or compatible equivalent.
The hardcopy format/sizes for various items shall be as follows:

v. Drawings: Standard A1 size paper. The scale for each drawing shall be selected
such that the information is presented without any clutter or ambiguity and is clearly
and easily legible without the use of magnifying aids other than a reader‘s normal
eye-glasses.
vi. All other information: Standard A4 or A3 paper size, except for any pre-printed
standard information such as brochures or catalogue information, which may be
submitted in the original size and format.
3.16.2.2 Design Stage Documents:
Design documentation shall be submitted to the Engineer as Contractor‘s design report.

The Contractor‘s design report shall as a minimum include the following elements.
i. Fully dimensioned general arrangement drawings for the buildings, tanks,
foundations, process units, access road, utility routes and general construction
details
ii. Hydraulic calculations and profiles
iii. Process and instrumentation diagrams (P&IDs)
iv. Process design calculations, results of dynamic simulation of process modelling
using BioWin®, or any other suitable programme, at designed average and peak
flows and loads with all assumptions, process flow and mass balance diagrams,
including flows in each area of the facility
v. Power single line diagrams
vi. Process data sheets to define design criteria, installed capacities and loading rates of
principal items of plant and equipment. Drawings to show physical sizes and layouts
of plant and equipment.
vii. Operation and Control philosophy report
viii. Load test schedules
ix. Instrument schedule
x. I/O schedule for each Motor Control Centre (MCC)
xi. SCADA/Instrumentation/Process Control system architecture
xii. Instrument list
xiii. Equipment electrical control schematics
xiv. Structural calculations for the structural components of the Works
xv. Building materials and finishes schedule
xvi. Materials handling procedures
xvii. Pipe work and ducting layout
xviii. Cable and wiring layout
xix. Hazardous area classification details
xx. Safety and health report
xxi. Disposal of unwanted materials offsite
xxii. Design and layout of earthing and lightning protection system
xxiii. Design and layout of lighting system

xxiv. Any other details/data/design required as per the proposed technology
3.16.2.3 Construction Stage Documents:
Construction or fabrication of any element of the Works and delivery or installation of

Plant and Materials shall not commence until relevant Contractor‘s Documents have
been submitted and the review has been completed by the Engineer. Relevant
Contractor‘s Documents shall include inter-alia:
i. All required approval and consents
ii. Approved Construction Environmental Management Plan (CEMP)
iii. Programme and Project Execution Plan.
iv. Construction method statements
v. Specifications
vi. Final design calculations
vii. Detailed construction drawings
viii. Materials, equipment and instruments approval documents
ix. Schedules
x. Inspection and test procedures
xi. Inspection and test certificates
xii. Safety certificates
xiii. Proof load tests
xiv. Performance curves
3.16.2.4 Plant and Equipment Documents
Plant shall not be delivered to Site until relevant Contractor‘s Documents have been
submitted and the review has been completed by the Engineer. Relevant Contractor‘s
Documents shall include inter alia:
i. Drawings of Plant and equipment
ii. Schedules of Plant and equipment
iii. Plant and equipment handling and installation method statements
iv. Test and inspection method statement
v. Test and inspection certificates
vi. Performance curves
vii. Safety certificates
viii. Certificate for equipment to be used in potentially hazardous atmospheres (where
relevant)
ix. Proof load tests for all lifting equipment
x. Plant delivery documents
xi. Vesting certificates (when equipment is to be placed into store and payment certified
by the Engineer).
3.16.2.5 Monthly Progress Reports during Design-Build Period:
The Contractor shall prepare and submit monthly progress. Each monthly report shall;
i. Provide the Employer with information reasonably required to assess the progress of
the construction and commissioning of the Works.
ii. Highlight current and potential future issues that may hinder progress.
iii. Project summary data including the planned date for the commencement of the
Operation Service Period.
iv. Labour resource data including a histogram of the actual and projected workforce on
Site.
v. Reference to the up-to-date construction programme.

vi. Progress against key milestones and key dates.

vii. A commentary on areas that are behind programme and details of measures being
taken to mitigate delays.
viii. An update on any proposed changes to the Contract.
ix. An update on the submission and review of Contractor‘s Documents.
x. Progress in obtaining all necessary approvals or permits.
xi. The health and safety record (including accident records).
xii. an update on toolbox talks
xiii. Environmental records (including records of complaints, breaches of permit
conditions and other environmental incidents, such as spillages on Site).
xiv. Details of any security incidents and changes to the Contractor‘s security measures.
xv. Details of any public relations incidents or activity.
xvi. Records of labour utilised and Contractor‘s plant and equipment on Site.
xvii. Copies of quality assurance documents, test results and certificates of Materials.
xviii. Details of the projected and actual payment profiles and estimated future
expenditure in quarterly periods.
3.16.2.6 As-built Documents
The Contractor shall prepare and submit as-built documents including drawings and
records during the Design-Build Period and shall submit them to the Engineer following
completion of each part of the Works, and within the periods stated in Clause 3.4 of this
document or as otherwise agreed with the Engineer.
As-built documents shall constitute a permanent record of the Works as completed or

executed.
As-built documents shall consist of final versions of those Contractor‘s Documents as are
necessary to fully record the design and construction of the Works, incorporating any
additional information that will assist the operator of the facility. They shall include inter
alia:
i. The final version of the design calculations
ii. Key construction records and tests
iii. Final versions of all drawings prepared during the Design-Build Period
iv. Final versions of the specifications
v. Quality control records for Materials
vi. Asset sheets
vii. Borehole records and soil test reports
viii. Survey records
ix. Any information requested to be provided in the form of as-built records elsewhere in
the Employer‘s Requirements.
Final approved as-built drawings shall consist of three copies on CD/DVD in AutoCAD
and pdf formats, plus three A1 and three A3 printed and durable copies.
3.16.2.7 Operation and Maintenance Manuals
The Contractor shall submit three hard copies of the Draft Operation and Maintenance
manuals for review and approval of the Engineer. Comments if any by the Engineer shall
be incorporated by the Contractor and six (6) hard copies and three (3) soft copies on
CD of the approved final version shall be submitted by the Contractor.

3.16.2.8 Submission of Documents and Drawings
The Contractor shall supply to the Engineer 5 (five) copies each of the drawings and
design calculations for the process and sizing of all components of the System including
architectural, structural, mechanical, and electrical and instrumentation equipment,
supported by flow diagrams and general arrangement drawings for approval.
3.17 Notice of Call for Inspection
The Contractor shall give full and complete written notice of all inspections to the
Engineer sufficiently at least 7 working days in advance to enable the Engineer to make
such arrangements as the Engineer may consider necessary for inspection and for any
other purpose. The Contractor shall not start any important operation without the written
approval of the Engineer.
3.18 Quality Management System
3.18.1 General
The Contract requires the Works to be executed and completed to a uniformly high
quality, to provide a treatment facility that is reliable, economic in operation with ease of
maintenance for the design life specified. The Contractor shall be responsible for
providing and operating his own quality control and checking procedures that shall be
demonstrably independent of those actually responsible for design and construction.
The Contractor shall institute, maintain and operate for the Contract Period a Quality
Management System complying with ISO 9001 as appropriate (accreditation is not a
requirement) or other equal and approved equivalent standard and of the Contract, for
the purpose of ensuring and demonstrating that all aspects of the Works and all other
matters for which the Contractor is responsible under the Contract are carried out in
conformity with the relevant provisions of the Contract.
The Contractor shall make a condition in each and every Subcontract and order for
Plant, Materials and services including design services whereby Subcontractors and
suppliers shall institute maintain and operate for the Design-Build Period a Quality
Management System complying with ISO 9001 as appropriate (accreditation is not a
requirement) or other equal and approved equivalent standard and of the Contract for
the purpose of ensuring and demonstrating the services or goods provided conform with
the relevant provisions of this Contract. Any such Subcontractor or supplier can achieve
compliance with the other provisions of this sub-clause by adopting and operating under
the Quality Management System and the Quality Plan as referred to elsewhere within
this part. The Contractor shall make a condition within each and every Subcontract to
provide for the Engineer access to facilities of a standard sufficient to enable him to take
such actions as he may consider necessary under this part.
Subject to the other requirements of the Contract the Contractor shall submit to the
Engineer for review his Quality Management System and his Quality Plan within the time
stated in clause 3.4.
The Contractor shall comply with the Quality Plan referred to in this part and shall ensure
that:
 the designer complies with the Quality Plan in respect of the design supervision of
the Works;

 the Contractor‘s subcontractors and suppliers comply with the Quality Plan referred
to within this part.
Where the Quality Plan refers to, relies on, or incorporates any quality manual or
procedure or method statement, then such quality manual or procedure or method
statement, or the relevant parts thereof, shall be submitted by the Contractor to the
Engineer at the time that the Quality Plan is submitted in accordance with this part. The
Employer may require the amendment of any such quality manual or procedure or
method statement to the extent necessary to enable the Quality Plan to satisfy the
requirements of this part.
The Contractor shall employ, for the duration of the Contract, a Quality Assurance /
Quality Control Engineer who shall have no other management role under this Contract.
The appointment of the Quality Assurance / Quality Control Engineer shall be subject to
approval by the Engineer.
Without limitation to the foregoing the Quality Assurance / Quality Control Engineer shall
be required to:
 Ensure the effective operation of the Quality Management System and the Quality
Plan;
 Audit the Quality Management System and the Quality Plan at regular intervals and
report the findings of such audit to the Engineer;
 Review the Quality Management System and Quality Plan at intervals to ensure their
continued suitability and effectiveness; and
 Liaise with the Engineer on all matters relating to quality management.
Without limitation to any other provision of this Contract, where required by the
Employer, any representative of the Employer may carry out audits of the Quality
Management System (including without limitation the Quality Plan and any quality
manuals and procedures) at approximate intervals of 3 months and may carry out
periodic monitoring, spot checks and auditing of the Quality Management System and
Quality Plan.
The Engineer reserves the right to audit, without prior notice, the quality of Works and
the Contractor‘s Quality Management System to verify compliance with the specified
quality requirements. The Contractor shall render every assistance and provide free and
unhindered assistance to the Engineer or any person authorised by him to carry out any
such audit.
All materials and workmanship shall be of the respective kinds described in the Contract
and in accordance with the Engineer or the Engineer‘s Instructions and shall be
subjected to the samples and tests required or reasonably implied by the terms of the
Contract and set out in the method statements, or which may be ordered by the
Engineer.
The acceptance by the Engineer of any part of the Quality Plan and the giving of his
consent to the procedures, proposals, records and certificates contained therein shall not
be construed as approval by the Engineer that the Works or any part of them have been
constructed or manufactured in accordance with the Contract.
The application of a Quality Management System by the Contractor shall in no way affect
either the Contractor‘s other obligations or the powers and duties of the Employer or
Engineer under the terms of the Contract.

3.18.2 Principal Requirements of the Quality Plan
The Contractor shall institute, maintain and operate a Quality Management System in
accordance with the provisions of this part. The Quality Management System shall be as
described in a written ‗Quality Plan‘ that shall be submitted by the Contractor to the
Engineer. The principal requirements that apply to the Quality Plan are set out below.
The Quality Plan shall be deemed to be part of the Contractor‘s Documents.
The Quality Plan shall cover but not be limited to the following items:
 Contractor‘s Organisation and management of the Contract;
 Contractor‘s Control of design;
 Contractor‘s Method statements and procedures for the Works;
 Contractor‘s Supervision of the Works;
 Contractor‘s Quality control for the construction of the Works;
 Contractor‘s Quality control for the Operation Service; and
 Subcontractor‘s or supplier‘s Quality Plans.
The Quality Plan shall show quality hold points where no further works or activity shall
proceed without the written approval of the designated person identified in the related
quality procedure, method statement or works instruction and quality witness points
where no further works or activity shall proceed without the designated person being
given the appropriate notice to visually inspect such works or activity as set out in the
related quality procedure, method statement or works instruction.
The Quality Plan shall contain, or incorporate by reference, documents which contain
requirements to produce quality records which shall include inter alia documents which
demonstrate the achievement by the Contractor of the Contract requirements such as:
 office and site logs,
 records of visits to any location or party in connection with the Works,
 office and site test results,
 records of verification,
 records of all supervision and witnessing with results carried out by the Contractor,
 All certificates and statements required by the Contract in respect of the Works.
Such records shall identify inter alia all design changes to products and specifications
and verification and traceability of all processes in connection with the design of the
Works.
The Quality Plan shall be demonstrated to be capable of controlling, indexing and cross-
referencing records of all drawings, designs, specifications, documents, test results,
certificates and construction documents which have relevance to the Works. The Quality
Plan shall be auditable and be subject to review by the Engineer and the Employer.
3.18.3 Engineer’s Monitoring of the Contractor’s Performance
The Contractor shall take due cognisance of any reports from the Engineer and action
them and integrate them into the Contractor‘s working quality procedures, method
statements or works instructions.
3.18.4 Particular Requirements of the Quality Plan
The Quality Plan shall conform with but not be limited to the requirements shown in
Clauses 3.18.4 (A) to 3.18.4 (G), as follows:
A) Contractor’s Organisation and Management of the Contract:

This part of the Quality Plan for the Contractor‘s organisation and management of the
Contract shall include but not be limited to:
i. the definition of the Contract and its documentation;
ii. the organisation of the Contract including the line of command and
communication links between all the parties involved in the Contract in the form
of annotated chart(s);
iii. the names, roles, responsibilities, curriculum vitae and authority of principals and
key personnel involved in the design, construction, operation and maintenance of
the Contract. These will include, where appropriate, the roles undertaken by the
project director, contracts manager, site agent/Contractor‘s project manager,
operatives, technicians, analysts, subcontractors, Contract Quality Manager,
representative for environmental protection, general foreman, foremen,
engineers, quantity surveyor, safety officer, Contractor‘s and Designer‘s
supervisor(s) for the Works, Designer‘s team leader(s) and Site representative(s),
checker‘s team leader(s), Contractor‘s and Designer‘s health and safety co-
ordinators and any other principal party involved in the Works;
a) documented procedures for the control of consultations, liaison and meetings
with third parties including the police, statutory bodies, undertakers and any
other companies;
b) the identification of the Contractor‘s staff responsible for overseeing and co-
coordinating each major activity including design, design checks, safety
audits and all Subcontract activities;
c) documented procedures for the control of Subcontracts which must include
the assessment of the Subcontractor‘s quality assurance and quality control
capabilities, the identification and implementation of additional controls
needed on such Subcontractors to fulfil the Contractor‘s obligations in respect
of this part and the Contract;
d) documented procedures for the control of all documentation including inter
alia documentation which has to be provided by the Contractor to the
Engineer or the Employer;
e) a programme for submission of designs, associated documentation, method
statements and Quality Plan;
f) the Quality Plans for Subcontractors and suppliers of work, Plant and
Materials which are the subject of quality management schemes;
g) documented procedures and method statements for the preparation, review
and adjustment of programmes for the effective progression and completion
of the Works in accordance with the other provisions of the Contract and the
recording of same;
h) documented procedures and method statements for the control and approval
of purchases of Materials;
i) documented procedures and method statements for the control of off-Site
activities;
j) documented procedures for the regular review and recording by the
Contractor which demonstrates that the Works meet the requirements of the
Contract;
k) documented procedures for the control of personnel selection which
demonstrate that such personnel have appropriate skill and experience for
undertaking their appointed role;
l) documented procedures for the management review/audits to monitor and
demonstrate control over the implementation of the Quality Plan;
m) documented procedures for the quality control of the Operation Service;
n) Any other relevant item which may during the Contract be brought to the
attention of the Contractor by the Engineer.

B) Contractor’s Control of Design
This part of the Quality Plan for the design shall include but not be limited to the
provision of:
i. the names and curricula of the key personnel who carry out the design;
ii. documented procedures and method statements for ensuring compliance with
the Employer‘s Requirements;
iii. documented procedures for the review of the design including the frequency of
and personnel responsible for such reviews;
iv. a description of arrangements for the checking of the design and liaison with the
checker;
v. a description of arrangements for the interface with supervision of the Works;
vi. Any other relevant item which may during the Contract be brought to the attention
of the Contractor by the Engineer.
C) Contractor’s Method Statements and Procedures for the Works
This part of the Quality Plan for the Contractor‘s method statements and procedures
for the Works shall include but not be limited to:
i. the names and curricula vitae of the key personnel who will carry out the
management;
ii. a list of Subcontractors to be employed on the Works;
iii. a list of the quality procedures and method statements to be provided;
iv. identification of specialist activities and personnel to be employed carrying out
such activities;
v. arrangements for quality control of purchased Plant and Materials;
vi. arrangements for quality control of all Plant and Materials sourced on or off site;
vii. detailed written method statements for each major activity whether such activities
are directly controlled by the Contractor or subcontracted;
viii. The written method statements shall identify quality hold points and witness
points and invoke for all activities:
a) work instructions;
b) quality control procedures;
c) compliance testing/inspection arrangements; and
d) Work acceptance procedure.
Method statements shall inter alia describe each stage of the construction, including the
layout of the Works and of the Operation Service. The method statements shall also
identify the Plant and Materials to be used in the Works, Temporary Works, safety
measures, working space considerations, and where appropriate the requirements for
skilled labour and/or special supervision and similar. Method statements shall show how
the proposed operations ensure that impacts are restricted to the best possible
environmental option and shall include contingency plans and environmental procedures
to minimise damage caused by accidents, spillages or other unforeseen events. The
method statements shall include procedures for notifying the public or statutory bodies
and authorised authorities.
The Contractor shall state where work is subject to environmental requirements, for
example, temperature, noise and dust control, working hours, traffic conditions, vehicle
routings, screening and the like.
The Contractor shall identify ―hold points‖ at stages of work where checks are necessary
before continuing. The authority for release of the ―hold points‖ shall also be identified by
the Contractor in the method statements.

The Contractor shall identify ―witness points‖ at stages of work where such witness
points are required. Such witness points shall include Engineer‘s witness points. The
Contractor shall state in the method statements the notice required to be given to
personnel carrying out such witnessing.
i. The identification of the relevant procedures in the Contractor‘s own Quality
Management System. Procedures invoked by method statements shall include
procedures from the quality controls required by the Contractor‘s construction quality
control:
a) the control, identification and traceability of materials;
b) procedures for the prevention of inadvertent use, installation or covering up of
non-conforming work; and
c) Any other corporate and/or contract specific work instructions to be applied.
ii. Schedules of tests and inspections proposed.
iii. Any other relevant item which may during the Contract be brought to the attention of
the Contractor by the Engineer.
D) Contractor’s Supervision of the Works
This part of the Quality Plan for the supervision of the Works shall include but not be
limited to:
i. the names and curricula vitae of all personnel to be employed in the supervision
of the Works;
ii. a description of arrangements for the interface with procedures and method
statements in respect of the construction of the Works;
iii. a description of the interface with procedures for design;
iv. arrangements for liaison and meetings with interested parties;
v. arrangements for the control of personnel selection which shall be based on
consideration of skill, care, diligence and experience qualities;
vi. a statement of the Contractor‘s (and his designer‘s) responsibility to supervise the
Works including the duty to supervise the construction, completion and testing of
the Works;
vii. documented procedures for undertaking the supervision of the Works detailing:
a) the stages of work when the inspection(s) is to be undertaken;
b) the personnel carrying out the inspection(s);
c) the frequency of inspection(s);
d) the procedures to be followed when detailing with non-conforming works; and
e) the recording of inspection(s)
viii. documented procedures for the review of the extent and frequency of
supervision;
ix. documented procedures for the issuing of construction certificates;
x. documented procedures for document control including the receipt, control and
retention of all documents;
xi. documented procedures for reporting progress and the identification of problems;
and
xii. documented procedures for the observation of sampling, testing and the reporting
of results of testing; and
xiii. any other relevant item which may during the Contract be brought to the attention
E) Contractor’s Quality Control for the Construction of the Works
This part of the Quality Plan for the Contractor‘s quality control for construction of the
Works shall include but not be limited to:

i. a statement of the Contractor‘s organisation for quality control and shall identify
the:
a) responsibility for the initiation and updating of the Quality Plan;
b) responsibility for the adequacy of the quality records produced.
ii. documented procedures for the arrangements for ―receiving‖ and ―in-process‖
testing;
iii. documented procedures for the control of test laboratories;
iv. documented procedures for the control of test, measuring and inspection
equipment;
v. documented procedures for document control and shall include their
identification, traceability requirements, control of document issues and their
status. Documents recording the verification, review, approval, release and
amendment of the Works shall similarly be controlled;
vi. documented procedures for monitoring and recording the inspection, test and
approval status of the construction/installed work including the identification of
―hold points‖;
vii. documented procedures for tests and inspections for the purpose of the
Contractor certifying that prior to covering up, each part of the Works is complete
and conforms to the Contract. The procedures shall identify the proforma and/or
database to be used for recording the inspection and test results, and the
proforma to be used for recording the certification of compliance of all items of
the Works by authorised key personnel. The Contractor shall identify each
submission separately;
viii. documented procedures for the review of work submitted for review but not
accepted as conforming to the Contract. These procedures shall include options
for identification of non-conforming work and proposals for reworking and
remedial work;
ix. documented procedures for the collation of quality records;
x. documented procedures for inspection and testing of Plant, Materials and
equipment; and
xi. any other relevant item which may during the Contract be brought to the attention
F) The Contractor’s Quality Control for the Operation Service
This part of the Quality Plan for the Contractor‘s operation and maintenance quality
control for the Works shall include but not be limited to:
i. a statement of the Contractor‘s organisation for quality control and shall identify
the:
a) responsibility for the initiation and updating of the Quality Plan;
b) responsibility for the adequacy of the quality records produced;
ii. documented procedures for the control of test laboratories;
iii. documented procedures for the control of test, measuring and inspection
equipment;
iv. documented procedures for identifying the procurement of Plant conforming to
the design requirements and for ensuring the continued performance to these
standards;
v. Documented procedures for identifying the introduction of new legislation,
standards, Laws and regulations and their implementation;
vi. documented procedures for document control and shall include their
identification, traceability requirements, control of document issues and their
status. Documents recording the verification, review, approval, release and
amendment of the Works shall similarly be controlled;

vii. documented procedures for the review of work submitted for review but not
accepted as conforming to the Contract. These procedures shall include options
for identification of non-conforming work and proposals for reworking and
remedial work;
viii. documented procedures for the collation of quality records; and
ix. documented procedures for inspection and testing of Plant, Materials, equipment
and any other relevant item which may be brought to the attention of the
Contractor by the Engineer.
G) Subcontractor’s or Supplier’s Quality Plans
The Quality Plan for Subcontractors (including suppliers of Plant and Material) shall
include but not be limited to:
i. a definition of the product or service which is to be provided;
ii. Annotated chart(s) showing the organisation structure of the Subcontractor
describing the line of command and stating the name of the senior manager
responsible for the contracted work and the name of the Subcontractor‘s on-site
management representative. The Subcontractor shall provide contact addresses,
telephone numbers and the like. This must address all activities, including those
which have been sub-let. The Subcontractor shall provide names of any suppliers
involved in the production;
iii. the identification of the relevant parts of the Subcontractor‘s Quality Management
System relevant to the product or service being provided;
iv. documented procedures for the control of personnel selection (at Works and on
Site), including special requirements for skilled personnel for example;
certification of welders, training of operatives, experience requirements and the
like. The Subcontractors shall provide evidence that the training and experience
requirements given in the appropriate Quality Management System are being
met;
v. documented procedures for the receipt and examination of certificates of
conformity and test results for purchased products;
vi. documented procedures for product identification and traceability. Each piece or
bundle of delivered product shall be indelibly marked and where appropriate, the
lot identification shall be included on each package;
vii. documented procedures for handling, storage, packaging and delivery to Site and
storage and handling on site, including instructions for repair of damaged
products where appropriate; and
viii. documented procedures for compiling records which shall include documents to
demonstrate the achievement of the requirement standard for example; site logs,
record of visits, records of verification, review and release, certificates of
conformity and records of all design modifications to products and specifications.
3.18.5 Monitoring during the Operation Service Period
The Contractor shall develop monitoring and sampling plans as part of Contractor‘s
Quality Plan for the Operation Service. These plans shall be implemented to ensure that
all required analyses and reports are completed fully and accurately to exacting
specifications, following standard methods and procedures, in a timely manner and in
support of other performance requirements of the contract.
The plans shall clearly distinguish between the monitoring required to meet regulatory
requirements and the monitoring required meeting the Contract requirements. The plans
shall include:

 A list of all parameters to be monitored as part of these plans. These plans shall
include a schedule of the proposed monitoring quality control requirements,
describing which parameters will be monitored on a daily, weekly, biweekly and
monthly basis.
 A laboratory manual, which shall describe the Contractor‘s approach to attaining the
highest standards of laboratory performance. The manual must outline the methods
for each test to be performed. The plan shall identify which tests will be conducted in-
house and those to be performed by Contract laboratories. All laboratories
performing tests shall be subject to approval by the Engineer. In addition, the
laboratory manual shall specify the type and model of all equipment to be used in
performing all tests by the Contractor.
 Minimum experience and qualifications of individuals or Contract laboratories
performing testing services.
 A description of analysis techniques that will be implemented to ensure that all
regulations and standards are met. The plan must provide examples of any tools
such as flow charts, check sheets or any other data presentation and evaluation
techniques that will be utilised.
 A description of all calibration techniques, quality control procedures, including those
to be utilised for all equipment used for testing and measuring different parameters
within the treatment process and at the in-house laboratory and Contract
laboratories. The description shall address the calibration practices, including the
frequency and accuracy requirements. The calibration procedures shall consider
intermediate spot and cross checks, in addition to the scheduled formal calibration
checks.
3.18.6 Submission of Quality Plan
Sections of the Quality Plan as far as they relate to the Design-Build Period, shall be
submitted by the Contractor to the Engineer for his approval within the date stated in
Clause 3.4 for the submission of the Quality Plan, the remaining sections being provided
as soon as practicable thereafter.
Sections of the Quality Plan as far as they relate to the Operation Service Period, shall
be submitted by the Contractor to the Engineer for his approval within the date stated in
Clause 3.4 for the submission of the Quality Plan, the remaining sections being provided
as soon as practicable thereafter.
The Contractor shall submit the remaining parts of the Quality Plan to the Engineer for
review at least two weeks prior to commencement of any associated work or activity and
to the programme included with item 3.18.4 (A).
3.18.7 Review of Nominated Laboratory
A Nominated Laboratory shall mean one or more laboratories located on Site or off Site
and used for the purpose of undertaking all tests for acceptance, compliance or payment
purposes, nominated by the Contractor. A Nominated Laboratory shall be nationally
accredited (NABL) for all tests that are to be undertaken. The Contractor shall ensure
that the accreditation is maintained throughout the Operation Service Period. The
Nominated Laboratories shall operate to ISO 17025.
At least one month prior to any testing or analysis at the proposed laboratories the
Contractor shall inform the Engineer of his intended Nominated Laboratories and which
tests are to be undertaken in each of the Nominated Laboratories. This may be more
than one laboratory. The Contractor shall carry out an assessment of the Nominated

Laboratories to ensure that they are accredited. The Contractor shall provide an
assessment report to the Engineer for review.
The Nominated Laboratories shall be subject to the approval of the Engineer, which
approval shall not be unreasonably withheld.
The sampling gathering and testing protocol(s) shall be based on or equal to the latest
edition of APHA/AWWA/WEF Standard Methods for the Examination of Water and
Wastewater. The accredited testing laboratory shall be fully conversant with these
methods.
3.19 Licences and Consents
The Contractor shall be responsible for obtaining all consents, permits, licenses and
approvals/clearances (including pending, re-validation and renewals) required for the
project. The Contractor shall also allow sufficient time for the necessary procedures in
his programme. Any delays associated with obtaining any licenses, permits, and
consents shall be the responsibility of the Contractor. No extension of the contract shall
be granted/given due to delays in obtaining consents, permits, licenses and
approvals/clearances (including pending, re-validation and renewals) required for the
project.
The Contractor shall carry out the Operation Service in accordance with all consents,
permits, licenses and approvals required.
The Contractor shall submit to the Employer in advance a list of licenses, permits and
consents required for the Contract and the Employer shall determine which of these shall
be in the name of the Employer. However, the Contractor shall bear all costs associated
with the licenses, permits and consents.
In case, during period of operation and maintenance any additional permits, consents
clearances etc. are required due to change in government laws, policy etc, the contractor
shall obtain the same at no extra cost to the Employer.

4 Process Requirements
4.1 General Requirements
The Contractor is responsible for the design and construction of the Works and for the
subsequent provision of the Operation Services in accordance with the Contract. The
Contractor shall select the type, number, sequence and configuration of process units
needed to achieve the effluent standards. The Contractor's design of the Works shall be
in accordance with these Employer‘s Requirements.
The Works shall be capable of conveying and treating the maximum flows and loads.
The Contractor shall also allow in his hydraulic and process design for the full treatment
of recirculation flows (and associated loads), including but not limited to the dirty
washwater from the screenings and grit treatment systems, supernatant and filtrate and
miscellaneous other liquors from the sludge treatment processes in addition to any other
relevant design parameters not specifically identified here.
The process units shall be selected and sized based on minimum process design
parameters given in this section. All tenderers shall complete and return the schedule of
design parameters with their tenders – no departure from the minimum design
parameters shall be accepted without written approval from the Employer.
4.2 Process Requirements
The following main treatment processes are envisaged in the contractor‘s design of the
works: -
Sewage Treatment Plants:
Sr. Average Daily Flow,

Process Unit Peak Flow, MLD
No. MLD
Raw Sewage Pumping Station
1. 1
Receiving Chamber 75 150
2. Coarse Screen Channel 75 150
3. Raw Sewage Sump 75 150
Preliminary Treatment
4. Inlet Chamber 75 150
5. Fine Screen 75 150
6. Grit Chamber 75 150
Primary Treatment
7. Primary Clarification 75 150
Secondary Treatment
Biological / Secondary 75 150
8.
Treatment

Part 4: Process Requirements
Sr. Average Daily Flow,

Process Unit Peak Flow, MLD
No. MLD
Tertiary Treatment
9. Disinfection 75 150
10. Tertiary Filtration 75 150
Sludge Thickening
11. Sludge Thickener Based on sludge production
Digestion & Biogas Storage
12. Anaerobic Digestion Based on Primary &
13. Biogas Holding Secondary Sludge generation from Primary &
Biological Treatment
Energy Recovery Using
14.
Digester Biogas
Sludge Dewatering Unit
15. Sludge Dewatering Unit Based on Sludge Generated from Digester
Storage and disposal of all wastes including screenings, grit & sludge
The provision of Primary Clarification Tanks is a requirement of the Contract. It is

considered that increased biogas production and energy recovery can be achieved from
Primary Sludge.
The Works at the treatment facility shall also include but not be limited to the items listed
below:
 Transfer of flows via open flow channels and underground conduits
 Flow measurement at various locations
 All ancillary mechanical and electrical installations associated with the main
treatment processes, including relevant safety and firefighting equipment, and
ventilation and odour control, where appropriate.
 Suitable and appropriate lifting equipment for maintenance and operation
 Potential septicity treatment (if required)
 Facilities for collection of refused material such as screenings, grit, dewatered sludge
etc.
 Provision of Electricity, Water and other utilities and services to the site and within
site
 Cabling and all electrical installation equipment and materials
 Process Control, monitoring and instrumentation
 SCADA System, telemetry and Alarm Equipment
 Provision of Testing and Laboratory Facilities
 Provision of Spare Parts
 Dewatered Sludge Storage facilities at site for a maximum of 7 days period;
 Grit storage facility at site for a maximum of 7 days period;
 Sludge Handing Facilities
4.2.1 Standby Requirements
The Contractor shall design the Works such that each stage of the process includes
appropriate standby capacity and bypass arrangements. The works must be designed
such that at Peak Flow any individual unit can be taken out of service for planned
maintenance work without breaching the specified performance requirements. This

requirement includes all process and hydraulic units including biological treatment and
settlement tanks.
All mechanical and electrical plant shall be arranged in duty/standby configurations with
automated rotation of duty to ensure even wear, and automated changeover to standby
units in the event of plant failure. Standby plant shall be of the same type and capacity
as the duty plant. The following table gives the minimum standby capacity requirement
versus the number of duty plant units.
Table 4-1 Minimum Standby Requirements
No of duty units Minimum Standby (%)

1 100
2 50
3 33
>3 25
For all process units, tanks and containers, the Contractor shall build in facilities for
draining down and bypassing without the need for portable equipment, except for
emergency provision. The Contractor shall automate draining down where appropriate
and shall make allowance in the treatment stages for return of liquors generated during
draining down and cleaning of the works.
4.2.2 Bypass Requirements
The Contractor shall provide an emergency bypass channel or pipe for the whole of the
Works capable of handling the Peak Flow. The emergency bypass shall lead from a
designed emergency overflow at the Inlet Chamber to the Outfall and include
connections from key points in the process such that in the event of a blockage or
complete process failure, partially treated effluent from Grit Chamber, Primary
Clarification, and Secondary Treatment could continue to be discharged to the river.
Access points to the bypass (i.e. designed overflow points in the Works) shall include
devices to record overflow events with instantaneous and cumulative flow data, which
shall be logged in the SCADA system
4.3 Influent Wastewater Characteristics
For design purposes, the characteristics of raw sewage are to be taken as follows,
considering the fact the Employer is implementing various initiatives to channelize the
sewage to the treatment plants and the design parameters adopted are similar to those
at other STP‘s.
Parameter Influent Quality Unit

pH 7.0-8.0
BOD3 (3 days at 270C) 250 mg/L
COD 450 mg/L
TSS 350 mg/L
TKN 45 mg/L
NH4-N 35 mg/L

Parameter Influent Quality Unit

Total Phosphorus 6 mg/L
Alkalinity 300 mg/L
0
Min. Sewage Temperature (Tmin) 22 C
0
Max. Sewage Temperature (Tmax) 28 C
0
Min. Ambient Temperature 10 C
0
Max. Ambient Temperature 45 C
4.4 Effluent Quality Requirements
The contractor shall design the process in such a way that the treated effluent quality (at
plant outlet) meets the following standards or better.
Particulars To be Guaranteed by Bidder

pH 6.5-9.0
0
BOD3 (3 days at 27 C) ≤ 10 mg/L
TSS ≤ 10 mg/L
Total Nitrogen ≤ 10 mg/L
Ammonical Nitrogen (NH4-N) ≤ 5 mg/L
Total PO4-P (TP) ≤ 2 mg/L
Fecal Coliform < 230 MPN/100ml
The contractor shall maintain guaranteed parameters for treated effluent quality listed
above during defect liability period and O&M period.
4.5 Dewatered Sludge Quality Requirements
The sludge quality requirements to be met are listed below:
Sludge Quality Requirements (Dewatered Sludge)

Sludge Quality Digested Stabilized Sludge
Minimum Sludge consistency after dewatering 25% (+/-) 2% w/w
The dewatered sludge should be truck-able & be suitable for disposal by open body
truck.
4.6 Treatment Process
Bidder shall construct the proposed STP of design average daily flow of 75 MLD.
Existing Bhairoba Pumping Station Capacity is currently not in operation. This non-
functional pumping station is to be demolished and cleared for the construction of
proposed 75 MLD STP
The Bidder can propose any treatment scheme in which the liquid treatment biological
process is aerobic activated sludge process with biological de-nitrification, and the

sludge/solids treatment process is anaerobic digestion followed by mechanical

dewatering, and biogas cleaning and power generation.
For Secondary Treatment and for Anaerobic Digestion, if the Bidder is proposing
proprietary technology not owned by / not licensed to the Bidder, then the Bidder shall
include the MoU with the Technology Provider in his Bid as per the format given in
Volume I. Client / End-user certificates shall be enclosed for the proposed technology to
demonstrate that wastewater treatment facilities; at least One number of minimum 55
MLD ADWF capacity or Two numbers of minimum 35 MLD ADWF capacity or Three
numbers of minimum 25 MLD capacity; have been operating successfully with the
nominated technology for minimum period of last 5 years.
4.7 General Design Requirements
The Bidder shall include Capacity / sizing calculations in the Technical Bid as per the
procedures given in Metcalf & Eddy latest edition, and the adopted design values
(retention times, loading rates, performance / removal rates etc) shall be compliant with
those in Metcalf & Eddy latest edition and the Manual on Sewerage and Sewage
Treatment Systems published by CPHEEO in November 2013 (latest edition). Flow and
load from Return streams (dewatering centrate, supernatant etc) is to be accounted for in
the design.
The hydraulic calculations shall be as per the procedures and design parameters
specified in Manual on Sewerage and Sewage Treatment Systems published by
CPHEEO in November 2013 (latest edition), and any hydraulic elements not covered in
the CPHEEO Manual shall be designed as per standard hydraulic design textbooks such
as Fluid Mechanics and Hydraulic Machines (6th Edition) R.K. Bansal, and Waste Water
Treatment Plants - Planning, Design and Operation (2nd Edition) by Syed R Qasim.
The following general design requirements shall be met for all ISPSs, Pumping Mains,
and STPs. These requirements shall be fully met regardless of whether or not such
requirements or any related components are shown in any drawings included in the
contract documents.
 The Contractor shall perform a complete Hazardous Area Classification analysis

per IS 5572 for all ISPSs, Pumping Mains, and STPs in this contract and shall
submit a complete report of such analysis as well as Hazardous Area
Classification Drawings that delineate boundaries of all classified areas and
indicate the classification of each area. All electrical or other powered equipment,
instrumentation, or components shall fully comply with all requirements of IS
5571.
 All components (including but not limited to equipment such as pumps, blowers,
screens, diffusers, inline devices; instruments such as flow meters; and
distribution and collection channels or pipes) shall be provided with appropriate
isolation devices such as valves, gates, or other devices in order to allow
isolation, drainage, cleaning, calibration, servicing, and maintenance of such
components.
 Bypasses shall be provided around all magnetic flow meters and other in-line
instrumentation for pipe sizes larger than 300mm such that the instrument can be
isolated and removed for calibration and maintenance without interrupting the
flow, regardless of whether or not such bypasses are shown in any drawings
included in the contract documents. For in-line instruments with pipe diameter
smaller than 300mm, spool pieces shall be provided such that the instruments

can be removed for calibration and maintenance with minimum interruption to the
flow.
 Where necessary, equipment shall be provided with acoustic, sound-dampening
enclosures to limit ambient noise during normal operation to the limits detailed in
the General Requirements.
 All equipment shall be arranged and buildings and structures designed to permit
safe and easy access to and removal of all equipment.
 Fixed runways, lifting eyes, cranes, hoists, or other appropriate devices and
means shall be provided to permit safe and easy removal of all equipment for
maintenance or any other purpose
 All structures, whether liquid-holding or not, shall be designed such that they can
be fully and completely drained and will not float or move when empty, because
of groundwater buoyancy or any other reason. The structures shall be designed
to counteract any possible floatation without the use of any type of groundwater
pressure relief valves.
 Non-liquid-holding areas, structures, or buildings where leakage or other wet
activities can occur, whether in normal use or during maintenance, shall be
provided with covered drainage channels which shall direct the spillage either to
a suitable gravity drain or to a sump equipped with standard dual submersible
sump pumps discharging to the Plant Drain Pump Station.
 All concrete structures in contact with sewage and/or sludge upstream of the
Aeration Basins shall be provided with full interior corrosion protection linings
and/or coatings of appropriate material and thickness – to be approved by
Employer and Engineer. This also applies to all concrete structures in contact
with any type of sewage sludge anywhere in the plant. For Aeration Basins,
interior lining shall extend from the top of wall down to 1 meter below the lowest
operating water level.
 All channels carrying process liquid shall be fully covered with solid non-skid
GRP cover plates (not grating) designed for at least human traffic live loads, and
heavy vehicle live loads wherever the channel crosses traffic paths.
 All piping shall be of corrosion–resistant material appropriate for the service and
shall be provided with interior lining, exterior coating, and other corrosion
protection as appropriate. All piping shall be fully and adequately supported and
braced to comply with all applicable codes and standards. All supporting
hardware shall also be of corrosion-resistant material. The design of pipe
supports and anchors shall fully account for static and dynamic vertical, lateral,
longitudinal, and seismic loads, fluid flow, and thermal expansion. Seismic
bracing, thrust restraints and/or thrust blocks, and appropriate expansion joints or
loops shall be provided as needed. Pipe lengths and joints shall be assembled
and arranged for ease of removal in such a way that individual runs can be
changed without dismantling adjacent pipes, by providing dismantling joints at
regular intervals.
 All liquid service pipes shall be provided with appropriate means for safe and
easy drainage of the pipes when not in service.
 All pipes shall be colour banded and suitably labelled with the stream designation
and direction of flow to enable individual lines to be identified throughout their
run.
 Particular attention shall be paid to the layout of the chemical piping, which shall
be arranged without clutter and shall be functional and neat in appearance.
Generally, where piping is installed in ducts, it shall be supported not less than
150 mm clear of the floor.
 All piping routed under any type of structure or equipment shall be fully and
completely encased in reinforced cement concrete, with the encasement

thickness beyond the outer diameter of the pipe being at least 200 mm on all
sides. The encasement shall extend along the pipe length for a minimum
horizontal distance of 1500 mm in each direction beyond the footprint of the
overlying structure or equipment.
 All piping connecting to, entering, or exiting any and all structures shall be
provided with appropriate restrained flexible connections and/or joints at all such
interfaces with structures to allow for differential movement between pipe and
structure in all directions without stressing or breaking the pipes.
 Appropriate restrained flexible connections and/or joints shall be provided for all
pipes where they connect to any and all of the following:
o Equipment such as pumps, blowers, or inline devices
o Valves
o Wall, floor, or roof penetrations
 Where piping or other materials susceptible to damage from ultraviolet radiation
are employed, they shall be protected from such radiation through the use of
appropriate additives and/or coatings and shall be physically shielded from direct
sunlight at all times in their normal service location using enclosures, covers,
canopies, roofs, and/or other similar means.
 Platforms, handrails/guardrails, ladders, and stairs shall be provided where
necessary for proper, safe, and easy access to and/or operation of valves, gates,
instruments, control panels, and other devices, equipment, or structures.
 Appropriate sampling ports and/or sampling valves shall be provided to allow
easy, safe sampling of all process streams without spillage or contamination and
without the need to interrupt normal operation.
 The influent flow meter and influent sampling location shall be selected such that
the true influent flow and characteristics will be measured without inclusion of in-
plant recycles or other extraneous streams. Separate flow measurement and
sampling shall be provided for the recycle streams.
 Foam, scum, fats, oil, grease, or any other floating material removed from any
location in the STP shall be completely removed from the process flow path along
with waste, digested, and/or dewatered solids leaving the STP and shall under no
circumstances be recycled or returned to any location in the plant.
 For secondary clarifiers and also for gravity sludge thickeners, the design shall
provide for separate and independent measurement and control of the flow rate
of sludge withdrawal from each individual clarifier or thickener unit. Such
individual control shall be achieved through direct withdrawal of sludge from each
unit using one or more dedicated pumps and feedback flow control using
separate measurement of flow from each unit. Designs using a common suction
header or common wet well shall not be acceptable.
4.8 Demolition of or Interfaces and Tie-Ins with Existing Facilities
All existing facilities that are to be demolished shall be properly decommissioned,

removed, and appropriately disposed of by the Contractor in accordance with all
applicable laws, regulations, and standards. Items, components, or materials, whether
buried, exposed, submerged, or otherwise, shall not be abandoned or left on site unless
explicitly indicated in the Tender Documents. For facilities that are to be eventually
demolished but must remain in service until alternate or replacement facilities are
constructed and commissioned, whether under this contract or a different contract, the
Contractor shall ensure that the facilities are protected and remain functional until such
time as the alternate or replacement facilities are constructed, tested, commissioned,
and accepted by Employer.

All existing facilities that must remain in service permanently shall be protected by the
Contractor such that they remain fully functional, operable, and serviceable throughout
construction, testing, and commissioning of the new facilities. The Contractor shall be
fully responsible for installation and, if necessary, ultimate removal of any temporary
facilities or connections (piping, utilities, power, controls, etc.) that may be necessary to
maintain existing facilities fully operational throughout construction and commissioning.
Temporary or permanent interfaces between existing and new facilities may involve
making connections or ―tie-ins‖ to existing live structures, piping, wiring, cabling,
equipment or other components. The Contractor shall be fully responsible for detailed
design, planning, and implementation of such interfaces in a safe and secure manner.
4.9 Process and Facilities Description
4.9.1 Raw Sewage Pumping Station - 75 MLD
Gravity sewer of xxx dia will discharge raw sewage into Receiving Chamber of RSPS
(Raw Sewage Pumping Station) to be located at the STP site with sluice gate from
where it will be conveyed into downstream Coarse Screen Channels. RSPS shall be
designed for 75 MLD average daily flow and 150 MLD peak flow.
4.9.1.1 Receiving Chamber
The Receiving Chamber shall be provided for receive incoming flow and the same shall
be designed for Peak Flow. The Receiving chamber shall be covered.
Design Criteria for Receiving Chamber

Design Flow : 6250 m3/hr (Peak Flow)
Average Flow : 3125 m3/hr (Dry Weather Flow)
Minimum HRT at Peak Flow : 30 Sec
Minimum No. of Units : 1
4.9.1.2 Coarse Screening
Screening is essential for removal of floating materials which are mainly sachets, plastic
sheet bits, leaves, fibres, rags, etc. If these are not removed, they may obstruct the
treatment units, plant internal pumping, sludge removal equipment, valves, channels and
pipelines creating problems during plant operation and maintenance.
Contractor shall have to provide automatic mechanical coarse screens to remove

particles larger than 20 mm size. Motorised Penstocks (upstream and downstream of
each screen) shall be provided for isolation of each screen.
The screens shall be equipped with an automatic cleaning system to prevent blockage.
The Contractor shall ensure that the screen cleaning system can be operated
intermittently and can be controlled by both an adjustable timed cycle and a pre-set
differential head across the screen. The screens shall be equipped with multiple rakes
such that the maximum time between raking any point on the screen is 20 seconds in fair
season and 10 seconds during monsoon.
The Contractor shall ensure screenings removed from the flow are conveyed through a
belt / screw conveyor to a washer and compactor where the screenings shall be washed,
dewatered and compacted. The screens shall be provided with an organic washing and

return system utilising final effluent. The Contractor shall provide all necessary treatment,
filtration and pumping for the treated effluent which is necessary for this purpose.
The Contractor shall return the dirty wash water and organics from the screening
systems to the main wastewater stream upstream of the screens for treatment.
In order to minimize odour nuisance, the screenings should be stored in suitable

enclosed containers. There shall be proper provision for storage of empty screenings
containers/bags on the STP Site. These containers shall be thoroughly clean and odour
free. The Screenings shall be safely transported and disposed to a legal, licensed
Landfill Site.
Design Criteria for Coarse Screening

Mechanical Multi Rake Bar
Type of Screen :
screen
MOC of screen : SS 316L
Angle of inclination of screen : 70 to 80 Degrees
Maximum velocity through screen opening at
: 1.2m/s
Peak flow
Maximum screen opening : 20 mm
Maximum head loss at 50% blocked condition : 300 mm
Screenings conveyor;
Ancillary equipment : Screenings washer and
compactor
Minimum dry content of compacted screenings : 35%
Maximum organic content of washed
: 20%
screenings
Minimum volume reduction due to compaction : 50%
4.9.1.3 Raw Sewage Sump (Wet Well)
Screened sewage will enter into wet well of the respective sewage pumping station.
Suitable configuration of Submersible Pumps will be provided to cater the pumping
requirements.
Design Criteria for Wet Well

Minimum HRT at Design flow for Volume of
: 5 min
Wet Well (Civil Construction)
2 m min with additional depth required
Effective Operating Sewage Depth :
for the submergence of pumps
Pumping Requirements : Based on Design Flow of 2344 m3/hr

4.9.2 Preliminary Treatment
4.9.2.1 Inlet Chamber
The Inlet Chamber shall be provided to receive incoming flow and the same shall be
designed for Peak flow plus any waste streams (centrate, wash water, drain flows etc.)
designed to be returned to the head of the Works.
The inlet chamber shall receive the flows from outlet of Raw sewage pumping station.
Provision shall be made for the measurement of received flow. The installation shall
include isolating penstocks to both inlet pipes installed on the inside face of the Inlet
Chamber. The Inlet Chamber shall be covered.
Design Criteria for Inlet Chamber

Minimum HRT at Peak Flow : 30 Sec
Minimum No. of Units : 1
4.9.2.2 Fine Screening
The Contractor shall provide mechanically operated screening equipment suitable for
open channel type flow. The Contractor shall provide a means of isolating each screen
with motorized penstocks (upstream and downstream of each screen) capable of manual
operation. During normal operation, screens shall be utilised such that the flow is evenly
distributed to all duty screens.
The screens shall be equipped with an automatic cleaning system to prevent blockage.
The Contractor shall ensure that the screen cleaning system can be operated
intermittently and can be controlled by both – a level differential across the screen and
an adjustable timed cycle.
The Contractor shall ensure screenings removed from the flow are conveyed through a
belt / screw conveyor to a washer and compactor where the screenings shall be washed,
dewatered and compacted. The screens shall be provided with an organic washing and
return system utilising final effluent. The Contractor shall provide all necessary treatment,
filtration and pumping for the treated effluent which is necessary for this purpose.
The Contractor shall return the dirty wash water and organics from the screening
systems to the main wastewater stream upstream of the screens for treatment.
The compacted screenings shall be free of faecal matter. In order to minimise odour
nuisance, the Contractor shall store the screenings in suitable enclosed containers. The
capacity of the screenings treatment plant shall be adequate to treat the peak screenings
loads, which may occur following a storm. The Contractor shall demonstrate that this has
been taken into account in the design of the screenings handling system.
The Contractor shall be responsible for the transport and disposal of screenings to a
legal, licenced Landfill Site.

The Contractor shall remove screenings from the Site in sealed bags/containers
designed to ensure no release of odours or liquid to the environment along the route to
the disposal location.
Design Criteria for Fine Screening


Mechanical Multi Rake Bar screen
Type of Screen :
/ Step Screen / Drum Screen
MOC of screen : SS 316L
Maximum velocity through screen opening at
: 1.2m/s
Peak flow
6 mm for non-MBR
Maximum screen opening :
2 mm for MBR
Maximum head loss at 50% blocked condition : 300 mm
Screenings conveyor;
Ancillary equipment : Screenings washer and
compactor
Minimum dry content of compacted screenings : 35%
Maximum organic content of washed
: 20%
screenings
Minimum volume reduction due to compaction : 50%
4.9.2.3 Grit Removal
The Contractor shall provide grit separators downstream of the screens. The Contractor
shall provide sufficient number of appropriately sized units operating in parallel to treat
the Peak Flows and Loads.
The Contractor shall provide a means of isolating each grit separator.
The Contractor shall dewater and classify the grit using inclined gravity separators with
surface organic return mechanism.
The Contractor shall design the dewatering system to achieve an organic matter content
of less than 10% of the dry solids content (in the cleaned grit) measured on a weight
(w/w) basis.
The Contractor shall return the dirty water from the grit separator to the main inlet flow
upstream of the fine screens. The Contractor shall design the grit separation, grit
handling, loading and collection units to minimise odour nuisance. The Contractor shall
be responsible for the storage, transport and disposal of grit and the Contractor shall
design the facilities to prevent release of odour and liquids to the environment.
The Contractor shall make provision for storage of sufficient number of containers on the
STP Site. The Contractor shall ensure that these containers are kept thoroughly clean
and odour free when empty. The container design shall be suitable to lift/unload/
transport through refuse vehicle so that screenings/grit shall not spill/fly away.

Design Criteria for Grit Removal

Type of Grit Removal : As per Bidder‘s requirement
Grit removal efficiency for grit having : > 95% of grit more than 0.2mm
specific gravity of 2.65 or more > 85% of grit more than 0.1 mm
Ancillary equipment : Grit removal pump, grit washing,
organic return pump
Maximum organic content of washed grit : 10%
Minimum dry solids content in washed grit : 80%
4.9.3 Primary Treatment
Primary settlement tanks are required to collect primary sludge for improving the
effectiveness of sludge digestion and gas generation.
The Contractor shall provide sufficient number of appropriately sized units operating in
parallel to meet the Employer‘s Requirements for the Flows and Loads. The Contractor
shall ensure that the design can adequately manage the full range of flows expected at
the treatment facility, in conjunction with the requirement for individual process units
being taken offline for maintenance.
Design Criteria for Primary Clarification

35-50 m3/m2/day (Average)
Surface Overflow Rate :
80-120 m3/m2/day (Peak)
Side Water Depth : Minimum 3.0 m
Weir Loading : 125 m3/m/day (Average)
Minimum BOD removal : 30%
Minimum TSS removal : 50%
The Contractor shall design the tanks based on the ―Surface Overflow Rate‖. Primary
Settlement Tanks may be square or circular radial flow tanks, rectangular cross flow
settlement tanks, or rectangular lamella settlers.
Primary settling tanks of conventional type should be appropriately sized with circular
central column supported with central drive. The skimming device could be operated by
the same scrapper mechanism used for sludge scrapping at the bottom of the tank. Each
Primary settling tank shall be fitted with a scum collection & removal system. Solids
concentration of Primary Sludge would be 2 to 3% dry.
The design of the primary settlement tank sludge draw-off pipework and the location of
the desludging pumps (if considered) shall ensure a positive head on the pump suction
during normal operation. The sludge head loss calculations on all sludge pipework shall
take account of the sludge characteristics including the variations in viscosity arising
from changes in the dry solids content of the sludge. The configuration of the sludge

draw-off pipework shall allow for easy access for clearance of blockages in the event of
sludge consolidation occurring.
4.9.4 Biological Treatment
Biological treatment systems shall observe the design parameters from internationally
recognised references including CPHEEO manual.
The Kinetic Coefficients for heterotrophic, nitrification and de-nitrification bacteria shall
be as per CPHEEO Manual latest edition or as given in ‗Wastewater Engineering –
Treatment and Reuse‘ by Metcalf and Eddy Inc., Fourth Edition may be used for design
in the absence of representative data for Indian conditions.
The hydraulic design of the bioreactor shall be capable of handling the peak hydraulic
flow.
The biological treatment shall be designed for nutrient removal to achieve the effluent
parameters. Modified Ludzack Ettinger (MLE), Membrane Bio Reactor or Sequential
Batch Reactor processes are suitable processes. The Contractor is permitted to offer
any of these or any other biological process; however, if the Contractor offers any of
these three processes then the design criteria given herein shall be complied with.
Regardless of the biological treatment selected, the minimum design parameters shall be
achieved and the sedimentation process design shall be based on flux theory.
The Aeration Basins (except for SBRs) shall have plug flow geometry. Each basin shall
be physically divided into anoxic, and aerobic zones. A minimum of three (3) anoxic
zones and four (4) aerobic zones shall be provided in each aeration basin. The
Contractor can provide anaerobic zone prior to anoxic zone for biological phosphorous
removal, and if provided, then minimum of two (2) anaerobic zones shall be provided in
each basin. The anaerobic-anoxic and anoxic-aerobic zone interfaces shall be concrete
partition walls that serve as overflow weirs, and head loss across the weir shall not be
less than 75 mm under all operating and hydraulic conditions. Anaerobic-anaerobic and
anoxic-anoxic zone interfaces can be concrete baffle walls designed to provide side-to-
side flow within the zones. All anaerobic and anoxic zones shall be provided with
mechanical mixers. Physical partitions are not necessary between the aerobic zones
(aerobic-aerobic zone interfaces). However, each aerobic zone shall have a separate
diffuser grid supplied by a separate air drop pipe with the air flow controlled by a
separate valve and measured by a separate flow meter, and a dedicated dissolved
oxygen meter.
For STPs where SBRs are proposed as the treatment process, the SBR sizing and
design shall be such that the proposed cycle times, number of cycles per day, and phase
times within each cycle shall all remain fixed up to the specified design peak flow when
all SBR basins are in service. No acceleration or premature advancing of cycles shall be
allowed up to the peak flow. The Cycles may be advanced as necessary for level control
only when the actual influent flow exceeds the specified peak flow, or during
maintenance, i.e. when all SBR basins are not in service. Process air blowers as well as
air piping and valves for SBRs shall be configured such that one or more blowers are
dedicated to each SBR basin that is in the aeration phase at any given time. The
discharge from any given blower shall be routed to no more than a single SBR basin at
any given time.
Modified Ludzack-Ettinger Process (MLE)

MLE process consists of the modification of a conventional activated sludge process for
Biological Nitrogen Removal with an Anoxic -Aerobic Operating Sequence zone. The
influent wastewater is fed to an anoxic zone which is followed by aerobic zone. The
process relies on the nitrate formed in the aerobic zone being returned via the RAS and
internal recycle to the anoxic zone to feed more nitrate to the anoxic zone directly. The
aerobic zone shall be oxygenated using fine air bubble diffused aeration.
Design Criteria for MLE Reactor

Design Flow : 75 MLD + Mixed Liquor Recycle flow +
Return Sludge Flow + Other flows
Peak Factor : 2
Peak flow : 254 MLD
Hydraulic Retention Time for Anoxic Zone : 2 – 5 Hrs
Mixing requirement for Anoxic Zone : Turnover frequency of one tank volume
per hour
Hydraulic Retention Time for Aerobic : 4 – 12 Hrs
Zone
Total Hydraulic Retention Time of Reactor : 8 Hrs minimum
Solids Retention Time : 7 – 20 Days
MLSS : 3500 mg/l maximum
Return Activated Sludge(RAS) of Influent : – 100 %
Internal Recycle (% of Influent) : 100 – 400 %
Sequential Batch Reactor
The Sequential Batch Reactor (SBR) Process shall be an advanced activated sludge
process with in-built nitrification and de-nitrification. The process shall operate in batch
mode without overlapping of settling or decanting with any other process. The SBR
Reactors shall be oxygenated using fine air bubble diffused aeration and shall effectively
bio-degrade the organic matter and organic/ Ammonical nitrogen in the primary treated
sewage to the required soluble BOD/ nitrogen level of purity.
During Decanting phase, the supernatant shall be removed from top with the help of
Decanters and excess sludge shall be wasted with the help of Waste Pumps.
Design Criteria for SBR Reactor

Design Flow : 75 MLD + Return Sludge Flow (if applicable) + Other
flows
Peak Factor : 2
Peak flow : 254 MLD
Cycle Time : As required between 3 – 6 Hrs
Cycle time change / : Not allowed as the peak factor is less than 3.0
acceleration
Fill Time During Peak Flow : 50% of Total Cycle Time
Aeration Time : 50% of Total Cycle Time

Decanting range : Maximum 2.4m

MLSS : 4000 mg/l maximum
MLVSS/MLSS : 0.7 for design purpose
F/M Ratio (BOD) : 0.1 - 0.15
Hydraulic Retention Time : Min. 10 hours
(HRT)
SVI : 120 - 150 mL/g
Minimum depth between the : 40% of the sludge depth
bottom water level and the
top of the settled sludge
Decanter weir loading rate : 125 m3/m/hr maximum
Decanting Device
No. of Decanter : One per Basin
Operation : Variable speed mode of operation
Rate of Travel of Decanter in Air and in Liquid
surface shall be automatically adjusted to a
calculated rate of operation
Design Travel Rate : 60 mm /min (Maximum)
Arrangement : Fitted with Scum retention mechanism to prevent
surface scums and floatables from exiting with the
treated effluent
Fail safe Overflow protection
Membrane Bio Reactor
The MBR membrane basins shall be fully covered with solid / chequered non-skid GRP
cover plates. The design shall provide for easy isolation of each MBR basin and shall
include all required facilities for complete and automatic clean-in-place (CIP)
functionality. An electric overhead bridge crane or monorail chain pulley block with
travelling trolley shall be provided for easy removal of the membrane modules. The
crane or block shall provide adequate vertical clearance to safely lift the membrane
modules above all piping, equipment, or other items that may be located in the travel
path from the module location in the tank to an adequately-sized adjacent membrane
―lay-down‖ area designated for membrane maintenance. The crane coverage shall
include the entire MBR basin area plus the lay-down area, if required.
The Contractor shall provide one configuration of the MBR System out of the following
two configurations.
CONFIGURATION 1
MLR Permeate
P
DEAERATION ANOXIC AEROBIC

P
MBR
RAS P
WASTEWATER
WAS

CONFIGURATION 2
Permeate
P
DE-
WASTEWATER AEROBIC MBR AERATION
ANOXIC
MLR / RAS WAS

P
The scope of supply for the MBR system shall consist of, but not limited to the following:
a) A complete microporous membrane system with relevant track record in sewage

treatment application and associated pumps and process equipment as necessary to
meet the performance requirements listed subsequently.
b) All equipment associated with the backwash system (if the membrane is backwash-able)
including pumps, chemical addition systems, air blowers, air compressors, dryers and
receivers as necessary to sustain the permeability of microporous membranes;
c) Chemical storage, handling, injection and mixing systems, pumps, tanks, heaters and
instrumentation associated with the microporous membrane Clean-In-Place (CIP)
system;
d) All interconnecting pipe works, fittings and valves,
e) All interconnecting wiring (power and control)
f) All required process control and monitoring instrumentation, and
g) All on-line analysers for performance monitoring and verification.
All the MBR associated equipment such as Scour Air Blowers, Permeate/ Backpulse
Pumps, RAS Pumps shall be housed inside a building or on a concrete pad with roof. In
addition, the MBR Equipment building / pad shall house all equipment necessary for all
types/modes of membrane cleaning. The Process Air Blowers for the Aeration Tank
may also be housed in the MBR building or a separate building.
Design Criteria for MBR Process

Membrane Basins
Membrane volume to be No
considered part of aerobic volume
for SRT calculation
Min No of trains At least equal to the number
of bioreactor basins
Min No of membrane basins As per Bidder‘s design
Basin MOC RCC with double epoxy

coating or HDPE lining - fully
covered with solid GRP non-

skid cover plates
Clean-In-Place (CIP) Provide CIP capability

Membrane installation Submerged in mixed liquor in
dedicated membrane basins,
separate from aerobic basins
Membrane chemistry PVDF, PES, or chlorinated
PE
Membrane support/reinforcement Required
Max membrane pore size - microns 0.4
absolute (NOT "nominal" pore size)
Membrane format Hollow fiber or flat sheet
Module format In-basin immersed
Permeate / filtrate forward flow Outside-In
direction
Membrane Operating Conditions
TSS Range mg/L 3,000 to 12,000
Maximum net flux L/m2/hr
(lmh)
At Avg flow with all (n-1) basins 25
AT Peak flow with (n-1) basins 50
Minimum spare capacity (blank % of min 5%
spaces) per membrane Basin total
effective
membrane
area
Normal design average operating kPa 35
transmembrane pressure (TMP)
Maximum operating kPa 50
transmembrane pressure (TMP)
Minimum design average recovery % 95
(i.e. filtrate production less
membrane cleaning requirement)
Minimum availability of a % 90
membrane unit (i.e. percent of time
filtering)
MBR Scour Air Blowers

Min number of blowers - Working To be same as the number of
membrane basins proposed
Min number of blowers – Shelf 1 per train or 15% of the total
spare number of working blowers,
whichever is higher
MBR Permeate/Backpulse Pumps
Min no of pumps – Working To be same as the number of
membrane basins proposed
Min no of pumps – shelf spare 1 per train or 15% of the total

number of working blowers,

whichever is higher
Pump Type As per membrane supplier
Minimum forward permeation cum/hr As per membrane supplier

capacity per pump
Membrane CIP System
CIP chemical storage tanks As per membrane supplier
CIP chemical dosing pumps As per membrane supplier
Chemical injection and As per membrane supplier
neutralization system
4.9.5 Aeration Requirements
Design Criteria for Aeration Requirements

BOD Oxidation Oxygen Requirement : 1.2 x Inlet BOD Load (min)
Nitrification Oxygen Requirement : 4.6 Kg O2 per kg of NH4 –N Nitrified
: BOD Oxidation + Nitrification Oxygen
Total Requirement
Requirement
Max Oxygen Credit from denitrification : 50% of de-nitrification
Net Oxygen Requirement : Total Requirement – Oxygen Credit
Oxygen Demand Safety Factor : 20%
Type of diffuser : Fine bubble diffusers
: PU for intermittent aeration operation;
Diffuser membrane material PU / Silicone / EPDM for continuous
aeration operation
: 0.60 for non-MBR process
Max Alpha value for Submerged Diffuser
0.40 for MBR process
Max Beta value for Submerged Diffuser : 0.95
Fouling Factor for fine bubble Diffuser : 0.8
Application of Correction factor : As per equation provided in
―Wastewater Engineering – Treatment
and Reuse‘ by Metcalf and Eddy Inc.,
Fourth Edition may be used for design
Oxygen content in Air (by weight) : 23%
Maximum allowed Standard Oxygen : 6% per meter depth of submergence
transfer efficiency (SOTE) of Diffuser per
meter depth of submergence - % per
meter depth for design purpose
4.9.6 Return Sludge and Excess Sludge Pumps (applicable to all above processes)
Dedicated Return Sludge and Excess Sludge Pumps shall be provided as per the
requirement of biological treatment process offered by the bidder. The Pumps shall be

suitable for handling biological sludge of 0.8 – 1% solids consistency. Capacity and
Heads shall be decided based on process requirements. Each Tank/Basin/Reactor shall
be provided with suitable lifting arrangements to facilitate lifting of these Pumps if
required for maintenance.
Design Criteria for RAS/WAS Pumps

Design Flow : As per requirements
Liquid : Biological Sludge of 0.6 – 1% solids consistency
Solid size : 40 mm (maximum)
4.9.7 Secondary Settlement Tank (if required)
Secondary Sedimentation tank is having importance in activated sludge process as the

efficient separation of biological sludge is necessary not only for ensuring final effluent
quality but also for return of adequate sludge to maintain the MLSS level in the aeration
tank. The biomass generated during the biodegradation in the aeration tanks will be
separated from the wastewater to obtain a clear liquid relatively free from solids suitable
for further treatment. A part of the solids settled in these tanks will be continuously
recycled back as Return Activated Sludge (RAS) to the aeration tanks to maintain a
desired concentration of biomass (MLSS/MLVSS). The remaining part of the settled
solids will be wasted (WAS) and diverted to sludge management system.
Secondary clarifiers are designed on surface overflow rate. The secondary settling tanks
shall be circular radial flow tanks. The inlet pipe shall discharge within a stilling box or
diffusion mechanism located at the centre of the tank and this shall occupy a minimum
liquid surface area of 5% of the liquid surface area of the tank. The settled sludge will be
scraped in a continuous radial type pattern at the bottom of each tank, finally ending up
at the sludge hopper.
The secondary settlement tanks shall be provided with automatic Return Activated
Sludge (RAS) pumps and Waste Activated Sludge (WAS) systems.
Design Criteria for Secondary Clarification

Design Flow : 3125 m3/hr (Dry Weather Flow) + RAS flow +
any other flow
Peak factor : 2
Surface Overflow Rate : 15 – 28 m3/m2/day (Average)
40 – 50 m3/m2/day (Peak)
Solids Loading : 70-140 Kg/day/m2 (Average)
Side Water Depth : ≥ 3.0 – 3.5
Weir Loading : 185 m3/m/day (Average)
4.9.8 Tertiary Filtration
It is envisaged that due to low space availability at site, Tertiary Filtration will be required
to achieve effluent standards. Secondary treated effluent shall flow to tertiary filtration
units by common channel under gravity for tertiary treatment.

Tertiary treatment facility shall be provided with a roof and filter unit liquid retaining
structure shall be RCC. The filtration system should be capable of operating under low
head and should be capable of continuous filtration with automatic, on-line backwashing,
specifically designed for low head filtration. Design criteria for Cloth Media Disk Filter are
given below; however, the Contractor is free to propose any other filtration equipment.
Design Criteria for Tertiary Filtration

Design Flow : 75 MLD + Other flows
Peak Factor : As per the Secondary Treatment effluent flow
Design inlet TSS : 20 mg/L (minimum)
Average Filtration Rate : 10 m3/m2/hr (maximum) of effective filtration
surface area with all units in service
Peak Filtration Rate : 15 m3/m2/ hr (maximum) of effective filtration
surface area with all-but-one (N-1) units in
service
Maximum Filtration Size : 10 micron
Number of Units : As per manufacturer‘s design
Total Backwash Water Required : Shall not exceed 5% of the design influent
flow
Ancillary equipment : Portable automatic chemical cleaning unit
4.9.9 Disinfection
The level of disinfection required, i.e. dose of disinfecting agent (UV / chlorine / other) is
dependent on the level of treatment provided by the contractor. The contractor shall
provide justification of his design basis and shall observe the design parameters from
CPHEEO manual and internationally recognised references including ‗Wastewater
Engineering – Treatment and Reuse‘ by Metcalf and Eddy Inc., Fourth Edition. The
Contractor shall offer disinfection equipment from reputable international manufacturers.
The contractor shall ensure that excess levels of disinfection chemicals are neutralised
prior to discharge to the environment.
Where the disinfection facility is designed by using chlorination, following should be

noted.
In case in future, anytime during period of contract (DB and operation service period of
10 years) if use of chlorine /chlorination system for disinfection is banned or disallowed
due to any change in law or by directives/circular issued by any government body/
pollution control board (state or central) the contractor shall at no extra cost replace his
chlorination disinfection facility by other acceptable disinfection facility.
Design criteria for disinfection system are given below.
Design Criteria for Disinfection

Design Flow : 75 MLD + Other flows
Peak Factor : As per the Secondary Treatment effluent flow
Design inlet TSS : 10 mg/L (maximum)
Required coliform log removal : 2 log (minimum); however, the plant outlet
shall meet the specified effluent quality
Minimum contact time if chlorine is : 30 minutes at average flow

used
Residual chlorine concentration at : Between 0.2 – 1 mg/L
the plant outlet
Minimum dose if UV is used : 30 mJ/cm2 at the end of lamp life
UV transmittance of the influent : Maximum 60%
UV lamp efficiency : Maximum 42% for design purpose
Type of UV disinfection system : In channel or in-pipe
4.9.10 Sludge Thickening
All sludge produced by the Works shall be subjected to thickening, anaerobic digestion
and dewatering to produce a product which complies with the performance standards.
Sludge to be thickened (Cosettled sludge from primary clarifier / separate sludge from
primary clarifier and WAS) shall be pumped to the sludge thickener. Thickened sludge
shall be stored into the thickened sludge hopper from where thickened sludge shall be
pumped to Anaerobic Digester through Thickened Sludge Pumps continuously /
intermittently as required for anaerobic degradation.
Design Criteria for Sludge Thickener

Design Flow : Primary Sludge + Waste Activated Sludge
(Secondary Clarifier)
Operating Hours : 20 hrs per day, 7 days a week
Solid concentration in thickened
: 5.0% (Minimum)
sludge
Min Solids recovery : 90% without polymer addition;
95% with polymer addition
The Thickened Sludge tank & pumps are to be provided to collect and transfer the
thickened sludge from sludge thickener to Anaerobic Sludge Digester.
Design Criteria for Thickened Sludge Tank

Design Flow : Based on Mass Balance of Thickened sludge
Minimum Hydraulic Retention Time : 4 Hrs
Design Criteria for Thickened Sludge Pump House

Size : The size of the Pump House shall be designed
to accommodate Thickened Sludge tanks &
thickened sludge pump sets with starter
panels, control panel and other accessories.
The Sludge Pumping Station shall include all
accessories and associated works including all
interconnecting piping works for the sludge
pumps, specials, appurtenances, supporting
Allied works :
structures, lifting arrangement shall be
provided for maintenance of pumps and
motors. Mechanical Ventilation system,
Firefighting system shall also be provided.

The Contractor shall provide a sufficient number of appropriately sized sludge thickening
streams (including all associated ancillaries such as pumps and polymer dosing
equipment) operating in parallel to meet the Employer‘s Requirements for the Flows and
Loads. The Contractor shall ensure that the design can adequately manage the full
range of flows expected at the treatment facility, in conjunction with the requirement for
individual process units being taken offline for maintenance in accordance.
Sludge thickening systems shall be located in a sludge building or otherwise enclosed

and sealed from the outside atmosphere. Adequate ventilation shall be provided to
eliminate odour nuisance.
The configuration of the sludge handling pumps and associated valves and pipe work
shall ensure that no backflow is possible through each pump when the pump is not
running.
The sludge head loss calculations in all sludge pipe work shall take account of the
specific sludge characteristics for different types of sludges including the variations in
viscosity arising from changes in the dry solids content of the sludge.
4.9.11 Anaerobic Digesters
Digesters for anaerobic digestion of thickened sludge and production of biogas shall be
provided as specified, along with all required ancillary equipment. There shall be no
moving parts or other components requiring routine maintenance or servicing inside the
digesters. The design shall ensure that maintenance of all equipment and components
can be safely and easily accomplished from outside the digester and without draining its
contents.
Anaerobic digesters shall be provided for the digestion of thickened sludge and scum.
The Anaerobic digesters shall have facility for gas mixing and / or hydraulic pumped
mixing, and contents inside the digester shall be continuously kept under homogenous
mixed condition with these mixing systems. The digesters should also be heated to
maintain almost constant digester temperature throughout the year. Each digester shall
be fitted with necessary safety equipment such as pressure and vacuum release,
process control instrumentation such as temperature indicators and transmitters inside
the digester and at the heat exchanger, monitoring instruments such as sludge and
biogas flow measurement, digester sludge pH measurement etc.
Design Criteria for Anaerobic Digester

Design Flow : Thickened Sludge Flow as per
Contractor‘s design
Solids Retention Time : 15 days Minimum with all
digesters in service;
12 days minimum with one
digester out of service
Solids concentration of inlet sludge : 5% (minimum)
pH of Digested Sludge : 7-8
Specific Gravity of Raw Sludge : 1.05
Volatile Solids Destroyed During Digestion : 50% (minimum)
Biogas Production per Kg of Volatile solids : 0.8 - 1.2 cum/Kg
destroyed

Temperature of digestion : 35 - 39 Degree C

Solids concentration in the Digested Sludge : 4% (maximum)
Minimum digester active volume : 90%
Minimum allowance for grit accumulation : 1m
Minimum allowance for scum accumulation : 1m if scum removal facility is not
provided
Bottom shape : As per Bidder‘s design
Sludge wasting mechanism : Either through overflow (fill-and-
spill method); or through a pump
The location of the digester feeding points in each digester shall minimize the short
circuiting.
Design Criteria for Digester Mixing

: Recycling of biogas through biogas compressor
Anaerobic Digester Mixing type OR hydraulic pumped mixing OR combination of
both
Turn over requirement : 1 digester volume in maximum 8 hrs.
Minimum mixing energy input : 6 w/m3 of digester sludge volume
into the digester
The Contractor shall specify the method of mixing and mixing intensity.
Design Criteria for Digester Heat Exchanger

Ancillary equipment : Heat exchanger Associated valves and
piping
Hot water temperature : 70 deg C maximum at heat exchanger
inlet
Heat exchanger MOC : Stainless steel
Heat exchanger heat transfer coefficient 350 - 500 W/m2/0C
The heat exchangers shall incorporate arrangements for the clearance of sludge
blockages and drainage of water and sludge. The exchangers shall be supplied
complete with all control and isolating valves and shall be provided with the hot water
control valve and temperature sensors for inlet and outlet sludge and water. A by-pass to
the heat exchanger or a spool piece shall be provided to facilitate heat exchanger
maintenance.
The design of the anaerobic digestion system shall maximise safety and security of
operation.
4.9.12 Gas Storage
Gas take-off from the digester shall be from the apex of the digester roof. A flame
arrestor and flow meter shall be provided on the gas line from each digester.

The biogas generated during digestion shall be directed to a gasholder and utilised at the
digestion plant to heat the sludge and to generate power. Due to shortage of space on
site, biogas storage can be provided on top of the digester itself through a floating
membrane roof.
Design Criteria for Biogas Holder

Design Flow : Bio Gas Generation as per Contractor‘s design
Minimum storage capacity of : The minimum bio gas storage shall be 25% of the
Biogas daily bio gas production
Gas Velocity : 15 m/s (Maximum)
Operating Pressure : Normal Gas Operating Pressure of the digesters,
gas piping, storage systems 300 mm WC
With a vacuum protection of minus 50 mm WC
Gas holder type : Floating roof / Membrane type / Steel bell
The gasholder and collection pipes must be sized for minimal head loss such that if the
digester sludge volume changes, biogas (and not air) will be drawn into the digester and
the biogas will not be lost by displacement.
4.9.13 Biogas Scrubber Area
Biogas generated from digesters will contain hydrogen sulphide (H2S). This H2S shall be
scrubbed from Biogas before using it in gas engine to reduce corrosion in the engine
parts and to reduce pollution. The system should give less than 200 ppm of H2S or lower
if so required by the gas engine manufacturer at the outlet of the scrubbing process in a
single stage scrubbing. The system should be capable of producing elemental sulphur as
a by-product of the Scrubbing Process of H2S gas.
4.9.14 Biogas Flaring System
Biogas Flare system shall be provided as specified for safe flaring of excess biogas.
Flaring system shall be auto flaring type. Necessary interconnection with SS 316 lines,
measuring instruments, control valves, shall be provided. Flaring system should be
complete flaring system including main burner with pilot burner, wind shield,
thermocouple, spark igniter, control panel, electrically operated butterfly valve, solenoid
for pilot line, etc as per the local Pollution Controls norms & complying with CPCB
norms.
4.9.15 Power Generation
To generate heat and electrical energy, Combined heat and power (CHP) units shall be
used. It will incorporate an internal combustion engine using bio-gas as the primary
engine fuel source. The energy to be recovered from the combined heat and power units
shall be in the form of electrical power and heat. If the duty CHP units alone cannot
provide the digester heating requirement in winter owing to operational problems or
during process start-up, a secondary fuel source (natural gas) may be provided for the
CHP engines. Diesel as an alternative fuel for the CHP engines is not permitted.
The generators shall be connected to the plant‘s electrical power system in such a way
that when they are in operation, they shall serve as the primary power source and the
generated power shall be utilized to the fullest possible extent. Power from the outside

grid shall be used only when, and only to the extent that, the plant‘s total power demand
exceeds the power being generated by the gas engines.
The biogas engine should have features of black start with the help of clean gas from
clean gas holder. The engine should be able to operate at a turn down ratio of 50%, and
minimum engine efficiency at maximum turn down should be 35%.
Biogas engine shall be suitable for operation with variable composition of Biogas. The
Biogas Engine Generator Sets shall be provided as a package system.
4.9.16 Sludge Dewatering
Digested sludge shall be collected in a closed tank and stored prior to dewatering.
Design, sizing, construction, and operation of the dewatering units and related
equipment, including but not limited to solids and hydraulic loadings, shall be adequate
to ensure that all specified performance requirements, including but not limited to
dewatered sludge concentration and solids capture, are fully met under the specified
dewatering operating schedule.
Where belt presses are proposed, filtered treated effluent shall be used for belt washing
except, optionally, during start-up and shut-down.
Where centrifuges are proposed, controls shall be put in place to adjust the differential
speed of the bowl and the scroll.
Sludge dewatering system shall be located in a sludge building or otherwise enclosed

and sealed from the outside atmosphere. Adequate ventilation shall be provided to
eliminate odour nuisance.
Design Criteria for Sludge Dewatering

Design Flow : Digested Sludge from Anaerobic digester as per
Contractor‘s design /mass balance
Minimum Quantity : As per Contractor‘s design including minimum
50% standby
Operating Hours : Up to 2 shift per day, i.e., 16 operating hours per
day and 7 days/week
Solids Concentration in the Cake : 25% (+/-) 2% w/w
Minimum Solids Capture : 95%
Digested sludge storage : 1 day (minimum)
retention time
Polyelectrolyte solution preparation / storage systems with standby solution preparation

systems shall be provided with sufficient capacity for all mechanical devices used for
sludge dewatering. The selection of the type of polymer (powder or emulsion) shall be
based on preliminary bench scale testing by different polymer suppliers. Dosing of
polymer solution to condition the digested sludge prior to dewatering shall be linked to
the operation of each dewatering unit and shall be fully automatic. The volumetric
polymer solution dosing rate from each polymer dosing pump shall be automatically
adjustable.

Design Criteria for Polymer Dosing

Type : Dry polymer with batch tanks / package units
Polyelectrolyte dosing : 5 kg/ton dry solids (Minimum)
Poly Solution Strength : 0.25% (maximum)
4.9.17 Sludge Disposal (Off Site)
The Contractor shall be responsible for identifying suitable disposal location/land/site and
route(s) for all sludge arising from the Works and dispose of the sludge and for paying all
tipping & transportation charges and other associated costs including that for land/site.
The Contractor shall dispose of any hazardous materials off-site in accordance with
existing laws and regulations. All permissions and consents from respective authorities
shall be obtained by the contractor. Potential disposal routes that are common and
acceptable to the Employer are listed below.
a) Recycling to agriculture;
b) Recycling to forestry;
c) recycling to land reclamation as an alternative to subsoil /topsoil;
d) application to short rotation coppice;
e) incineration by the Operator/or a third party;
f) gasification;
g) use as low-grade fuel.
h) any other suitable option which is beneficial to the employer and environment
friendly.
The Contractor may use one or more of these Potential Disposal Routes, or any other
identified by him, at any time.
The Contractor shall comply with the requirements described in this section for any of the
disposal routes he uses. In any case, the Contractor shall comply with all relevant
national laws, regulations and international good practice.
4.9.18 Plant Water and Potable Water Distribution
Plant Water System:
The Contractor shall provide a pressurised, automatic plant-water booster system to

supply plant-water to appropriate locations throughout the Works via a pressurised plant-
water distribution ring main. The Contractor shall design the plant-water booster system
to maintain a minimum pressure of 2.5 bar at the furthest point on the ring main from the
booster set under conditions of maximum plant-water use.
The plant-water ring main shall provide hose connection hydrants where required for
cleaning of principal process units and equipment. The Contractor shall identify potential
points of spillage and shall provide hose connection hydrants for washing down within
buildings and areas where sludge or liquor spillage may occur. The hydrants shall be
specially identified as ―Non-Drinking Water‖:
The plant-water booster system shall include duty/standby booster pumps, pressure
vessel and a dual filtration unit to allow replacement of one of the filter elements whilst
the other element is operational. Automatically backwashed filters shall be provided. Any
plant-water used for cleaning equipment, vehicles or contaminated areas shall be
drained and returned to the main wastewater stream for treatment.

Pressure gauges complete with isolation valves shall be provided and fitted by the
Contractor to all delivery lines and booster set pressure vessels
Potable Water System:
The Contractor shall provide a separate booster set to supply potable water to a potable
water ring main. This water shall be drawn, via a break tank, from the mains feed to the
Site. The break tank shall be included with the potable water booster set. The potable
water booster system shall be designed to maintain a minimum pressure of 2 bar at the
furthest point on the ring main from the booster set under conditions of maximum water
use.
The Contractor shall provide separate suction pipe work for each booster set pump
complete with isolation valve, non-return valve and strainer.
Pressure gauges complete with isolation valves shall be provided and fitted by the
Contractor to all delivery lines and booster set pressure vessels.
4.10 Flow Measurement, Sampling and Monitoring
4.10.1 General
The Contractor shall provide sufficient measuring devices and sampling equipment to
comply with the Employer‘s Requirements in respect of the proper operation and
maintenance of the facility and to enable the proper monitoring, sampling and analysis to
be carried out.
Flow measurement and sampling facilities shall be provided by the Contractor for the
following purposes:
 determination of the incoming wastewater pollutants load for payment purposes;
 determination of the quality and quantity of flows discharged to the outfall for
compliance and payment purposes;
 determination of operational loads onto particular process units for process control
and operation.
More detailed sampling and measuring will be required during the Tests on Completion
of Design-Build and Tests Prior to Contract Completion.
4.10.2 Sampling
The Contractor shall carry out sampling at various stages of the process. The exact
locations of the sample points shall be agreed between the Contractor and the
Employer‘s Representative.
For the sampling points which are directly connected to the performance requirements or
payments or statutory compliance, refrigerated automatic samplers shall be permanently
installed. Influent and Final Effluent automatic samplers shall be flow or time
proportional. Any automatic samplers which are utilised for determination of the loads for
payment purposes shall be capable of collecting flow and/or time proportional composite
samples.

4.11 Hydraulic Design
4.11.1 General
The principal hydraulic design requirements applicable to the Works are:

 all aspects of the design of the hydraulics shall be based on sound principals and
good common engineering practice typical for municipal engineered works;
 the STP and all parts thereof shall be capable of passing the required wastewater
flows, including returned and recycled flows;
 the flows shall be evenly distributed between the numbers of streams and process
units in operation for all flow conditions;
 suspended sediment entering the facility shall be kept in suspension and transported
through the facility by the flow as far as the treatment unit where it is to be removed
or separated from the main wastewater flow;
 inlets into tanks, reactors, or other structures via pipes, channels, valves, or gates
shall be designed such that the incoming flow does not cause any damage or
excessive wear whatsoever to the structure or any equipment in the vicinity under
any hydraulic condition, including but not limited to the condition when the structure is
empty;
 The floors of all liquid-holding structures shall be appropriately sloped and trenches
and drain sumps shall be provided at the bottoms of such slopes to facilitate
complete drainage of liquid. Appropriate drain pipes and valves connected to the
drain sump(s) shall be provided for all structures. Where the drain pipe connects to
the structure, the top-of-pipe elevation shall be at least 150 mm lower than the lowest
floor elevation for the structure. The drain piping shall be routed from the structure
being drained to the Plant Drain Pump Station and shall be continuously sloped
downward in the direction of flow with a minimum slope of 1 percent. For liquid-
holding structures, the drain piping and fittings shall be sized such that the entire
structure can be drained by gravity in no more than six (6) hours. The Plant Drain
Pump Station, Plant Drain Pumps, and other related equipment and controls shall be
designed and sized to allow draining of the structure with the largest volume from full
to empty within six (6) hours. The highest design water level (High High Alarm) in the
Plant Drain Pump Station wet well shall be at least 300 mm lower than the lowest
pipe invert elevation amongst all drain pipes connecting to the wet well.
 For liquids and sludge, the minimum pipe flow velocity shall be no less than 0.5 m/s
and the maximum pipe flow velocity shall be no more than 1.5 m/s for pumped
suction and no more than 2.0 m/s for pumped discharge or gravity flow. All mixed
liquor and sludge lines shall be minimum 200 mm diameter and shall be provided
with appropriate cleanouts and flushing arrangements for safe and easy flushing
using high-pressure water. The normal pipeline peak flow velocity for gases shall be
no more than 25.0 m/s.
 the hydraulic design shall comply, where applicable with relevant international
standards.
4.11.2 Levels
Published level data is as follows and is relative to Mean Sea Level (MSL).
a) Original GL: 546.0 - 548.0 m
b) Highest Water level (H.W.L.): 543.8 m
c) Invert Level of Gravity Sewer: 542.5 m

4.11.3 Design Flows
The hydraulic design flows throughout the facility shall take full account of recycled and
returned flows. The hydraulic design calculations shall demonstrate the hydraulic
carrying capacity of the facility if any one of the process units were to be out of service
for maintenance.
The division of flow between the process streams and between individual treatment units
in each process stream shall be achieved by the use of suitable control structures, such
as freely discharging weirs or flumes. These may be sited at the inlet or outlet to each
treatment unit, or at a distribution chamber upstream of the treatment units.
All gas flow distribution shall be using automatic feedback flow control using inline flow
measurement and modulated flow control valves with electric actuators.
Where the applicable control structures are sited downstream of the chamber or other
location where the division of flow occurs, then the intervening channels, culverts and
pipes shall, as far as practicable, be functionally identical in terms of conduit dimensions,
lengths, bend angles, etc. so as not to impair the even division of flow.
Hydraulic calculations shall be based on the Colebrook-White or Hazen-Williams

formulae for pipe and the Manning equation for open channel flow. The hydraulic design
calculations shall show clearly the methods of calculation and analysis used, including all
assumptions made. The calculations shall include a hydraulic profile and full details of
the depths, velocities, water surface or pressure head elevations, energy (or total head)
elevations and (for open channels or closed conduits flowing partially full) Froude
numbers throughout the STP.
The head loss calculations in all sludge pipe work shall take account of the specific
sludge characteristics for different types of sludges including the variations in viscosity
arising from changes in the dry solids content of the sludge (for example, by using the
methods described in the recommendations of ―How to Design Sewage Sludge Pumping
Systems‖, Technical Report TR185, WRC).
All parts of the Works shall be designed with allowances for the most adverse
combinations of anticipated maximum and minimum settlements or other movements of
the structures concerned. In particular, the minimum freeboard in hydraulic structures
shall include an appropriate allowance for anticipated settlement.
4.11.4 Pipelines and Culverts
The hydraulic design calculations for pipes and culverts flowing full shall include profiles
of the static head and total energy elevations in relation to the soffit of the conduit. No
designs shall cause, assume or require the occurrence of sub-atmospheric pressures
within any conduit. All pipe and culvert intakes shall be designed to reduce air vortices.
4.11.5 Channels
The Manning Formula or similar shall be used for the design of open channels and shall,
except where expressly permitted otherwise, be designed for sub-critical flow, with a
Froude number no higher than 0.5.
Channels collecting flows from weirs along one or both sides of the channel shall be
designed and analysed taking account of both friction losses and losses due to mixing of

the incoming flow. The modified ‗Camp‘ formulae may be used for headloss calculation
for ‗staged flows‘ in effluent launders with weirs.
4.11.6 Control and other Hydraulic Structures
As far as practicable, sharp crested weirs with free discharge shall be used and shall be
designed with standard profiles for which flow characteristics are readily available, so
that their hydraulic performance can be predicted reliably from reputable hydraulic texts.
Sharp-crested weirs shall include adequate provision for maintaining atmospheric

pressures beneath the nappe.
Flumes shall be designed with the appropriate approach distance and the discharge
shall be designed to be free flowing (not drowned) with the appropriate maximum
submergence. Flumes shall be designed to work under all hydraulic flow conditions from
minimum to maximum.
4.11.7 Penstocks
Penstocks in channels shall be designed so that, when fully open, there is no

encroachment on the cross-sectional area of the maximum flow depth.
4.11.8 Hydraulic Gradient
The hydraulic gradient shall be calculated according to the following criteria:

a) the roughness coefficient ―C‖ or ―K‖ shall be as per common engineering practice
(pipes and channels), the pipe manufacturer‘s guidelines, taking into account
whether the use is for wastewater or surface water.
b) a freeboard of at least 25 mm shall be provided to upstream weir crests under
maximum flow conditions when one stream is isolated, and at least 100 mm shall be
provided under full flow with all streams operational.
c) the ADWF hydraulic gradient shall be calculated assuming one stream of process
plant is offline, and weir levels set accordingly.
d) self-cleansing velocities shall be achieved in all pipes and channels as appropriate at
least two times per day.

5 Particular Civil & Structural Requirements

Part-A: Standard Specifications - Civil & Structural Works
The ―Standard Specifications for Civil and Structural Works for Sewage Treatment Plants
Contracts‖ issued by the PMC, set out the specifications that shall be followed for
construction of General Works under the PMC. Specifications for additional specialized
items of civil and structural works are as set out in Part B, Particular Technical
Specifications, of this Section.
In the event of any discrepancy between the provisions of the Standard Specifications
and the Particular Technical Specifications, the provisions of the Particular Technical
Specifications will prevail.
Part-B: Particular Civil and Structural Requirements
5.1 Design Submissions
Before proceeding with design and drawing preparation the Contractor shall submit
detailed general philosophy of design (Design Basis Report) of various parts of (all) the
structures and equipment foundations along with explanatory sketches for review. Only
after the review and incorporation of comments on the general philosophy, as offered
during the review, the Contractor shall submit any design document and/or drawing for
review and approval for construction. Please refer to Appendix 1 for complete list of
submission.
5.2 Design Standards
All the designs shall be based on the latest Bureau of Indian Standard (BIS)
Specifications or Codes of Practice. The design standards adopted shall follow the best
modern engineering practice in the field based on any other International Standard or
specialist literature subject to such standard reference or extract of such literature in the
English language being supplied to and approved by the Engineer. In case of any
variation or contradiction between the provisions of the BIS Standards or Codes and the
specifications given along with the tender document, the provision given in this
Specification shall be followed.
All Reinforced concrete structural design/details shall conform to the following recently
published publications of the Indian Standards Institution:
(i) I.S. 456 : Code of Practice for plain and reinforced concrete
(ii) I.S. 875 : Code of Practice for design loads for buildings and
structures (Part I to V)
(iii) I.S. 3370 : Code of Practice for concrete structures for the storage of
liquids (Part I to IV)
(iv) I.S. 1893 : Criteria for earthquake resistant design of structures
(v) I.S. 2911 : Code of Practice for design and construction of Pile
foundations
(vi) I.S. 2974 : Code of Practice for design and construction of machine
foundations

Part 5: Particular Civil & Structural Requirements
(Part 1 to 4)
(vii) I.S. 4326 : Code of Practice for Earthquake Resistant Design and
Construction of Buildings
(viii) I.S. 13920 : Ductile Detailing of Reinforced Concrete Structures
subjected to Seismic forces- Code of Practice
(ix) IRC: 6 : Standard specification and Code of Practice for road
bridges Loads and Stresses
(x) SP: 16 : Design Aids for Reinforced Concrete to IS 456
(xi) SP: 34 : Handbook on Concrete Reinforcement and Detailing
(xii) 3370 (part I-IV) : Code of practice for concrete structures for the storage of
liquids
All structural steel design shall conform to the following recently published publications
of the Indian Standards Institution:
(i) I.S. 800 : Code of Practice for general construction in steel

(ii) I.S. 806 : Code of Practice for use of steel tubes in general building
construction
(iii) SP: 38 : Handbook of Typified Design of Structures with Steel Roof Trusses
5.3 Design Life
The design life of all structures and buildings shall be as described in Volume II Part -3
Approval conveyed to the contractor will neither relieve the firm of its contractual
obligations and its responsibility for the correctness of the dimensions, material, of the
construction, weights, quantities, design perimeters, dimensions, assembly, its
performance, particulars, conformity of the supplies with Indian statuary laws as may
applicable nor will it limit the Employer rights under the contract.
5.4 Design Loadings
All buildings and structures shall be designed to resist the worst combination of the
following loads/stresses under test and working conditions; these include dead load, live
load, wind load, seismic load, stresses due to temperature changes, shrinkage and
creep in materials, and dynamic loads:
5.4.1 Dead Load
This shall comprise all permanent construction including walls, floors, roofs, partitions,
stairways, fixed service equipment‘s and other items of machinery. In estimating the
loads of process equipment all fixtures and attached piping shall be included, but
excluding contents, shall be considered.
The following minimum loads shall be considered in design of structures:
1 Weight of water : 10 kN/m3

2 Weight of soil (irrespective of strata available at
site and type of soil used for filling etc). : 20.00 kN/m3
However, for checking stability against uplift,

actual weight of soil as determined by field test

shall be considered
3 Weight of concrete : 24.00 kN/m3
4 Weight of reinforced concrete : 25.00 kN/m3
5 22.00 N/m2 per mm thickness
Weight of brickwork (exclusive of plaster) :
of brickwork
6 Weight of plaster to masonry surface : 18.00 N/m2 per mm thickness
7 Weight of granolithic terrazzo finish or
: 24.00 N/m2 per mm thickness
rendering screed, etc.
8 78.5 N/m2 per mm thickness
Weight of MS plates :
of plates
9 Weight of sand (filter media) : 24.0 kN/cu.m
5.4.2 Live Load
Live loads shall be in general as per IS 875. However, the following minimum loads shall
be considered in the design of structures.
Sr.
Location Live Loads
No.
1 Office, Conference Hall 400 kg/sq.m
2 Floor supporting Pumping Machinery 1,000 kg/sq.m
3 Storage 750 kg/sq.m
4 Platform, Staircase, Corridors, Walkways 500 kg/sq.m
5 Administration Building – Hall, Toilet 200 kg/sq.m
6 Laboratory 400 kg/sq.m
7 Roof Slab 150 kg/sq.m
8 Surcharge load for earth retaining structures 1200 kg/sq.m
In the absence of any suitable provisions for live loads in IS Codes or as given above for
any particular type of floor or structure, assumptions made must receive the approval of
the PMC prior to starting the design work. Apart from the specified live loads or any other
loads due to material stored any other equipment load or possible overloading during
maintenance or erection/construction shall be considered and shall be partial or full
whichever causes the most critical condition.
5.4.3 Wind Load
Wind loads shall be as per I.S. 875 Part (III).
5.4.4 Earthquake Load
Earthquake loads shall be conforming to I.S. 1893 part 1-2016, IS1893 Part 4 - 2005 and
IS1893 Part 2 -2014 considering seismic (Zone III). Importance factor shall be taken as
per Table 6 (Clause 6.4.2) of IS 1893 (Part 1), but not less than 1.5.

5.4.5 Dynamic Load
Dynamic loads due to working of plant items such as pumps, blowers, compressors,
switch gears, travelling cranes, etc shall be considered in the design of structures.
5.4.6 Vehicular Wheel Load
For any structure or pipeline below the roads, Class A loading of IRC 6 shall be
considered.
5.4.7 Temperature load
All structures will be designed for a temperature variation of minimum plus minus 5 deg.
celsius along with other loads. Parts of structures prone to thermal exposure / cracking,
etc. shall be designed for a temperature variation as mentioned in IS 875.
5.5 Joints
Movement joints such as expansion joints, complete contraction joints, partial contraction
joints and sliding joints shall be designed to suit the structure. However, contraction
joints shall be provided at specified locations spaced not more than 7.5 m in both right
angle directions for walls and rafts.
Expansion joints of suitable gap at suitable intervals not more than 30 m shall be
provided in walls, floors and roof slabs of liquid retaining structures.
Construction joints shall be provided at right angles to the general direction of the
member. The locations of construction joints shall be decided on convenience of
construction. To avoid segregation of concrete in walls, horizontal construction joints are
normally to be provided at every 2m height. PVC water stops of 150 mm width shall be
used for walls and 230 mm width for base slabs.
5.6 Design Criteria for Underground or Partly Underground Liquid Retaining Structures
All underground or partly underground liquid containing structures shall be designed for
the following conditions:
i. Liquid depth up to full height of wall: no relief due to soil pressure from outside to be
considered;
ii. Structure empty (i.e., empty of liquid, any material, etc.): full earth pressure and
surcharge pressure wherever applicable, to be considered;
iii. If water table exists, earth pressure to be considered for submerged soil conditions
with reference to the geotechnical recommendations;
iv. Partition wall between dry sump and wet sump: to be designed for full liquid depth up
to full height of wall;
v. Partition wall between two compartments: to be designed as one compartment empty
and other full;
vi. Structures shall be designed for uplift in empty conditions with the water table as
indicated in geotechnical report;
vii. Walls shall be designed under operating conditions to resist earthquake forces from
earth pressure mobilization and dynamic water loads (Hydrodynamic Impulsive
Pressure);
viii. Underground or partially underground structures shall also be checked against
stresses developed due to any combination of full and empty compartments with
appropriate ground/uplift pressures from below to base slab. A minimum factor of 1.2
shall be ensured against uplift or floatation by considering 90% of Dead Loads only.
ix. For general retaining walls and sliding by considering 90% of Dead Loads only.

x. The limiting crack width will be 0.1 mm for tank containing reactive water such as raw
sewage, primary sludge, combined sludge etc. For all other tanks limiting crack width
can be 0.2mm
xi. In case of Large and Deep Underground Tanks such as Wet Wells, the analysis can
be carried by Finite Element Method using STAAD.Pro or any other equivalent
software predominantly used and accepted in the industry.
xii. All blinding and levelling concrete shall be minimum 100 mm thick in concrete grade
M10 for Building & minimum 150 mm thick for Water Retaining Structure.
xiii. All structural reinforced concrete shall be with a maximum 40 mm aggregate size for
footings and base slabs and with a maximum 20 mm aggregate size for all the Water
Retaining Structures & other structural members.
xiv. All liquid retaining structures shall be designed as per IS:3370. The minimum grade
of concrete shall be M 30.
xv. The maximum free water cement ratio shall not exceed 0.40 for all liquid retaining
structures.
xvi. Use of pressure relief valves to reduce uplift pressure due to ground water table shall
not be allowed.
xvii. Any pipelines crossing below roads shall be designed for Class AA of IRC loading
or as classified by the respective authority. NP3 RCC pipe as encasing shall be used
below roads inside the plant.
xviii. Minimum Bar Diameter

Sr.
Member Diameter (mm)
No.
1 Major Foundation 10
2 Block Foundation – Main Bars 10
3 Block Foundation – Tie Bars 8
4 Minor Foundation (Local Foundation etc.) 8
5 Column, Pedestal – Main Bars 12
6 Column, Pedestal – Ties 8
7 Beam – Main Bars 12
8 Beam – Anchor Bars 10
9 Beam – Stirrups 8
10 Slab – Main Bars 8
11 Slab – Distribution Bars 8
12 Wall – Main Bars 8
13 Wall – Distribution Bars 8
14 Minor elements such as chajjas, Lintel Beams etc. 8
The bar spacing shall be as per design and conform to IS: 456 – 2000.
Sr.
Member Minimum (mm) Maximum (mm)
No.
1 Foundations 125 200
2 Slabs 100 250
3 Stirrups for Beams 100 250

Sr.
Member Minimum (mm) Maximum (mm)
No.
4 Ties for Columns, Pedestals 100 250
5 Walls 100 250
5.7 Foundations
i. The minimum depth of foundations for all structures, equipments, buildings and
frame foundations and load bearing walls shall be as per IS 1904 but in any case,
this shall not be less than 1.0 meter in the original soil.
ii. Maximum safe bearing capacity of soil strata shall be taken as determined by the
Contractor through his own independent investigations. Geotechnical reports of
proposed STP sites covered under the contract are provided with the Bid
Documents. It may be used by Contractor as part of, in addition to, or in lieu of such
investigations at his own risk.
iii. Care shall be taken to avoid the foundations of adjacent buildings or structure
foundations, either existing or not within the scope of this Contract. Suitable
adjustments in depth, location and sizes may have to be made depending on site
conditions. No extra claims for such adjustments shall be accepted by the Employer.
iv. Special attention is drawn to danger of uplift being caused by the ground water table.
All underground structural slabs shall be designed for uplift forces due to ground
water pressure.
v. EGL (Existing ground level) and FGL (Finished ground level) shall be marked on all
drawings showing foundation/sub-structure details and related design documents.
vi. Machine/static equipment foundations shall be separated from adjoining parts of
buildings, other foundations and floor/pavement slabs. Joints at floor/pavement slabs
shall be suitably sealed.
vii. Foundations and structures for machines subject to vibrations shall be so
proportioned that the amplitude and frequency of the foundation/structure are within
the permissible limits as per relevant BIS codes (or as required by the machine
vendor).
viii. Machine foundations shall be designed and detailed as per IS: 2974. All appendages
to such foundations shall be reinforced suitably to ensure integral action.
5.8 Design Requirements
The following are the design requirements for all reinforced or plain concrete structures:
a) All blinding and levelling concrete shall be a minimum 100 mm thick in concrete
grade M10.
b) All liquid retaining reinforced concrete structures, concrete shall be of a minimum
M30 grade with a maximum 20 mm aggregate size for all - structural members and
For Buildings, reinforced concrete shall be of a minimum M25 grade (Footings, Plinth
Beams, Columns, Slab and beams, etc., i.e. which are other than liquid retaining
structures) with a maximum 40 mm aggregate size for footings and base slabs and
with a maximum 20 mm aggregate size for all other structural members. Further, if
there are any liquid retaining RCC tanks coming up with in the buildings, concrete
shall be of minimum M30 grade for such RCC tanks also.
c) The reinforced concrete for all structures shall have a minimum cement content of
375 kg/m3 with a maximum 20 mm size aggregate and 350 kg/m3 with a maximum 40
mm size aggregate. Reinforced concrete shall have maximum slump of 100mm with
maximum water cement ratio of 0.48.

d) As a design consideration to control crack, though general requirements of IS 3370

shall be followed, All liquid retaining structures where reactive water is present shall
be designed based on the serviceability crack width limit state (i.e. 0.1 mm crack
width) and other limit state requirements also to ensure an adequate degree of safety
and serviceability. For tanks containing non-reactive water 0.2mm crack width shall
be followed.
e) The minimum cover to the main reinforcing bars for different members for:
1) Non-liquid retaining structures shall be as follows unless stated otherwise:
Slab (Floor, Roof, Canopy, and Staircase) 25 mm

Beams (Sides, Bottom & Top) 40 mm
Columns 50 mm
Pedestals (in contact with earth) 50 mm
Basement wall, retaining walls
i) Face in contact with earth 50 mm
ii) Interior face 40 mm
Foundations (Top, Bottom and sides) 50 mm
Lintels (all around) 30 mm
2) Liquid retaining structures shall be as follows unless stated otherwise:
Walls - Face in contact with earth 50 mm

Walls - Face in contact with Water 50 mm
Base Slab in contact with Water 50 mm
Base Slab in contact with Soil 50 mm
Launders/Gutter Slabs 25 mm
f) In general, reinforcement for buildings and sewage treatment units shall be HYSD-
CRS (Corrosion Resistant Steel) of Grade Fe 500. All physical and chemical
properties of this Fe 500 grade steel shall conform to IS: 1786-2008. Welded wire
fabric shall conform to IS: 1566 as shown or specified on the drawing. The CRS
(corrosion resistant steel) index shall be at least 1.35 when tested for Salt Spray test
as per ―ASTM B 117 – 2009 test procedure for 120 hours when compared with the
Fe 500 normal reinforcement bars and with same bar diameter. All test results
(including physical and chemical properties and salt spray tests) have to be produced
for the respective bar diameter for each consignment of steel delivered at site and at
a frequency of every 20 Metric Tons.
Reinforcement bars and structural steel to be procured only from Primary steel
producers/Integrated Steel Plants such as TATA/SAIL/RINL/JSW/SHYAM STEEL
using iron ore as the basic raw material and having in-house iron making facilities
followed by production of liquid steel and crude steel with in-house rolling, adopting
BF-BOF route or DRI-EAF technology as per Ministry of Steel guidelines. No
Re-rolled material/secondary steel will be accepted or allowed for any structural
works.

The steel manufacturing company should have latest ISO accreditation for Quality
Management System.
g) The minimum amount of reinforcement in each of the two directions at right angles
within each surface zone should be provided as per clause 8.1 of IS 3370 (Part
2):2009. Definition of surface zones is clearly shown in Figure 1 and Figure 2 of IS
3370 (Part 2): 2009. For slabs, minimum of 10 mm dia bars shall be used to avoid
any deformation of lesser diameter bars under loads prior to construction.
h) All buildings shall have a minimum 1 meter wide, 100 mm thick plinth protection
paving in M15 grade concrete or stone slabs/tiles. All plinth protection shall be
supported on well compacted strata.
i) All pipes and ducts laid below the structural plinth and road works shall be
surrounded with concrete of grade M15 having minimum 150 mm thick concrete or
D/4 (D = outer dia. of pipe) thickness whichever is more.
j) Use of pressure relief valves to reduce uplift pressure due to ground water table shall
not be allowed.
k) Detailing of the reinforcement shall be considered as per latest Indian standard code
of practices and special publications as applicable.
l) Sliding layer or slip layer shall be provided between sub base and structural slab
(Raft). Polythene sheets of 500 gauge shall be provided as sliding layer as per IS
specification.
m) Water tightness testing of water retaining structures shall be done in accordance with
IS: 3370, Part I - 2009. It is described in Clause 10.22 of this document. The depth of
water for testing shall be up to the soffit of the covering slab.
n) Concrete for all Sewage treatment works shall be prepared using sulphate resistant
cement.
The following minimum thicknesses shall be used for different reinforced concrete
members, irrespective of design requirements:
Walls for liquid retaining structures : 250 mm

Roof slabs for liquid retaining structures (Other than flat slabs) : 150 mm
Bottom slabs for liquid retaining structures : 300 mm
Floor slabs including roof slabs, walkways, Canopy slabs : 125 mm
Walls of cables / pipe trenches, Underground pits etc. : 200 mm
Column footings : 300 mm
Parapets, chajja : 100 mm
Precast trench cover : 75 mm
Column Dimensions : 300 mm
Launder Base Slab : 200 mm
Launder Vertical Wall, Baffle Walls : 150 mm
Grade Slabs : 150 mm

5.9 Materials in General
The term "materials" shall mean all materials, goods and articles of every kind whether
raw, processed or manufactured and equipment and plant of every kind to be supplied
by the Contractor for incorporation in the Works.
Except as may be otherwise specified for particular parts of the works the provision of
clauses in "Materials and Workmanship" shall apply to materials and workmanship for
any part of the works.
All materials shall be new and of the kinds and qualities described in the Contract and
shall be at least equal to approved samples.
As soon as practicable after receiving the order to commence the Works, the Contractor
shall inform the Engineer of the names of the suppliers from whom he proposes to obtain
any materials but he shall not place any order without the approval of the Engineer which
may be withheld until samples have been submitted and satisfactorily tested. The
Contractor shall thereafter keep the Engineer informed of orders for and delivery dates of
all materials.
Materials shall be transported, handled and stored in such a manner as to prevent

deterioration, damage or contamination failing which such damaged materials will be
rejected and shall not be used on any part of the Works under this contract.
5.10 Samples and Tests of Materials
The Contractor shall submit samples of such materials as may be required by the
Engineer and shall carry out the specified tests directed by the Engineer at the Site, at
the supplier's premises or at a laboratory approved by the Engineer.
Samples shall be submitted and tests carried out sufficiently early to enable further
samples to be submitted and tested if required by the Engineer.
The Contractor shall give the Engineer seven days' notice in writing of the date on which
any of the materials will be ready for testing or inspection at the supplier's premises or at
a laboratory approved by the Engineer. The Engineer shall attend the test at the
appointed place within seven days of the said date on which the materials are expected
to be ready for testing or inspection according to the Contractor, failing which the test
may proceed in his absence unless instructed by the Engineer to carry out such a test on
a mutually agreed date in his presence. The Contractor shall in any case submit to
Engineer within seven days of every test such number of certified copies (not exceeding
six) of the test results as the Engineer may require.
Approval by the Engineer as to the placing of orders for materials or as to samples or

tests shall not prejudice any of the Engineer's powers under the Contract.
The provisions of this clause shall also apply to materials supplied under any nominated
sub-contract.
5.11 Standards
Materials and workmanship shall comply with the relevant Indian Standards (with
amendments) current on the date of submission of the tender.

Where the relevant standard provides for the furnishing of a certificate to the Engineer, at
his request, stating that the materials supplied comply in all respects with the standard,
the Contractor shall obtain the certificate and forward it to the Engineer.
The specifications, standards and codes listed below are considered to be part of this
specification. All standards, specifications, codes of practices referred to herein shall be
the latest editions including all applicable official amendments and revisions.
In case of discrepancy between the Specification and the Standards referred to herein,
the Specification shall govern.
a) Materials
IS: 269 : Specification for 33 grade ordinary Portland cement
IS: 383 : Specification for coarse and fine aggregates from natural sources for
concrete
IS: 428 : Specification for distemper, oil emulsion, colour as required
IS: 432 : Specification for mild steel and medium tensile steel bars and hard
drawn steel wire for concrete reinforcement (Parts 1 & 2)
IS: 455 : Specification for Portland slag cement
IS: 458 : Specification for precast concrete pipes (with and without
reinforcement)
IS: 650 : Specification for standard sand for testing of cement
IS: 651 : Specification for salt glazed stoneware pipes and fittings
IS: 808 : Specification for dimensions for hot rolled steel beam, column channel
and angle sections
IS: 814 : Specification for covered electrodes for manual metal arc welding of
Carbon and Carbon Manganese steel
IS: 1003 : Specification for timber panelled and glazed shutters (Parts 1 & 2)
IS: 1038 : Specification for steel doors, windows and ventilators
IS: 1077 : Specification for common burnt clay building bricks
IS: 1398 : Specification for packing paper, water proof, bitumen laminated
IS: 1489 : Specification for Portland pozzolana cement (Parts 1 & 2)
IS: 1566 : Specification for hard drawn steel wire fabric for concrete
reinforcement
IS: 1580 : Specification for bituminous compounds for water proofing and caulking
purposes
IS: 1786 : Specification for high strength deformed steel bars and wires for
concrete reinforcement
IS: 1852 : Specification for rolling and cutting tolerances for hot rolled steel
products
IS: 1948 : Specification for aluminium doors, windows and ventilators
IS: 1977 : Specification for Low Tensile structural steel (Ordinary quality)
IS: 2062 : Specification for steel for general structural purposes (Hot Rolled Low,
Medium and High Tensile Structural Steel).

IS: 2185 : Specification for concrete masonry units (Parts 1, 2 & 3)

IS: 2202 : Specification for wooden flush door shutters (Parts 1 & 2)
IS: 2645 : Specification for integral cement water proofing compounds
IS: 2750 : Specification for steel scaffoldings
IS: 2835 : Specification for flat transparent sheet glass
IS: 3384 : Specification for bitumen primer for use in waterproofing and damp
proofing
IS: 3502 : Specification for steel chequered plates
IS: 4021 : Specification for timber door, window and ventilator frames
IS: 4350 : Specification for concrete porous pipes for under drainage
IS: 4351 : Specification for steel door frames
IS: 4990 : Specification for plywood for concrete shuttering work
IS: 9862 : Ready mixed paint, brushing, bituminous, black, lead free, acid, alkali,
water and chlorine resisting
IS: 10262 : Recommended guidelines for concrete mix design
IS: 12330 : Specification for sulphate resisting Portland cement
IS: 12709 : Glass fibre reinforced plastics (GRP) pipes, joints and fittings for use
for potable water supply
b) Tests
IS: 516 : Method of test for strength of concrete

IS: 1182 : Recommended practice for radiographic examination of fusion - welded
butt joints in steel plates
IS: 1199 : Methods of sampling and analysis of concrete
IS: 2386 : Methods of test for aggregates for concrete (Parts 1 to 8)
IS: 2720 : Methods of test for soils (Parts 1 to 39)
IS: 3025 : Methods for sampling and test (physical and chemical) for water and
wastewater (Parts 1 to 63)
IS: 3495 : Method of test for burnt clay building bricks (Parts 1 to 4)
IS: 3613 : Acceptance tests for wire flux combination for submerged arc welding
IS: 4020 : Methods of tests for wooden flush doors shutters: Type tests
IS: 4031 : Methods of physical tests for hydraulic cement (Parts 1 to 15)
IS: 5807 : Method of test for clear finishes for wooden furniture (Parts 1 to 6)
IS: 7318 : Approval tests for welders when welding procedure approval is not
required (Parts 1 and 2)
IS: 13311 : Methods of Non-destructive testing of Concrete- Part 1 & Part 2

c) Codes of Practice for design/detailing
IS: 456 : Code of practice for plain and reinforced concrete

IS: 783 : Code of practice for laying of concrete pipes
IS: 800 : Code of practice for general construction in steel
IS: 806 : Code of practice for use of steel tubes in general building construction
IS: 816 : Code of practice for use of metal arc welding for general construction in
mild steel
IS: 817 : Code of practice for training and testing of metal arc welders
IS: 875 : Code of practice for design loads (other than earthquake) for building
structures (Parts 1 to 5)
IS: 1081 : Code of practice for fixing and glazing of metal (steel and aluminium)
doors, windows and ventilators
IS: 1172 : Code of practice for basic requirements for water supply, drainage and
sanitation
IS: 1477 : Code of practice for painting of ferrous metals in buildings (Parts 1 & 2)
IS: 1597 : Code of practice for construction of stone masonry (Parts 1 & 2)
IS: 1742 : Code of practice for building drainage
IS: 1893 : Criteria for earthquake resistant design of structures
IS: 1904 : Code of Practice for Design and Construction of Foundation in Soils:
General Requirements.
IS: 2065 : Code of practice for water supply in buildings
IS: 2212 : Code of practice for brickwork
IS: 2338 : Code of practice for finishing of wood and wood based materials (Parts
1 & 2)
IS: 2394 : Code of practice for application of lime plaster finish
IS: 2395 : Code of practice for painting, concrete, masonry and plaster surfaces
(Parts 1 & 2)
IS: 2470 : Code of practice for installation of septic tanks (Parts 1 & 2)
IS: 2502 : Code of practice for bending and fixing of bars for concrete
reinforcement
IS: 2571 : Code of practice for laying in-situ cement concrete flooring
IS: 2595 : Code of practice for radiographic testing
IS: 2751 : Recommended practice for welding of mild steel plain and deformed
bars for reinforced construction
IS: 2974 : Code of practice for design and construction of machine foundations
(Parts 1 to 4)
IS: 3114 : Code of practice for laying of Cast Iron pipes
IS: 3370 : Code of practice for concrete structures for the storage of liquids (Parts
1 to 4)
IS: 3414 : Code of practice for design and installation of joints in buildings
IS: 3558 : Code of practice for use of immersion vibrators for consolidating
concrete

IS: 3658 : Code of practice for liquid penetrant flaw detection

IS: 3935 : Code of practice for composite construction
IS: 4000 : Code of practice for High strength bolts in steel structures
IS: 4014 : Code of practice for steel tubular scaffolding (Parts 1 & 2)
IS: 4111 : Code of practice for ancillary structures in sewerage system (Parts 1 to
5)
IS: 4127 : Code of practice for laying of glazed stoneware pipes
IS: 4326 : Code of practice for Earthquake Resistant Design and Construction of
Buildings
IS: 4353 : Recommendations for submerged arc welding of mild steel and low
alloy steels
IS: 5329 : Code of practice for sanitary pipe work above ground for buildings
IS: 5334 : Code of practice for magnetic particle flaw detection of welds
IS: 5822 : Code of practice for laying of welded steel pipes for water supply
IS: 7215 : Tolerances for fabrication of steel structures
IS: 9595 : Recommendations for metal arc welding of carbon and carbon
manganese steels
IS: 10005 : SI units and recommendations for the use of their multiples and of
certain other units
SP: 16 : Design Aids for Reinforced Concrete to IS 456
SP: 34 : Handbook on Concrete Reinforcement and Detailing
SP: 38 : Handbook of Typified Design of Structures with Steel Roof Trusses
d) Construction Safety
IS: 3696 : Safety code for scaffolds and ladder (Parts 1 & 2)
IS: 3764 : Safety code for Excavation work
IS: 7205 : Safety code for erection of structural steel work
5.12 General Arrangement of Plant
The following general guidelines shall be followed in the preparation of general

arrangement of Plant:
 Sufficient room shall be allowed between items of plant and adjacent Plant or fixed
structures to permit safe and convenient access for operation and maintenance;
 An area adjacent to all mechanical Plant shall be provided as maintenance lay down
area;
 fixed runways, lifting eyes or other means shall be provided to permit the removal of
Plant that may be required to be removed during the course of its normal operational
life for maintenance or any other purpose;
 areas where leakage is likely to occur whether in normal use or during maintenance
shall be provided with covered drainage channels which shall direct spillage either to
a suitable plant drain or to a sump from where it can be pumped to plant drain;

5.13 Orientation
The works shall be laid out within the confines of the Site in order to interface to the
existing infrastructure of roadways and inlet and outlet pipe work. Underground services
requiring to be relocated in order to accommodate the proposed site layout shall, with the
approval of the Engineer, be relocated by the Contractor.
5.14 Buildings and Structures
All the building and structure works shall generally comply with the following Employer‘s
Requirements unless otherwise specified elsewhere:
1. All building works shall be of reinforced concrete framework (Concrete Grade of M25
as a minimum).
2. All external walls shall be in solid cement concrete blocks of concrete grade M15 and
shall be provided as per IS: 2185 (Latest Revision) and shall be 200 mm thick. All
internal partition walls shall be in solid cement concrete blocks of concrete grade
M15 and shall be provided as per IS: 2185 (Latest Revision). All internal walls shall
be 200mm thick except for toilets. Toilet partition walls shall be in 100 mm thick solid
concrete block.
OR
3. All internal partition walls except for toilet shall be in 230 mm thick brick masonry built
in cement mortar 1:5 with transoms and mullions. Toilet partition walls shall be in 115
mm thick brick masonry built in cement mortar 1:4 and shall have transoms and
mullions similar to (2) above and shall form panels not exceeding 1200 mm x 1200
mm in size.
4. (a) Finishes to concrete liquid retaining structures shall be:

F1 - External surfaces, buried
F2 - External surfaces exposed and up to 300 mm below ground level
F2 - Internal surfaces
(b) Finishes to other concrete structures shall be:

F1 - Buried
F1 - Exposed, where plastering is specified
F2 - Exposed
The type of finishes is explained in Vol 2 Section VI-B, Chapter 9 of Part 13 ―Standard
Specifications for Civil and Structural Works‖
5. All internal masonry surfaces finish shall have 12 mm thick plain faced cement
plaster in cement mortar (1:4) with neat cement finish on top. Over this, one coat of
primer and two coats of plastic emulsion paint of approved quality and shade shall be
provided.
6. All external masonry and concrete with rough board finish shall have 20 mm thick
sand faced cement plaster in two coats, base coat 12 mm thick in cement mortar 1:4
and finishing coat 8 mm thick in cement mortar 1:4. Waterproofing compound of
approved make and quality shall be added to the cement mortar in proportions as
specified by the manufacturer.
7. All external surfaces above ground level shall have one coat of primer and two coats
of waterproof cement based paint of approved quality and shade. A coat of silicone
water repellent paint shall also be applied thereon.

8. Toilet areas, walls and ceilings, shall have one coat of primer and two coats of plastic
emulsion paint.
9. Toilet floor slab shall be filled with brick bat coba (broken bricks in lime) and provided
with waterproofing as per the specifications of an approved specialist waterproofing
company.
10. The finished floor level in toilet areas shall be 25 mm below general finished floor
level elsewhere in the building.
11. The flooring in all areas except toilets, staircases, pumping stations, chlorination
building, centrifuge building, workshop, D.G.Room shall be in 250 mm x 250 mm x 20
mm thick vitrified tiles of approved make unless otherwise specified, shade and
pattern and placed in cement mortar 1:4 to give overall thickness of 50 mm. Half tile
skirting shall also be provided in these areas.
12. The flooring in the pumping stations, chlorination building, centrifuge building,
workshop, D.G. Room shall be 60mm thick cement flooring with Metallic concrete
hardener topping, under layer of 42mm thick cement concrete 1:2:4 (1 cement : 2
coarse : 4 graded stone aggregate 16mm thick nominal size) and top layer of 18mm
thick metallic concrete hardener consisting of mix 1:2 (1 cement : 2 stone aggregate
6mm nominal size) by volume & mixed with metallic hardening compound of
approved quality @ 3 kg/m2. Including cement slurry and rounding off edges.
13. The flooring in operator‘s room, loading/unloading bay, MCC cum Panel room shall
be in 25mm thick Kota stone slab of approved shade and pattern and placed over 20
mm thick base of cement mortar 1:4 to give overall thickness of 45 mm. Half tile
skirting shall also be provided in these areas.
14. Toilet areas shall have 450 mm x 450 mm x 25 mm thick polished Kota stone tiles
placed in cement mortar 1:4 to give an overall thickness of 50 mm. 2100 mm high
dado, in 150 mm x 150 mm x 6 mm thick glazed tiles (approved make, shade and
pattern) placed in cement mortar 1:3 shall also be provided in these areas.
15. The flooring along with skirting in administration cum laboratory building shall be 20
mm thick mirror polished, machine cut granite slab of approved shade and pattern
placed in cement mortar (1:4). 150mm high skirting shall be provided in these areas.
Granite stone shall be provided for laboratory platforms fixed over double
sandwiched cuddappah support as directed and the edges of granite is to be
embedded into the wall.
16. The Gents toilet facilities, on each floor, shall include at least :
a) 2 Nos. Water closets with one white porcelain Orissa pan minimum 580 mm long
with low level flushing cistern of 10 litres capacity, and one white porcelain
western toilet with flushing cistern of 10 litres capacity
b) 2 Nos. Urinals of sizes 600 mm x 400 mm x 300 mm flat back type in white
porcelain separated by a marble partition of size 680 mm x 300 mm.
c) 2 Nos. wash basins of size 510 mm x 400 mm in white porcelain with inlet, outlet
and overflow arrangements.
d) 2 Nos. mirror of size 400 mm x 600 mm wall mounted type fitted over wash
basins.
e) 2 Nos. plastic liquid soap bottles
f) 2 Nos. chromium plated brass towel rails minimum 750 mm long.
g) All stopcocks, valves and pillar cocks shall be heavy duty chromium plated brass.
h) All fittings such as `P‘ or `S‘ traps, floor traps, pipes, downtake pipes etc.
i) The sewage from toilet blocks shall be led to the wet well of terminal sewage
pumping station if present or included under this contract or to the closest gravity
sewer.
17. The Ladies toilet facilities, on each floor, shall include at least :

a) 2 Nos. Water closets with one white porcelain Orissa pan minimum 580 mm long
with low level flushing cistern of 10 litres capacity, and one white porcelain
western toilet with flushing cistern of 10 litres capacity
b) 2 Nos. wash basins of size 510 mm x 400 mm in white porcelain with inlet, outlet
and overflow arrangements.
c) 2 Nos. mirror of size 400 mm x 600 mm wall mounted type fitted over wash
basins.
d) 2 Nos. plastic liquid soap bottles
e) 2 Nos. chromium plated brass towel rails minimum 750 mm long.
f) All stopcocks, valves and pillar cocks shall be heavy duty chromium plated brass.
g) All fittings such as `P‘ or `S‘ traps, floor traps, pipes, downtake pipes etc.
h) The sewage from toilet blocks shall be led to the wet well of terminal sewage
pumping station if present or included under this contract or to the closest gravity
sewer.
18. Additional toilet block with one Gents toilet and one Ladies toilet shall be provided at
easily accessible central location within the site boundary. This toilet block shall also
have separate shower area for ladies and gents.
19. All staircases shall have 25 mm thick kota tiles for treads and 25 mm thick plain kota
tiles for risers and half tile skirting set in cement mortar in 1:4 to give an overall
thickness of 50 mm. All concrete stairs shall have aluminium nosing over 2 mm thick
rubber strip of width same as nosing for the full length of the tread. Nosing shall be
fixed with countersunk screws.
20. Stairways shall be provided to permit access between different levels within
buildings. Staircase shall be minimum 1000mm wide, minimum Tread = 250 mm,
maximum Riser = 175 mm and maximum 15 number of steps per flight unless
specified otherwise. Staircases in general shall not be steeper than 40°. Staircases
having space constraints may be steeper than 400. The maximum vertical run for a
single flight of stairs shall be 3.0 M.
21. All roof tops and overhead tanks shall be made accessible with ladder provision.
Vertical step ladders fitted with landing point extensions will be permitted where
considered appropriate by the Engineer to access areas not frequently visited.
Steel staircases shall be constructed of standard channel stringers with M.S. grating
treads 25mm thick with non skid nosing. Steel Ladders shall be minimum 600mm
wide and shall not exceed 6m of straight run. The ladders shall be painted with epoxy
paint.
22. All hand railing shall be provided with 6063-T6 Aluminium Alloy with an ultimate
tensile strength of at least 207 MPa and yield strength of at least 172 MPa. The
minimum height of hand railing shall be 1m and maximum spacing of verticals shall
be 1.5 m. Number of horizontal rails shall be 3 (1 top, 1 intermediate and 1 bottom)
OR 2 rails ( 1 top, 1 intermediate) with a 100 x 6 toe plate at the bottom.
23. The reinforced concrete roofs shall be made waterproof by application of an
approved roof polythene / bitumen membrane / brick bat coba. The finished roof
surface shall have adequate slope to drain quickly the rain water to R.W down take
inlet points.
24. All roof floors shall have minimum 750 mm height solid concrete block parapet wall
where accessible is provided and shall have minimum 300 mm height solid concrete
block parapet wall where accessible is not provided
25. For roofing drainage, cast iron or uPVC rainwater down takes with C.I. bell mouth or
uPVC bend and C.I. or uPVC grating at top shall be provided. For roof areas up to
40 sq m minimum two nos. 100 mm diameter down take pipes shall be provided. For
every additional area of 40 sq m or part thereof, at least one no. 100 mm dia. down
take pipe shall be provided.

26. Top surfaces of chajjas and canopies shall be made waterproof by providing a
screed layer of adequate slope or application of an approved roof membrane and
sloped to drain the rain water.
27. Building plinth shall be minimum 450 mm above average finished ground level
around building or high flood level whichever is more.
28. All doors, windows, rolling shutters shall have lintels above. Chajja protection to
lintels on external walls shall be such as to prevent the rain water splashing into the
building. Chajja projection of minimum 750 mm for rolling shutters, 600 mm for doors
and 450 mm for windows shall be provided to prevent the rain water splashing into
the building. Chajja shall be projected 150 mm on either sides from size of
doors/windows/rolling shutters.
29. All windows and ventilators shall have 25 mm thick Kota stone sills bedded in cement
mortar (1:3).
30. All doors and windows shall be painted with two coats of synthetic enamel paint over
a priming coat (ready mixed Zinc Chromate Yellow primer of approved brand and
manufacturer confirming to I.S.: 127-106, 341 and 340).
31. All doors, windows and ventilators shall be made of aluminium confirming to latest
version of IS: 1948. All fixtures for doors, windows and ventilators shall also be of
aluminium. Aluminium grills shall be provided in all the windows. Doors shall be in
two panel and both panels shall be glazed/unglazed. Minimum weight of aluminium
doors & windows shall be as follows
I. Single Glazed Window : (Weights indicated shall be aluminium)

a) Openable
Outer Frame : Weight 0.70 kg/Rmt
Shutter Frame : Weight 0.97 kg/Rmt
Intermediate Mullion : Weight 0.97 kg/RMt
Beading : Weight 0.31 kg/Rmt
Fixing Louvers windows/ventilators

II. Double Glazed Window

Intermediate Mullion : Weight 0.98 kg/Rmt
Beading : Weight 0.31 kg/Rmt
III. Sliding Windows

Bottom & Top Frame : Weight 0.70 kg/m
Shutter Frame : Weight 0.42 kg/m
Interlocking Section : Weight 0.47 kg/m
IV. Aluminium Door

Bottom Stile : Weight 2.508 kg/Rmt
Glazing shall be 5.5 mm thick glass.
32. Openings of the windows & ventilators shall be minimum 25% of the external wall
area.
33. Ventilator shall be provided where height of floor is more than 3m.
34. All windows and ventilators shall have wire mesh. Frame of doors, windows and
ventilators shall be of aluminium of standard rolled section. Doors, Windows and

Ventilators shall be of size as per schedule to be submitted by the Contractor for

approval of Engineer. The minimum size shall be as per below:
 Door of opening size 1.2m x 2.1m
 Door of opening size 0.75m x 2.1m for toilets
 Glazed widows of minimum size 1.2m x 1.2m
 Ventilators of minimum size 0.6m x 0.6m
35. Rolling shutters shall be made of 80 x 1.25 mm MS laths. Rolling shutter shall be of
minimum size 3m wide x 3.0m high. Rolling shutter shall be provided in MCC cum
panel room, chlorine tonner shed, at entry and exit of the pump house for access to
pumps, motors, valves, panels and as wherever required.
36. All concrete channels and ducts used for conveying liquid shall have inside finish of
type F2. The width of concrete channels shall not be less than 500 mm. All open
channels shall be provided with Aluminium hand railings (3-rail) or concrete walls to a
minimum height of 1 m from the access surface elevation. All concrete surfaces of
structures conveying raw sewage or primary effluent upstream of the aeration tanks
shall be protected from corrosion with an approved internal lining as specified in
Clause 10.21 of this document.
37. Kerbs to be provided below the hand railing on the catwalks/pathways should be as
per relevant sections of Factory Act. It shall not be less than 150mm.
38. All exposed surfaces of inserts embedded in concrete shall be painted with two coats
of enamel paint over one coat of red oxide zinc chrome primer. Surfaces in contact
with concrete shall not be painted.
39. All structural steel members shall be painted with two coats of enamel paint over one
shop and one field coat of red oxide zinc chrome primer.
40. All rooms in the treatment plant buildings shall be provided with appropriate sign
boards indicating the function of the rooms involved written in Kannada and English
Languages.
41. The design of buildings shall reflect the climatic conditions existing on site. Process
buildings shall as far as is possible permit the entry of natural light, and the use of
glazed panelling shall be kept to a minimum and preference given to wall openings
protected by weather canopies.
42. Emergency exit doorways shall be provided from all buildings in order to comply with
local and international regulations. Stairways and paved areas shall be provided at
the exit points.
43. Toilet blocks in process buildings and control blocks shall be provided with a sink
with two drinking water taps of 20 mm size with adequate inlet and outlet
connections.
44. All the walkways shall have minimum 1 m width and shall be covered with mosaic
tiles. Walkways to be provided with 6063-T6 Aluminium Alloy hand railings.
45. All concrete structures in contact with sewage and/or sludge upstream of the
Aeration Basins shall be provided with full interior corrosion protection linings and/or
coatings of appropriate material and thickness – to be approved by BWSSB. This
also applies to all concrete structures in contact with any type of sewage sludge
anywhere in the plant. For Aeration Basins, interior lining shall extend from the top of
wall down to 1.0 meter below the lowest operating water level.
46. For structures containing water or process liquid, the top of the wall shall be atleast
0.5m higher than the maximum water surface level calculated at high flood level and
peak plant flow. The top level of internal plant roads and approaches shall be atleast
0.5m above the site High Flood Level.
47. If the High flood level is more then Ground Level then road shall be constructed on
the earthen embankment. Earthen embankment shall be constructed with side slope
of atleast 2 horizontal to 1 vertical. Stone pitching shall be provided at both sides of
the embankment as per IS: 8237. Top width of embankment shall be taken as 6.0m.
Top level of embankment shall be 0.5m above high flood level. Excavated earth from

the plant can be used for embankment construction and if required, extra earth can
be borrowed from the borrow pit as approved by Engineer.
5.15 Roadways, Pathways & Hard standings
A comprehensive network of roadways shall be provided around the treatment plant to

link in with the existing road network and permit access to the plant for necessary
maintenance, delivery of consumables and personnel access. All roads shall be of
asphalt macadam and minimum 6 metres wide. Vehicular access shall be provided for all
Plant structures and buildings. All roads shall be provided with drainage and shall be
constructed to prevent standing water.
Paved pedestrian access ways shall be constructed to provide a network of logical

routes interlinking plant areas. Damage to any existing roads on account of their use by
the Contractor shall be made good to the satisfaction of the Engineer.
Hard standing areas with shading facility shall be provided to permit the parking of
vehicles involved in the delivery of consumables from blocking site roadways during
unloading or loading. The road system shall be designed such that vehicles involved in
the delivery of consumables can follow a continuous route through the works and out
again.
5.16 Site Drainage
The Contractor shall provide a site drainage system. The system shall comprise of the
following:
 Storm Water Drainage
 Foul Drainage
5.16.1 Storm Water Drainage
Storm water drains adjacent to the existing and proposed roads (under this Contract)
shall be sized for a rainfall intensity of 50 mm/hr, allowing for 100% runoff. Drains
adjacent to roads shall be in stone masonry in CM (1:4) of appropriate thickness, topped
with 75 mm thick M10 concrete and internally flush pointed in cement mortar (1:4), 20
mm thick. The minimum width of drain shall be 450mm.
The storm water drainage system shall also be designed to cater the run-off from the
existing plot areas and structures, if necessary depending upon the site topography.
5.16.2 Foul Drainage
The foul drainage system shall accept discharge from toilets, washrooms, offices and the
laboratory. The foul drainage system shall be conveyed to either wet well of the terminal
sewage pumping station wherever exist or proposed under this contract or nearest public
sewer wherever exist.
5.17 Cable and Pipe Work Trenches
Cable and pipework trenches shall generally be constructed in reinforced concrete.

However, 500 mm x 500 mm size or smaller trenches, not on fill may be constructed in
200 mm thick solid cement concrete blocks over 150mm thick M 15 PCC base. The
trenches will be 20mm thick plastered internally with cement mortar (1:4) and externally
in cement mortar (1:3).

All floor cut-outs and cable ducts, etc. shall be covered with M20 precast concrete covers
(Heavy Duty) or MS grating as per direction of Engineer in outdoor areas and M.S.
chequered plates, suitably painted of adequate thickness in indoor areas. All uncovered
openings shall be protected with hand railing. The pipe, cable trenches shall be suitably
sloped to drain off rainwater to a suitable location.
Layout of trenches outside the buildings shall allow space for construction of future
trenches where necessary with due consideration for planning for future developments.
This aspect shall be brought to the notice of the Engineer while planning the works.
5.18 Pipes and Ducts
R.C.C ducts for drainage shall have minimum 1 metre pre-cast cover (M20 concrete,
Heavy duty) while laid under roads. Access shafts of size not less than 600 mm x 1000
mm shall be provided.
All drains (except storm water drains adjacent to roads) shall be covered and designed
structurally for appropriate loads.
5.19 Main Gate
Each proposed treatment plant shall have one main gate to access the plant irrespective
of existing gate at the premises of existing plant site. Minimum width of main gate shall
be 6m. Main gate shall have 1.5m wide wicket gate. Main gate shall have as external
framework of GI pipes and internal framework of MS flats. Gate shall be fixed on RCC
columns. The design and pattern of gate with drawing shall be submitted for approval of
the Engineer. The gate shall have all necessary hinges, locking arrangement, rolling
arrangement and painting complete, as approved by the Engineer.
5.20 Landscaping
The site shall be landscaped once the Works are substantially complete. Landscaping
area shall be marked in the layout plan of STP site.
Landscaping shall include planting of suitable trees, shrubs and development of

lawn/grassed areas. Landscaping in general shall meet ecological and environmental
conditions of the site. Road widths shall determine the size of the tree height and spread
to be selected for planting. Trees and shrubs suitable for local conditions shall be
selected as approved by the Engineer. Medicinal and fruit trees shall be avoided.
Landscaping shall be maintained in good condition till the completion of the contract.
Area for landscaping will be equal to total area of project site minus area for the
treatment plant units and the area required for roads, sidewalks and drains.
5.20.1 Tree Planting
Pits dug a few days in advance of actual planting shall be allowed to weather and be
filled with top soil mixed with manure. Size of the pit shall be as per standard
requirement. Only one tree shall be planted in each pit. A guard made of bamboo with
wire mesh or bricks or M.S. ring as approved by Engineer, shall be provided.
5.21 Specification for Anti-Corrosive Internal Lining protection of Concrete Surfaces
Application limits of Anti-Corrosion Internal Lining for Concrete Surfaces:

1) All units upstream of and including Primary Clarifiers will have to be provided with
internal lining for the full internal surface area (Walls and base slab)
2) For the units - Anaerobic Zone, Anoxic Zones, Aeration Zones and Aeration Basin
Effluent Channels, internal lining shall be provided on the walls only from the top of
the structure to 1.0 m below the lowest operating liquid level
3) For the units handling the solids part such as: Gravity Sludge Thickener, Sludge
Storage tank, internal lining shall be provided for the entire internal surface area.
Contractor shall adopt any one of the following materials for internal lining and submit his
methodology for approval of Engineer.
5.21.1 Intertol Poxitar or equivalent
This is a two component reaction hardening coating of low solvent content based on a
coal tax epoxy combination with mineral fillers manufactured by Sika India Pvt Ltd, which
is provided for long term protection to concrete and steel structures against chemical
corrosion. This component has excellent resistant to water and chemicals. It has
resistant to microbes also.
5.21.1.1 Application Methodology
For steel structure, sand blasting or wire brushing is essential. Surface of steel shall be
free from oil, dirt and grease. For Concrete structure, remove cement skin, loose particle
from the surface. Cavities, pin holes should be levelled.
For Concrete structure, surface shall be primed using 1 part of Inertol Poxitar and 5%
Sika Thinner DS. Surface shall be primed using above materials at a rate of 0.20 kg/ m2.
As seal coat, two coats of Inertol Poxitar is applied with rate of 0.20 kg/ m 2 per coat.
Inertol Poxitar is basically consisting of two parts Part-A & part-B. Part A and part-B are
mixed in 16:84 ratios (by weight).
For Steel Structure, surface shall be primed with Fraizinc-R with the rate of 0.20 kg/ m2.
After this, two coats of Inertol Poxitar is applied over the primer with the rate of 0.20 kg/
m2 per coat.
Part-A & part-B are mixed thoroughly with electric stirrer with up and down movement.
These shall be mixed for at least 3 minutes. Apply mix with by brush or roller. Over
coating shall be done after minimum 4 hours or maximum 7 days.
Properties of Inertol Poxitar are given below:
Colour : Black
Solids by weight : 77%
Mixed Density : 1.50 at 27 C
Pot Life : At 30 C 120 Minutes
Subs Temp Min Max
10 C 16 hours 7 days
Over-coating Time :

Mixing Ratio : Part A : part B =16:84 (by Weight)

Curing Time : 7 days
5.21.2 Shalipoxy-CTE or equivalent
Shalipoxy-CTE is a two component Coal Tar Epoxy coating manufactured by Shalimar

Tar Product limited, black in colour, used to protect steel, concrete structures in corrosive
environment. It cures to a hard smooth surface and possesses exceptional resistance to
the effect of water immersion, slat water, oils, acids, minerals, crude oils etc.
For Concrete Structures- Mechanical grinding or other suitable surface preparation is

recommended for obtaining best results on concrete. Compressed air is used to remove
residual dust or use brush to remove dust completely. Compressed air should be oil free.
Apply only to dry surface.
For Steel Structures- Steel structures which are to receive Shalipoxy-CTE coating
should be prepared by sandblasting or power tool or mechanical cleaning to a
commercial Grey metal finish. If moisture or other contaminants contaminate prepared
surface, they should be reblasted. Use suitable Shali Zinc Epoxy primer over the
prepared surface.
Mix (by volume) 4 parts of Component A to 1 part of Component B by stirring thoroughly

for at least 3 minutes. Allow the mix to stand for 10 minutes before application.
Apply two coats of Shalipoxy-CTE by brush, roller or spray. First coat should be allowed
to dry tack before application of second coat. The second coat should be applied within
72 hours, wipe first coat with MIBK and wipe dry with cloth before second coat.
Covering capacity of Shalipoxy-CTE for concrete structure shall be 4 m2 per litre per coat
and for Steel structures it shall be 6 m2 per litre per coat.
Properties of Shalipoxy-CTE are given below:
Colour : Black
Solids by weight : 76%
Pot Life : At 30 C 240 Minutes
Over Coating Time : 12 Hours
Dry Film Thickness, in two Coats : 300 Microns
5.21.3 Masterseal-SP120 or equivalent
The high build, pitch extended epoxy coating shall be MASTERSEAL SP 120
manufactured by BASF Construction Chemicals, a 100% solids, solvent free, tough
abrasion resistant protective coating. The product shall exhibit excellent bond strength
with the substrate at least exceeding 2.5 MPa, when tested as per ASTM D4541. The
product shall be formulated have high build thickness exceeding 150 microns per coat on
average and shall be applied to achieve overall thickness of 300 microns in two coats.

The product shall be formulated to resist exposure to accelerated weathering test as per
ASTM D4587 and shall not exhibit any flaking or blistering.
Concrete Structure- First it shall be ensured that concrete shall be at least 28 days old
and sound. Oil, grease, mould release agent, curing membrane and such other
contaminants must be removed by mild detergent and water, and by thoroughly
scrubbing with a soft brush. If the wall surface is damp or water is seeping out, stop the
leakage before coating. Even out all unevenness such as blow holes , pin holes and
other surface defects with CONCRESIVE 2200 manufactured by BASF Construction
Chemicals India Private Limited , before application of coating.
Steel Structures- Remove all previous treatments and corrosion products by sand/shot
blasting to bright metal finish. Do not allow long time gap between surface preparation
and the coating to prevent re-oxidising of metal before application of product.
Masterseal SP120 is two component products, Masterseal SP120 Base and Masterseal
SP120 Hardener. Both these products are mixed in ration 1:1 (by weight) Mix both the
components for 3 minutes with a slow speed drill and wing style mixing paddle at 300-
400 rpm until a homogeneous colour is achieved. Keep the paddle below the surface to
avoid entrapping air. This shall be applied in two coats, each at a W.F.T. of 150 microns.
The second coat applied after first coat has dried (4-6 hours) and at right angles to it.
Should the application of second coat be delayed, abrade the previous coat to give an
adequate mechanical key and wipe with SOLVENT NO 2 before application.
Properties of Masterseal SP120 are given below:
Colour : Black viscous liquid

Solids by volume : 100%
Mixed Density : 1.65 Kg/l at 27 C
At 25 C 60 Minutes
Pot Life :
At 40 C 30 Minutes
Over Coating Time : 12 Hours at 25 C

Mixing Ratio : Part A : part B =1:1 (by Weight)
Dry Film Thickness, in two Coats : 300 Microns
5.21.4 Nitocote ET550 or equivalent
Nitocote ET 550 is a Epoxy tar based high performance resin coating Thixotropic pitch
extended epoxy amine adduct formulation containing reinforcing inert fillers and special
blend of solvents. The product is supplied as a two-component system comprising a
special blend of an epoxy resins and a separate low viscosity amine hardener. Nitocote
ET 550 is applied as a two coat application. It is generally applied at a wet film thickness
of 265 micron per coat (175 microns DFT per coat). The product shall exhibit excellent
bond strength with the substrate when tested as per specification.

All surfaces to be treated with Nitocote ET550 must be clean and free from dust or loose
material.
Concrete Structure- All laitance must be removed by grit blasting or other suitable
removal methods. The general standard of surface preparation should be in accordance
with ACI 503R-89, Chapter 5 paragraph 5.4. Following the preparation of a concrete
structure, care should be taken to ensure that any surface irregularities are filled with
Nitomortar FC
Steel Structures- Any metal surface should be grit blasted to a bright finish, meeting the
requirements of Swedish Standards SA 21/2. BS4232, First Quality All metal surfaces
should be coated immediately after preparation.
5.21.4.2 Mixing
Nitocote ET550 should always be mixed in an open, well ventilated area. The contents of
the base shall be stirred thoroughly to disperse any settlement. The entire contents of
the hardener shall be poured into the base container ensuring that the sides and bottom
of the container are well scraped. The two components should be mixed mechanically
using a mixing paddle fitted on a heavy duty, slow speed electric drill. The mixing should
be carried out continuously for 3-5 minutes, until a uniform consistency is achieved.
Application: Brush application
Nitocote ET550 should be applied in two coats. The thoroughly mixed material should be
applied with a suitable brush. The first coat must be firmly applied and be well scrubbed
into the surface, ensuring a uniform coating with a wet film thickness not less than 265
microns, be allowed to dry for not less than 16 hours at 20°C. The second coat should be
applied as above, again achieving a wet film thickness of 265 microns. The number of
coats to achieve a total wet film application of 530 microns.
5.21.4.3 Properties of Nitocote ET550 are given below:
Sr. Allowable
Property Method
No. Standard
1 Dry Film Thickness, in two Coats
2 Adhesive bond strength :>1.5 N/mm2 ASTM D 4541
3 Hardness Test
a) Gauge Hardness H to 6H ASTM-D 3363-92a
b) Scratch Hardness H to 6H ASTM-D 3363-92a

Chemical Test
Specimens Immersed for 30 days in

1) H2 SO4 1% ASTM-C 210-92
2) NaOH 1 % ASTM-C 210-92
3) Deionsed water ASTM-C 210-92

4) HNO3 10% No attack

5) NaOH 30% No attack
6) Period of Exposure to methane at 2.0 kg/sq.cm No attack BS 5493
pressure for 720 hours
No attack means no signs of swelling, scratches, peeling or discolouration of Epoxy Tar

specimen
5.21.5 Interzone 954
Two-component, high build modified epoxy barrier coat - hydrocarbon modified

epoxy cured with a cycloaliphatic amine adduct curing agent and formulated to give good
barrier protection in both immersed and external atmospheric exposure conditions. The
product is supplied as a two-component system comprising of a pigmented epoxy base
and a clear amine curing agent.
The product is supplied as a two-component system comprising a special blend of an

epoxy resins and a separate low viscosity amine hardener. The coating can be applied
as a single coat system achieving a dry film thickness of 500 microns (588 microns wet
film thickness) sprayed in one coat.
Surface Preparation
Concrete Structure - Surfaces must be clean, dry and free from curing compounds,
laitance, releasing compounds, oil, grease, dirt, chalk, or previously applied coatings.
Laitance must, therefore, be removed by sweep blasting or other means prior to coatings
application. Ensure that the concrete is sufficiently dry to receive coatings; use a
moisture meter. The 6% maximum moisture content shall be permissible. A primer coat
of a solvent-free epoxy primer must be applied at a thickness of 40-50microns before
application of the topcoat.
Steel Structures- All surfaces to be coated must be clean and free from dust or loose
material. Interzone 954 can be applied directly to blasted steel as per SSPC/SP-6, a
minimum surface profile of 50- 75 microns is recommended.
Previously Painted Surfaces - Remove all rust, rust scale, other corrosion products,
loose or heavy chalk and loose or scaling paint by ‗Hand or Power Tool Cleaning‖
(SSPC-SP2 or 3 respectively / AS 1627 St2 or St3). ‗Feather‘ thick edges of existing
coating. Sand or sweep blasts any glossy areas until dull. Spot prime bare areas as
recommended.
5.21.5.2 Mixing
The mixing ratio of Base (Part A) to Curing Agent (Part B) is 4:1. Material is supplied in
two containers as a unit. Always mix a complete unit in the proportions supplied. The
product, once mixed, must be used within the working pot life specified.
1) Agitate Base (Part A) with a power agitator
2) Combine entire contents of Curing Agent (Part B) with the Base (Part A) and mix
thoroughly using a power agitator.
Application: Airless Spray Application

Airless spray is the preferred method of application as air spray techniques will not
produce satisfactory film build without the need for ―multiple pass‖ applications. The
pump should have a minimum ratio of 45:1. It is also advisable to check that adequate
air volume is present.
Airless Spray
 Tip Range: 0.53-0.66mm (21-26 thou)

 Total Output: Minimum 176kg/cm2
 Fluid Pressure: 2500 p.s.i
5.21.5.3 Properties of Interzone 954 are given below:
Sr.
Property Allowable Standard Method
No.
Dry Film Thickness,
1 500 microns DFT gauge
in a single coat
Adhesive bond
2 Not less than 10MPa (10 N/mm2) ISO 4624
strength
3 Tensile Strength An average of 11MPa (11 N/mm2) ASTM D2370
Average of 88mg weight loss per
4 Abrasion Resistance 1000 cycles using CS10 wheels ASTM D4060
and a 1Kg loading.
ISO 2812 Part 2 -
No film defects after 1 year of
5 Immersion "Resistance to water
exposure
immersion @ 40°C"
Direct Impact Resistance – 2.5
6 Impact Resistance ASTM D2794
Joules
Chemical Test

1 H2SO4 1% No attack ASTM-C 210-92
2 NaOH 1 % No attack ASTM-C 210-92
3 Deionised water No attack ASTM-C 210-92
4 Period of Exposure to methane at 2.0 kg/sq.cm *No attack
pressure for 720 hours
*No attack means no signs of swelling, scratches or peeling of coating specimen
Surface Preparation
Concrete Structure- Surfaces must be clean, dry and free from curing compounds,
laitance, releasing compounds, oil, grease, dirt, chalk, or previously applied coatings.
Laitance must, therefore, be removed by sweep blasting or other means prior to coatings
application. Ensure that the concrete is sufficiently dry to receive coatings; use a
moisture meter. The 6% maximum moisture content shall be permissible. A primer coat

of a solvent-free epoxy primer must be applied at a thickness of 40-50microns before

application of the topcoat.
Steel Structures- All surfaces to be coated must be clean and free from dust or loose
material. Interzone 954 can be applied directly to blasted steel as per SSPC/SP-6, a
minimum surface profile of 50- 75 microns is recommended.
Previously Painted Surfaces - Remove all rust, rust scale, other corrosion products,
loose or heavy chalk and loose or scaling paint by ‗Hand or Power Tool Cleaning‖
(SSPC-SP2 or 3 respectively / AS 1627 St2 or St3). ‗Feather‘ thick edges of existing
coating. Sand or sweep blasts any glossy areas until dull. Spot prime bare areas as
recommended.
5.21.5.5 Mixing
The mixing ratio of Base (Part A) to Curing Agent (Part B) is 4:1. Material is supplied in
two containers as a unit. Always mix a complete unit in the proportions supplied. The
product, once mixed, must be used within the working pot life specified.
1) Agitate Base (Part A) with a power agitator
2) Combine entire contents of Curing Agent (Part B) with the Base (Part A) and mix
thoroughly using a power agitator.
Application: Airless Spray Application
Airless spray is the preferred method of application as air spray techniques will not
produce satisfactory film build without the need for ―multiple pass‖ applications. The
pump should have a minimum ratio of 45:1. It is also advisable to check that adequate
air volume is present.
Airless Spray
Tip Range: 0.53-0.66mm (21-26 thou)
Total Output: Minimum 176kg/cm2
Fluid Pressure: 2500 p.s.i
5.21.5.6 Properties of Interzone 954 are given below:
Sr.
Property Allowable Standard Method
No.
1 Dry Film Thickness, 500 microns DFT gauge
in a single coat
2 Adhesive bond Not less than 10MPa (10 N/mm2) ISO 4624
strength
3 Tensile Strength An average of 11MPa (11 N/mm2) ASTM D2370
4 Abrasion Average of 88mg weight loss per ASTM D4060
Resistance 1000 cycles using CS10 wheels
and a 1Kg loading.
5 Immersion No film defects after 1 year of ISO 2812 Part 2 -
exposure "Resistance to water
immersion @ 40°C"
6 Impact Resistance Direct Impact Resistance – 2.5 ASTM D2794
Joules

Chemical Test

1) H2SO4 1% No attack ASTM-C 210-92
2) NaOH 1% No attack ASTM-C 210-92
3) Deionised water No attack ASTM-C 210-92
4) Period of Exposure to methane at 2.0 *No attack
kg/sq.cm pressure for 720 hours
*No attack means no signs of swelling, scratches or peeling of coating specimen
5.22 Hydraulic Testing of Liquid Retaining Structures
In addition to the structural test of structures as applicable, the liquid retaining structures
shall also be tested for water tightness test at full supply level as described in clauses
12.1,12.1.1, 12.1.2 and 12.1.3 of latest version of IS 3370 (Part I).
On completion of the structure and before its commissioning, the Contractor shall carry
out a water tightness test for the maximum water head condition i.e. with the water
standing at Full Supply Level (FSL). This test shall be carried out preferably in dry
season and prior to internal lining in accordance with the procedure given below:
The water tightness test shall be carried out when the construction of liquid retaining
structure is done and when it is possible to fill the structure and ensure that uniform
settlement of the structure as a whole or as directed by the Engineer. Before the filling
operations are started the structure shall be inspected by the Engineer and the
Contractor's Representative and the condition of surfaces of walls, contraction joints
shall be noted and it shall be ensured that the jointing material filled in the joint is in
position and all openings are closed. The Contractor shall make necessary arrangement
for ventilation and lighting of the structure by way of floodlights, circulators etc. for
carrying out proper inspection of the surfaces and inner conditions if so desired by the
Engineer. Records of leakages starting at different levels of water in the reservoir, if any,
shall be kept.
The liquid retaining structure once filled shall be allowed to remain so for a period of
seven days before any readings of drop in water level are recorded. The level of the
water shall be recorded against the subsequent intervals of 24 hours over a period of
seven days. The total drop in surface level over a period of seven days shall be taken as
an indication of the water tightness of the structure, which for all practical purposes shall
not exceed 40 mm. Also there shall be no indications of the leakages around the opening
or on the walls.
If the structure does not satisfy the condition of test and the daily drop in water level is
decreasing, the period of test may be extended for a further period of seven days and it
the specified limit is then reached the structure may be considered as satisfactory.
The external faces of structure shall not show any signs of leakage and shall remain
apparently dry over the period of observation of seven days after allowing a seven day
period for absorption after filling.
In case the drop in level exceeds the permissible level limit and signs of leakage with the
stipulated period of test, the Contractor shall carry out such additional works and adopt

such measures as may be directed by the Engineer to reduce the leakage within the
permissible limits. The entire rectification work that shall be carried out in this connection
shall be at the Contractor's cost. The water required for subsequent testing shall be
supplied to the Contractor free of cost, if the same is available near the site. Contractor
shall have to make arrangement for filling emptying the structure at his own cost.
If the test results are unsatisfactory, the Contractor shall ascertain the cause and make
all necessary repairs and repeat the water retaining structures test procedures, at his
own cost. Should the re-test results still be unsatisfactory after the repairs, the structure
will be condemned and the Contractor will dismantle and reconstruct the structure, to the
original specification, at his own cost.
During testing and during defect liability period the impression marks created due to
seepage shall be rectified and made good.
No separate payment shall be made for water tightness test and the cost thereof shall
deem to be covered in the rates quoted of different items of work of Treatment Plant.
5.23 Non-Destructive Testing of RCC Structures
Non-Destructive Testing (NDT) shall be carried out as per latest version of IS: 13311
codes as per the instruction given by Employer.
5.24 General Painting and Protection Requirements
5.25 General
The following, in general, are the surfaces to be painted.

 All exposed piping and other metal surfaces, interior and exterior.
 All submerged metal surfaces.
 All Structural and Miscellaneous steel, including tanks.
 Exterior, above ground concrete and brick masonry as specified.
 The interior of structures as specified.
 Equipment furnished with and without factory finished surface except as
specified hereafter.
 Door woodwork and architectural trim work.
Unless otherwise approved by the Engineer, the following surfaces shall in general not
be painted.
 Concrete surfaces subject to pedestrian traffic

 Plastic surfaces, except for colour code labelling.
 Non-ferrous metals (galvanised metal shall not be considered as a non-ferrous
metal in this context).
 Mechanical equipment and electrical equipment with approved factory finishes.
 Non-ferrous piping.
 Chain link fencing
The preparation, application and conditions for work shall comply with the
recommendations of IS 1477 and IS 800 Clause 11.15/11.9 or if the protection is of a
special nature, in accordance with the manufacturer's directions.

Paints, primers and undercoats shall be obtained from the same manufacturer and
except where a definite time is specified between mixing and application, shall be ready
mixed for use. They shall be compatible with one another.
Paints shall be delivered in sealed containers bearing the manufacturer's name, batch
number, etc. and shall carry a label giving details of quality and instructions for use.
No site painting shall be carried out unless the surface to be painted is dry, the air
temperature above 4oC and the relative humidity less than 85%.
Surfaces shall be prepared for painting in accordance with these specifications and the
paint manufacturer‘s written recommendations. Surfaces shall be clean of dirt, oil, grease
or other deleterious substance. Painting shall not commence until surface preparation
has been inspected and approved by the Engineer.
Test plates carrying finishes from the actual coating used may be required by the
Engineer for inspection and test purposes. To facilitate inspection, no consecutive coats
of paint shall be of the same shade except in the case of white. Priming to two mating
surfaces shall be applied prior to assembly.
All items of Plant and equipment shall be delivered to Site with the shop paint finish
applied unless specified otherwise. A further coat of final finish paint shall be applied at
Site, of sufficient thickness to produce a uniform colour and appearance. Such painting
shall be carried out within one month of successful acceptance trials for the Plant.
All paint thicknesses shall be checked using an alkometer or equivalent instrument,

supplied by the Contractor, for each layer of paint, to the reasonable satisfaction of the
Engineer.
5.25.1 Colour Coding and Labelling of Pipes and Equipment
All pipes and equipment shall be colour coded to a schedule to be agreed with the
Engineer before any site painting starts, or earlier if necessary to suit manufacturing
procedures. Contractor shall prepare the schedule at the appropriate time and submit to
Engineer with reasonable time allowed for comment and approval. Valves and fittings
shall be painted in the same colour as the pipe of which they form a part. Where a pipe
enters or leaves a piece of equipment the pipe colour shall extend up to but not including
the flange attached to the equipment.
All pipelines shall be identified by painted-on labels or stick-on 90 micron thick vinyl film
labels showing the name of the material to be carried by the pipeline and an arrow
indicating the direction of flow. Stick-on labels shall have an effective service life of not
less than 10 years. In the case of stick-on labels, letters of titles shall be pre-spaced on
carrier tape and the complete title protected by one piece removable liners. Titles shall
be at intervals not less than 8 m, but shall in any case be provided in every space
through which the pipe passes. Locations of labels shall be subject to prior approval by
the Engineer. Lettering sizes shall be between 16 mm and 75 mm in height depending
on the size of the pipe.
Pipes smaller than 22 mm outside diameter shall be labelled by the use of tags instead
of labels. Tags shall be made of brass no smaller than 65 mm x 16 mm by 1.5 mm thick,
with lettering etched and filled with black enamel.

Titles shall also be provided on all equipment in locations and in sizes to be approved by
the Engineer.
5.25.2 Products
Paints, oils, varnishes etc. of approved brand and manufacture shall be used. Ready
mixed paints as received from the manufacturer without any admixture shall be used. If
for any reason, thinning is necessary in case of ready mixed paint, the brand of thinner
recommended by the manufacturer or as instructed by the Engineer shall be used.
Approved paints, oils or varnishes shall be brought to the site of work by the Contractor
in their original containers in a sealed condition. The materials shall be brought in at a
time in adequate quantities to suffice for the whole work or at least a fortnights work. The
empty containers shall not be removed from the site of work until the relevant item of
work has been completed and permission obtained from the Engineer.
The Contractor shall consult with the paint manufacturer before commencement of the
work to certify the suitability of the surface to receive paint and the paint to be used.
The painting systems specified herein have been chosen with regard to the different
service conditions and shall not be changed except with the explicit permission of the
Engineer. All paint materials shall be first quality products of the required type and
composition. Trade names, where given; are only meant to clarify the quality required
and are not meant to be restrictive in any other sense. Products of other reputed
manufacturers complying with the following requirements shall be eligible for use.
5.25.3 Painting and Finishing at Place of Manufacture
This Clause governs the methods for the protective coatings to be applied to structural
steel, metalwork and ironwork as corrosion protection systems. The systems designed
as specified here shall be applied as specified under Protective Coatings. In case of
conflict, protective coatings specified elsewhere for particular works such as pipes and
cladding shall take precedence over any conflicting requirements specified herein. This
specification makes reference to the following standard:
B.S.5493 "code of practice for the protective coating of iron and steel against corrosion"
The Contractor shall design each protective coating system and shall submit details of
each system to the Engineer for approval. Submissions shall be in the format of the
examples with additional information and samples as the Engineer may require enabling
the system to be assessed.
Protective coatings shall be designed in accordance with B.S. 5493 to have a long life,
generally of at least 10 years to first maintenance. Protection systems shall be chosen to
be easily maintained in the future and to allow non-specialist on-site re-coating where
necessary using single part paints.
Interior spaces shall be considered to be dry in administration areas open to continuous

access and damp or immersed in other spaces. The protective coating of components or
structures which are continuously or infrequently immersed shall be designed for the
more onerous of these two conditions relevant to the protection system used. All exterior
exposed items to be coated shall have a final finish coat of aesthetically pleasing
appearance of a colour and type as approved by the Engineer.
Protective coating systems shall generally fall into one of the following basic systems:

 Galvanising;
 Galvanising plus painting;
 Multi-coat painting;
 Bitumen enamel;
 Others as proposed by the Contractor and approved by the Engineer.
The Contractor shall submit to the Engineer details of his proposals for the corrosion
protection (generally falling into the above categories) of each of the items listed below
and any other items requiring such protection:
 Trash screens, flooring, ladders, access covers and frames, step irons and
other components which are inaccessible but subject to abrasion/damage;
 Structural steelwork (including crane beams, monorails, crane structures and
chassis), bulkhead gates, stop logs, grappling beams, steel tanks and other
large items readily accessible for maintenance;
 Valves and other corrosion-susceptible items which may be buried and are not
covered by the provisions of other specifications :
 Other components not covered by the above for which the contractor may
propose a system which he considers to be more suitable for the duty;
 Electrical switchgear, transformers, control panels etc.
 Equipment, piping and miscellaneous metals.
All painting material shall be applied in strict accordance with the paint manufacturer's
instructions.
a) Plant supplied to site with final coating applied:
Cubicles, cabinets etc. other than those specified in Part 4 Section J
Before any steel work is painted the steel must be thoroughly cleaned and an approved
anti-rusting priming coat applied so that the possibility of rusting or corrosion taking place
is negligible. All surfaces should have not less than two stoved undercoats and two top
coats or air drying paint. The undercoats shall be easily distinguishable in shade or
colour form the priming and finishing coats. The two final coats shall be in a colour and
finish to be advised by the Engineer. The inside surfaces of any cubicles, cabinets etc.
where condensation is liable to occur, shall be coated with an approved anti-
condensation composition. The Contractor shall ensure that all component sections of a
switch board wherever manufactured shall have a finish of uniform texture and an exact
colour match.
Chromium plated parts: Where chromium plating is specified or offered by the

manufacturer it shall comply with the requirements of B.S. 1224 including the following
provisions. No blistering of any surfaces will be tolerated. The finished appearance shall
be bright.
Small bore pipes, valves and fittings etc., which are sited in architecturally finished areas
and selected by the Engineer shall be chromium plated. Any damage to chromium
plating shall be repaired before transfer of the facility to Owner.
Galvanised parts: All materials to be galvanised shall be of the full dimensions shown on
the approved drawings or specifications and all welding, bending, punching, cutting,
drilling, screw tapping and the removal of burrs shall be completed before the
galvanising process begins. Parts to be galvanised shall be shot blasted as specified
above. Such parts shall be galvanised not more than four hours after commencement of

shot blasting. Any Site modification of galvanized parts shall be covered well by zinc rich
primer and aluminium paint.
Wherever galvanizing has been specified the hot dip process shall be used. The
galvanized coating shall be of uniform thickness. Weight of zinc coatings for various
applications shall not be less than those indicated below:
 Fabricated steel
Thickness less than 2 mm but not less than 1.2 mm 340 g/m2
Thickness 2 mm and above 460 g/m2
 Fasteners
Up to nominal size M10 270 g/m2
Over M10 300 g/m2
Galvanizing of material shall be carried out in accordance with the latest editions
including all official amendments and revisions of IS 2629, 2633, 4759 and 6745.
All galvanising shall be done by the hot dip-process. No alternative process may be used
without the approval of the Engineer. No components shall be galvanised which are
likely to come into subsequent contact with oil.
The zinc coating shall be uniform, clean, smooth and free from spangle. In the case of
component parts the zinc coating shall weigh not less than 610 g/m2 of area covered and
shall not be less than 0.090 mm in thickness.
Bolts and nuts shall be sherardized. The Engineer may select for test as many
components to be weighed after pickling, and before and after galvanizing as he may
think fit.
All galvanised parts shall be protected from injury to the zinc coating due to differential
serration and abrasion during periods of transit, storage and erection. Damaged areas of
the coating shall be touched up with an approved zinc-dust paint or other approved flake
metallic compound.
Cast iron and steel pipework: (Internal surfaces)
The internal surfaces shall have an approved coating.
Where a bitumen based coating is used, it shall be in accordance with Type 2 of B.S.
4147. Prior to lining, the pipe shall be grit blasted and primed with an approved primer.
The lining shall be in accordance with B.S. 534. After installation, the internal lining shall
be made good and satisfactorily tested with a Holiday detector to 8 KV.
The coating shall be suitable for use in contact with the respective process fluids. The
type of coating shall be entered in Schedule L provided and the Engineer reserves the
right to call for test plates of the paint. The manufacturer shall at the time of ordering
carry out the `Taste and smell test' (Appendix E of B.S.4147) and `Effects on water test'
(Appendix C of B.S. 3416) and forward 3 copies of the test results to the Engineer for
approval.
Where pipes are to be welded after the protective coatings have been applied the pipe
surfaces shall be primed and all other coating stopped 250 mm short of the weld
preparation. Collars and fittings shall be primed but no other coating applied.

The manufacturer shall supply a sufficient quantity of suitable materials to repair damage
occurring during delivery to site and to provide a flush finished internal lining at welded
joints. Sufficient coating shall be supplied to fill in the recesses at internal welds over the
previously primed areas. The costs of these materials shall be included in the unit rates
for the supply of the pipes and specials.
The coating shall be applied in accordance with the manufacturer's instructions and with
Appendices J and K of B.S. 3416.
Machinery- (Internal surfaces) e.g. pumps, valves, strainers, rising and suspension
mains of wet well pumps:
As for cast iron and steel pipe work (Internal surfaces).
Cast iron and steel parts (External surfaces) immersed in Water:
All Ungalvanised metal parts which will be immersed in water shall be cleaned by grit
blasting and within four hours of blasting given a coating similar to that specified for
internal surfaces.
Cast iron and steel (External surfaces) in manholes and areas of high humidity.
Ungalvanised metal parts exposed in manholes or areas of high humidity shall be

cleaned by grit blasting and given two coats of a black bituminous solution.
b) Plant forwarded to site for final finishing.
Cast iron and steel parts (External surfaces) outside buildings:
All galvanised metal parts which will be exposed to the outside atmosphere shall be
cleaned by grit blasting and provided with two coats of an approved primer.
Cast iron and steel parts inside buildings:
All exposed metal surfaces which will not be immersed in water or exposed in areas
described above shall be rubbed down, cleaned by grit blasting and within four hours of
blasting given one coat of an approved primer before packing.
5.25.4 Painting at Site
Unless otherwise specified or approved by the Engineer, the paint and coating
manufacturer‘s printed recommendations and instructions for thinning, mixing, handling
applying and protection of the coating materials, preparation of surfaces for coating and
for all other procedures relating to coating shall be strictly observed.
Materials shall be delivered in manufacturer‘s original sealed containers, with labels and
tags intact and decipherable. Coating materials and equipment shall be stored in
designated areas. Coating containers shall be opened only when required for use.
Coating shall be thoroughly stirred or agitated to uniformly smooth consistency and
prepared and handled in a manner to prevent deterioration and inclusion of foreign
matter. Unless otherwise specified or approved, no materials shall be reduced changed,
or used except in accordance with the manufacturer‘s instructions.
Respirators shall be worn by all persons engaged in and assisting in spray painting.

Cloth and cotton waste that might constitute a fire hazard shall be placed in closed metal
containers or destroyed at the end of each day‘s work.
Paint and coating materials shall be shall be thoroughly stirred, strained and kept at a
uniform consistency during application. Materials of different manufacturers shall not be
mixed together. Packaged materials may be thinned immediately prior to application in
accordance with the manufacturer‘s directions.
All surfaces to receive paint and protective coating shall be cleaned as specified prior to
application of coating materials. The Contractor shall examine all surfaces to be coated
and shall correct all surface defects before application of any coatings. All marred or
abraded spots on shop-primed and factory finished surfaces shall be touched –up prior
to application of any other coating.
Skilled craftsmen and experienced supervisor shall be employed on all work. All paint
and coatings shall be applied in a workman like manner to produce an even film of
specified uniform thickness. Edges, corners, crevices and joints shall receive special
attention to ensure that they have been thoroughly cleaned and receive an adequate
thickness of paint. The finished surface shall be free of runs, drops, ridges, waves, laps,
brush marks and variations in colour, texture and finish. All coats shall be applied to
produce a film of uniform thickness. Special attention shall be given to ensure that
edges, corners, crevices, welds and similar areas receive a film thickness equivalent to
adjacent areas. Installation shall be protected by the use of drop cloths or other
approved precautionary measures.
Painting, except the priming coat, shall generally be taken in hand after all other builders
work is completed. The rooms should be thoroughly swept and the entire building
cleaned at least one day in advance of the paint work being started.
Hardware, hardware accessories, machined surfaces and similar items not to be coated
but which are in contact with coated surfaces shall be removed or masked prior to
surface preparations and painting operations. Following completion of coating of each
area or unit, removed items shall be re-installed by workmen skilled in the respective
trades.
Doors, windows, floors, articles of furniture and such items not to be painted or coated
shall be protected from being splashed. Splashes and droppings, if any, shall be
removed by the Contractor and the surfaces cleaned.
Each paint application shall be carried out strictly in accordance with the manufacturer‘s
instructions.
Fabricated metal work and equipment which requires coating may be shop-primed with
specified primer. Any such work delivered to the site with any other shop coat shall have
this coat removed and the specified coating applied in the field if so instructed by the
Engineer. Manufactured equipment with approved corrosion resistant factory finishes
and galvanized finishes shall be exempt from this requirement. Where a dry film
thickness (in micron) has been specified, such thickness shall be achieved and verified
for each coat.
The Contractor shall conduct thickness measurements and inspection of the coated
surfaces with equipment supplied by him and acceptable to the Engineer and shall
recoat and repair as necessary for compliance with these specifications. Any surfaces or

parts thereof found to be unsatisfactory shall be rectified by the Contractor to the

satisfaction of the Engineer.
5.25.5 Waterworks Finish
A high standard of finish, defined as "Waterworks finish" is required for all Plant as
detailed below.
5.25.6 Welding and flame cutting
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
5.25.7 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.
5.25.8 Covers
All covers shall be firmly fixed. Weldmesh shall sit square in its frame. Where panels are
placed next to each other the patterns shall line up.
5.25.9 Flanges and beadings
All bolt holes shall be spot faced parallel with the mating face for good seating of nuts
and bolt heads. Surplus jointing shall be removed from mating faces and peripheries.
5.25.10 Items to be Chromium Plated
Name plates, instruction plates, rotation arrows, indicators and pointers, small bore
pipework, tundish oil level gauges and fittings, small valves (including air valves), plugs
and grease nipples, which are sited in architecturally finished areas and as selected by
the Engineer, shall be chromium plated. Damage to chromium plating shall be made
good. All pipes, fittings and appurtenances, shall be fitted in a straight, neat symmetrical
manner so as to present a pleasing appearance.
5.25.11 External Screws, Bolt Heads, Nuts and Washers
These shall be chromium plated sherardized or shall be of stainless steel.
5.25.12 Gauges
All indicating gauges fitted to any machine assembly shall be of similar appearance and
grouped together to present a pleasing aspect. They shall all have chromium plated
cases, bezels, cocks and fittings.

6 Particular Mechanical Requirements
6.1 General Requirements
The Contractor is responsible for the Design and Build of the Works, and after
commissioning, its operation for a period set-out in the Contract documents. The
Employer however retains a vested interest in ensuring the plant complies with his long-
term requirements. This chapter therefore sets out Particular Mechanical Requirements
for the Design and selection of Mechanical Equipment, and where appropriate, its
installation, testing and putting into service.
With regard to Design matters, this Particular Specification also defines the necessary
Quality Assurance Documentation, and appropriate Certification required which the
Contractor shall provide, covering design calculations, method statements for installation
and subsequently putting the equipment into service. Testing and Commissioning of
individual items of equipment and systems including the complete plant are covered in
Part 9 - Inspection, Testing and Commissioning Requirements.
Although the Process has been defined as ―Open Technology‖, meaning that the
Contactor may choose, within bounds, the type of process he adopts for the Sewage
Treatment Plant (STP), there are some items of equipment independent of the process
adopted which must be provided by the Contractor.
The list of items of equipment listed in this Particular Requirements are not exhaustive.
Consequently, the Contractor shall apply the same philosophy used herein for other
critical items of equipment, for which specialist documentation shall be prepared.
The Contractor shall supply dedicated service compressor and firefighting pumps
complete with firefighting water supply network in areas considered at risk of fire. The
Contractor shall carry-out a comprehensive Risk Assessment of areas vulnerable to fire,
including but not limited to Administrative Building, Workshops, laboratory, etc, as well as
plant associated with bio-gas and any other flammable gas areas. The Contractor shall
formally submit to the Client, his Risk Assessment and proposed mitigation measures for
review and ―no-objection‖.
6.2 Mechanical Requirements
In compliance with these Particular Mechanical Requirements, the Contractor shall

supply the numbers of equipment units specified in Part 4 of the Process Requirements,
including redundancy units.
The modes of operation of multiple units operating in parallel shall be adequately

considered in the Contractor‘s conceptual design.
The specific areas which are the focus of this particular requirements, include
 Kalyani Nagar Pumping Station.
 Aeration Blowers, and
 Bio-Gas Power Generation equipment.
Most of the remaining mechanical equipment is covered in the general requirements

elaborated in Part 14 Standard Specification - Mechanical. The respective Electrical and

Part 6: Particular Mechanical Requirements
Control systems for the equipment concerned is covered by Part 15 and Part 7, and Part
16 and Part 8 – Electrical, and Instrumentation/Control Specifications respectively.
6.2.1 Redundancy, and Standby Philosophy
Where not specifically alluded to (in Part 4 – Process Requirements), the Contractor
shall formally provide his own coherent philosophy for the specification of redundant and
standby equipment.
Normally, a single additional item of equipment shall suffice for standby purposes, but
other factors like batch processes, reliability of the equipment concerned which effects
down time, and risk of plant shut-down all play a part in the redundancy philosophy.
Furthermore, safety systems like chlorine gas monitoring, should be provided with triple
sensors and priority voting where executive responses are mandatory.
6.2.2 Existing Pumping Station at Kalyani Nagar
6.2.2.1 General
The scope of works associated with the existing Kalyani Nagar Pumping Station shall be
included in these Contract works, even though it feeds the existing 130 MLD Bhairoba
STP.
The scope of the works shall be as detailed below, but not limited to the equipment and
works listed, and shall include replacement and refurbishment of the equipment as
appropriate. As a minimum, the Contractor shall additionally consider the operation and
fitness-for-purpose of the equipment as a whole, ensuring all items are checked and
made operational as a system, covering conveyors, valves and valve actuators, Sluice
gate and overhead crane, etc
6.2.2.2 Belt Conveyor
The screenings collecting belt conveyor shall be refurbished assuring its effective
operation, replacing all roller if necessary or other faulty items as appropriate.
Additionally, all exposed steel parts shall be painted in the appropriate colour with
corrosion resistant paint.
6.2.2.3 Valves, Pipes and Supports
All valves and supports need checking and refurbishing if necessary, including replacing
the valve spindle on one of the knife gate valve (500 NB) which is bent.
6.2.2.4 Sluice gate at inlet chamber
The Sluice Gate at Inlet chamber to be replaced as per site condition.

6.2.2.5 Electric overhead crane
The reach of the existing electrically operated overhead crane ( 5 Tons ) is insufficient for
all operating modes. Where appropriate, the Contractor shall replace the winding ropes
and generally refurbish the crane providing full regulatory certification for the refurbished
crane under Indian statutory regulations.
6.3 Criteria for the selection of Aeration Blowers
Aeration blowers shall be provided as mentioned in Part 4- Process requirements on

Working and standby basis
The Contractor shall ensure the type and selection of blowers takes account of important
factors like control philosophy, and life cycle costs. Furthermore, air flow rates from
blowers shall be variable and controlled on the basis of oxygen demand determined by
an array of Dissolved Oxygen (DO) sensors in the aeration lanes. Blowers running in
parallel shall when permitted to, be shut-down so as to maximise blower efficiency.
Blowers shall be selected in accordance with the general requirements set-out in

Part 14 – Standard Specification - Mechanical, and the proposed Control philosophy,
taking account of operational efficiencies and life cycle costs.
Calculations shall be submitted to the Employer for review and his ―no-objection‖, which
shall include a full Cost Benefit Analysis which demonstrates minimisation of life cycle
costs.
Capital costs shall take account of the abatement of noise and vibration, etc where
appropriate including housing/building modifications.
6.4 Bio-gas System and power generation
Bio-gas produced in the sludge digesters shall be utilised as specified in Part 14 –

Standard Specification - Mechanical, by the provision of biogas holders, management
system and bio-gas engine and electrical generator set and all appropriate
appurtenances. The digester heating system shall be considered an integral part of this
bio-gas system, with the primary source of heat being waste-heat recovered from the
bio-gas engine. The heating boiler shall simply be considered as an auxiliary source of
heating for start-up conditions and periods of maintenance.
Power generation and related associated equipment is mandatory. The Contractor shall
carry-out a full Cost Benefit Analysis which shall be submitted to the Employer for his
review and ―no-objection‖.

7 Particular Electrical Requirements

7.1 Introduction
The specific design and performance requirements for all electrical equipment are given
in this part of the Specifications. The Requirement specified shall be fully met with by the
Contractor. In case of any deviations, the Contractor shall bring out the same in
―Schedule of Deviations from Particular Requirement‖ failing which it will be considered
that the Contractor fully complies with these requirements.
7.2 Scope
7.2.1 General
This section describes the electrical Plant and services to be provided by the Contractor
and specifies the requirements for the Works not covered elsewhere in the Contract.
The electrical Plant and services to be provided shall comprise all the necessary Works
for the completion of all main and ancillary installations, and shall include but not be
limited to:
The tapping of power supply post Metering Kiosk to the Site to cater for the Works
including Supply, Delivery, installation, testing, commissioning, operation and
maintenance.
The power distribution equipment, including Distribution transformer, distribution boards,

electrical protection, metering, earthing, cabling, and cable support systems for the
Works.
The electric motors and actuators to operate the mechanical equipment being installed at
the STP.
The electrical starting equipment, isolating equipment, electrical protection, controls and
interlocks for each Plant item at the STP.
The indoor, outdoor and emergency lighting including all poles, brackets, fixings, etc. for
the STP.
The Site electrical services including sockets, ventilation, etc.

 The fire detection and alarm systems and Fire Suppression system.
 The fire barrier/sealing system at substation and MCC rooms.
 The Safety Equipment‘s, Personnel Protective Equipment‘s(PPE) and Testing and
Measuring Instruments at substation and MCC rooms
 The gas detection and alarm systems.
 The telecommunications systems (PA system).
 The Earthing and lightning protection system.
 The construction phase electrical services.
 The Materials and accessories to provide a complete electrical installation.
 The equipment and control systems to interface with the power supply utility‘s
incoming supply and the power generated through bio-gas generation.
Contractor shall ensure connectivity to downstream side of Metering kiosk as point of

supply (POS)provided to the contractor by the Employer. ..
Section 6A: Employer‘s Requirement 7-121 Bid Document

Part 7: Particular Electrical Requirements
Variable frequency drives (VFD) shall be provided for the following equipment as a
minimum:
 RAS pumps,
 Process blowers,
 Thickened sludge scraper pump,
 Centrifuges
 Any other as per process requirement.
It has to be ensured that the motors being operated through VFD shall be of inverter duty
type. All inverter duty motors shall have class H insulation. All inverter duty motors shall
be manufactured as per Vacuum Pressure Impregnated (VPI)or Inverter Grade
Treatment method. Inverter duty motor shall have insulated bearing with shaft grounding
ring, as applicable. Bidder shall consider that for distribution transformer, evaluation of
loss capitalization will be based on latest CBIP guidelines.
7.2.2 Kalyaninagar IPS
At present the Kalyaninagar IPS receives its power supply from 11 kV feeder originated
from the 11 kV substation at the 130 MLD Bhairoba STP.
Contractor shall do the thorough inspection of the existing electrical power distribution
system. The work shall involve comprehensive servicing, overhauling of the existing
electrical equipment‘s so as to make them functional enough and do its operation and
maintenance for period of 10 years.
Contractor shall ensure suitability, safety, and reliability of existing power distribution
network to meet the load at Kalyaninagar IPS. Contractor shall provide upstream side
end termination and straight through joints along this feeder, as applicable. Contractor
shall provide new end termination on downstream side of this feeder as well as on
Transformer feeders of the RMU.
The contractor shall terminate the existing 11 kV cable at proposed new high voltage
switchboard at Kalyaninagar IPS, as applicable, in consultation with Engineer and
MSEDCL, as applicable.
The contractor shall replace the existing 400 kVA Distribution Transformer with new 630
kVA Level-III Distribution Transformer with standard accessories, as applicable, in
consultation with the Engineer.
Contractor shall provide the new conventional high voltage switchboard of suitable
capacity to feed the load. The high voltage switchboard shall have one number Vacuum
Circuit Breaker (VCB)as an incomer and one number Vacuum Circuit Breaker (VCB) as
outgoing feeders to transformer and one number VCB as spare feeder.
Contractor shall do and submit the detail design calculation for required sizing of the
Transformation capacity to the Engineer of the contract. Pump operation philosophy shall
be considered for this purpose, as well,
Contractor shall replace the existing PMCC that feeds existing submersible pumps and
auxiliary loads at Kalyaninagar IPS.

Contractor shall do Design, Engineering, Manufacturing, Supply, Erection, Testing and

Commissioning of new PMCC. New PMCC shall be IEC 61439 compliant comprising bus
coupler arrangement and shall feed all the existing and proposed load as applicable.

Commissioning of Energy Monitoring System, Reactive Power Compensation and
Harmonic Mitigation system, as applicable, in line with MSEDCL requirement.

Commissioning of Control Cable, Termination its accessories and cable containment
system, as applicable for the existing electrical loads at Kalyaninagar IPS.

Commissioning Junction boxes, Local Push Button Stations and miscellaneous, as
applicable for existing electrical loads at Kalyaninagar IPS.

Commissioning indoor and Outdoor Illumination System and miscellaneous, as
applicable for Kalyaninagar IPS.

Commissioning of complete Earthing system and Lightning protection system so as to
commensurate with, as applicable for existing electrical loads at Kalyaninagar IPS in
compliance with CEA Regulations 2010 ,MSEDCL requirement and IS/IEC:62305 .
Existing Lighting and Power Distribution Boards needs to be refurbished and replaced as
applicable to feed the small power and lighting loads.
Contractor shall provide Safety equipment‘s and PPE comprising of Fire Extinguishers,
Fire buckets, Shock Treatment charts, Danger boards/label, First Aid Box with
medicines, Rubber mats, Safety Gloves, Safety Shoes, Safety Belts, Line Testers, etc.
shall be provided in pump house, as applicable in line with statutory requirement.
7.2.3 Bhairoba STP
The utility i.e. Maharashtra State Electricity Distribution Company Ltd feeds the existing
130 MLD Bhairoba STP through one number 11 kV Express Feeder, originated from its
22/11kV Koragaon Substation.
Please refer schematic diagram that describes the battery limit for the Contractor to get
reliable power supply to 75 MLD Bhairoba STP.
As described, the battery limit of the contract for electrical works under this project starts
from the outgoing terminal of the 11 kV metering kiosk. It covers supplying, laying and
termination of 11 kV XLPE insulated power and control cable from Metering Kiosk to the
proposed 11 kV Switchboard (shall comprise minimum one incomer and two outgoing
circuit breaker feeder and one spare circuit breaker feeder) at substation to feed
proposed distribution transformers.

The scope covers all the electrical equipment‘s such as tapping from metering kiosk , 11
kV Switchgear and Control gear assembly (Switchboard), Transformer, LV Switchgear
and Control gear assembly/Switchboard, HV and LV power control cable and cable
containment system, Reactive Power Compensation and Harmonic Mitigation System,
Earthing and Surge Protection System, Indoor and Outdoor Illumination system, PABX
and PA system, Fire detection and alarm system at substation, Gas Detection system,
Fire barrier/sealing system at substation, Safety equipment‘s, Testing Instruments etc. to
make the plant operational.
7.3 Basis of Design
All electrical equipment‘s shall be rated for ambient design temperature of 500 Celsius.
All electrical equipment‘s installed in hazardous areas shall confirm to the selection of
equipment‘s and installation guidelines as specified in IS 5571.
7.4 Document and Calculation
All necessary documentation, drawings and schedules required to describe the design
shall be developed and maintained during the course of the works and be available for
inspection by the Engineer as requested as listed in Appendix.
Prior to key phases of design: detailed design and construction - these design
documents shall be presented to the Engineer as a base-line descriptions of the works
for review and approval.
From the following documents, schedules and drawings the Contractor shall agree, with
the Engineer, those required to describe the works at each base-line. The full breadth,
depth and scope of that documentation as well as the programme for their delivery shall
be agreed with the Engineer prior to commencement of the works:
7.5 Emergency Stop Equipment and Local Isolation
7.5.1 Local Control Stations
The Contractor shall provide each item of electrically powered rotating machinery with
local ‗start‘ and emergency ‗stop‘ pushbuttons. Where the drives have the capability to
run in forward and reverse, separate ―Start Forward‖ and ―Start Reverse‖ buttons shall
be provided. The pushbuttons shall be housed in the same enclosure, clearly labelled,
adjacent to the relevant access point or machinery. Ammeter shall be provided for all
motors rated 55 kW and above. Local/Off/Remote selector switch shall be provided as
per requirement of approved P&ID.
Where applicable, e.g. screen drive motors, the local control enclosure shall include
pushbuttons for ―inch forward‖ and ―inch reverse‖ control.
―Emergency Stop‖ buttons shall be of the ―Stay Put‖ type, twist or pull to release,
padlockable in accordance with IEC 60947.
Material of construction for enclosure of Local Control stations shall be polycarbonate/

polystyrene with IP 65 for outdoor application as per IEC 60529.
7.5.2 Local Isolation
The Contractor shall provide each item of electrically operated machinery with a local
isolator. Isolators shall be mounted in accessible locations adjacent to the motor, or for
submersible pumps, adjacent to the entrance to the sump.

Local isolators shall have auxiliary contacts to trip and lock out the contactor when the
isolator is open.
Local isolators shall be provided in all cases for valve or penstock actuators.
All local isolators shall be suitable for padlocking in both the ―on‖ and ―off‖ positions and
shall not be provided for use as an emergency stop facility.
Material of construction for enclosure of Local Isolators shall be polycarbonate/

polystyrene.
7.6 Emergency Power Supply
The Contractor shall design the Works such that the Primary source can be used in
conjunction with the onsite Biogas Engine unit to provide available energy to essential
services as required. The facility shall be capable of safe shut down of non-essential
services and of safe start up upon restoration of normal power. The Contractor shall
develop a procedure and demonstrate how this would be carried out in safe manner. As
such provision of dedicated Air Circuit Breaker (ACB)in Power Control Centre (PCC) for
its connectivity to separate emergency power supply arrangement (Diesel Generator
Set) shall be done.
It shall be ensured that all critical services e.g. Chlorination Gas Emergency Ventilation
System, Gas Detection System, Electrical Overhead Travelling (EOT) Crane, lighting in
selected area shall have availability of power supply from utility as well as that from Bio
Gas Generation System.
7.7 Electrical Power Supply Design
. The existing works currently receives its power supply from one 11kV feeder at
respective plant locations. This power supply to these feeder is made available from
sources arranged by the utility at their end. The Contractor shall provide a power
connection system for the new works, so as to receive power from the metering kiosk
(provided by the Employer in different project) at proposed 75 MLD Bhairoba STP so as
to terminate in in proposed 11 kV Switchboard..
The Contractor shall design the system such that the utility power source shall be used
in conjunction with the onsite bio-gas source for normal operation of the Works.
The Contractor shall establish the maximum demand for the Site., and hand over these
details to the Employer so that Employer in discussion with the power supply utility, will
ensure the best method for provision of secure supply.
The Contractor shall ensure that the size of, high voltage switchboards, transformers,
busbars, cables and capacitor used in the power supply are adequate for the Work‘s
requirements and that they are installed in a manner to provide maximum reliability of
supply and flexibility of operation.
The Contractor shall establish the size and nature of the power supply requirements for
the testing, commissioning and operation of the facility. The Contractor shall provide a
detailed schedule of all electrical loads together with the rated current, power factor,
efficiency and diversity factor of each load sector.

From the above load schedule the Contractor shall establish the Works loading in
kilowatt hours consumption per annum and the peak demand of the wastewater
treatment facility..
The Contractor shall establish the nature of the power supply and hand over all these
requirements to the Employer so that Employer shall ensure that they are reliable and
adequate for the operation of the STP without constraints.
 Incoming Supply Conditions-Voltage and variations:11 kV, 22 kV +6% -9%,3 Phase,

3 Wire.
 Frequency and variations-50 Hz +3% Combined variation: + 10%.
 Fault level at 11 kV- 25 kA(Maximum) for 3 seconds, 22 kV -40 kA(Maximum) for 3
seconds (This shall be confirmed with Electric Supply company)
 System Ground-neutral solidly grounded.
 Low voltage power distribution:415V,50Hz, 3Phase,4Wire, neutral solidly
earthed.;240V,1Phase,2Wire, neutral solidly earthed.
 Voltage and variations:415 V +6 %.
 Frequency and variations-50 Hz +3% Combined variation: + 10%.
 Lighting :240V,50Hz,1Phase,2Wires derived from 415 V,50Hz,3Phase,4Wire system.
 Welding sockets:415 V,50Hz,3 Phase,4 Wire, neutral solidly earthed.
 Convenience sockets:240V,50Hz,1Phase,3Wire derived from 415 V,3Phase,4Wire
system
 Voltage drop: The maximum voltage drop during steady state and during starting
state of motor shall be as follows.
Sr No. System element Maximum permissible

voltage drop in %
1 Bus duct or cable between transformer secondary 0.5
and LV Switchboard or PCC/PMCC
2 At motor terminals at full load for LV motors 5
3 At motor terminals during starting for LV motors 10
4 At the switchgear busbars during starting of 10
highest motor
5 Feeders to light fittings and socket outlets 2.5 up to maximum of
5 to farthest light
fitting/socket outlet
7.8 Power System Studies and Selective Coordination
The Contractor shall prepare and submit a schedule of the electrical loads for the Works.
This schedule shall show the total connected load in each category, together with the
calculated diversity factor, the probable load and the maximum demand likely to be
experienced.
This information shall be submitted to the Engineer for review. The Contractor shall
design the electrical power system to suit the ratings and duty cycles of the Plant items
and auxiliary systems which are to be installed.
The power distribution shall be designed to suit the voltages at which power is supplied
by the electricity supplier.

The Contractor shall select the necessary voltage and current transformers together with
suitable protection relays to protect the electrical distribution system. This protection
shall include thermal overload, short circuit, ground fault and single phasing as a
minimum.
The electrical protection shall be graded so that indiscriminate tripping is prevented

under fault or surge conditions.
The Contractor shall co-ordinate the electrical protection at the Site with the power
supply utility system protection and shall submit to the Engineer during the design a
tabulation to demonstrate the protection settings to be employed and the appropriate
discrimination curves for the power system.
7.9 Power Factor Correction and Harmonic Mitigation
The Contractor shall design the power system to operate at a minimum power factor of
0.996 lagging at the point of supply of the power supply utility.
Automatic power factor correction systems shall be provided at all MCC‘s that feed the
blowers. In addition, an intelligent APFC system shall be installed at the PCC to meet the
desired power factor.
Care shall be taken to ensure that harmonic distortions are limited in compliance with the
requirement of power supply utility and the Contractor shall consult the power supply
utility concerning the impedance of their supply network at the frequencies most liable to
cause resonance.
7.10 Switchgear and Controlgear
7.11 High Voltage (HV) Switchgear and Controlgear Assembly
High voltage switchgear shall be designed by the Contractor for operation at 11/22 kV,
as applicable.
HV distribution switchgear shall be conventional high voltage switchgear and controlgear
assembly as per the requirement.
The Contractor shall ensure that the HV switchgear is designed to accept the power
supply utility‘s power. The Contractor shall distribute the power on the Site, by taking into
account the location of the ‗on-site‘ generation and the various power demands around
the Site.
The Contractor shall ensure that the HV switchgear and controlgear assembly is rated
for the fault levels likely to be encountered on the Site and the system protection
installed. Seismic withstand capacity of the high voltage switchboards shall be at least
for seismic zone 3
The Contractor shall ensure that circuit breakers on the HV system are interchangeable
where this is possible and logical and that the HV switchgear and controlgear assembly
panels () are suitable for extension at both ends.
An ammeter shall be fitted to each outgoing circuit breaker panel. Readings from these
meters shall be displayed and recorded on the SCADA system.
A digital kilowatt hour meter with maximum demand indicator shall be supplied and
installed by the Contractor at the incoming power supply point in switchboard and this

shall be used to verify the power supply utility power consumption figures. Energy
measured by this kWhr meter shall be displayed and recorded on the SCADA system.
Protection relays shall be numerical type.
7.11.1 LV Switchgear and Controlgear Assembly and Power Control Centre (PCC) and
Motor Control Centre (MCC)
LV switchgear and controlgear assembly i.e. power control centre and motor control
centre assembly shall be of intelligent type. All single/double front PCC and MCC shall
be Design Verified Assembly according to IEC 61439 and also internal arc tested (IAC)
as per IEC 61641. Seismic withstand capacity of the MCC and PCC panels shall be at
least for seismic zone 3. Type of internal separation for PCC/MCC panel shall be as per
Form 3B. Lighting board or small distribution board separation shall be either as per
Form 1 or Form 2.Air circuit breakers shall be used for rating greater than 400A.MCCB‘s
shall be considered for rating equal to or less than 400A.Components for motor starter
feeders shall be selected as per Type 2 coordination.
Each incoming feeder of all PCC and MCC‘s shall be equipped with a Multifunctional
Energy Meter incorporating the functions of a voltmeter, an ammeter, a kilowatt hour
meter, a power factor meter and a frequency meter. The parameters monitored by the
energy meter shall be available for monitoring and recording on the SCADA system.
The Contractor shall select the starter appropriate to each drive motor and shall ensure
that starting sequences are programmed to minimize disruption of the power supply and
maximise Works availability.
When designing the low voltage distribution assemblies, the Contractor shall ensure that
they are dimensionally suitable for delivery and installation on Site.
The Contractor shall ensure that provision is included in the low voltage switchgear to
interface with the necessary on-site generators and this provision shall include all the
necessary control gear, protection and interlocking between generator and supply
authority to enable the ‗on-site‘ generators to synchronise.
The necessary volt free contacts and analogue signals shall be provided by the
Contractor on each panel for interfacing with the SCADA system.
LV switchgear and controlgear assembly for PCC and MCC shall be manufactured by
panel manufacturer having following as minimum eligibility criterion.
The panel manufacturer shall be having valid ISO 9001:2008 certification.
The panel manufacturer shall have adequate experience of minimum 10 years in
manufacturing of Low voltage or High voltage of switchgear and controlgear assembly.
manufacturing of intelligent type Low voltage switchgear and controlgear assembly
for water or waste water or sewage application in India.
manufacturing of harmonised IEC 61439 compliant low voltage switchgear and
controlgear assembly in association with recognised Original Equipment Manufacturer.

7.12 Measurement of Electricity Usage
The Contractor shall be responsible for the provision of electricity meters to permit
assessment of compliance with the Energy Generation requirements and to assess
whether Performance Damages are due.
As a minimum electricity meters shall be installed to measure the electricity provided by

the electricity utility service provider for the Works (this meter shall be other than the
service meter used by the electricity utility service provider for billing purposes) and the
energy generated by the Energy Generation System.
Each of the above meters shall be read by the Contractor every Day at the same
approximate time. The Contractor shall record and maintain with its records each such
reading for the purposes of calculating whether the performance requirements relating to
energy generation have been met, and if applicable calculating the Performance
Damages.
7.13 Cabling
7.13.1 General Cabling
This section covers the supply and installation of the necessary cabling and earthing
systems not covered elsewhere in the Employer‘s Requirements.
HV cables, forming part of a dual supply to the STP shall be from underground duct and
separated both outside and within the Site by at least 2.5 m to reduce the possibility of
physical damage causing a complete power failure to the Works.
For the consideration of the Engineer, the Contractor shall provide detailed schematic
and block diagrams, together with schedules of all cables he proposes to install for
power and control systems. The schedules shall include the following information:
a) Type of cable;
b) Size of conductors (including circuit protective conductor);
c) Number of cores;
d) Voltage grade;
e) Cable gland;
f) Cable identification reference number;
g) Cable source;
h) Cable destination;
i) Cable length;
j) Installation method;
k) Terminal references.
7.13.2 Types of Cables
Cables shall have a ―Fire Retardant and Low Smoke‖ (FRLS) outer sheath as per IS
10810, and ASTM D 2863 to restrict release of toxic fumes from the cable in the event of
a fire. XLPE cable shall be as per IS 7098 whereas PVC cables shall be as per IS 1554
Cables of different categories shall be installed so as to maintain satisfactory clearances

for safety and in order to reduce the possibility of electrical interference. The following
Table details the distances in mm that shall be maintained between the different
categories of cables.
Cable Category HV Power LV Power C&I/Protection Telecomms

HV Power N/A 300 500 500

LV Power 300 N/A 300 300
C&I/Protection 500 300 N/A 100
Telecomm 500 300 100 N/A
The following types of cables shall be provided:
a) HV power circuits
AL/XLPE/PVC/F/FRLS, 3.3 kV – 22 kV (E) grade
b) LV power circuits
For conductor sizes above 2.5 mm2 AL/XLPE/PVC/W/FRLS, 650/1100V grade
For conductor sizes 2.5 mm2 or less, CU/XLPE/PVC/FRLS, 650/1100V grade,

Unarmoured
c) Auxiliary control and protection circuits

CU/XLPE/PVC/FRLS, 650/1100V grade, Unarmoured, Stranded
d) Telecommunications Cables
Cables for telephone and data outlets shall be Category 6A Unshielded Twisted Pair
(UTP) type with FRLS sheath.
7.13.3 Cable Sizes
The short time fault current ratings of all power cables shall match the maximum fault
ratings of the associated switchgear plant and protection systems.
The Contractor shall determine by site investigation the values of:

 Soil temperatures;
 Soil thermal resistivity.
With the exception of special cables for analogue signal and measuring circuits, the
minimum core size for auxiliary power and control cables shall be 1.5 mm 2. All multicore
cables provided for the Works protection, control and monitoring systems shall
incorporate 20% spare cores. All spare cores shall be terminated and identified.
7.13.4 Cabling Within Buildings
Cable installations within buildings shall be run in ducts or trenches, or run in cable
containment installed on or suspended from structural walls or ceilings. Cables in
general building areas shall be installed on heavy duty Hot Dip Galvanised tray.
In all locations of the works affected by chemicals creating a chemically corrosive

condition, cable tray systems shall be of Hot Dip Galvanised with powder coating, of
approved type and manufacture.
For fixing cable trays in trenches, cable galleries, etc. galvanised steel channel inserts
shall be embedded into the concrete, spaced at centres not exceeding 1,500 mm. Civil
structures utilised to support cable tray systems shall be designed to withstand the
additional loading.

Whenever cables pass through walls below ground level, the point of entry shall be
sealed against the ingress of water particularly in all PCC and MCC rooms. This shall be
achieved with cable sealing system as specified elsewhere.
7.13.5 External Cabling
External cables shall be contained within underground cable concrete ducts or trenches
unless specifically agreed with the Engineer in advance.
7.14 Earthing
The Contractor shall provide and install a complete earthing system in accordance with
the requirements of IS 3043 rules.
Contractor shall perform soil resistivity test (as a prerequisite to sound earthing design)
at site during dry season at least in two directions at different depth by following standard
engineering method.
The Contractor shall design the system to meet the following requirements:
a) Under normal and abnormal operating conditions, there shall be no danger to

persons in any place to which they have access;
b) The maximum current from any point of fault shall be conducted back to the
electricity system neutral without giving rise to dangerous potential gradients either in
the ground or between pieces of apparatus and a person who could be in
simultaneous contact;
c) The passage of fault current shall not result in any thermal or mechanical damage to
the system.
d) Earthing system for Electrical, Instrumentation control and Automation (I&C) and
lightning protection systems shall be laid separately. Contractor shall be responsible
for interconnection of these grids.
The Contractor shall satisfy the power supply utility that the earthing arrangements on
the electrical installation are compatible with their system requirements.
Earth tape and conductors installed in areas subject to chemical corrosion shall be
sheathed with green/yellow FRLS insulation.
It is essential to adopt earthing enhancing compound particularly in areas having high

soil resistivity, strata is comparatively rocky in nature and where the previous experience
regrading earthing protection is poor. The earthing enhancing compound shall be
chemically inert to the sub soil and shall meet Toxicity Characteristic leaching procedure
requirement.
7.15 Lightning Protection
The Contractor shall provide and install a lightning protection system where required, in
accordance with IEC 62305: Protection against Lightning. Early streamer emitter type
lightning protection shall not be used.
Selection, installation and maintenance of surge protection devices for protection from
indirect lightning surges and switching surges shall be as per IEC 61643.

Earthing for lightning protection system shall be as per IS 3043 or IEC 62561.
The Contractor shall provide the anaerobic digestion complex with lightning protection
including the CHP exhaust stack(s) and the waste gas burner stack(s), as applicable.
7.16 Building and Site Services
7.16.1 Power Supply
7.16.1.1 General
This section describes the building and site services required, and specifies particular
requirements not covered elsewhere in the Contract.
The Contractor shall provide the power supply for all building and site services from the
building services switchboards or otherwise derived from distribution boards which, as
far as practicable, shall form an integral part of the main LV distribution and plant control
switchboards.
Sub-distribution boards not forming part of LV switchboards shall be complete with

outgoing miniature circuit breakers for connection to the services and other equipment.
Distribution board providing power for lighting shall have provision of Residual circuit
breaker with over current protection (RCBO).
At least 3 spare ways for each type and size of circuit breaker in the distribution boards
shall be included.
At least 2 no. 240 V single phase 5/15A outlets shall be provided in each room and in
any case shall be within 15 m of any internal part of a building.
At least 1 no. 415 V three phase socket/ power receptacle shall be provided in each
Plant area for maintenance purposes.
Contractor shall ensure that all rooms in substation and PCC, MCC rooms shall be
provided with suitable ventilation system to maintain minimum air change requirement as
per Original Equipment Manufacturer (OEM) recommendation.
7.16.1.2 Solar power generation system
Contractor shall provide grid tied solar power generation system. The contractor shall
maximize use of solar power through centralized solar power generation system to
provide the power supply for building and site services as applicable with a provision of
auto switch over to normal electric supply in case of emergency/any problem with solar
system. No batteries shall be provided. The energy generated shall be consumed locally
to feed Alternating Current loads.
7.16.2 Lighting Design
The building internal lighting design shall take into consideration:

a) Operating environment;
b) Energy efficiency;

c) Activities to be performed in the areas concerned;

d) Type and style of architectural finish;
e) Access for maintenance;
f) Operating life;
g) Sustainability.
Lighting circuits shall be supplied from the small power and lighting distribution boards
incorporating manually reset miniature circuit breakers. For large areas or buildings,
separate distribution boards may be located to serve discrete areas.
Switching shall be convenient to doors and entrances, two-way switching being provided
where areas have more than one entrance.
For large areas, lighting shall be contactor controlled. Contactors shall where practical be
incorporated within the respective distribution boards.
In areas housing rotating machinery, lighting shall be arranged on multi-phase circuits to
prevent stroboscopic effects.
The arrangement of circuits shall be such as to provide balanced loading of the phases.
The Contractor shall prepare detailed layout and installation drawings to show the
location of the distribution boards, conduit routes, lighting and other fittings, etc. for
consideration by the Engineer, together with illumination level design calculations to
support and confirm the proposals.
Except in any building where ceiling or wall finishes permit conduits to be concealed, the
installation shall be carried out in surface run uPVC conduit. All lighting switches, socket
outlets, etc. shall be metal-clad surface mounting type.
Area Illumination Level (Lux)

Pump house 200 Lux
Battery room 150 Lux
Machinery service area 200 Lux
Offices and conference rooms 300 Lux
Switchgear room 200 Lux
Control rooms/ SCADA room 300 Lux
Chemical and general stores 150 Lux
Chemical plant room 200 Lux
Cable basement 100 Lux
All other indoor areas 100 Lux
Outdoor platforms and walk ways 50 Lux
Building entrance 100 Lux
Outdoor plant areas 20 Lux
Outdoor transformer yards
- General 20 Lux
- On equipment 30 Lux
Roads 20 Lux

7.16.3 Emergency Lighting
The Contractor shall provide emergency lighting for all control rooms, buildings and exit
and escape routes to facilitate the safe evacuation of personnel from all buildings and
structures in the event of power failure and shall be in accordance with IS:9583.
The Contractor shall also provide emergency lighting in any area where work may be
required during a power failure.
The emergency exit lighting luminaries shall be bulkhead LED, maintained and non-
maintained types, incorporating self-contained battery/charger/inverter modules with a
minimum battery life of two hours.
The emergency luminaries shall be directly connected to the respective area main
lighting circuits, to cover both total power and sub-circuit failures.
Emergency luminaries shall incorporate test unit switches to simulate failure of the
normal supply. These test switches shall be situated in a position within the area covered
by the lighting system to be tested and shall be suitably identified. Switches situated in
positions accessible to unauthorised persons shall be of the tamper-proof, key operated
type. All such switches shall be operated by a common key and the Contractor shall
supply two keys for each switch installed.
7.16.4 Street Lighting
The Contractor shall provide street lighting systems to illuminate all site roadways within
the treatment facility areas and access road. Lux level for outdoor site shall be as per IS
1944.
The lighting systems shall comprise:

1) LED street light with integral lamp control gear, and weatherproof body
2) Galvanized octagonal poles
The lanterns shall incorporate LED lamps with integral lamp control gear, and weather-
proof body.
The poles shall be sited a minimum of 1m from the road kerb edge with non-extended
brackets to locate the lanterns at the kerb.
The street lighting shall be fed on independent radial buried cable circuits fed and
controlled from a street lighting switchboard. The cables laid for outdoor lighting
application shall be wire armoured.
Each circuit shall be contactor switched, controlled by an astronomical timer and manual-
auto control selector switch. The contactor, time switch and manual control switch for
each area shall be incorporated in the LV road lighting distribution switchboard.
7.16.5 Site Area Lighting
Site area lighting installations shall provide an overall minimum service luminance as per
IS 1944 over the whole of the Site.
A minimum of three high mast flood lighting columns shall be provided. Columns shall be
a minimum of 15 m high, or higher if so required by the site layout or building

arrangement. The columns shall be located to suit the proposed layout so as to ensure
no areas are in shadow when all flood lights are energised. The flood lighting shall
provide a minimum horizontal illuminance over the whole of the Site of 5 lux and shall be
designed to provide lighting levels which are uniform and to minimise overspill of lighting
outside the boundary.
Area flood lighting shall be fed from service distribution boards incorporated in the
respective plant or ancillary switchgear buildings. Area lighting shall be capable of
manual control from each respective building and the security control room and shall be
capable of being switched on by a security intruder signal.
7.16.6 Low Voltage (LV) Portable Equipment
For each building the Contractor shall provide one set of low voltage equipment
comprising the following:
240 V, 50 Hz weatherproof, portable, heavy duty floodlight and plug for 240 V centre
tapped earth socket outlet complying with IEC 209 and colour coded.
The portable emergency lighting fixtures supplied shall have a built in battery rated for
two hours and be complete with battery chargers and solid state inverters, and be
supplied with all necessary supporting brackets of galvanised steel suitable for
wall/column mounting. The portable emergency lighting fixtures shall be of a single unit,
completely tropicalised, suitable for prolonged use with no maintenance, and shall light
up automatically in the event of failure of normal supply. The Contractor shall submit
schematic along with all details and general arrangement drawing for approval.
7.16.7 Fire Detection, Alarm System and Fire Suppression System
A) Fire Detection and Alarm System
The Contractor shall provide fire detection and alarm systems in Administrative
building, 75 MLD SCADA Control room, Laboratory and all process equipment
buildings throughout the Site in accordance with national standards. The Contractor
shall provide a detailed statement for fire protection and emergency evacuation
system with escape route to comply with national and or International standards. The
fire alarm system shall be connected to the 75 MLD SCADA system and emergency
services.
The fire detection and alarm systems shall comply with the following:
a) A fire detection system shall comprise automatic fire detectors and manual break
glass units.
b) In multiple room or plant area buildings the automatic and manual break glass
units shall be installed in zoned circuits covering each specific room or area.
c) The automatic fire detectors shall operate on rate of temperature rise and fixed
maximum temperature characteristics; the maximum temperature alarm actuating
at 20oC above peak design internal ambient. Each detector shall incorporate a
pilot lamp operation indicator.
d) Automatic heat and smoke detectors shall be ceiling mounting arranged to cover
substation areas and specific plant locations, as applicable.
e) The manual break-glass units shall be wall mounted, located at building
entrances, general walkways and corridors and in other areas such that no
location in a buildingis greater than 30 m from a unit

f) Sounders shall operate on 24 VDC nominal with sound level of at least 90 dBA ±
2dBA @ 1 metre from the device, with a frequency response of 2000-8000 Hz
with a lower power rating.
g) All detector and alarm circuits shall operate on a normally closed fail-safe circuit
principle.
h) Each fire detection system shall operate at 12 V dc or 24 V dc from a single fire
alarm control panel (FACP) which shall be located at a location subject to the
consideration of Engineer. The FACPs shall be of the totally enclosed metal clad
pattern each complete with integral battery/charger equipment. The FACPs shall
each incorporate alarm and status indicators together with circuit test facilities to
give visual alarm indication of:
i. Actuation of each alarm circuit and zoned protected area
ii. Input power system – healthy/failed
iii. Battery/charger output – healthy/failed
i) Operation of any fire detector or manual break glass unit shall operate audible
alarm(s) located internally and externally on each building. In areas with high
ambient noise the audible alarm shall also incorporate a visual flashing beacon
lamp.
j) Alarm system operation together with the operation of a control panel integral
equipment fault circuit shall also be annunciated on the SCADA system.
k) All component equipment in the fire alarm installations shall comply with a
specification which has been considered by Engineer. All cable and wiring
systems for the building alarm and detection circuits shall be of pliable fire
resistant/survival low smoke type armoured cable,. All cable terminations for
detector and manual break glass units shall be in stainless steel circular conduit
boxes.
l) Alarm circuits between substation and the central control panel shall be by
dedicated LSF/SWA/LSF control cables.
m) Lead acid type batteries shall be provided in the FACP panels. The batteries shall
have ample capacity to operate all components of the system, including all alarm
signalling devices 2 hours in standalone &minimum period of 30 minutes in alarm
mode upon a normal AC power failure.
n) Interface unit / modules shall be provided for integrating the Public Address
system with the FACPs. In the event of fire, the FACPs shall trigger the PA to
generate a pre-recorded announcement.
o) Interface unit/modules shall be provided for integrating fire fighting system with
the FACPs. In the event of fire, the FACP‘s shall activate the fire pump so as the
energise the fire hydrant network. Firefighting system requirement has been
detailed in particular Mechanical Requirements.
B) Cable sealing or Fire barrier system
Contractor shall provide the cable sealant system for the PCC and MCC rooms. The
cable sealing system shall ensure full-proof protection against hazards induced by
water, dust, fire, as well as rodents & insects.
Cables passing through penetration on wall or floor shall be provided with fire barrier
composite sheet System, fire stop mortar and Intumescent fire stop sealant provided
in compliance with ASTM/UL standards.
Contractor shall provide the fire rated walls and doors as applicable for substation
and MCC rooms. Fire walls between transformer and that between transformer and
switchgear room shall be 2 hours. The height of fire wall between transformers shall
be 500 mm above the top of the transformers. The width of this fire wall shall be

beyond the transformer dimensions. Fire wall between transformer and switchgear
shall be full height of building.
The substation including transformers shall be provided with fire extinguishing
system in compliance with IS 3034 and Central Board of Irrigation and Power (CBIP)
guidelines.
C) Linear Heat Detection tubing and Direct Fire Suppression System
Contractor shall provide the Automatic clean agent flooding system comprising fire
detection tubing system, cylinder, valves, adapter, pressure switches, annunciation
system, auxiliary contacts for remote monitoring etc. The system shall detect the fire
in electrical panels i.e. dry type transformer yard, high voltage switchboard and low
voltage switchboards, Power and Motor control center and automatic power factor
correction panels connected to PCC and MCC only. Contractor shall provide the
linear pneumatic device that responds to the combination of heat and radiant energy
from the fire. The fire detection tubing system shall have the relevant valid test
certification against ageing test, leakage test and pressure test from accredited third
party laboratory.
All the detecting devices, alarm, indicating devices, containers and other related
equipment shall be UL Listed and/or FM approved and/or LPCB approved. The
installation shall conform to NFPA norms.
D) Nitrogen Injection Fire Prevention System (NIFPS)
Nitrogen Injection Fire prevention system shall be used to prevent explosion of

transformer and possible fire in case of internal fault and as such act as fire
preventer. The system shall be suitable for protecting the Transformer tank from
explosion and also Transformer OLTC and cable box from fire. The system operation
shall be automatic and also made to operate with remote control from control box
and manually from extinguishing cubicle in the event of power loss.
NIFPS shall be provided in compliance with the CEA (Measures relating to Safety
and electric supply) Regulation 2010.
7.16.8 Gas Detection System
The Contractor shall provide minimum of 2 numbers of portable gas monitor based
systems units which can detect CO2, CH4, O2 and H2S, accompanied by the necessary
procedures and systems to ensure their correct application shall be supplied and
employed where appropriate by the Contractor.
7.16.9 PA (Public Address) System
The Contractor shall provide Digital Public Address (PA) system to satisfy the
communication, safety, evacuation and management requirements of the Contract.
A Public Address system shall be designed with centralized Controller and Amplifier
system so as to transmit routine voice messages, emergency evacuation messages and
alarm tone in a reliable and effective manner from central control room to the selected
strategic locations across the plant through loudspeakers.

7.17 Miscellaneous Materials and Accessories
The Contractor shall be responsible for the supply and installation of all miscellaneous
Materials and accessories necessary to provide a complete electrical installation to
conform to the Employer‘s Requirements.
7.17.1 Safety Equipments and PPE
The contractor shall provide the following safety equipment‘s and Personnel Protective
Equipment‘s (PPE) as a minimum in line with the requirement of Electrical Inspectorate,
Electricity Act 2003 and Central Electricity Act (Measures relating to Safety and Electric
Supply) Regulations 2010.
 Fire extinguisher
 Insulating mat
 Shock treatment chart
 Hand gloves
 Ear Plug, Ear muff
 Sand fire bucket
 Safety Goggles
 Safety shoes
7.17.2 Electrical Measuring and Testing Instruments
Contractor shall provide following testing Instruments as a minimum for basic

measurement, trouble shooting and safe and reliable operation of the Electrical power
distribution system
 Digital Earth /Ground Tester
 Battery capacity tester
 Cable fault locator/Tester
 Digital Multimeter
 Insulation resistance tester
 Clamp on ammeter or Tong tester
 Continuity tester
 Tape measure
 Non-contact AC voltage detector
 Electrical Tester
 Tachometer
 Infra red temperature monitoring device
Contractor shall provide following necessary tools and tackles as a minimum…………

 Hydraulic Crimping Tool with accessories
 Allen wrench set
 Phillips Screwdriver
 Straight blade Screwdriver
 Side cutter diagonal plier
 Wire stripper/plier
 Channel lock plier
 Lineman plier
 Combination plier
 Claw hammer with handle
 Fish tape /Draw Tape/wire puller
 Drill bit and Drill machine set

 Tool bag with belt

 Bearing puller
11 kV Earthing Truck/ Trolley
a) 22 kV Metal Enclosed Switchboards
Sr. No. Description Unit Technical Particulars

1.1 Make As per Preferred Makes/
Manufacturers Refer Appendix
1.2 Type As per Specification
1.3 Applicable Standards As per Specification
1.4 Quantity No. (*)
1.5 Switchgear cubicles and Bus bar
ratings
(a) Rated voltage, phases and 22 kV, 3 phase, 50 Hz
frequency
(b) System Neutral Earthing Solidly earthed
(c) Maximum system voltage kV 24
(d) One minute power frequency kV (rms) 50
withstand voltage
(e) 1.2/50 sec impulse withstand kV (peak) 125
voltage
(f) Short circuit withstand
(i) Short time (1 sec) at rated kA(rms) 26.25
voltage
(ii) Dynamic rating kA(peak) 65
(g) Reference ambient temperature 50 °C
(h) Maximum temperature of bus Joints, Silver faced : 100oC
bars droppers connectors and Busbars and other joints : 85o C
contacts at continuous current
rating under site reference
ambient temperature
(i) Continuous current rating of bus A (*)
bar
(j) Bus bar material Aluminium
(k) Bus bar Insulation Fully insulated by encapsulation
in epoxy resin with mould caps
protecting all joints
(l) Cable entry Bottom
(m) Cable type for Incoming and 22 kV(E), XLPE Aluminium
Outgoing feeders conductor with Round wire GI
armouring
1.6 Switchgear constructional
Requirement
(a) Thickness of sheet steel Frame – 2.5min.


Frame, Frame enclosures, Doors/Covers/partitions – 2.0min.
doors, covers and partitions mm
(b) Degree of protection IP4X for panel enclosure & IP52
for metering compartment.,
(c) Colour finish shade Interior - Glossy white
Exterior - Siemens Pebble Grey

RAL-7032
(d) Earthing bus i) Material GS Flat
ii) Size mm x mm (*)
(e) Earthing i) Material
conductor GS Flat

1.7 Breaker Particulars
(a) Circuit breaker type 3 pole, Vacuum draw out type,
truck mounted with Surge
Supressor, trip free mechanism &
anti pumping feature
(b) Voltage, phases and frequency 24 kV, 50 Hz, 3 Ph
(c) Rated operating duty O – 3 min – CO – 3 min - CO
(d) Rated current at reference
ambient temperature
Incoming breakers A (*)
Outgoing breakers A (*)
(e) Rated breaking capacity kA (rms) 26.25
(f) Rated making current kA (peak) 65
(g) Short time current withstand for kA (rms) 26.25
1 sec duration
(h) Total break time Less than 50 ms
(i) Operating mechanism type Motor spring Charged stored
(Normal) energy type for closing and
tripping
Operating mechanism type Manual Spring Charged for
(Emergency) closing and tripping
(j) Minimum no. of auxiliary 6 NO+ 6 NC
contacts
(k) Withstand test voltage
(i) One minute power frequency kV (rms) 50
(ii) 1.2/50  sec impulse kV (peak) 125
(l) Auxiliary control voltage
(i) For closing / tripping coil 110 V DC
(ii) For spring charging motor 240 V AC


(iii) For space heaters and 240VAC
lighting
(iv) Permissible variation in 85to110% for closing coil
operating voltage of closing & 70 to 110% for tripping coil
tripping coils
(m) Anti pumping feature To be provided
(n) Latching requirement Trip free
1.8 Current Transformers
(a) Type Cast resin, window type
(b) Class of insulation Class E or better
(c) Rated current ratio and burden
(i) Incomers and bus couplers (*)
(ii) Outgoing feeders (*)
(d) Accuracy class
(i) Metering 0.2S
(ii) Protection 5P10 and PS for core connected
to Restricted Earth fault relay
(e) Short time 1 sec current rating kA (rms) 26.25
(f) Dynamic rating kA (peak) 65
1.9 Voltage Transformers
(a) Type Cast resin
(b) Rated Voltage
(i) Primary V 22000/3
(ii) Secondary – S1 V 110/3; 110/3
(c) Method of connection
(i) Primary – P Star, earthed
(ii) Secondary – S1 Star, earthed
(d) Application – S1 Metering and protection
(e) Rated burden VA (*)
(f) Accuracy class Metering 0.2
Protection 3P
(g) Rated voltage factor
(i) Continuous 1.1
(ii) Short time 1.5
(h) Insulation class Class E or better
1.10 Meters
(a)
Make
(b) Accuracy Class
(i) Indicating Meters Class 1.0
(ii) Energy Meter Class 0.2S


1.11 Protective Relays
Type Numerical Type
Auxiliary supply 110V DC
1.12 Annunciations
(a) Following alarm annunciations shall be provided for each Incomer & Bus coupler
circuit breaker
(i)Tripped on fault
(ii)O/C&E/F operated
(iii) Trip circuit supervision unhealthy
(iv)DC fail
(v)AC fail
(b) For each Outgoing transformer feeder circuit breaker, as applicable
Tripped on fault
O/C&E/F operated
Bucholz
WTI, OTI trip
Trip circuit supervision unhealthy
DC fail
AC fail
Bucholz, WTI, OTI, Oil level low alarms
(c) For Bus PT
Under voltage trip
DC fail
AC fail
(d) Spare windows Min. 2 Nos.
1.13 Cubicle Components
Each 22 kV circuit breaker cubicle shall be provided with the following minimum
standard accessories
(a) One control switch ‗trip-neutral-close‘ spring return to neutral position
(b) One control selector switch ‗Local-remote stay-put‘ type

(c) LED Indicating lamps
(i) ‗Red‘ for breaker in ‗On‘ indication
(ii) ‗Green‘ for breaker ‗Off‘ position
(iii) ‗Amber‘ for breaker tripped on fault ‗White‘ for trip circuit healthy
(iv) ‗Red‘ for breaker in ‗Service‘ position
(v) ‗Clear‘ for breaker in ‗Test‘ position
(vi) ‗Blue‘ for breaker spring ‗Charged‘
(vii) ‗Amber‘ for DC fail
(viii) ‗Amber‘ for AC fail
(xi) ‗Red‘, ‘Yellow‘, ‘Blue‘ for supply healthy for incomers.
(d) Mechanical trip push button to trip the breaker when control supply is lost. The
push button shall be shrouded type
(e) One electrical anti-pumping relay
(f) Double pole control supply MCB one each for AC&DC control supply.
(g) Cubicle space heater of adequate capacity with thermostat
(h) 240V, 1 Phase, 50Hz, 15/5A, 6 pin receptacle with switch


(i) Cubicle lamp with door interlock switch
1.14 Auxiliary A.C. Supply
240 V, 1 Ph, 50 Hz supply shall be made available to each cubicle of 22 kV Metal
Enclosed Switchboards separately for provision of following
(a) Spring charging motor
(b) Cubicle space heater
(c) Cubicle lamp
(d) 240 V, 1 Ph, 50Hz 15/5A 6 pin receptacle with switch
1.15 Inspection and test categories Category A (#)
b) 11 kV Metal Enclosed Switchboards

Make As per Preferred Makes/
Manufacturers, Refer Appendix
Type As per Specification
Applicable Standards As per Specification
Quantity No. (*)
Switchgear cubicles and Bus
bar ratings
(a) Rated voltage, phases and 11kV, 3 phase, 50 Hz
frequency
(c) Maximum system voltage kV 12
(d) One minute power frequency kV (rms) 28
withstand voltage
(e) 1.2/50 sec impulse withstand kV (peak) 75
voltage
(f) Short circuit withstand
(i) Short time (1 sec) at rated kA(rms) 26.25
voltage
(ii) Dynamic rating kA(peak) 65
(g) Reference ambient temperature 50 °C
(h) Maximum temperature of bus Joints, Silver faced : 100oC
bars droppers connectors and Busbars and other joints : 85o C
contacts at continuous current
rating under site reference
ambient temperature
(i) Continuous current rating of bus A (*)
bar
(j) Bus bar material Aluminium


(k) Bus bar Insulation Fully insulated by encapsulation
in epoxy resin with mould caps
(l) Cable entry Bottom
(m) Cable type for Incoming and 11 kV(E), XLPE Aluminium
Outgoing feeders conductor with GI armouring
Switchgear constructional
Requirement
(a) Thickness of sheet steel Frame – 2.5min.
Frame, Frame enclosures, doors, Doors/Covers/partitions –
covers and partitions mm 2.0min.
(b) Degree of protection IP4X for panel enclosure & IP52

for metering compartment.,
(c) Colour finish shade Interior - Glossy white
Exterior - Siemens Pebble Grey
RAL-7032
(d) Earthing bus i) Material GS Flat
(e) Earthing i) Material
conductor GS Flat

Breaker Particulars
(a) Circuit breaker type 3 pole, Vacuum draw out type,
truck mounted with Surge
Suppressor, trip free mechanism
& anti pumping feature
(b) Voltage, phases and frequency 12 kV, 50 Hz, 3 Ph
(c) Rated operating duty O – 3 min – CO – 3 min - CO
(d) Rated current at reference
ambient temperature
Incoming breakers A (*)
Outgoing breakers A (*)
(e) Rated breaking capacity kA (rms) 26.25
(f) Rated making current kA (peak) 65
(g) Short time current withstand for 1 kA (rms) 26.25
sec duration
(h) Total break time Less than 50 ms
(i) Operating mechanism type Motor spring Charged stored
(Normal) energy type for closing and
tripping
Operating mechanism type Manual Spring Charged for
(Emergency) closing and tripping


(j) Minimum no. of auxiliary contacts 6 NO+ 6 NC
(k) Withstand test voltage
(i) One minute power frequency kV (rms) 28
(ii) 1.2/50  sec impulse kV (peak) 75
(l) Auxiliary control voltage
(i) For closing / tripping coil 110 V DC
(ii) For spring charging motor 240 V AC
(iii) For space heaters and 240VAC
lighting
(iv) Permissible variation in 85to110% for closing coil
operating voltage of closing & 70 to 110% for tripping coil
tripping coils
(m) Anti pumping feature To be provided
(n) Latching requirement Trip free
Current Transformers
(a) Type Cast resin, window type
(b) Class of insulation Class E or better
(c) Rated current ratio and burden
(i) Incomers and bus couplers (*)
(ii) Outgoing feeders (*)
(d) Accuracy class
(i) Metering 0.2S
(ii) Protection 5P10 and PS for core connected
to Restricted Earth fault relay
(e) Short time 1 sec current rating kA (rms) 26.25
(f) Dynamic rating kA (peak) 65
Voltage Transformers
(a) Type Cast resin
(b) Rated Voltage
(i) Primary V 11000/3
(ii) Secondary – S1 V 110/3; 110/3
(c) Method of connection
(i) Primary – P Star, earthed
(ii) Secondary – S1 Star, earthed
(d) Application – S1 Metering and protection
(e) Rated burden VA (*)
(f) Accuracy class Metering 0.2
Protection 3P
(g) Rated voltage factor
(i) Continuous 1.1


(ii) Short time 1.5
(h) Insulation class Class E or better
Meters
(a) Make
(b) Accuracy Class
(i) Indicating Meters Class 1.0
(ii) Energy Meter Class 0.2S
Protective Relays
Type Numerical Type
Auxiliary supply 110V DC
Annunciations
(a) Following alarm annunciations shall be provided for each Incomer & Bus coupler
circuit breaker
(i)Tripped on fault
(ii)O/C&E/F operated
(iii) Trip circuit supervision unhealthy
(iv)DC fail
(v)AC fail
(b) For each Outgoing transformer feeder circuit breaker, as applicable
(i) Tripped on fault
(ii) O/C&E/F operated
(iii)Buchholz
(iv)WTI, OTI trip
(v) Trip circuit supervision unhealthy
(vi) DC fail
(vii) AC fail
(viii) Buchholz, WTI, OTI, Oil level low alarms
(c) For Bus PT
(i) Under voltage trip
(ii) DC fail
(iii) AC fail
(d) Spare windows Min. 2 Nos.
Cubicle Components
Each 11 kV circuit breaker cubicle shall be provided with the following minimum
standard accessories
(a) One control switch ‗trip-neutral-close‘ spring return to neutral position
(b) One control selector switch ‗Local-remote stay-put‘ type

(c) LED Indicating lamps
(i) ‗Red‘ for breaker in ‗On‘ indication
(ii) ‗Green‘ for breaker ‗Off‘ position
(iii) ‗Amber‘ for breaker tripped on fault ‗White‘ for trip circuit healthy
(iv) ‗Red‘ for breaker in ‗Service‘ position
(v) ‗Clear‘ for breaker in ‗Test‘ position
(vi) ‗Blue‘ for breaker spring ‗Charged‘
(vii) ‗Amber‘ for DC fail


(viii) ‗Amber‘ for AC fail
(xi) ‗Red‘, ‘Yellow‘, ‘Blue‘ for supply healthy for incomers.
(d) Mechanical trip push button to trip the breaker when control supply is lost. The
push button shall be shrouded type
(e) One electrical anti-pumping relay
(f) Double pole control supply MCB one each for AC&DC control supply.
(g) Cubicle space heater of adequate capacity with thermostat
(h) 240V, 1 Phase, 50Hz, 15/5A, 6 pin receptacle with switch
(i) Cubicle lamp with door interlock switch
Auxiliary A.C. Supply

240 V, 1 Ph, 50 Hz supply shall be made available to each cubicle of 11 kV Metal
Enclosed Switchboards separately for provision of following
(a) Spring charging motor
(b) Cubicle space heater
(c) Cubicle lamp
(d) 240 V, 1 Ph, 50Hz 15/5A 6 pin receptacle with switch
Inspection and test categories Category A (#)
c) 22/11 KV/ 0.433kV Transformers

Type As per Specification (Dry Type/ Oil
filled
Rated output KVA (*)
Quantity required Nos. (*)
Transformer location Outdoor/Indoor
No load transformer ratio kV/kV 22/11/0.433kV
Number of phases 3
Rated frequency Hz 50
Impedence at all taps % Value as per IS 2026
Number of winding / material of Two/Copper/class-A
conductor / Insulation class
Core Lamination Grade M4 or better ($)
Flux density 1.55 Tesla maximum
Efficiency % Minimum level III for oil immersed
transformer
Method of connection
(a) HV winding Delta


(b) LV winding Star
Vector group Dyn 11
LV Neutral Solidly earthed
Type of cooling ONAN/AN
Tap changer Full capacity, microprocessor based
On-load type on HV side with local
marshalling box and Remote Tap
Changing panel
Tap range % + 5 % to -15 %
Tap step % 1.25 %
(a) Terminal connection Cable box suitable to 22/11 kV, (E)
HV terminals XLPE, Aluminium Conductor, Round
wire armoured cable of size (*)
(b) LV terminals Cable box suitable for 1100 V
XLPE, Aluminium Conductor
armoured cables (*) For transformer
ratings greater than or equal to
1000kVA should be suitable for
termination of Non-Segregated
Aluminium Bus duct (*)
Current Transformer
(a) On LV (*)
(b) On LV Neutral
LV Neutral earthing LV Neutral shall be brought out
through a 1.1 kV rated bushing, both
inside the cable box for forming the
3 Ph, 4-wire system and outside the
cable box for direct connections to
earth by means of Copper earthing
conductor(*)
Insulation of Windings H.V. L.V.

(a) One minute power frequency kV 28/50 3.0
withstand voltage (dry and wet) (r.m.s)
(b) 1.2/50 micro second full wave kV 75/125 -
impulse withstand voltage (peak)
Insulation of bushings H.V. L.V.
(Line and Neutral)
(a) Rated Voltage of bushing kV 1.2 times 1.1
continuous or
1.5 times for
30 seconds
(b) One minute power frequency kV 38/50 3.0
withstand voltage (r.m.s)
(c) 1.2/50 microsecond full wave kV 95/125 -
impulse withstand voltage (peak)


Minimum creepage distance mm 25mm/kV on 25mm/kV on 3kV
(d) 17.5kV
Vacuum withstand capability of 250mm of mercury
transformer main tank with
bushings, radiations, fitting and
accessories.
Inspection and test categories Category A(#)and as per IS 1180 for
Oil immersed Transformer
($) The successful bidder shall be required to submit the manufacturer‘s test report showing the
Watt Loss per kg and the thickness of the core lamination, to ascertain the quality of Core
materials.
The Employer reserves the right to get sample of the core material tested at any Government
recognized laboratory.
d) 415 V Metal Enclosed Switchgears (PCC) /MCC
Sr. No Description Unit Technical Particulars

Type As per Specification
Quantity No. (*)
415 V Switchgear and Busbar
Ratings
(a) Rated voltage phase and 415 V, 3 Ph 50 Hz
frequency
(c) Maximum system voltage V 476
(d) One minute power frequency
voltage
i) Power circuits V 2500V (rms)
ii) Control circuits V 1500V (rms)
iii) Aux. Circuits connected to V 1500V (rms)
Sec of CTS
(e) Continuous current rating of Rating (*)
Busbars under site reference Material Aluminium
Ambient Temperature and type
& material
(f) Busbar insulation Fully insulated encapsulation in
epoxy resin with moulded caps
o
(g) Reference Ambient C 50
Temperature
o
(h) Maximum Temperature of C 85o C for bus bars and non silver
Busbars, Droppers and plated joints
Contacts at Continuous current
rating under site ambient 90o C for non silver plated joints


temperature
100o C for silver plated joints
(i) Short Circuit current withstand
for Busbars and droppers
(i) Short time 1 sec kA (rms) 50
(ii) Dynamic Rating kA (peak) 125
(j) Circuit Breaker
Breaking capacity Ics=Icw=Icu
Feature required Anti-pumping, Mechanical Indicator
(k) iMCC Relay Compliant with minimum Pollution
category 3C3 as per IEC-60721
Switchgear Constructional
Requirement
(a) Type of Construction Single front fixed type (Except for
incomer/Outgoing air Circuit
Breaker which shall be drawout
type). Construction features shall
be as per specification.
(b) Form of separation Form 3b and above
(c) Thickness of sheet steel
(i) Frame, Frame enclosures, mm CRCA– 2.0 /Alu-Zinc 2.0
doors, covers and partitions
(d) Degree of protection IP 54 indoor and IP55 for outdoor
(e) Colour finish shade Interior : Glossy white
Exterior : Siemens Pebble Grey
RAL-7032
(f) Earthing bus Material GS
Size mm x mm (*)
Earthing Material GS
conductor
Size mm x mm (*)
(g) Minimum clearances in air of
live parts
(i) Phase to Phase mm 25.4
(ii) Phase to Earth mm 19.4
(h) Cable entry to cubicles (*)
Instrumentation
Transformers
(a) Current transformer
(i) Ratio (*)
(ii) Burden VA (*)
(iii) Accuracy Class 1.0
(b) Voltage transformer
(i) Ratio (415V 3 ) / (110V 3)
(ii) Burden VA 50
(iii) Accuracy Class 1.0
Inspection and test categories Category A(#)
e) 415 V Power Capacitor and Control Panel


General
(a) Make As per Preferred
Makes/Manufacturers Refer
Appendix
(b) Type As per Specification
(c) Applicable Standards As per Specification
(d) Quantity No. (*)
(e) Rated Capacity KVAR (*)
(f) Rated supply voltage V 415
(g) Rated frequency and phases 50 Hz, 3 Phase
o
(h) Reference Ambient temperature C 50
(i) Cable gland required Yes
(j) Type of cable 1.1 kV, XLPE, Al. Conductor
(k) Size of cable (*)
(l) Cable entry (*)
Constructional Requirement
(a) Thickness of sheet steel
i) Frame, Frame enclosures, mm CRCA 2.0
doors covers and partition
(b) Degree of protection IP 54
(c) Colour finish shade Interior : Glossy white
Exterior : : Siemens Pebble Grey
RAL-7032
(d) Main busbars and size Copper and (*)
o
(e) Maximum Temperature of C 85o C for bus bars and non silver
Busbars, Droppers and Contacts plated joints
at Continuous current rating 100o C for non silver plated joints
under site ambient temperature
(f) Earthing bus Material GS
Size mm x mm (*)
Earthing Material GS
(g)
conductor
Size mm x mm (*)
Design Requirement
(a) Insulation level kV (rms) 3.0
(b) Capacitor bank connection Delta
(c) Short circuit withstand for
busbars kA (rms) 50
i) Short time (1 sec)
ii) Dynamic kA (peak) 125
(d) Type of switching Automatic switching responsive to


power factor through power factor
sensing relay intelligent 4
quadrant operation
(e) Switching steps Minimum 8 steps
(f) Switch and Rating of contactor To suit KVAR of unit (switching
duty)
(g) Incomer MCCB current rating To suit rated capacity of capacitor
banks (switching duty)
(h) O/L capacity of capacitors 30% of rated capacity as per IS
(i) O/V capacity of capacitors 10% of rated voltage as per IS
(j) Protections O/V, U/V and O/L
f) Variable Frequency Drives

Make As per Preferred
Appendix
Type of Drive Inverter Controlled A.C Drives
Rated voltage, frequency and 415, V 50 Hz, 3 Phase
phases
Variation in voltage 415 V + 10
Variation in frequency 50 Hz + 5
Type of Duty 100% continuous, 150 %
overload for 2 minute once in
period of 24 hours, 200 %
overload for 10 seconds once in
period of 24 hours
Design Ambient Temperature 500C
Overall Harmonic Limitation Less than 5% as per limits given
in IEC 61800
Application As per Part 12 – Particular
Electrical Plant Requirements
Interfaces Serial or Profibus
g) Battery

Make As per Preferred

Appendix
Type of battery Ni-Cd
Number of battery banks required (*)
Ambient conditions Min. Temp. 25 C
Max. Temp 50 C
D.C. system voltage V 110
Ampere hour capacity of battery Ah As per the Requirement
at 27 Deg. C at 5 hour rate to
give final cell voltage of 1.16
volts/cell
Momentary load/duration A
Emergency load/duration A To be furnished by the Bidder
Continuous load/duration A
Nominal voltage V 1.2 V per cell
Cell voltage - initial/final V 1.42/1.14 V
Discharge rate Hours 5
Number of cells per bankr Nos (*)
equired to give rated voltage
Number of spare cells per bank Nos (*)
Mounting arrangement Multi tier
Charging method Float cum boost charging
h) Battery Charger

General
Appendix
(b) Applicable Standards As per Specification
(c) Type Float and Float cum Boost
Charge
(d) Number required
Nos (*)
(e) Rated Output voltage (DC) V 110
(f) Rated Output kW (*)
(g) DC System Earthing Unearthed


(h) Voltage regulation from no load to % 1
rated load
(i) AC ripple in DC out put voltage Less that 1%
at rated continuous load
(j) Type of rectifier SCR, full wave fully controlled
(k) Transformer Copper double wound dry type
with class-F insulation
(l) Ambient Design Temperature Deg. C 50 C
(m) Float/Trickle charging current mA As per manufacturer
of battery
(n) Boost Charging Current of Battery A As per manufacturer
(Maximum)
(o) Boost Charging Voltage of Battery V As per manufacturer

(maximum)
(p) Maximum Time for Boost charging hr As per manufacturer
of Battery
AC System Data
(a) Supply Voltage V 415
Phase 3
(b) (i) Variation in supply Voltage %  10
(ii) Variation in supply frequency % 5
(c) Short Circuit level kA 50
(d) Type of earthing Solidly Earthed
Performance
(a) DC voltage setting adjustment for 10% of nominal voltage
float charger
(b) Voltage stabilisation for constant 1% of set D.C. voltage, with AC
voltage regulator input variation and DC load
variation from 0 to 100%
(c) Maximum permissible variation  1%
in DC voltage (no load to full load)
(d) D.C. voltage setting adjustment 70% to 100% of max. boost
for boost charging charging voltage
(e) D.C. current adjustment for boost 30% to 100% of max. boost
Charging charging current
(f) Current stabilisation for constant  2%
current regulator for boost charger
(g) Minimum permissible power factor 0.8
to rated continuous load
(h) Permissible ripple content at rated 3% (maximum)
continuous load


(i) Relay for auto changeover from Yes
Float to boost mode to be provided
(in case of float-cum-boost charger)
Constructional Features
(a) Thickness of sheet steel Frame,
Frame enclosures, doors,
covers and partition mm CRCA 2.0(min.)

RAL-7032
(d) Busbar material & size Aluminium, size as per
requirement
(e) Earthing bus Material GS
Size mm x mm (*)
(f) Earthing conductor Material GS
Size mm x mm (*)
(g) Cable entry Bottom
(h) Cable Sizes
(i) Battery sq.mm (*)
(ii) DC output sq.mm (*)
(iii) AC input sq.mm (*)
Inspection and test categories -- Category A(#)
i) DC Distribution Board

General
Appendix
(b) Applicable standards As per specification
(c) Quantity Nos (*)
(d) DC System voltage (Nominal) V 110

(e) DC System Earthing Unearthed

(f) Ambient Design Temperature Deg. C 50 C
(g) Bus bar material, rating and size Aluminium, Rating & Size (*)
DC Bus Load
(a) Total continuous DC load A (*)
(b) Short time loads (Additional to
continuous loads)
(i) DC lights/Facia lamps A (*)
(ii) Starting current and duration A (*)
of Largest Connected DC Secs (*)
Motor
Constructional Features
(a) Thickness of sheet steel Frame, mm CRCA2.0
Frame enclosures, doors,
covers and partition
RAL-7032
(d) Earthing bus Material GS
Size mm x mm (*)
(e) Earthing conductor Material GS
Size mm x mm (*)
(f) Cable entry (*)
(g) Cable Sizes
(i) DC Input from Battery sq.mm (*)
(ii) DC output to Load sq.mm (*)
Inspection and test categories -- Category B(#)
j) Cables

22/11kV (E) XLPE Insulated
Power Cables
(a) Make As per
Preferred Makes/Manufacturers
Refer Appendix
(b) Applicable Standards As per specification
(c) Cable size selection As per requirement


(d) Continuous current rating with A (*)
cable laid in air/ ground under
specified ambient temperature
(e) Conductor material Stranded, aluminium, EC
grade/class-2
(f) Conductor screening Semiconducting compound by
extrusion
(g) Insulation Extruded XLPE
(h) Screening on Insulation Semiconducting compound by
extrusion (non metallic), copper
tape (metallic)
(i) Identification of codes By providing strip of Red, Yellow &
Blue colours
(j) Inner sheath Extruded PVC, type ST-2
(k) Filler material PVC
(l) Armouring Galvanised steel round wire
(m) Outer sheath Extruded PVC, type ST-2,FRLS
(n) Overall diameter of cable To be furnished by the Bidder
(o) Recommended minimum bending mm To be furnished by the bidder
radius
(p) Standard length of cable on each mts (*)
drum
1100 V Grade XLPE Insulated
Power Cables
(a) Make As per
Preferred Makes/Manufacturers of
Part-6, General requirement.
(c) Cable size selection As per requirement
(d) Conductor material Stranded, aluminium/copper, EC
grade
(e) Insulation XLPE
(f) Inner sheath Extruded PVC, type ST-2
(g) Armouring Galvanised steel flat strip/round
wire
(h) Outer sheath Extruded PVC, type ST-2,FRLS
(i) Overall diameter of cable To be furnished by the Bidder
(j) Recommended minimum bending mm To be furnished by the bidder
radius
(k) Standard length of cable on each mts (*)
drum


650/1100 V Grade XLPE
Insulated Control Cables
(a) Make As per
Preferred Makes/Manufacturers
Refer Appendix
(c)
(d) Cable size selection As per requirement
(e) Conductor material Stranded, copper, EC grade
(f) Insulation XLPE
(g) Inner sheath Extruded PVC, type ST-2
(h) Armouring Galvanised steel round wire
(i) Outer sheath Extruded PVC, type ST-2,FRLS
(j) Standard length of cable on each mts (*)
drum
k) Lighting Fixtures and Accessories

General
(a) Make As per Preferred Makes/
(b) Type As per specification
(c) Illumination levels at various As per Building Services Part 12-
premises Particular electrical requirements
(d) Normal supply voltage, phase AC 240 V, 1 ph, 2 wire, 50 Hz
and frequency
DC 110 V, 2 wire, unearthed
(e) Variation in supply:
(i) Voltage (AC & DC) % + 10
(ii) Frequency % +5
(iii) Combined voltage & % + 10
frequency
0
(f) Design ambient air C 50 C
temperature
Luminarie terminal suitable for
(a) Indoor area
(i) Conductor material Copper/Aluminium
(ii) Cable size Coresxm (*)
m2


(b) Outdoor area
(i) Conductor material Copper/Aluminium
(ii) Cable size Cores (*)
xmm2
Luminaire earthing terminal
suitable for
(i) Conductor material G. I. wire
(ii) Conductor size SWG (*)
l) Lighting System and Equipment

System Particular
(a) Voltage
(i) 3 Phase, 4 wire 50 Hz system
 Rated V 415
 Maximum V 476
 One minute withstand voltage 3000 V AC.
(ii) D.C. system
 Rated V 110
(b) System short-circuit level
(i) At 415 V, A.C. kA (rms) 10
(ii) At 110 V.D.C. kA (D.C.) 6
0
(c) Reference ambient temperature C 500 C
Distribution Board/Panels
(a) Main, floor mounted distribution
boards
(i) Main Lighting distribution
board(A.C.)
 Make As per Preferred
Makes/Manufacturers of Part-6,
General requirement.
 Type Floor standing, sheet steel
Enclosed
 Degree of protection IP 54
 Bus bar material Aluminium
 Bus bar current rating A (*)
 Short circuit current rating kA (*)


 Cable entry Based on Layout Top or bottom
 Location Indoor
(ii) Emergency lighting panel (D.C.)
Appendix
 Type Wall mounting, sheet steel
Enclosed
 Degree of protection IP 54
 Bus bar material Aluminium
 Bus bar current rating A (*)
 Short circuit current rating kA (*)
 Cable entry Based on Layout Top or bottom
 Location Indoor
(iii) Single phase DBs, wall/structure
mounting
SLDB for indoor area
Appendix
enclosed
 Degree of Protection IP 54
(iv) SLDB for outdoor area
 Make As per Preferred Makes/
enclosed
 Degree of Protection IP 55
(v) Paint Finish
(i) Colour shade: Interior : Glossy white
Exterior: Siemens Pebble Grey
RAL-7032
Street Light Poles and Flood

(a) Light Poles
Street Light Pole
Total Height: m -
Quantity: Nos. (*)
(b) Floodlight Light Pole


Total height: (minimum) mts. 15
No. Of floodlights to be fixed per No. (*)
pole
m) Earthing and Lightning Protection System
Technical Particulars
Sr.
Description No. of Leads &
No. Size Material
Quantity
Main Earthing Grid Quantity as per
(a) Buried in earth (*) MS requirement
(b) Buried in floor slabs in buildings (*) MS Quantity as per
requirement
Conductor Leads to Equipment
(above ground)
(a) Transformers
(i) Transformer neutral to bottom of (*) Copper Number of
tank Leads
(ii) From bottom of tank to earth grid (*) GS As per relevant
Standards,
(iii) Transformer tanks and radiator (*) GS Quantity as per
bank requirements
(b) Fence posts and gates (Flex. (*) GS
braid)
(c) 11kVMetal Enclosed (*) GS
Switchboard, 415V switchgear/
MCC.
(d) Motors
(i) 415V Motors above 10 kW (*) GS
(ii) 415V Motors up to 10 kW (*) GS
(iii) Fractional horse power motors (*) GS
Other Items
(a) Capacitor panel, Battery charger (*) GS
panel, DC distribution board,
Main lighting D.B, Control panels
and sub-lighting distribution
boards
(b) Hand Rails (*) GS
(c) Cable trays (*) GS
(d) Tanks (*) GS
(e) Junction boxes (*) GS wire
(f) Lighting fixtures, receptacles, (*) GS wire

Sr. Description Technical Particulars

No. lighting conduits
(g) Push button stations, limit (*) GS wire
switches
Crane rail (*) GS
Street lighting, flood lighting poles (*) GS
and junctions boxes
Metallic non current carrying (*) GS
structures
Lightning Conductors
(a) Lightning protection down comers (*) GS
for building
(b) Lightning protection horizontal (*) GS
roof conductor for building
Electrodes (*) Heavy duty Quantity as per
(a) Pipe electrode (*) CI/GI pipe requirements
3000 mm
long
Inspection and test categories Category C (#)
Note :
1) Any requirement /features /provisions not specifically mentioned in the Specification, but are
necessary for trouble free and smooth operation of the Plant System shall be included.
2) (*) – The numbers, ratings, sizes etc have to be worked out by the contractor during
execution and to be approved by the Engineer.
3) (#) As defined in Part 9, Volume -2 of the Bid document.

8 Particular Instrumentation & Control Requirements
8.1 Introduction
This part covers the general requirements for the design, supply, installation, inspection
and testing of the Instrumentation, Control and Automation and associated plant and
materials.
8.2 Reference Standards
Unless otherwise approved, all equipment shall comply with relevant quality standards
test procedures and codes of practice collectively referred to as Reference Standards
including those listed below in accordance with the requirements detailed elsewhere in
this specification.
Generally, the following latest edition of codes and standards prevailing at the time of
award of contract shall be applicable.
8.2.1 Temperature Measurement
a) Instrument and apparatus for temperature measurement - ASME PTC 19.3 (1974).
b) Temperature Measurement - Thermocouples - ANSI - MC 96.1 - 1982.
c) Temperature Measurement by electrical resistance thermometers – IS : 2806
d) Thermometer-element-Platinum resistance - IS: 2848 / DIN 43760
8.2.2 Pressure Measurement
a) Instrument and apparatus for pressure measurement - ASME PTC 19.2 (1964).
b) Bourdon tube pressure and vacuum gauges - IS: 3624/1996.
8.2.3 Flow Measurement
a) Instruments and apparatus for flow measurement - ASME PTC 19.5 (1972) Interim
supplement, Part-II
b) Measurements of fluid flow in closed conduit - BS 1042.
8.2.4 Electronic Measuring Instruments and Control Hardware
a) Automatic null balancing electrical measuring instruments -ANSI C 39.4 (Rev. 1973),
IS 9319
b) Safety requirements for electrical and electronic measuring and controlling
instrumentation - ANSI C 39.5 / 1974.
c) Compatibility of analog signals for electronic industrial process instruments - ISA-S
50.1: ANSI MC 12.1 / 1975.
d) Dynamic response testing of process control instrumentation - ANSI MC 4.1 (1975) -
ISA -S26 (1968).
e) Surge withstand capability (SWC) tests - ANSI C 37.90A (1989), IEC-255.4.
8.2.5 Instrument Switches and Contacts
a) Contact Rating - AC services NEMA ICS Part-2 125, A-600

b) Contact Rating - DC services NEMA ICS Part-2 125, N-600
Section 6: Employer‘s Requirement 8-163 Bid Document

Part 8: Particular Instrumentation & Control Requirements
8.2.6 Enclosures
a) Enclosures for Industrial Controls and Systems–NEMA ICS-6-110.15 through 110.22

b) Racks, panels and associated equipment -EIA: RS-310-B-1983 (ANSI C83.9 - 1972).
8.2.7 Apparatus, Enclosures and Installation Practices in Hazardous Area
a) Classification of hazardous area - NEMA Article 500, Volume-6, 1978.

b) Electrical Instruments in hazardous dust locations - ISA-RP 12.11.
c) Intrinsically safe apparatus - NFPA Article 493 Volume-4 1978.
d) Purged and pressurized enclosure for electrical equipment in hazardous location
e) - NF Article 496 Volume-4, 1978.
8.2.8 Sampling System
a) Stainless Steel material of tubing and valves, for sampling system - ASTM A269-79
GRTO-316.
b) Submerged helical coil heat exchangers for sample coolers -- ASTM D11-98.
8.2.9 Annunciators
a) Specifications and guides for the use of general-purpose annunciators - ISA RP 18.1.
b) Surge withstand capability tests -ANSI C37.90 a -1971 and IEEE Standard 472- 1974
8.2.10 Interlocks, Protections
a) Relays and relay system associated with electric power apparatus - IEEE Standards
3.13.
b) Surge withstand capability tests - ANSI C37.90 a - 1971 and IEEE Standard 472-
1974.
c) General requirements and tests for switching devices for control and auxiliary circuits
including contactor relays - IS-6875 (Part-I)/1973.
8.2.11 UPS System
a) Practice and requirements for semi-conductor power rectifiers - ANSI C34.2.

b) Relays and relay systems associated with electrical power apparatus IEEE Standard
- 3.13.
c) Surge withstand capability tests - ANSI C 70.90 A/1971, IEC-255.4.
d) Recommended practice for sizing large lead storage batteries for generating stations
and sub-stations - IEEE-485.
e) Ni-Cd Battery - IEEE Std. 1106 /IS 10918
8.2.12 Instrument Tubing
a) Seamless Carbon Steel Pipe - ASTM-A-106.

b) Forged carbon steel fittings - ASTM-A-105.
c) Dimensions of fittings - ANSI-B16.11.
d) Code for pressure piping, welding, hydrostatic testing - ANSI-B 31.1.
e) Nomenclature for instrument tube fittings - ISA-RP 42.1 / 1982.
f) Seamless Stainless Steel Tube ASTM A-213 TP 316 / ASTM A-269 TP 316
g) Seamless Alloy Steel Pipe ASTM A 335 P22
h) Seamless Stainless Steel Pipe ASTM A-312 TP 316

8.2.13 Cables
a) Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy-
IPCEA S-61-402
b) Guide for design and installation of cable system in power generating station
(insulation, jacket materials) - IEEE Standard 422.
c) Requirements of vertical tray flame test - IEEE 383
d) Standard specification for tinned soft or annealed copper wire for electrical purpose -
ASTM B33.
8.2.14 Electronic Cards, Subassemblies and Components
a) Unpackaged
i. Vibration : IEC-68.2.6
ii. Shock : IEC-68.2.27
iii. Drop & Topple : IEC-68.2.31
b) Packaged
Vibration, Drop & Static Compression - NSTA.
c) Electromagnetic Compatibility
i. Electrical Fast Transient : IEC-801.4
ii. Surge Withstand : IEC-255.4
iii. Radiated Electromagnetic Field : IEC-801.3
iv. Electrostatic Discharge : IEC-801.2
v. Electromagnetic Emissions : VDE 0871, Class-B
8.2.15 Cable Trays, Conduits
a) Guide for the design and installation of cable system in power generating station
(cable trays, support systems, conduits) - IEEE Standard 422, NEMA VE-1, NEC-
1981. Test Standards NEMA VE-1-1979.
b) Galvanizing of carbon steel cable trays - ASTM A-386.
8.2.16 Characteristics
1) ISO 9000 and 09004 - Quality Systems

2) IEEE 587 - Power Supply Surge Protection\
3) IEC 61158-2 - Communication Protocols
4) ISO 9075 (BS 6964) - Structured Query Language (SQL)
5) BS 5515 - Documentation of Computer Based Systems
6) BS 7165 - Recommendation for Achievement of Quality in
Software
7) BS EN 50081 - Electromagnetic Compatibility
8) ISO 3511 - Process measurement control functions –
Instrumentation symbolic representation
9) ISO-OSI - 7 Layer Communication Model
10) IEEE 472-1974 - Surge protection.
All standards which the Contractor intends to use but which are not part of the above
Standards or other listed Reference Standards, shall be submitted to the Employer
Representative for consent before any design against that standard proceeds.

8.3 Project Requirements
1) Contractor shall provide material, equipment & services specified or otherwise

required within the scope boundary to fulfill the intent of specification and to integrate
into a fully functional Instrumentation and Control system ensuring operability,
maintainability and reliability and durability for comprehensive operation &
maintenance period of ten (10) years described in this specification.
2) Contractor shall furnish their offer based on the requirements as described in the
specification.
3) The scope of supply shall include but shall not be limited to the following within the
scope boundary:
a) Field instruments and sensors for remote measurement, Primary flow elements
along with branch pipes, root valves, nipples, flanges, nuts, bolts, gaskets and
accessories.
b) Instrumentation pair, triad & core cable, instrumentation power cable, optical fiber
cable, special cable etc, cable trays. as required.
c) Control panel, panel instruments, field junction boxes, instrument enclosures
accessories and furniture (system consoles), as required.
d) Required power supply
e) Supply of all start-up, commissioning and recommended spares in addition to the
mandatory spares.
f) Under Package 12, regular Asset data update in prescribed format & its
Integration with Engineering Document Management System & Asset
Management System is proposed i.e., Implementation of GIS, MIS, & Asset
Management in Sewers, STP‘s & IPS‘s.
Under Package-12, Pune Municipal Corporation will possess Engineering
Document Management System (EDMS) & Asset Management System (AMS),
which is initiated to bring together series of project deliverables on a unified
platform at project level as well as Pune Corporation‘s enterprise level. It will
include related functions for existing and proposed sewers, STP‘s & IPS‘s and
utilize the underlying data created and matured during the project lifecycle in a
systematic manner for better and consistent monitoring, control during design,
construction and operation & maintenance.
Regular cross-functional interaction between different project packages is
required to maintain overall desirable quality, integrity, and relevance of asset
data across all project phases.
For systematic development and implementation of proposed EDMS & AMS
under Package 12, It is mandatory for the package 6 contractor to assign
dedicated staff and provide information in prescribed format (to be progressively
developed and provided to the package 6 contractor) regarding regular updates
of all the documentary evidence such as design approvals, inspection records, as
built drawings, etc. and for this purpose maintain regular interaction with Project
Management Consultant‘s Team.
Under package 6,The system (individual systems for each software) shall be
installed in the SCADA control room to be established in the administration
building under this contract. The hardware specifications shall be similar to the
SCADA hardware specifications which are specified elsewhere in this
specification. Separate system console shall be provided for housing the above
equipment. The system shall be connected to the control room UPS system.
4) Contractor shall provide local panels for local start/stop monitoring of auxiliaries and
equipment‘s as per the requirements to be decided during detail engineering stage.
Ingress protection of panels shall be as per requirements mentioned in this
document.

5) Local Panels, Gauge Boards and Transmitter Racks, stanchions, brackets etc. as
required.
6) Process connection and piping materials including impulse pipes of different grades
& stainless steel tubes, stub, bosses, root valves, isolation & drain valves, valve
manifolds, gauge valves, condensate pot, fittings, stands, brackets etc. as applicable,
for satisfactory installation of all field instruments and analysers.
7) Pneumatic tubing along with fittings and isolating cocks for air consumers.
8) Erection hardware including junction boxes, canopies, structural steel items viz steel
angles, channels, flats.
9) Complete cable accessories viz flexible conduits, sub-trays/perforated trays, pull
boxes, inspection covers, bends, elbows, mounting brackets, clamps, nuts and bolts,
glands, lugs, ferrules, connectors, markers, tray supports, rigid conduits, tie wraps
etc.
10) Complete optical fiber cable /special cables with accessories like optical fiber
distribution box, patch cord / pigtail, converter, terminators, taps, heavy duty conduits
etc. to make the system complete in all respect.
11) Rating plates, Nameplates and Labels.
12) Maintenance, calibration, commissioning, site testing and troubleshooting equipment.
13) Fiber optic cable and accessories including tray /conduit for system data network and
for data collection through modbus, Ethernet or OPC connectivity, wherever required.
14) Arranging all performance test instruments and equipment.
15) Instrument control panels.
16) Performing tests on all equipment as per Quality Plan prior to shipment.
17) Contractor shall be responsible for software licensing, design, development,
debugging, system engineering, customizing, installation, site modification, tuning,
adjustments, commissioning and furnishing manuals, documentation etc.
18) Drawings and Documents: Contractor shall furnish system description, operational
write-up, bill of materials, drawings, data, information, technical catalogues, test
certificates and other details to establish the proveness, capability and performance
of the equipment and systems offered.
19) Final Drawings
a) Contractor shall secure approval on the design drawings from Employer for the
drawings identified as ―Approved‖, in writing. Any manufacture done prior to
approval of the drawings shall be rectified in accordance with the approved
drawings by Contractor at his own cost and the equipment shall be supplied
within the stipulated period.
b) Contractor shall furnish final drawings and documents in multiple (3 sets) hard
and soft copies. Contractor shall furnish instruction manuals containing various
components, sub-assemblies, method of installation, check-ups and tests to be
carried out during erection and commissioning of the equipment. The manual
shall also include instruction for step checking, trouble shooting and fault
rectification for different components and sub-assemblies.
c) Contractor shall incorporate all modifications in the drawings carried out at site
during trial run, start-up performance and guarantee tests till hand over of the
units to Employer and submit these final as-built drawings both in hard and soft
copy.
d) Final documents shall be submitted in proper bounded form. All catalogs and
literature (including sub-suppliers‘ catalogs), datasheets, Instrument list, input
output list, function control diagram, loop diagrams, configuration diagram etc.
shall be bounded together in indexed volumes. All O&M manuals shall be in
handy size and neatly bound for carrying it to the work place.
e) Contractor shall convert all drawings and documents, manuals under this contract
in to PDF format and store it in operator work station at the SCADA control room.
f) Operation and maintenance instructions

1) Composite manual describing the functional and operation of each piece of

equipment.
2) Composite manual for testing and servicing every system and individual item.
g) Original manuals and CDs from OEMs.
h) Training material shall be provided which shall include the presentations used for
trainings and also the required relevant documents for the topics.
1) The selected Contractor shall submit a complete set of
2) Floor Layout Drawings,
3) Single Line diagram.
4) Complete cabling system layout (as installed), including cable routing.
5) The layout shall detail locations of all components and indicate all wiring
pathways.
i) The Contractor shall be responsible for preparing process documentation related
to the operation and maintenance of each and every component of the
Instrumentation, control & Automation system.
j) The prepared process document shall be formally signed off by end user before
completion of final acceptance test.
k) The Contractor shall document all the installation and commissioning procedures
and provide the same to end user, within one week of the commissioning of
project along with final configuration dumps and implemented solution details.
l) The Contractor shall be responsible for documenting configuration of all devices
and keeping back up of all configuration files, so as to enable quick recovery in
case of failure of devices.
8.4 Qualification Criteria for Instrumentation vendor, Integrator and Automation vendor,
Integrator, and Lab equipment Vendor
All vendors/integrators shall be operating under an accredited ISO 9001-2015 or above

Quality System on a minimum.
The contractor shall submit the credentials of the system integrator proposed for
approval of the Employer Representative, before commencing any design or works.
Instrumentation:
The Instrumentation system integrator on a minimum shall be operating under an

accredited ISO 9001:2015 systems.
The instrumentation system integrator should have minimum 10 years of experience in

India in the field of instruments supply, installation, commissioning and operation and
maintenance of instruments in plants as required under this contract, within India and
shall demonstrate capability and resources for integrating/interfacing control systems
from different manufacturers as well as coordination with multiple agencies for contract
execution. The instrumentation system integrator shall be an authorized channel partner
for the instrumentation equipment. Verification certificates signed not less than the
country head of OEM shall be submitted.
The instrumentation system integrator shall have executed & completed at least three
project of minimum 100 MLD STP capacity within India during the last five years period,
inclusive of supply, installation, commissioning and operation and maintenance period of
minimum 1 year within India.
Automation:

The Automation system integrator on a minimum shall be operating under an accredited

ISO 9001:2015 system with a minimum of 10 years’ experience of having executed &
completed SCADA projects(PLC based SCADA system) inclusive of supply, installation
and commissioning; and operation and maintenance period of minimum 1 year on a
single facility within India and shall demonstrate capability and resources for integrating/
interfacing control systems from different manufacturers as well as coordination with
multiple agencies for contract execution.
The Automation system integrator must be an authorized channel partner for the named
PLC hardware & SCADA software for at least 5 years. Verification certificates signed not
less than the country head of OEM shall be submitted.
The Automation system integrator shall have executed & completed at least three project
of minimum 100 MLD STP capacity of similar process within India during the last five
years period, inclusive of supply, installation, commissioning.
Note: The Automation and Instrumentation contractor should have minimum 10

engineers for design with minimum ten years‘ experience in, programming, installation
and Commissioning. The engineers shall be on its permanent employment. Proof of
ESIC/PF should be submitted to demonstrate the permanent employment. (Associate
Employer Representatives/ Advisers/ consultants shall not be considered). The
integrator shall have his workshop/ Engineering office including facility to carry out
maintenance activity and service support within 250 km from Pune, Maharashtra
Lab Equipment
The vendors/integrators shall be operating under an accredited ISO 9001-2008 or above

Quality System on a minimum.
The lab equipment vendor shall be an authorized channel partner for the equipment.
The vendor shall have executed & completed at least five projects for setting up of STP
/drinking water lab & testing facility within India in Public sector units/Govt. agencies
during the last three years period, inclusive of supply, installation, commissioning of the
laboratory equipment. Verification end user performance certificates shall be submitted
for the same.
8.5 Submissions to be made by the contractor during the contract period:
1) The Contractor shall make submissions to the Employer Representative of all design
drawings, schedules and complete documentation on spare parts relating to
instrumentation and control equipment and systems provided under this Contract.
2) These submissions shall include, the following:
 Functional design specification (FDS) The Contractor shall submit a complete
functional
 Design specification (FDS) for approval by the Employer Representative within
five (5) months of the award of the Contract. The Contractor should take note of
the importance of this clause.
 The functional design specification shall be submitted for the following:
A. Instrumentation

a) The FDS shall include on a minimum, Instrument index, Instrument location

layouts, Instrument datasheet, OEM product brochure, Instrument hook up
diagrams and quality Assurance plan for inspection.
b) General arrangement drawings of field-mounted instruments showing installation
details.
c) General arrangement drawings of instrument and control panels, fully
dimensioned in plan and elevation views, showing foundation and fixing details,
access doors, clearances, cable-entry positions, weight and lifting arrangement.
d) Layout drawings of panel fascias showing instruments, controls and details of all
labels.
e) Internal circuit and wiring diagrams for instrument and control panels.
f) Schematic control diagrams.
g) Instrument loop diagrams.
h) Instrument wiring and piping diagrams.
i) Interconnection wiring diagrams.
j) Cable block diagrams, drawings and schedules.
k) Instrument system and panel power distribution diagrams.
l) The FDS shall describe control actions taken and monitoring functions which
remain available during a power failure, and any automatic controls or
sequencing which take place during system start-up and shut-down.
m) The FDS shall be presented in a clear and precise manner and shall include
figures or drawings where appropriate.
n) Comprehensive testing schedules for all off-site, on-site, pre-commissioning and
commissioning tests and take-over tests.
B. Control & Automation
1) This document shall serve as the primary mechanism by which the Employer
Representative may confirm that the Contractor possesses an accurate
understanding of the system and its control requirements.
a) On a minimum, FDS shall comprise an overall description of the plant, its
functioning and control, and a detailed description of each section of the
control system covering modes of operation, manual overrides, set-point and
parameter selection and adjustment. The detailed description shall include a
step-by-step control description which defines the function of each piece of
equipment and each control action and interlock, including details of the
program in each programmable item. Flow charts shall be used to depict the
control philosophy along with the write up for the same.
b) Proposed SCADA screens shall be an integral part of the submissions.
c) The FDS shall describe the ‗fail-safe‘ features incorporated into the design for
the event of failure of a plant item or system, or loss of an input signal.
d) The FDS shall describe control actions taken and monitoring functions which
remain available during a power failure, and any automatic controls or
sequencing which take place during system start-up and shut-down.
e) The FDS shall be presented in a clear and precise manner and shall include
figures or drawings where appropriate.
2) Drawings and schedules as part of FDS (For both Instrumentation & Control &
Automation):
a) Process and instrumentation diagram shall be as per ISA 5.1 latest release.
The P&ID shall contain the following on a minimum and in sequence:
1) Legend sheet inclusive of process line abbreviations, line designation,
process designation, symbols of all equipment, etc.

2) Tag Identification system. (Note: The tagging philosophy shall be

submitted before the submission of the P&ID for review and approval
before the tag i.d is incorporated in the P&ID.)
3) Typical Signal interface sheet
4) Process & Instrumentation sheets as per each process, which shall depict
the interlock sequence for each equipment & process operation. The
interlock sequence shall be depicted by using interlock numbering next to
the equipment/process.
5) Interlock sheet detailing every interlock for the system (Pumps, drives,
blowers, valves, etc.). For e.g.: Start, Stop, Trip, sub process sequence,
etc.
6) Each P&ID shall be submitted along with the process control philosophy.
7) The above requirements are also applicable for vendor supplied systems
P&ID.
b) General arrangement drawings of field-mounted instruments showing
installation details.
c) General arrangement drawings of instrument and control panels, fully
dimensioned in plan and elevation views, showing foundation and fixing
details, access doors, clearances, cable-entry positions, weight and lifting
arrangement.
d) Layout drawings of panel fascias showing instruments, controls and details of
all labels.
e) Layout drawings of panel interior showing equipment, terminal blocks and
cable ways.
f) Annunciator arrangement and engraving details.
g) Internal circuit and wiring diagrams for instrument and control panels.
h) Schematic control diagrams.
i) Instrument loop diagrams.
j) Instrument wiring and piping diagrams.
k) Interconnection wiring diagrams.
l) Cable block diagrams, drawings and schedules.
m) Instrument system and panel power distribution diagrams.
n) Programmable-device functional design specifications which shall include
hardware details, logic flow charts, ladder diagrams and program listings.
o) Schedules of inputs to and outputs from programmable controllers and
telemetry outstations.
p) Labelling & tag schedules.
q) Comprehensive testing schedules for all off-site, on-site, pre-commissioning
and commissioning tests and take-over tests.
3) All other drawings necessary for the provision of ducts, openings, trenches, fixing
holes for panels and the like and for the complete understanding of the operation,
maintenance and extension of the system including any required for the
Purchaser to dismantle, repair, maintain, modify or extend the Plant.
4) Control room, RIO Room interior design layouts, interior design diagrams, control
room wiring layout, access control point diagrams, etc.
5) Data and calculations
a) Manufacturers‘ catalogues and data sheets.
b) Calculations to support control system design.
c) Specification for protective coatings and painting.
6) Certificates
a) Manufacturers‘ works tests.
b) Pre-installation checks.
c) Pressure-testing schedules.

d) Instrument loop test check sheets.

e) Installed instrument performance tests.
f) System tests.
g) Statutory certificates of compliance (such as hazardous area equipment).
Note: The Contractor shall submit and obtain approval of the FDS from the Employer
Representative before beginning procurement. The contractor should take note of the
importance of this obligation.
8.6 Design Requirements for Instrumentation, Control & Automation system
Minimum Design Consideration
The instrumentation, control & automation system shall fully comply with design
standards, regulations and the material and workmanship requirements of the
Specification.
The electrical plant installations associated instrumentation control and automation

systems shall also comply with and be tested in accordance with the latest edition of BS
7671 or equivalent Indian standards.
All equipment and materials incorporated in the system shall be selected, designed and
rated to operate under the defined performance duties and specified site conditions and
to maintain a high level of operational reliability.
The instrumentation control and monitoring system equipment and materials shall have
an operational life of not less than ten (10) years.
Instrumentation, Control, Automation system shall be designed, manufactured and
installed to achieve the following basic requirements:
 to maintain the highest standards of availability, reliability and accuracy and to give
clear warnings of any deterioration in performance;
 to suit the abilities of the staff who will:
o use the systems;
o service the systems;
 to measure, indicate, process, store and control the relevant parameters, as
specified;
 to give clear warnings of dangerous and other abnormal conditions and to initiate
plant safety procedures, shutdowns and corrective measures as specified to assure
the safety of ‗operations and maintenance‘ personnel and plant and to store and
collate the data, as required;
 to derive, present and utilize, as required, such additional data as required to
facilitate:
o the most efficient operation of the plant;
o the routine maintenance of the plant
Equipment and system shall be designed and constructed to perform accurately and
safely under the environmental and operating conditions described or implied in this
specification without undue heating, vibration, wear, corrosion.
Equipment and systems shall be supplied as per the vendor list indicated in specification
elsewhere. Contractor shall obtain Employer‘s approval for the selected manufacturers
as will be identified during execution of the Contract as ―Employer‘s Hold‖ items.

The equipment, systems and accessories furnished shall be designed and constructed to
meet the performance specification during the continuous service life of the plant.
Contractor shall indicate the year in which the offered models of the instruments and
control system have been introduced and how long the commercial production of the
same is expected to continue. In any case, Contractor shall ensure supply of spare parts
for minimum period of ten years. In case if it is felt by Contractor that certain equipment/
component is likely to become obsolete, Contractor shall clearly bring it to the notice of
Employer and indicate step proposed to deal with such obsolescence like maintaining
―bonded spares‖ with the manufacturer/s.
Any part/ module of the C&I system which are not listed under recommended spares
shall be deemed as having life expectancy not less than ten years.
Contractor shall supply proven latest version of hardware and software available at the
time of system designing. In case of future up-gradation of software, Contractor shall
remain committed to upgrade the supplied system at per with the new version within the
warranty period and O&M period and ensure successful integration of the system.
For the sake of completeness of the system and in order to ensure desired performance
& safety measures, any hardware or software item felt required, shall be in the scope of
Contractor irrespective of their explicit or implicit inclusion in the accompanying
document.
Technical details furnished in the accompanying documents are subject to change in
future within reasonable limits, which Contractor shall abide by.
8.7 General Technical Requirements
8.7.1 Local Instruments
Required local instruments including gauge boards, level indicators etc. shall be
provided.
8.7.2 Cabling Concept
Instrumentation cables shall be copper, overall screened unless manufacturer‘s

recommendation dictates use of pair or triad shields apart from overall shield. All cables
shall generally be armoured, other than short run cables which may be unarmoured.
Unarmoured cables shall run through conduits.
Binary and analog signals shall not run through the same cable. Signals of different
voltage levels shall not be routed through the same cable. The screen shall be grounded
at the control room end only.
Conductor cross section for single pair or triad signal cables shall not have individual
conductor cross section below 1.5 mm2 and multi-pair or multi-triad cables shall not have
individual conductor cross section below 0.5 mm2. For solenoid valves, depending on
pick-up VA, individual conductor cross section shall not be below 2.5 mm2. For
interposing relay drive connection individual conductor cross section shall not be below
1.5 mm2.

8.7.3 Design Criteria
This section lays down the general design criteria to be adapted in designing the
instrumentation and control system
8.7.4 General Requirements
Instrumentation and control devices and accessories shall be designed with the following
considerations:
a) Stable in spite of temperature fluctuations.
b) Able to withstand high humidity.
c) Weather proof.
d) Dust proof.
e) Corrosion resistant.
f) Erosion resistant.
g) Able to withstand high vibration.
h) Entire control System for the plant shall be designed for complete auto mode of
operation with all operational interlocks required.
i) Easily accessible for operation & maintenance.
Parts subject to high pressure, temperature or other severe duty shall be of materials
and construction suitable for the service conditions and long operating life.
8.7.5 Instrument Accuracy, Standard Scales and Ranges
8.7.5.1 Instrument Accuracy
Instruments shall meet the following general requirements.

a) Pressure measurement shall be linear with respect to the measured pressure.
b) Flow meter shall meet the specified accuracy criteria when operating between 25 and
100 % of full-scale flow. The accuracy shall include the effect of errors in the
differential head measuring device, square root converter and signal generator.
c) Level measurement shall be linear with respect to the measured level based on a
water specific gravity of 1.00.
8.7.5.2 Instrument Scale Displays
a) All displays shall be in engineering units. Instrument scales displayed on screen will
have graduations with scale divisions based on multiples of 10. The smallest division
shall preferably be a whole number approximately 1% of the scale range if not
otherwise impracticable.
b) Pressure instrument shall have the unit suffixed with ‗a‘ or ‗g‘ to indicate absolute or
gauge pressure, respectively.
c) Scales and charts of all instruments shall have linear graduations
8.7.5.3 Instrument Ranges
Instrument range shall be selected to have the normal reading, preferably between 50%
and 70% of full scale for linear parameters and 70% to 80% for flow measurements.
Deviation indicators shall have the null position at midscale. The normal operating
parameter shall be identified with a clear green mark.

8.7.6 Established Reliability & Availability of individual instrument system
The target reliability of each component/module shall be established by taking into

consideration its Mean time between failure (MTBF) and Mean time to repair (MTTR), so
that availability of each system is assured for 99.7% of the time.
In order to establish the target reliability Contractor shall perform necessary availability
tests. Surge protection for solid state systems, selection of proper materials,
manufacturing processes, quality controlled components and parts, adequate derating of
electronic components and parts shall be ensured to meet the reliability and life
expectancy goals.
Continuous self-checking features shall be incorporated in system design with automatic

transfer to healthy/redundant circuits to enhance the reliability of the complete system.
8.7.7 Measurement & Channel Redundancy
To meet the failure and self- checking criteria for the control system, measurement
redundancy shall be provided for all the critical parameters. Throughout the control
system, the security and validity of signals are to be ensured based on the following
design principles.
a) Where a plant measurement is to be duplicated or triplicated such signals shall be
separately fed to the different input modules.
b) Signals, after due security and validity checking by means of voting, averaging,
median, difference monitoring or similar technique shall be used for control functions.
c) Where duplicated measurements are used, provision shall be there for selecting any
one as the duty signal. Continuous monitoring of difference between the signals shall
be made.
d) Signals shall be verified against cable failure.
8.7.8 Design of Enclosures
Design of outdoor enclosures shall be weather proof, dust-tight, drip-proof and shall take
into account the environmental conditions.
Enclosures shall be adequately sized so that the maximum permissible temperature rise
above ambient is 10 OC (maximum).
Enclosures design shall also take into account greatest possible personnel safety.
8.7.9 Electrical Noise Control
Equipment furnished by Contractor shall incorporate necessary techniques to eliminate

problems caused by electrical noise interferences and power line borne surges
encountered in power plant environment. Equipment, which is vulnerable to electrical
noise interference or surge, shall be suitably immunized to eliminate possible problems.
8.7.10 Surge-Protection for Solid State Equipment
All solid-state equipment shall be able to withstand the surges inherent in a working
environment. Equipment shall be designed to successfully withstand surges without
damage to components and/or wiring on application of surge wave whose shape and
characteristics are defined in ANSI publication C37.90-a (IEEE-472-1974) entitled "Guide
for Surge Withstand Capability (SWC) Tests".

To immunize the system against surge, coupling free- wheeling diodes, surge
suppressors, optical / galvanic isolators shall be used as required.
8.7.11 Panels, Cubicles and Enclosures
8.7.11.1 General
a) All panels, cubicles and enclosures shall be furnished complete with integral piping,
internal wiring, convenience outlets, internal lighting, grounding, ventilation, space
heating, vibration isolating pads and other accessories.
b) Unless otherwise specified cable entry for panels / desks / cabinets shall be through
bottom via glanding plate. Fireproof seal shall be used to seal the bottom to prevent
entry of dust.
c) Panels and cabinets shall be constructed from steel sheet reinforced as required to
provide true surface and adequate support for devices mounted thereon. Thickness
of the steel plate shall conform to the requirements of UL 50 or equivalent standard.
Panels and cabinets shall be of adequate strength to support mounted components
during shipment and to support a concentrated load of 100 Kilograms on their top
after erection.
d) Panel/ cabinet shall have eyebolt on top for lifting.
8.7.11.2 Surface Preparation and Painting
Sheet metal exterior steel surfaces shall be sand blasted, ground smooth and painted as
specified below:
Suitable filler shall be applied to all pits, blemishes and voids in the surface. The filler
shall be sanded so that surfaces are level and flat; corners are smooth and even.
Exposed raw metal edges shall be ground burr-free. The entire surface shall be blast
clean to remove rust and scale. Oil, grease and salts etc. shall be removed from by one
or more solvent cleaning methods prior to blasting.
a) Two spray coats of epoxy primer surfacer shall be applied to all exterior and interior
surfaces, each coat of primer surfacer shall be of dry film thickness of 1.5 mil. A
minimum of two spray coats of final finish color (Catalyzed epoxy or polyurethane)
shall be applied to all surface of dry film thickness 2.0 Mil. The finish colors for
exterior and interior surfaces shall conform to the following shades:
i. Exterior – RAL 7032
ii. Interior - Brilliant White.
b) Paint films, which show sags, cheeks, blisters, teardrops, fat edges or other painting
imperfections shall not be acceptable.
8.7.11.3 Wiring
Wiring within the panels shall conform to NEC standards and shall be factory installed
and tested at the works. All interior wiring shall be installed neatly. Features shall not be
limited to the following :
a) All spare contacts of relays, switches and push buttons shall be wired up to the
terminal blocks.
b) Each wire shall be identified at both ends with wire designation as per approved
wiring diagram. Heat shrinkable type ferrules with indelible computerized print shall
be used with cross- identification.

c) Wire termination shall be made with insulated sleeve and crimping type lugs. All
external connections shall be made with one wire per terminal. Wire shall not be
spliced or tapped between terminals. Open-ended terminal lugs shall not be used.
d) Internal wiring should be terminated uniformly on one side of the terminal block
leaving the other side available for termination of outgoing cables.
e) Analyzer measuring lead wires, or any other lead wires carrying measuring signal of
the order of low millivolt or micro volt shall be electrically and physically isolated from
other AC and DC wiring.
f) All low-level signal cables shall be separately bundled from control cable.
g) Wires shall be dressed and run in troughs with clamp-on type covers. Wirings shall
be neatly bunched in groups by non-metallic cleats or bands. Each group shall be
adequately supported along its run to prevent sagging or strain on termination.
h) Shield wires shall be terminated on separately.
i) Common connections shall be limited to two wires per terminal.
j) Wiring to door mounted devices shall be provided with multi-strand wires of (49
strands minimum) adequate loop lengths of hinge-wire so that multiple door openings
will not cause fatigue to the conductor.
k) Wiring shall be arranged to enable instruments or devices to be removed and/or
serviced without disturbing the wiring. No wire shall be routed across the face or rear
of any device in a manner, which will impede the opening of covers or obstruct
access to leads, terminals or devices.
l) Panel internal wiring shall follow distinct color-coding to segregate different voltage
levels viz. 24V DC, 48V, 110V AC, 240V AC, 220V DC etc.
m) Panels/ cabinets/ desks shall be provided with removable gasketted cable gland
plates and cable glands. Split type grommets shall be used for prefab cables.
n) Wire shall be multistranded annealed flexible high purity copper conductor with heat
resistant FRLS PVC insulation and shall pass vertical flame test per IPCEAS-1981.
o) Wire sizes used for internal wiring shall not be lower than the followings :
i. Control wiring : 1.5 Sq.mm
(switchs, pushbuttons etc.)
ii. Power supply/ receptacle : 2.5 sq. mm or higher as per load.
 illumination wiring
iii. 4-20mA DC current : 1 Sq. mm
 and low voltage signal
 up to 48V DC
p) Identification of conductors shall be done by insulation color-coding identified on
drawings or by printed wiring lists.
q) All cables terminated in the terminal block (both signal cables and power cables)
shall be ferruled. Ferruling shall be double cross ferruling, i.e., source and destination
addresses shall be marked on both sides of the tube ferruling.
8.7.11.4 Grounding
a) System cabinet AC and DC ground shall be electrically isolated from each other and
also electrically isolated from the Instrumentation signal ground. All the above ground
shall be individually connected to the single point on the ground pit. Dedicated
redundant earth pit shall be provided which shall be away from the HV equipment.
This earth pit shall not be shared with other electrical equipment ground and shall
also be insulated from other electrical system ground to ensure single point
grounding of the system. Grounding resistance shall be better than 1.0 ohm. IEEE
guideline shall be followed while designing the grounding system.
b) Panels and cabinets shall be provided with a continuous tinned copper ground bus
bar of minimum 25 mm x 6 mm cross section, extending along the entire length of the

panel / desk / cabinet assembly. The ground bus shall be bolted to the panel
structure and effectively ground the entire structure.
c) The panel/ desk/ enclosure/ JB ground shall have two (2) bolt drilling with GI bolts
and nuts at each end to connect to GI/ copper flat ground riser by means of insulated
copper ground cable of required cross section with lug.
d) Circuits requiring grounding shall be individually and directly connected to the panel
ground bus.
e) For electronic system cabinets, the electronic system ground bus shall be similar but
insulated from the cabinet and shall be separately connected to the system ground.
Signal cable shields shall be grounded at the panel end only and shall not be left
open. The ground in between panels of a shipping section shall be firmly looped.
f) Electrical meters, relays, transmitters and switching devices, operating at a voltage
less than 50V may be grounded through the steel structure.
8.7.11.5 Panel / Cabinet/ Desk/ Enclosures Environmental Protections
a) Panels, cabinets, desks, distribution boxes, terminal boxes and all other field
mounted equipment / enclosures shall suit the environmental condition of the area
and shall not Be inferior to the requirement indicated in the following table:
Sr.
Location Enclosure type
No.
Indoor type non-ventilated enclosure in
1. IP-54
non-hazardous area
Indoor type ventilated enclosure in non-
2. IP -42
hazardous area
IP-22 with suitable canopy at top to
3. Enclosure in Air conditioned area
prevent ingress of dripping water.
4. Outdoor type in non-hazardous areas IP-65
As per requirements of the NEC /
6. Outdoor in hazardous areas
IS Code for the location
b) The construction of electrical enclosures located in areas subject to conditions

classified in the National Electrical Code (NEC)/IS Code as hazardous shall be of a
type designated suitable for the environment in which they are located.
8.7.11.6 Terminal Blocks
a) Terminals shall be chromated galvanized DIN rail mounted screwless cage clamp
type. Terminals shall have screwed connection for conductor cross-section above 2.5
mm2. Terminal blocks shall conform to IEC 947-7-1.
b) The characteristics of the terminal blocks shall be as follows.
i. High contact force, independent of conductor cross-section and large contact
surface area.
ii. Self-loosening protection.
iii. Resistant to thermal aging and vibration.
iv. Low and constant voltage drop
c) Tension spring shall be made of high quality, non-rusting, acid-resistant steel. The
current bar shall be of tin-lead plated copper or brass.
d) Terminals shall be of non-flammable suitable thermoplastic material such as
polyamide.
e) Terminal blocks shall be mounted vertically in panels and cubicles with clearance for
at least 100 mm between two sets and between wall and terminal block.

f) Terminal blocks shall be provided with white marking strips / self-adhesive marker
cards. Power terminals shall have protection covers.
g) At least 20 percent spare unwired terminals shall be provided for all panels /cabinets
/desks /junction box etc. This shall be in addition to 20% spare wired terminals of
spare IO channels and 10% wired spare modules.
h) Bottom of the terminal block shall be at least 200 mm above the cable gland plate for
bottom entry type panels.
i) For extending 24 V DC supply to panels, the size of the terminals shall be decided
based on voltage drop and not based on current.
j) Other requirements of the terminal blocks are as follows.
k) The last block in a rail-mounted assembly shall be closed with an end plate and end
bracket.
l) For visual and electrical separation of terminal groups, partition plates shall be
provided,
m) which can be push fitted after forming an assembly.
n) Design shall permit testing of incoming and outgoing signals by using suitable test
plug and socket without disconnecting the cable connections.
o) It shall be possible to use jumper plugs through the test plug socket to connect
adjacent
p) terminals.
q) Where more than one connection to a terminal block is required, two tier terminals
shall be used.
r) Terminal blocks shall be of different colors depending on voltage levels.
8.7.11.7 Nameplates and Labels
a) Each item shall have permanently attached to it, in a prominent position, a rating
plate of non-corrosive material upon which is to be engraved the manufacturer's
name, equipment, type / model number, range, serial number, together with details of
the loading conditions under which the item of plant in question has been designed to
operate.
b) Such nameplates or labels are to be of white non-hygroscopic material with engraved
black lettering, or alternatively of transparent plastic material with suitably colored
lettering engraved on the back.
c) The nameplates shall be held by self-tapping screws. The size of nameplate shall be
approximately 20 mm x 75 mm for equipment and 40 mm x 150 mm for the panels.
d) Items of plant such as valves, which are subject to handling, are to be provided with
an engraved chromium plated nameplate or label with engraving filled with enamel,
suitably mounted or as fixed with strong rustproof chain.
e) All such nameplates, instruction plates, lubrication charts etc. shall be with English
inscriptions.
8.8 Metering Bases And Chart Units
The following system of units shall be followed for various displays and scales unless
otherwise mentioned:
i) Pressure : Kg/cm2
ii) Differential Pressure : mm of H2O column / Kg/cm2
iii) Draught : mm of H2O column
iv) Vacuum : Kg/cm2 (abs)/ mm of Hg column
v) Temperature : Degree Celsius (O C)
vi) Flow (Water) : Tonnes / hr, M3/Hr
vii) Flow (Oil) : M3 / Hr, Liter/ Hr
viii) Flow Air : Tonnes / hr / M3 / Hr.

ix) Density : gms / c.c.

x) Level : Mm /%
xi) Conductivity : Siemens / cm
xii) Dissolved Oxygen / Silica / Sodium : ppm /ppb
xiii) Turbidity : NTU
xiv) Residual Chlorine : ppm
xv) UV Transmittance : %
8.9 Process Connection & Instrument Hook Up
Instrument connection to the process system (piping, vessel etc.) shall be according to
the process & piping specification up to and including the root valves. Root valves shall
be installed as close as possible to the piping or vessel.
Each instrument shall have its own independent connection to the process except for
instruments located on standpipe. Each instrument shall be connected independently to
the standpipe through isolation valve.
Isolation and drain valves adequate for duty and capable of withstanding continuous
design condition of main process shall be provided. For process pressure equal or above
40 kg/ sq.cm double blowdown valves shall be used connecting to blowdown header.
Instrument manifold / gauge valve shall be installed close to the instrument.
Process connection for instruments lines and vessels shall be in accordance to

standards such as ASME or other recognized international standards. Table below
indicates the type of connection generally to be used.
Instruments Equipment / Pipe Side Instrument Side

Level Instruments
Internal Displacer 4‖ - Flanged 4‖ - Flanged
External Displacer 2‖ - Flanged 2‖ - Flanged
Level gauge ¾‖ -Flanged ¾‖ - Flanged
DP Type ½‖ (min.)-welded ½‖- NPT
External cage Level switch 1‖- welded 1‖- welded
Flow Instruments
DP Type ½‖ - welded in general ½‖ - NPT
Pressure Instruments
Conventional ½‖ (min.)-welded ½‖ - NPT
Diaphragm type- Fuel Oil
3‖- Flanged 3‖- Flanged
application
Temperature Instruments
Generally - M 33 X2 (M) ½‖ NPT
Thermowell
1½‖ Flanged- For air path
application
Analyzer
Liquid analyzer ½‖- 1‖ - welded ½‖

Separate stubs and take-off points with thermowell / root valves shall be provided for
performance guarantee test.
Impulse pipes shall be clamped at suitable interval not exceeding 1.5 meter. Process
pipe shall not be used for supporting the impulse pipe.
Fittings shall conform to ANSI B 16.11. Threads of piping component shall be of tapered
construction.
Instrument blowdown header shall in no case be lower than the material grade ASTM A
106 Gr. C.
Impulse pipe shall be laid at least with slope of gradient 1:10 to avoid any air pocket or
water accumulation.
Expansion loop shall be provided at the end of each termination.
Orientation of tappings shall be as follows:

a) For liquid service within 45 O at lower half of the pipe horizontal plane.
b) For air service within 90 O at upper half of the pipe horizontal plane.
As a rule tap orientation of high and low pressure side should be parallel and
symmetrical.
Pressure & Differential pressure instruments in liquid services shall be located below the
taps and the piping shall be sloped to avoid formation of air pocket.
Pressure & Differential pressure instruments in air service shall be located above the
taps and the piping shall be sloped back to process to avoid formation of any liquid.
Impulse pipe including taps for coal mill application shall be provided with air purge
connection. Differential instruments for such application shall have continuous and as
well as intermittent purging. Whereas, pressure measurement shall have only
intermittent purging.
Material of impulse pipe for the instruments mounted on rack and enclosure shall be
same as that of main process pipe except stainless steel tube of Gr. 316H or better shall
be provided for connection in between impulse pipe (from tee connection on impulse
pipe) and instrument manifold valve & instruments. Impulse pipe, tubes, fittings and
accessories shall have the same design pressure and temperature applicable for the
related main pipe.
A. Site Conditions
 Temperature and Humidity Range. The equipment shall be installed in an
environment having a temperature range of 0 °C to 55 °C and a maximum relative
humidity of 100 % (noncondensing). The Contractor shall use, where required, fans,
heaters, and air conditioning units to maintain a correct working temperature for his
equipment. All Parts of the equipment shall be constructed of materials or treated to
prevent the formation of mould, fungus or any corrosion over the temperature and
relative humidity ranges specified.
 EMI/RFI Noise Immunity. The equipment to be provided shall be adequately
protected against interference from the use of radio transmitters, at any point external
to the equipment housings and no malfunction of the equipment shall result from this

cause. Responsibility for the correct and reliable operation of the equipment shall rest
with the Contractor, who must ensure that the equipment is adequately protected
against the ingress of radiated, mains-borne signal-borne interference.
 Generated Interference. The Contractor shall ensure that the computer,
instrumentation and communications equipment conforms to BS EN 50081-1or
equivalent Indian Standard for noise emissions.
 Coordination. The Contractor shall check with other trades to ensure that equipment
and material can be installed in space provided. Provide other trades with information
necessary for them to execute their work. Details on Drawings, which are specific
regarding dimensions and locations, are for information purposes. Coordinate with
other trades to ensure work can be installed as indicated.
 Sequencing. The Contractor shall make applications to the local telecommunications
Service Provider for provision of communications and coordinate with the sub-
contractor responsible for installation of power supply services under this contract.
Applications shall be made in time to ensure services are available for installation
and commissioning of the telemetry equipment.
B. Panel Details
I. Enclosures and mounting boards
Enclosures shall be any form of board, cabinet, panel, desk, box or case used to
protect, contain or group instrumentation, telemetry or control equipment.
All equipment in or on enclosures shall be arranged logically and, as far as possible,

symmetrically, with projections kept to a minimum. Each enclosure and board shall
be designed on ergonomic principles and shall permit in-situ and safe access for any
normal adjustment, maintenance and servicing. The tops of plant-mounted
enclosures shall be sloped downwards from front to rear.
Enclosures mounted inside buildings shall have a minimum rating of protection to

IP 54.
Enclosures for use outside buildings or in places where splashing may occur shall
have a minimum rating of protection to IP 65 and have tops which project sufficiently
to protect the vertical faces of the enclosure and any component mounted thereon
from splashing, inclement weather and direct sunlight. Also, when enclosures for use
outside buildings are located where exposure to direct sunlight will give rise to high
top-panel surface temperatures such that the internal temperature rises above the
manufacturer‘s recommendation (normally 40°C), the enclosure shall include a sun
shield fitted to the top of the enclosure. The sun shield shall prevent direct sunlight
from reaching the instrumentation for the full day throughout the year, and shall have
louvered ventilation.
Fixing arrangements for surface-mounting enclosures shall be external to the

enclosure and shall ensure that the rear face of the enclosure is not in contact with
the surface to which it is fixed.
Enclosures shall have hinged access doors, fitted with recessed lockable handles.
Doors shall be of rigid construction and provided with close-fitting flexible seals in
recesses to prevent the ingress of liquids, moisture, dust and vermin. Hinges shall be
of the lift-off pattern and one hinge shall engage before the other for ease of fitting.

Wherever necessary, removable access covers secured by quick-release fasteners

shall be provided to ensure ease of maintenance for all installed apparatus.
Mounting plates, brackets and racks shall be provided for all other internal equipment
which shall be hinged or otherwise arranged with quick-release fasteners or captive
screws to give quick and easy access to equipment, securing screws, terminals and
wiring.
Enclosures for two or more devices with electrical circuits shall have gland plates and
terminal blocks as specified elsewhere.
Each enclosure shall be designed for the safe testing and servicing of equipment with
the power on. Each part which may be live under any circumstances shall be so
covered or shielded as to prevent inadvertent contact.
II. Panel design and construction
Unless otherwise specified, all instrument panels, instrument cubicles, control panels,
control consoles and desks, associated equipment and terminal racks, telemetry and
electronic equipment racks and the like shall be free-standing, floor mounted units
and shall conform to the requirements of this part and will hereafter be referred to as
panels.
The design and dimensions of control consoles and desks shall be determined
according to their intended function and shall be in accordance with the requirements
of the Specification. The height shall not exceed 1400mm above the finished floor
level.
Unless otherwise specified the height of panels shall be not greater than 2130mm
overall (excluding lifting devices) above finished floor level.
Controls, switches and push-buttons shall be positioned below or adjacent to any

associated reading instrument. Panels for use in locations such as pumping stations
and machinery rooms shall have anti-vibration mountings.
The clearance between the extremities of apparatus mounted on the internal walls
shall allow safe and unobstructed access to all terminals and to parts requiring
maintenance.
Panel layout drawings shall normally include a list of all instruments, accessories and
components contained therein. If the drawings have insufficient space for the list, a
separate schedule of instruments, accessories and components shall be provided
and the panel drawing shall contain a cross reference to the contents list and an
indication of the panel location of each item on the list.
III. Panels - Major
Panels shall be constructed generally as specified in the preceding clause. Panel

material shall be prime-quality, cold-rolled and annealed mild steel or zinc-coated
mild steel sheet, suitably braced and stiffened as necessary with flat bar or angle to
form a rigid structure.
Panel fronts shall be flat and free from bow or ripple. Exterior corners and edges
shall be rounded or welded and ground to give a smooth overall appearance.

Flanged edges shall be straight and smooth.
Materials shall be chosen with due regard to the panel size, number of cut-outs,
instrument weight and position of center of gravity and method of fabrication, with the
following minimum thickness:
 instrument bearing surfaces, gland plates and pneumatic distribution plates,
3mm;
 internal mounting plates, 3mm;
 doors, covers and filler panels, 2mm as a minimum.
No design involving the use of externally-visible assembly or fixing bolts and screws
or any design resulting in dust or water-collecting crevices will be accepted.
When a panel is constructed in sections, the sections shall be designed for ease of
assembly during installation and, in any case, shall not exceed 2m in length. All
panels shall have a minimum width of 900 mm and shall not exceed 2mtr in length in
any case. All necessary nuts, bolts, washers and the like shall be supplied and
included in the same shipment as the relevant sections. Sections exceeding 1m in
length shall be provided with double doors.
Each panel shall be mounted on a self-draining base frame fabricated from 150mm
deep, steel channel section which shall be drilled or provided with clamps for bolting
to the floor. The base frame shall be set back from the panel front face to give a toe
space of not less than 25mm. The outside of the base frame shall be covered with an
approved kicking strip.
Ceiling and other filler panels shall be fabricated from sheet steel and adequately
stiffened. Each section shall have 50mm returned edges along all four sides and
shall be braced to the main steelwork of the panel.
A chequer- plate floor shall be provided inside and above the level of the base frame,
having openings suitable for the bottom entry of cables when applicable.
Sufficient removable un-drilled gland plates, in sections convenient for handling, shall
be fitted close to the appropriate terminal blocks and not less than 230mm above the
panel floor or not less than 230mm below the panel top. The gland plates shall have
removable side covers giving access to both sides of the gland plate and ensuring
vermin-proof and dust-proof construction. Gland plates of a surface mounted
enclosure may form a part of the base or top.
Panels containing instruments using a fluid as the transmission medium shall have
distribution plates with bulkhead unions for the termination of internal and external
pipework.
All doors shall open outwards and all doors in one panel assembly shall use the
same lock and key combination.
Panel design shall ensure adequate ventilation and air circulation without permitting
the entry of vermin or dust. Panels installed in control rooms or other clean condition
areas shall have louvres to allow air circulation. Temporary closures shall be
provided to prevent the entry of dust and vermin during transit and installation. After
commissioning has been completed, all entries except air circulation louvres shall be
sealed.

No equipment other than front-of-panel items shall be mounted on panel wall

surfaces.
If electrical and non-electrical instruments are mounted in the same panel, the panel
shall be subdivided internally to separate the electrical and non-electrical sections.
All connections shall be arranged to ensure that no accidental damage to cabling or

electrical components can occur in the event of failure of any non-electrical
component or connection.
Provision shall be made for safe and easy handling during transit and installation.
If lifting eyes are provided, they shall be reversible and panel tops shall be reinforced
where necessary.
Where equipment is specified to be installed at a future date, space shall be

allocated, and cut-outs with removable masking plates, brackets, supports, wiring,
terminals and piping and the like shall be provided.
Panels shall be finish-coated at the place of manufacture before commencing the

installation of apparatus and other fittings.
IV. Panels - Minor
Panels for installation on the Plant which contain relatively few items of equipment, or
where so specified elsewhere, shall be classed as minor panels and shall be
constructed generally as specified in the preceding clause and comply with this
Clause.
Panels shall be fabricated from sheet steel or other approved material less than
2.5mm thick suitably braced to form a robust and rigid structure. Exterior corners and
edges shall be rounded to give a smooth overall appearance and assembly bolts,
screws or rivets shall not be visible on the front face.
The design shall be such as to ensure adequate ventilation and air circulation where
required, without permitting the entry of vermin. Openings for cables shall be made
vermin-proof. Doors shall be hinged and shall be provided with close-fitting flexible
seals in recesses to prevent the ingress of liquids, moisture, dust and vermin. Unless
otherwise specified, panels shall be suitable for floor mounting and shall not exceed
2130mm in height. Where surface-mounted panels are provided, the fixing shall
prevent the ingress of moisture and the rear of the enclosure shall be not less than
10mm from the wall.
Lifting eyebolts shall be removed, issued to the Purchaser and subsequently

replaced with bolts after installation.
Panels shall be extensible, and symmetrically arranged as far as possible with

projections kept to a minimum. Where two or more panels are fitted together, they
shall form a flush-fronted continuous panel of uniform height. Front door and top
cover dimensions shall match. Instruments, relays, and control devices shall be
mounted at a height not more than 2000mm and not less than 300mm from floor
level.

The arrangement of equipment within each enclosure shall be such as to permit easy
access for installation and maintenance. No instruments, relays or other components
shall be mounted on rear access doors or removable covers.
V. Panels - Composite
In situations where space limitations preclude the use of separate instrumentation,

control and automation (ICA) and switchgear panels and, at the sole discretion of the
engineer, ICA equipment may be combined within a single enclosure subject to the
following conditions:
 The observance of all other clauses herein relating to enclosures, mounting
boards and minor panels;
 The written assurance of each supplier of ICA equipment that the proximity of the
switchgear will have no detrimental effect on the life or performance of any ICA
component;
 The total segregation of ICA equipment and switchgear including the glanding
and termination facilities;
 The absence of any voltage exceeding 250vac or 50vdc from any compartment
containing ICA equipment;
 The use of the full height of the panel (excluding the bus bar chamber and Cable
space) for any ICA equipment compartment.
VI. Panel Protection
Adequate facilities for isolation and protection by miniature circuit breaker or fuse for
each instrumentation and control circuit and sub-circuit shall be provided and shall be
so arranged that any interruption causes minimum disruption of plant, operates the
appropriate alarm and cannot result in any unsafe operating condition.
All fuses shall be of the cartridge pattern and main fuses shall be of the high
rupturing capacity type. Fuse and solid-link carriers and bases shall be of plastic
molded insulating material of an approved make. Ceramic materials will not be
accepted. Live connections shall be efficiently shrouded and it shall be possible to
change fuses with power on without danger of contact with live metal. The fuses shall
be rated to give maximum protection to the equipment in circuit and the rating shall
be permanently inscribed on the fuse label and on the fuse carrier. Unless necessary
for the protection of particular equipment, miniature circuit breakers used for
individual circuits in a panel or control desk shall not trip on over-voltage or under-
voltage.
Bases for solid links shall not be interchangeable with those for fuses. Fuses and
links in the same circuit shall be mounted opposite each other in separate adjacent
rows and shall not alternate in the same row. At least 10% and not less than two
unallocated miniature circuit breakers or fuses and links shall be provided in each
panel distribution board. Miniature circuit breakers and fuses of similar size and
rating shall be of the same make and type.
At least 20%, and not less than two, spare fuses and links of each rating shall be
provided and fitted in clips inside the panel.
Each instrument requiring a power supply shall be individually wired and protected so
that, in the event of a failure in one circuit, the remainders are unaffected. Power
supply circuits shall be of sufficient rating that any protective device may operate

without reducing the voltage at the terminals of any other component to an

unacceptable level.
VII. Panel isolation
Clearly-labelled isolating circuit breakers shall be provided for each incoming power
supply. Switches shall be of the quick make-and-break type with 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.
Circuit breakers for panel power supplies shall be mounted near an access point and
in positions where they may be operated easily from a standing position.
Plug-in isolating links or devices of an approved type shall be provided in any circuit
that may still be live when the power supply isolators are in the ‗off‘ position, as, for
example, in circuits controlling equipment whose power supply is independent of the
panel. Such links or devices shall be properly screened and, if not incorporated in or
adjacent to their associated outgoing terminals, shall be labeled with suitable warning
notices.
Any item of panel equipment to which panel internal wiring is connected with a plug
and socket instead of terminals shall be wired in flexible cable of adequate rating
between the ‗free‘ plug and a socket mounted adjacent to the device.
The power supply connector shall be a socket.
VIII. Panel terminal blocks
External wiring for panel power supplies shall be terminated on the appropriate
isolator. Signal cables from strain gauges, analyzers, resistance thermometers,
retransmitting slide-wires and thermocouples may be terminated at their appropriate
instruments.
A terminal block shall be provided as the interface between the corresponding

conductors of each internal and external wire and each internal and external
connection except those listed above. The terminal blocks shall be mounted vertically
where possible and not nearer than 230mm to the floor or less than 230mm from an
incoming cable gland.
Terminal block rows shall be spaced apart by not less than 150mm and arranged to
permit convenient access to wires and terminals and to enable ferrule numbers to be
read without difficulty.
Other circuits shall be grouped on the terminal blocks according to the classification
given in the clause for ‗Panel internal wiring‘ which shall be clearly marked along the
corresponding section of each terminal board. Groups of different voltages on the
same board shall be separated by insulated barriers.

All connections shall be made from the front of terminal blocks and no live metal shall
be exposed at the back. All terminal blocks shall be of the type which clamps the wire
securely and without damage between two plates by means of a captive screw and
which permits removal of any terminal without disturbance to adjacent terminals.
Pinch-screw type terminal blocks will not be accepted. Terminal moldings shall be in
melamine to BS 1322, polyamide or equivalent. Terminal rails shall be hot-dip
galvanised. Current bars between the two connection points of each terminal block
shall be of copper or brass with tin/lead alloy plating. All steel parts shall be zinc-
plated and passivated with a yellow chromate layer. Terminal blocks for input and
output analogue signals and for circuits containing volt-free contacts internal or
external to the cabinet shall be of the Klippon type SAKC or equivalent which permit
the connection of a test millimeter or continuity meter without disconnecting any
wiring. Terminal blocks for power supplies for equipment external to the panel shall
permit the isolation of the item of external equipment without affecting the operation
of any other circuit within or outside the panel.
No more than one core of external cables or two internal wires shall be connected to
any terminal. If terminal blocks are used as common points for two or more circuits,
individual terminals with the appropriate number of permanent cross connections
shall be provided. The lengths of exposed cable cores shall be sufficient to reach any
terminal in the appropriate row or rows. The cores shall be formed into a neat loom
and a separate loom shall be provided for each cable.
Each row of terminal blocks shall contain at least 20% spare terminals over the
number required for terminating all cores of external cables in that row. Unless
otherwise specified, each external cable shall contain at least 20% spare circuits,
with a minimum of one spare circuit.
Terminal blocks shall be numbered consecutively in a sequence different from that

used for identifying wiring. The terminal numbers, voltage grouping and terminal
board layout shall correspond precisely with wiring diagrams so that quick and
accurate identification of wiring can be made.
All the terminal boards shall be provided with covers of transparent insulating
material that does not sustain combustion and shall be sectionalised where possible
to give access to groups of terminals without uncovering all boards. Terminals which
may be live when the panel is isolated from its main supplies shall be suitably
labelled to minimise the risk of accidental contact.
IX. Panel internal wiring
Panel circuits shall be segregated into the following categories:
Group 1: Power control and very-high-level signal wiring (above 50V):

1.1 ac power supplies;
1.2 dc power supplies;
1.3 ac current signals above 50mA (such as CT circuits);
1.4 ac voltage and control signals above 50V (such as PT circuits).
Group 2: High-level signal wiring (6V to 50Vdc):

2.1 signals from conventional electronic transmitters and controllers (such as digital
or 4mA to 20mA);
2.2 circuits to alarm annunciators and other solid-state devices
2.3 digital signals;

2.4 emergency shut-down and tripping circuits;

2.5 on/off control circuits;
2.6 intrinsically safe circuits;
Group 3: Low-level signal wiring (5V dc and below):

3.1 signals from thermocouples;
3.2 signals from resistance thermometers and re-transmitting slide-wires;
3.3 signals from analytical equipment and strain gauges.
For Group 3 wiring, internal connections to the instruments shall be made by one of
the following methods:
(a) The twisted, screened conductors of the external cable shall be led direct to their
appropriate instruments via ducting systems installed for this purpose during
construction of the panel;
(b) The conductors of the external cables shall be terminated on terminals
segregated from all other categories and the connections to the appropriate
instruments shall be made using twisted pairs with individual screening installed for
this purpose during construction of the panel.
Internal wiring for all circuits in Group 2 except those sharing a common connection
shall be multi-stranded, twisted pair, 0.75mm² minimum copper conductor with HPDE
or PVC-insulated cable of adequate grade and rating.
Wiring for circuits in other Groups or sharing a common connection shall be run in
stranded, 1.0mm² minimum copper conductor with 250V grade, PVC-insulated cable
of adequate grade and rating.
Wiring sheath colors shall be black for ac circuits, and grey for dc circuits (excluding
thermocouple circuits) and blue for Group 2.6 circuits. Circuits supplied at 240V,
between 240V and 110V dc shall also be physically segregated from each other and
from other circuits. Access to wiring and components of circuits having voltages
exceeding 240V shall not be possible unless and until the circuit has been isolated.
Separate ducts, trunking, cable looms, tray work and the like shall be provided within
the panel for each category with at least 150mm between parallel paths of Group 1
and those of any other Group. Intrinsically-safe circuits and their terminals shall be
segregated from other circuits and terminals.
All wiring shall be neatly and securely fixed by insulated cleats, bunched and secured
by approved plastic strapping or run in approved insulated wiring trunking or non-
corrodible flexible tubing. Not more than 75% of the capacity of trunking, ducts,
looming, or tubing shall be used. Insulated earth wiring shall be so arranged that
access to any equipment or connection point or the removal of any item of equipment
is unimpeded.
Wiring for future equipment shall be secured and terminated on terminal blocks.
Lacing for wiring looms shall be of rot-proof cord or plastic strips. Inter-section wiring
in multi-section cabinets shall be via a terminal block in each section.
X. Panel wiring identification and termination
Identification ferrules shall be fitted at both ends of each wire. The numbers or letters
used shall correspond with the appropriate wiring diagram. The ferrules shall be of

plastic insulating material with permanent black characters on a color coded

background for numbers and on a white background for letters, unaffected by oil or
water. They shall be so arranged that they can be read logically from left to right
when viewed normally.
The system of wire identification shall be such that wires in the same circuit on
opposite sides of a terminal shall have the same reference, and this system shall be
continued through all external cabling.
Terminal ferrules (spade, tongue, crimped connections) shall be provided on each

conductor.
XI. Panel Earthing
A continuous copper earth bar of not less than 25mm x 6mm cross section shall run
the full length of each panel and shall be securely fixed and bonded electrically to the
main frame. The cable gland-plates and the earth bar shall be provided with suitable
brass terminals of not less than 6mm diameter for connecting the metal cladding or
armoring of all incoming and outgoing cables to the station earthing system.
A second continuous copper earth bar of not less than 25mm x 6mm cross section,
electrically isolated from the steelwork of the panel and metal cladding and armouring
of cables, shall be provided for earthing the signal earth connection of each
instrumentation and control device and the screen(s) of each instrument cable not
earthed elsewhere to the station instrumentation earth plate. The earth bar shall have
sufficient brass terminals as specified above for each instrumentation and control
device and the screen of every shielded cable plus 25% spare terminals.
In multi-section panels, each earth bar shall be electrically bonded to the

corresponding bars in the adjacent section(s).
The earth pit for instrumentation system shall be separate. Electric earth pit shall not
be used for earthing of instrumentation equipment. All signal cable screens
(analogue and digital) shall be terminated onto the instrument earth bar. Signal cable
screens shall be earthed at the control panel end only. Screens at the field end shall
be tied back and insulated.
SPD s associated with the control and instrumentation system shall be earthed to the
instrument earth in accordance with the SPD manufacturer‘s recommendations.
XII. Panel lighting
Each panel shall be adequately illuminated internally, as evenly and as free from
dazzle as possible, by fixed LED lighting controlled from totally-enclosed light
switches and by totally-enclosed door-operated switches positioned so as not to
interfere with access. The control switch for an inspection lamp shall form part of the
lamp assembly. Lighting circuits shall be fused independently of any instrumentation
and control circuit and designed to allow lamps to be replaced safely and shall be fed
from a distribution board and circuit breaker connected on the live side of the main
panel ac supply circuit breaker.
XIII. Panel ventilation

Each panel shall be provided with ventilation fans as required to ensure that
equipment within the panel is maintained within manufacturer‘s recommendations,
with due regard to the environment in which the panel will be mounted. Fans shall be
controlled by a suitably-labelled enclosed switch mounted internally in an accessible
position.
Fans shall be mounted with their axes horizontal and shall be arranged to draw clean
air into the panel. Air entries shall have filters which can be renewed from outside the
panel and shall be designed to prevent the entry of rain, spray, injurious fluids, sand
or dust.
XIV. Panel labels
All control gear shall be fully labelled, identifying the equipment designation/function,
all external and internal components, all rating data, detailed equipment operating
data and for danger and hazard warning.
Labels shall be provided for every panel to describe the duty or otherwise identify the
panel and its sections and every instrument, component and item of equipment
mounted internally and externally. Where applicable, front-of-panel labels shall be as
detailed in the Specification. Wording shall be clear, concise and unambiguous and
shall be subject to review by the Employer Representative before manufacture. Each
label shall be permanently secured to the surface near the item to which it refers.
Externally-fitted labels shall be of Perspex or other approved transparent plastic, with
letters and numbers rear-engraved and filled with black.
The rear surface of each Perspex label shall be finished with a coat of paint of the
same colour as the panel external finish. Instrument duty labels fitted externally shall
be below the item to which they refer. Embossed tape or similar adhesive labels will
not be approved.
Laminated materials or rear-engraved and filled plastic shall be used for internally
fitted labels, which shall be white with engraved black letters.
Labels conforming to the requirements of the preceding paragraphs or other
approved means shall be provided:
 To describe or identify circuits or circuit components;
 To identify dc polarity;
 To warn or remind about dangerous or potentially-dangerous circumstances;
 Wherever elsewhere specified.
Unless otherwise specified, all engraving shall be in plain block letters, minimum
4mm high.
The minimum practicable number of different sizes shall be used.
Note: Contractor shall note that Manufacturers‘ nameplates shall not be fitted on
panel external surfaces. Only equipment Tag I.D shall be located on the panel
exterior surface. The same is applicable for filed junction boxes, panels, etc.
XV.Panel Finish
All panels, desks and cubicles shall be hard, smooth, durable and finish free of
blemishes, shall be provided. Before painting, all external welds and any rough areas
shall be smoothed, and all surfaces shall be thoroughly cleaned and free from scale,
contaminates, corrosion or grease. If rust-proof or Zintec steel has not been used in

the construction, the panel shall be treated with a passivating agent such as
phosphoric acid. All internal surfaces shall have a minimum of three coats of paint of
which the first shall be an approved anti-rusting priming coat and the final coat shall
be an opaque gloss white enamel. All external surfaces shall have not less than five
coats of paint of which the first shall be an approved etch-priming coat, and the
second and third suitable undercoats, all of which shall be rubbed smooth when dry
before application of the next coat. The undercoats shall be easily distinguished in
shade or colour from the priming and finishing coats. The two final coats shall be of
stove enamel paint, gloss or semi-matt finish, to a colour and finish to be advised by
the Employer Representative. Stoving shall be carried out in accordance with the
recommendation of the paint manufacturer.
The overall dry film thickness (DFT) shall be between 85 and 120 microns.
Nuts, bolts, washers and other fixing devices which may have to be removed for
transit or maintenance purposes shall be galvanized or otherwise finished to an
approved standard.
C. Instruments and ancillaries

I. General
All instruments, gauges and control equipment which perform similar duties shall be
of uniform type and manufacture throughout the Works in order to facilitate
maintenance and the stocking of spare parts.
All equipment shall be fully tropicalized and suitable for the worst environmental
operating conditions. Panel-mounted instruments shall be of the electrically operated
flush mounted type and shall have damp-proof and dust-proof cases.
Instruments mounted outside instrument panels shall have weatherproof and

dustproof cases. Instrument cases shall be of corrosion-resistant material or finish.
Instrument screws (unless forming part of a magnetic circuit) shall be of brass or
bronze. Access to terminal compartments of instruments mounted outside panels or
other enclosures shall not expose any working part. Moving parts and contacts shall
be adequately protected from the ingress of dust. Where applicable instruments shall
be easily withdrawable from its housing for maintenance without interrupting its
signal.
Unless otherwise specified, instruments shall be finished in the manufacturer‘s

standard colour. Instrument dials shall be of such material that no peeling or
discolouration will take place with age under tropical conditions.
Plant-mounted indicators and gauges shall be sized to give full legibility when viewed
from a position with convenient and easy access or from the point at which any
operation requiring observation of the gauge is performed. The minimum diameter for
any gauge shall be 100mm except where forming part of standard instruments and
accessories such as air-sets.
Dials and bezels shall be of bronze and internal components shall be of stainless
steel, bronze or other corrosion-resistant material.
Unless otherwise specified, all functions shall be transmitted electrically and all
analogue signal-transmission systems shall be in accordance with BS 5863: Part 1 or
equivalent and shall use a signal of digital or 4mA to 20mA dc. Where possible,

measuring systems shall be designed so that any necessary power supply is taken
from the appropriate instrument panel.
Transmitting devices shall have integral indicators to monitor the output signal or
connections suitable for use with a portable test meter, and shall be capable of
meeting the performance requirements specified in the appropriate part of BS EN
60770-1or equivalent.
Equipment mounted in enclosures shall be suitable for continuous operation at the

maximum internal temperature possible in service, due account being taken of
internally-generated heat and heat dissipated by other plant. All components shall be
rated adequately and circuits shall be designed so that change of component
characteristics within the manufacturers‘ tolerances shall not affect the performance
of plant. All equipment shall be designed to operate without forced (or fan) cooling.
Equipment provided with anti-condensation heaters shall be capable of operating

without damage if the heaters are left on continuously. Unless provided with
unalterable factory configured ranges, measuring instruments shall have zero and
span adjustment.
Field mounted instruments shall be mounted such that they are easily viewable and
easily accessible for maintenance.
Instruments not mounted in panels shall be supplied complete with all brackets,
stands, supporting steelwork and weatherproof enclosures (separate from the
instrument cases) necessary for securing them in their working positions and
affording complete protection at all times including periods of servicing, adjustment,
calibration and maintenance.
Each installation shall incorporate a valve and pipework for obtaining a sample
representative of the fluid at the position of the permanent meter and drain. If the
measuring and sampling points are remote from each other, the test and sample
facilities shall be provided at both points.
In order that maintenance and inspection may be carried out safely and conveniently
instruments mounted in elevated and open work areas shall be provided with safety
ladders and a sufficiently sized working platform with sun shading.
a) Kilowatt-hour meters.
Kilowatt-hour meters shall comply fully with IS 722 or BS 5685 Class 2 and shall
have industrial grade accuracy (±2.5%). Three element units shall be used for 3
phase 4-wire systems. Two element units shall be used for 3 phase, 3-wire
systems.
Quantity : 1 No. for each pump and incomers of 3.3 kV (or more)
Switchboard (250 KW & above motors)
As per site conditions.
Purpose : Power and Energy Monitoring

It shall monitor voltage, current, kW, kVAr, kVA, power factor and frequency. The data of
these meters shall be communicated to the plant PLC based SCADA system for
monitoring.
Technical Particulars
Data logging
Data storage and it shall be retrieved via RS 485 port
Soft Integration
The meter shall be integrated with SCADA system to provide remote display of all
measured parameters and meter configurations. The metering shall be via. RS 485 port.
Measurement
 True RMS measurement
 Instantaneous phase voltages, line voltages, phase currents and line currents
 Frequency
 Active, reactive, apparent powers and power factor per phase and line
 Energy-Import and Export
 Maximum demand kVA, kW, kVAr
Communications
 RS 485
 Baud rates minimum 9600
Accuracy Class
 0.5 S
Accuracy Standards
 IS-14697:1999
Front Panel Display

 LCD with back lighting
 Display for all basic power and energy parameters
 Password protection for setup parameters
Ratings
Voltage Inputs
 50 to 347 VAC
 Accuracy VL-N: 0.25% reading
 Accuracy Hz : +/- 0.1 Hz
 Support 3 phase 3 wire, 3 phase 4 wire connections
 Standard screw in terminals
Current Inputs
 5 Amp. nominal
 Accuracy current: 0.25% reading
 20% over range full accuracy

Power Supply
 110 V to 240 VAC & VDC
Environmental Conditions
 As per process Requirement- Ambient Temperature.
 Humidity: up to 95% noncondensing
II. Indicator Lights
Indicator lights shall be not less than 20 mm diameter and shall be panel mounted
types with metal bodies adequately fastened so that the lamps shall be capable of
replacement from the front of the apparatus without disturbance to the lampholder or
panel wiring. Lampholders shall be keyed into panels to prevent rotation. Lens
colours shall comply with BS EN 60037 as follows:
 power on - white*
 running - green
 tripped/alarm - red
 status (open, closed, etc.) - blue
 ready to start - blue
 warning (no imminent danger) - amber
Note: *white may be used where doubt exists as to which other colour to use.
The lights shall be under-run to give long life either by use of a resistor to limit voltage to
90% normal value or by using higher voltage lamps.
The indicating lamps on control panel shall be cluster of LED's.
III. Pushbuttons
Colours of pushbuttons shall generally comply with IS 6875, BSEN 60947, 60037 or
IEC 60073 and in particular shall be as follows:
 stop, emergency stop - red
 start - green
 jogging/inching - black
 reset (when not also acting as a stop) - blue
 lamp test - blue
 override/alarm accept - yellow
D. Junction Boxes
I. Junction box (Instrument)
1 Construction - 3mm sheet steel hot

2 Protection - IP 65
3 Paint and shade - One coat of red oxide primer

Powder coated light grey as per

Shade 631 of is:5
4 Terminal strip - Elmex type capable of
Terminating 0.5 sqmm to 1.5 sqmm
Cable din rail mounted
5 No of terminal strips - 30/40/70
Rating:600v 10 a ac
6 Conduit & cable entry - Bottom side
7 Gland plant thickness - 3mm
8 Door of JB - Hinged with proper locking
Arrangement to avoid entry of
Dust & moisture the design of
Fixing screws of the lids of the
Junction box shall be such that
They do not come out of the lids
When completely unscrewed
(captive screws)
9 Dimension - Vendor to provide most
Economic dimension of JB based
On the no of Terminal bases and cable
Entry
10 Mounting - Frame mounted
11 Earthing - Two no of earthing bolts for JB
Earthing separate instrument
Earth bus on insulating clits to
be provided
12 Name plates - To be provided material: white
Engraved letters on black
Anodized aluminum sheet
Fixing: stainless steel screws
Lettering:- black with white
Engraved. Note: No vendor nameplate shall be
affixed to the junction box (exterior, interior)
II. Junction Box (Power & Control)
1 Construction - 3mm sheet steel hot

2 Protection - IP 65
3 Paint and shade - Power coated light grey as per
Shade 631 of IS:5

4 Terminal strip - Elmex type capable of

Terminating 0.5 sqmm to 1.5 sqmm
Cable din rail mounted
5 No of terminal strips - 30/40/70
6 Conduit & cable entry - Lower side
7 Gland plate thickness - 3mm
8 Door of JB - Hinged with proper locking
Arrangement to avoid entry of
Dust & moisture the design of
Fixing screws of the lids of the
Junction box shall be such that
They do not come out of the lid
When completely unscrewed
(captive screws)
9 Dimension - Vendor to provide most
Economic dimension of JB based
On the no of Terminal bases and cable
Entry clearly specifying GA
Drawing
10 Mounting - Frame mounted
11 Earthing - Two no of earthling bolts for JB
Earthing
12 Name plates - To be provided material: white
Engraved letters on black
Anodized aluminum sheet
Fixing: stainless steel screws
Lettering:- black with white
Engraved. Note: No vendor nameplate shall be
affixed to the junction box(exterior, interior)
E. Cabling
I. Instrumentation Cabling
Cables from conventional measuring transmitters and analogue process controllers,

such as digital or 4mA to 20mA dc output from a constant-current source,
(hereinafter referred to as high-level signals) shall be polyethylene or PVC insulated
with stranded conductors. Each cable shall have an overall screen of braided copper
or mylar backed aluminium foil giving a minimum coverage of 85%, a steel wire
armouring insulated from the screen and from any ducting and an overall PVC
sheath. For runs exceeding 30 metres or for all inputs to a data logger, computer or
microprocessor, multi-core cables shall have an individual screen of braided copper
or mylar-backed aluminium foil for each signal pair. The minimum conductor size
shall be 24/0.2mm but shall be of greater cross-sectional area if required for the

satisfactory operation of associated plant. Cables for intrinsically safe systems shall
comply with BS 5308 and the relevant certificate.
Cables from strain gauges, analyzers and the like, such as 0 to 100mV (hereinafter
referred to as low-level signals — see also below) shall be as specified above and
shall have an individual screen for each signal pair.
Cables from indicating devices to alarm or tripping circuits shall be as specified

above for high-level signals but shall use cables, cable trays, ducts and conduit
separate from those for other high-level circuits.
Cables for high-level signals, low-level signals, resistance thermometers and

thermocouples shall be segregated from each other and each shall be separated
from cables for power, communications and other electrical services. Other cables
run in the vicinity of instrumentation cables shall be separated from instrumentation
cables by a distance of not less than 300mm.
Initiating devices for plant protection and personnel safety shall be connected by
individual cables direct to the tripping or safety device and shall not be routed via any
intermediate junction, marshalling box, cabinet, relay or similar. The outer sheaths of
such cables shall be coloured orange.
II. Fiber Optic Cable
If cable sizes are not indicated on Drawings or in schedules, determine the correct
size based on total end to end signal attenuation not to exceed 40 dB, including all
splices and termination losses, and after taking into consideration.
a) Type of fiber
b) Ambient conditions
c) Method of installation
d) The disposition of each cable relative to others
All cables and wires shall be suitable for installation and continuous services in the
ambient conditions described elsewhere in this document.
Shop Drawings and Product Data shall be submitted for the approval of the engineer
as follows:
 Submit full technical details of each type of cable proposed.
 Submit copy of test certificates from the manufacturer
 Submit exact route of the cable run and relevant Sections in the shop drawings.
Each drum length of cable shall be allotted a distinct and separate reference number.
This number shall appear on the test certificate covering the respective length of
cable and shall also be clearly marked on the cable drum.
The Contractor shall advise the Employer Representative upon delivery to site of
each drum length, quoting the reference number, the test certificates shall be handed
to the Employer Representative for examination and approval.
All cables shall be delivered to site with the manufacturer seals, labels or other proof
of origin intact. These labels and seals shall not be removed until the cable is
required for use and shall be retained for inspection by the Employer Representative.
The Contractor shall be responsible for the off-loading and handling of the cables on
site, and shall ensure that cables are delivered to site on drums and properly

protected against mechanical damages. Where lengths are cut from cables, the open
ends shall be sealed.
The contractor shall be aware of the need to supply and install all cables for this
Contract which are most suitable for the special environmental conditions prevailing
in this project.
The cable shall comprise 6 fibers, loose tube, two fibers per tube with central 1.5 mm
nominal steel central strength member, moister barrier, steel tape armored in
continuous lengths up to a maximum of 6.0 km or as dictated by cable joint chamber
locations and route survey.
Single Mode
Core Diameter 9.0 ± 0.5 micro m
Cladding Dia 125 ± 2.0 micro m
Coating (outer) Diameter 250 ± 15 micro m Material UV curable acrylate
Numerical aperture 0.11 micro m
Attenuation <0.4 dB/km @ 1300 nm <0.2 dB/km @ 1500 nm
Bandwidth 1000 MHz @ 1300 nm
Chromatic Dispersion 3.5 ps/nm x km @ 1300 nm 20 ps/nm x km @ 1500
nm
Operating temperature range -30 to +80 deg. C
Crush resistance >200N/cm
Weight 500 kg/km (maximum)
Tensile strength 2000 N (minimum)
Multimode
Type of fiber Multimode, doped silica
Core Diameter 62.5 ± 3.0 micro m
Cladding Diameter 125 ± 2.0 micro m
Coating (outer) Dia 250 ± 15 micro m Material UV curable acrylate
Numerical aperture 0.275 + 0.15 micro m
Attenuation <3.2 dB/km @ 1300 nm <0.9 dB/km @ 1500 nm
Bandwidth 500 MHz x km @ 1300 nm
Operating temperature range -30 to +80 deg. C
Crush resistance >200N/cm
Weight 500 kg/km (maximum)
Tensile strength 2000 N (minimum)
III. Cable Termination Boxes
Cable termination boxes shall have double-ended screw terminals with removable
links to facilitate core isolation during testing. Each box shall contain sufficient

terminals for every conductor plus 20% spare terminals. Cable termination boxes
shall have cable sealing chambers and insulated glands with earthing terminals so
that the armouring may be earthed or isolated from earth, as circumstances dictate.
Termination boxes for use within buildings shall be of sheet steel with hinged or
removable front covers. All other termination boxes shall be cast steel or heavy
gauge sheet steel construction giving protection to IP55. All termination boxes shall
be hot-dip galvanised or approved equivalent finish. Each terminal box shall have a
removable, un-drilled gland plate and the Contractor shall supply and fit the requisite
number of cable glands.
At each cable termination box, each cable core (including spares) shall be identified
by a numbered slip-over type collet. The numbering for a particular cable core shall
be the same throughout its length.
Cable joints shall be at points approved by the engineer.

Each cable joint shall be of the straight-through type. The conductors shall be ferrule-
jointed with the insulation maintained by heat-shrink sleeving. Joint closure shall be
made with epoxy resin and the completed joint shall be impervious to water if
submerged or in waterlogged ground. If cast iron joint boxes be used, they shall be
provided with cable glands and, after installation and testing, shall be covered with
Densomatic HD compound or equal; so that all sharp corners, bolts and projections
are moulded to a smooth surface. Two lappings of Densopol grade ZN 50mm tape,
or equal, shall then be applied overall. Jointing shall be carried out on each
conductor, including any provided in excess of the minimum quantity specified. All
materials and things of every kind required for the cabling jointing shall be provided
by the Contractor.
IV. Cable Labelling
At each end of each cable, in a uniform and visible position, a label shall be fixed on
the cable to indicate the site cable number and route, and the number and size of
conductors. Labels shall be made of brass, aluminium, lead or copper strip, engraved
and retained by suitable non-rusting or non-corrodible binding wire passing through
two fixing holes, one at either end of the label. If the cable gland is not normally
visible, then the label shall be fixed inside the panel by means of screws.
Three-phase power cable cores shall be identified A, B, C or colour-coded red,

yellow, blue so that the correct three-phase sequence is preserved throughout the
system. Single-phase power cable cores shall be colour-coded red and black.
Control cables shall have individual cores identified by means of suitable permanent
ferrules bearing the same number at both ends. Core identification shall occur at
every point of termination using an approved system of colour-coded ferrule markers.
The size of these ferrule markers shall be such as to match the overall diameter of
conductor plus insulation. Numbering shall read from the termination upwards on all
cores.
Each cable and core shall bear the same number at both ends of the cable and core
respectively.
a) Power terminations - colour, number or letter.
b) Control terminations - letter or number or both.
V. Cable Terminations

All PVCSWAPVC, PVCPVC and XLPESWAPVC cables shall be terminated with

mechanical glands which shall comply with BS 6121. They shall seal the inner and
outer cable sheaths against ingress of dirt and moisture and provide adequate
mechanical support. Each cable gland shall be protected by corrosion-resistant
molded PVC hoods, covering the entire assembly from the overall sheath to the
gland neck.
Glands for armoured cables shall provide a positive armour clamp to the enclosure
so that no tension is applied to the termination. The clamp shall also provide a high
level of earth continuity and be of adequate size to withstand the full fault current of
the system for one second.
All glands shall be provided with an earthing tag. For cables of 4mm² or less, a
serrated washer may be used instead for earth continuity.
The cable termination and sealing equipment shall be obtained from the cable
manufacturer, or other approved supplier, and shall be purpose-made for the type,
size and grade of cable concerned. The application of these materials shall be strictly
in accordance with the manufacturer‘s instructions.
Through joints shall be permitted only on long cable runs outside buildings. Where
such joints are necessary; the cables shall be jointed with epoxy or acrylic resin Cold-
setting compound which has been pre-measured and pre-packed ready for use.
The boxes shall be of a split moulded plastic type with filling vents for compound.
Bonding straps shall be fitted with armour clamps across the joint and inspected by
the Employer Representative prior to filling the box with compound. Wrapped
pressure type joints shall not be accepted.
Conductor cores shall be jointed number to number or color to color.

VI. Cable Installation-General
Cables which are to be run on walls, ceilings or other building structures shall, unless
otherwise agreed by the Employer Representative, be secured on cable trays and
ladders or enclosed in conduit or trunking.
Every cable shall be neatly run vertically or parallel to adjacent walls, beams or other
structural members. Cables shall not be installed in areas of direct sunlight.
Where this is unavoidable, approved sun shields shall be supplied and installed.
Where the building structure incorporates purpose-built covered duct or trench

systems for main cables, instrumentation cables shall be segregated and installed on
tray work or otherwise secured to the sides of the duct or trench.
Where the structure incorporates general service ducts or trenches containing

pipework, chemical lines and other services, all cabling shall be segregated from the
other services and shall be run on the walls unless otherwise agreed by the
Employer Representative.
Cables shall be spaced to prevent interference between power and signal cables,
and to avoid unnecessary crossovers.

The spacing of clips, saddles and cleats shall prevent the sagging of the cables
during their installed life. The method of fixing clips and the like shall be by means of
non-corrodible screws inserted into approved wall fixings, such as rawplugs.
Cable hangers, cleats, saddles, brackets and similar supporting devices shall be of
an approved type and of adequate strength for the cables they are supporting. They
shall be treated to withstand Site conditions without corroding. Self-locking plastic
buckle clips and strapping shall not be used. The arrangement and fixing of each
cable shall permit the removal and replacement of any cable without disturbance to
any other cable or the fixings thereof.
When cables are terminated in any particular item of equipment, special care shall be
taken to ensure that the cables finally approach the equipment from a common
direction and are individually terminated in an orderly and symmetrical fashion.
Submissions which the Contractor shall submit the following in relation to cable
installations in addition to submissions detailed elsewhere in the Specification.
VII. Drawings and Schedules:
 Block diagrams to show control cabling systems with each cable and terminal
equipment being identified as in the cable schedules.
 Cable route and layout drawings. For those items which are underground, these
drawings shall include the following:
 Route plans and sectional views for all cable runs, cable trays, cable ducts and
cable trenches;
 The position of all marker posts, joints, draw pits and the like.
 Cable schedules shall detail the cable number, type, voltage, size, route length
and number of cores or pairs. Control-cable schedules shall detail the connected
and spare core numbers, diagram number for connected equipment, core ferrule
and terminal reference number.
VIII. Data and Calculations:
Manufacturers‘ catalogues and data sheets for all cables and fittings. Cable sizing
Calculations.
IX. Test Certificates:
Test certificates for all witnessed and routine tests carried out at the manufacturer‘s
works and at Site (calibration).
X. Cable Trays and Ladders
Cable tray and cable-support ladders shall be of heavy-gauge galvanised steel and
with an overall PVC coating when required to the approval of the engineer.
Cable tray and ladder systems shall be installed with joints and junction/bend pieces.
Wherever tray and ladder sections are cut and shaped on Site, cut edges shall be
dressed and painted with at least two coats of cold galvanising compound or lead-
based anti-corrosive paint.

Ladder systems shall be secured to walls and ceilings by pre-formed galvanized

interlocking channel.
XI. Flexible Conduits
Flexible conduit shall be of the waterproof galvanised type of PVC wire-wound type
with cadmium-plated mild steel couplings. Lengths of flexible conduit shall be
sufficient to permit withdrawal, adjustment or movement of the equipment to which it
is attached and shall have a minimum length of 300mm. Flexible conduit shall not be
used as a means of providing earth continuity. A single earth conductor of adequate
size shall be installed external to the conduit complete with earth terminations.
Where conversion from rigid conduit to flexible metallic conduit is to be made, the
rigid conduit shall terminate in a trough-type box. The flexible conduit shall extend
from this box to the equipment; the earth continuity cable shall be secured to the box
and to the piece of equipment. The use of lid facing screws and the like will not be
permitted. Adaptors shall incorporate a grub screw or a gland to prevent the flexible
conduit becoming loose.
XII. PVC Conduit
Where galvanised conduit would be liable to corrosion, PVC conduit shall be

installed.
PVC conduit shall be of the oval or round high impact non-flame-propagating type as
specified and self-extinguishing, to BS EN 61386-21. Surface and concealed
installations shall be generally as described for steel conduit.
PVC conduit fittings shall comply with BS 4607. They shall all be white unless
specified otherwise.
Jointing shall be carried out using PVC solvent and socketed accessories.
Expansion couplers shall be fitted in straight surface runs every 12m. The free end
shall be sealed with non-setting mastic to form a waterproof seal.
Purpose-made bends may be used providing that the cable bending radius is
maintained. Cracked or crinkled conduit will be rejected.
The conduit shall be suitable for use in ambient temperatures of between −5°C and
+60°C and shall not be installed in areas that receive direct sunlight. A separate
protective conductor (earth-continuity conductor) shall be installed.
Adaptable boxes and accessories shall be made from heat-resistant insulating

material. The minimum wall thickness of boxes having a nominal internal depth of
16mm or less shall be 1.5mm. For deeper boxes, the minimum wall thickness shall
be 2mm. All boxes which are intended to support luminaires or other heat sources
shall have either external fixing lugs riveted to the metal inserts or utilize steel insert
clips.
F. Cable installation methods

I. General

All cabling installation methods shall be subject to the approval of the Employer
Representative.
II. Installation directly into the ground
Where cables are buried in the earth, the bottom of the excavated trenches shall be
freed of sharp stones and other projections and covered with sand to a depth of
50mm.
Cables shall be unrolled from drums without loops and kinks, and care shall be taken
when laying to avoid damage to the outer sheath by drawing over sharp projections.
Cables shall be snaked into the trenches to avoid tension in the cables during
backfilling or from subsequent settlement. After laying, cables shall be covered to a
minimum depth of 100mm of compacted sand and shall have a layer of protective
interlocking concrete cable tiles. The tiles shall be overlaid with marker tape.
When cables of different voltages are laid together at the same depth, vertical cable
tiles shall be used to segregate the cables.
ICA and communication cables shall be laid not closer than 1000mm to high voltage
cables.
A sufficient number of rollers shall be provided so that the cable does not touch the
ground or twist during pulling.
III. Installation in underground ducts
Underground ducts shall be constructed of impact-resistant uPVC and laid at a

minimum depth of 500mm (to the duct centre), surrounded by at least 75mm of
sieved sand. At road crossings, uPVC ducts of minimum diameter 100mm shall be
laid at a minimum depth of 1000mm (to the duct centre). The ducts shall be encased
by 150mm concrete on all sides.
When installing cables in ducts, the following measures shall be observed:
 Cables shall be pulled in a straight line;
 Rollers shall be positioned at the edges of drawpits both at the drawing-in and
drawing-out points over which the cables shall be drawn;
 PVC pipes and cable sheaths shall be coated with an approved lubricant;
 Sufficient draw-in points shall be provided and adequate room allowed for
installation of cables;
 The pulling rope shall be guided by rollers.
Only one power cable shall be drawn into each duct.
Whenever a duct is laid in the ground, a draw-wire shall be pulled through with at
least 1000mm excess at each end and the draw-wire left in position if the duct is not
to be used immediately.
IV. Sealing cable entries into buildings
Whenever cables pass through walls below ground level, the point of entry shall be
sealed against the ingress of water. This shall be achieved with silicone foam or
similar.

All cable entries into a building shall be in ducts and where the cables pass in or out
of ducts, together with any spare ducts, the ducts shall be sealed against the ingress
of moisture by means of duct stoppers and bituminous compounds or by any other
method approved by the Employer Representative. The stopper shall have a fire
resistance of at least 30 minutes.
V. Marking of underground cables
The location of all underground cables shall be identified by:

 cast iron material plates with standard or custom design fixed to the exterior
surface of all walls of buildings 300mm above ground level and directly above the
point where cables pass through the wall;
 Marker posts in road verges and the like at intervals of not more than 100m and
at all junctions and changes of direction along the route;
 Marker posts at 10m intervals within an enclosed site and at all junctions and
changes of direction along the route.
Marker posts shall be of concrete, not less than 200mm high above ground with an
inscribed cast iron material plates with standard or custom design. The inscription
shall indicate the presence of a cable below, the depth, classification and voltage
rating.
A drawing or sample of a typical marker post shall be submitted for the approval of
the Employer Representative.
VI. Installation in cable trunking
Cable trunking shall be manufactured from mild steel of not less than 1.25mm and
shall be hot-dip galvanised. The Contractor shall ensure that the size of the trunking
is adequate for the number of cables to be installed together with 25% spare
capacity. Trunking shall have minimum dimensions of 50mm x 50mm.
Segregation of cables shall be carried out if required using continuous sheet steel
barriers with the bottom edge welded to the trunking. The trunking shall have two
return flanges for rigidity. Where necessary, additional strengthening straps shall be
fitted internally. The cover shall overlap the trunking and be made of the same
gauge. Fixing screws for covers shall be recessed and be of the self-retaining quick-
fix type. All bends, tees and intersections shall be of the gusset type and shall,
wherever possible, be purpose-made by the manufacturer and of a matching design
to the main trunking.
Cables shall be retained in the trunking when the cover is removed by means of
straps. Internal connecting sleeves shall be fitted across joints in the trunking and
earth continuity ensured by bonding each section of trunking to a continuous earth
wire.
Non-flammable fire barriers shall be inserted where the trunking passes through
walls or floors. Conduit connections to trunking shall be made by flanged couplings
and male bushes.
Trunking shall be supported at intervals not greater than 2m horizontally or 2.5m

vertically.

Crossings over expansion joints shall be made in flexible conduit.
Should it be necessary to cut or drill a section of trunking, the bared ends shall
immediately be given a coat of zinc-rich cold galvanising paint.
Cable and trunking runs shall be determined by the Contractor and agreed by the
Employer Representative before any work is started. The run shall be at least
150mm clear of plumbing and mechanical services.
Trunking systems erected outside a building shall be weatherproof.
VII. Installation in troughs and trenches
Where the building structure incorporates purpose-built covered trench systems,

power distribution cables may be laid on the floor of the trench. Control and
instrumentation cables shall be segregated and installed on supporting steelwork or
cable trays secured to the walls of the trench.
Where the building structure incorporates general service trenches containing

pipework, chemical lines and other services, all cabling shall be segregated from
other services and run on the trench walls. Crossovers shall be kept to a minimum
and cabling shall be taken above wet service pipework.
Cable trays shall be of perforated steel with formed flanges and of minimum
thickness not less than 1mm for trays up to 100mm width, not less than 1.25mm for
trays from 100mm to 150mm width and not less than 1.5mm thickness for trays from
150mm to 300mm width.
Cable-tray supports shall be of sufficient strength to maintain rigid support to the

fully-laden cable tray along its entire length. All brackets and tray work shall be
suitable for withstanding a temporary weight of 125kg.
Wherever possible, cable trays shall be installed in full lengths without cutting.
Should it be necessary to cut or drill a length of tray, the bared ends shall be dressed
and immediately be given a coat of zinc-rich cold galvanising paint. Similarly for PVC-
coated trays, the bared end shall be immediately sprayed using a PVC aerosol.
All cables shall be firmly secured to the tray using purpose-made saddles, as
approved by the Employer Representative, together with proprietary cable cleats.
VIII. Installation in buildings
Cables required to be run on walls, ceilings, or other structures shall be carried on

substantial cleats, either in groups or simply at spacings determined by rating
requirements, supported on tray or ladder racks or enclosed in conduit or trunking.
All cables shall be neatly run vertically or parallel to adjacent walls, beams or other
structural members.

The spacing of clips, saddles and cleats shall be such as to prevent the sagging of
the cables during their installed life. The method of fixing clips and the like shall be by
means of non-corrodible screws inserted into approved wall fixings.
Cable hangers, cleats, saddles, brackets and similar supporting devices shall be of
an approved type and of adequate strength for the cables they are supporting. They
shall be treated to withstand site conditions without corroding. Self-locking plastic
buckle clips and strapping shall not be used.
Hangers shall be spaced according to recommendations in the IEE Wiring

Regulations. Allowance shall be made for expansion and contraction of the cables.
Cables shall be located between 50mm pegs spaced at 40mm centres across a rung
so that a 40mm or 80mm space is maintained between cable centres. Cleats shall be
used where the ladder racking is vertical.
Cables shall be run at least 150mm clear of plumbing and below heating and hot
water pipework.
IX. Cable installation in conduits
Conduits shall be either galvanised heavy-gauge steel screwed type or light-gauge

steel non-screwed type, steel or PVC. Accessories shall either be malleable cast iron
or pressed steel.
A space factor of 40% shall not be exceeded and, in any case, conduit shall have a
minimum diameter of 20mm. The tubing is to be perfectly smooth inside and out and
free from imperfections. Both ends of every length of tubing shall be reamed and all
sharp edges removed before erection.
Where conduits converge, adaptor boxes shall be used. Conduits shall be connected
by means of male brass bushes and couplings. Where conduits are greater than
25mm diameter, straight-through joint boxes shall be of the trough type. Where
conduit or fittings are attached to equipment casings, the material of the casing shall
be tapped for a depth of not less than 10mm or male bushes and flanged couplings
may be used.
Hexagonal lock nuts shall be used at running joints. They shall seat firmly and evenly
on to mating faces. All function boxes, draw-in boxes, and inspection fittings shall be
placed so that the cables can be inspected, withdrawn and re-wired during the life of
the installation.
Generally not more than two bends or offsets or one coupling will be permitted
without a suitable inspection accessory. Fish wires shall not be left in conduits during
erection. The whole of the installation shall be arranged for a loop-in type of system
with joints being carried out at switches, isolators or appliance fittings.
Ends of conduits which are liable to be left open for any length of time during building
operations shall be plugged to prevent the ingress of dirt and covers shall be fitted on
all boxes.
Generally, conduits shall not cross expansion joints of buildings. Where they cannot
be installed in any other manner, a galvanised flexible conduit shall be used across
the expansion joint. A total of 150mm movement shall be allowed.

8.10 Process Instrumentation
8.10.1 General
 Instrumentation system shall be designed, manufactured, installed and tested to

ensure the high standards of operational reliability. All electronic components
shall be adequately rated and circuits shall be designed so that change of
component characteristics shall not affect plant operation.
 All instrumentation equipment shall be new, of proven design, reputed make, and
shall be suitable for continuous operation. Unless otherwise specified, all
instruments shall be tropicalised. The outdoor equipment shall be designed to
withstand tropical rain. Wherever necessary space heaters, dust and water proof
cabinets shall be provided. Instruments offered shall be complete with all the
necessary mounting accessories.
 All instruments shall be from the country of origin as indicated in the preferred
vendor list elsewhere in this specification.
 All instruments shall be offered for inspection & testing before dispatch, at
Manufacturers Factory works where the instrument has been manufactured. The
same shall be indicated in the QAP and submitted along with the equipment
datasheet for review and approval.
 Electronic instruments shall utilise solid state electronic components, integrated

circuits, microprocessors, etc., and shall be of proven design.
 No custom made hybrid type integrated circuits shall be used.
 Unless otherwise stated, overall accuracy of all measurement systems shall be

±0.5 % of measured value, and repeatability shall be ±0.5%.
 Unless otherwise specified, the normal working range of all indicating instruments
shall be between 30% and 80% of the full scale range.
 On resumption of the supply following a power failure the instruments and

associated equipment shall start working automatically.
 The instruments shall be designed to permit maximum interchangeability of parts

and ease of access during inspection and maintenance.
 Unless otherwise stated, field mounted electrical and electronic instruments shall
be weatherproof to IP-65.
 All outdoor instruments shall be fitted with IP65 enclosure to shield the
instruments against the weather, irrespective of the IP rating of the
instrument/transmitter. The enclosures shall be of lockable type.
 The instruments shall be designed to work at the ambient conditions of

temperature, humidity, and chlorine contamination that may prevail but in any
case not less stringent than those conditions detailed in the Project
Requirements. Instruments shall be resistant to corrosion in the atmosphere in
which they are expected to operate.

 All field instruments, and cabinets/panel mounted instruments shall have tag
plates/name plates permanently attached to them. Details of proposed
inscriptions shall be submitted to the Employer for approval before any labels are
manufactured.
 All coated parts of sensors shall be made out of noncorrosive material capable of
working with chlorine content of 5 ppm.
 For all instruments installed in the field, surge protection devices (SPD s) shall be
provided at both ends of the connecting cable for protection against static
discharges / lightning and electromagnetic interference.
 Individual pair screened, overall screened, armoured cables shall be used for
analogue signals and armoured, overall screened cable shall be used for digital
signal cables.
8.10.2 Flow Measuring Systems
8.10.2.1 General
Flow measuring system shall consist of flow sensor / transducers, flow computer and
flow transmitter.
Flow transducers shall be rugged in construction and shall be suitable for continuous
operation. Flow transducers shall have waterproof construction and shall be suitable for
installation in underground/above ground pipelines.
To avoid the effects of disturbances in the velocity profile, a straight and uninterrupted
run, upstream as well as downstream from the location of the flow sensor shall be
provided in accordance with the requirements of the flowmeter manufacturer.
The flow transmitter shall be suitable for field or panel mounting and shall accept an
input from the flow sensor. It shall process the input signal and provide 4-20 mA dc
output proportional to flow rate. The flow range shall be adjustable.
A zero span adjustment facility shall be provided for flow transmitter and indicator.
Flow measurement shall not be affected by physical properties of sewage viz.,

temperature, pressure, viscosity, density etc., within given limits. Contractor shall provide
compensating electronic circuits if required. The overall accuracy of flow measuring
systems shall be at least ± 0.5 % of the measured value unless otherwise stated.
8.10.2.2 Open Channel Flow Meter
Open channel flow measuring systems shall consist of level transducer, flow computer
and flow transmitter. The level of the fluid in the flume shall be measured by the
ultrasonic level transducer. The level measured shall be used along with the physical
characteristics of the flume to compute the flow rate.
The level transducer shall be suitable for flange or bracket mounting as required and
shall be environmentally protected as per IP67. It shall have ambient temperature
compensation and adjustable datum setting facilities.

The design and application of ultrasonic level meters shall take into account the channel
construction, the material size, shape, environment, process fluid or material, the
presence of foam, granules, size etc.
The installation shall avoid any degradation of performance from spurious reflections,
absorption, sound velocity variations, sensor detection area, temperature fluctuations,
specific gravity changes and condensation. For application where spurious reflections
are unavoidable the control unit shall be provided with facilities for spurious reflection
rejection.
The structure required for supporting the level sensor, platform, railings etc. shall be in
the Contractor‘s scope.
8.10.2.3 Electromagnetic Flow Meter (Full Bore):
The Electromagnetic Flow Meters shall be installed in RCC chambers for indication of
flow rate and total consumption of water in a transmission or distribution pipe work of w
system. The Electromagnetic Flow Meters shall withstand maximum working
temperature and working pressure shall be as per process requirement.
Full bore electromagnetic flow meters shall be designed, manufactured and calibrated to
ISO standard. The flow meter shall be capable of measuring bi-directional flow.
Electromagnetic Flow Meter shall be a velocity sensing electromagnetic type,

microprocessor based signal converter, Flow Integrator and Totalizer sealed housing,
flanged tube meter as per working pressure requirement. The meter shall be
manufactured to highest standard available for mag-meters. The accuracy shall be
inclusive of linearity, hysteresis, and repeatability, temperature and pressure effects. The
meter assembly shall operate within a range of 0.3 m/sec to 5 m/sec and pressure rating
shall be as per process requirement to be constructed as follows
Meter tube shall have a constant nominal inside diameter offering no obstruction to the
flow.
Signal Converter shall be pulsed DC coil excitation type with auto zeroing. The signal
converter shall be remotely mounted away from the meter. The converter shall indicate
direction of flow and provide a flow rate indication and a total of flow volume for both
forward and reverse directions.
The converter shall provide an isolated 4-20 mA output. The microprocessor based
signal converter shall have a self-diagnostic test mode and backlit display that
continuously displays ‗Rate of Flow‘ and ‗Total Volume‘.
The converter shall be compatible with Microsoft Windows and other software programs
with built in terminal communication capabilities of RS 485, HART or other protocols for
interface.
The converter shall be remotely mounted maximum up to 200 m from the sensor, and
shall be supplied with all calibration complete for desired requirements.
The converter cum transmitter shall be fully programmable from the front facia.
The programming shall be user friendly, self-prompting menu driven.

The length of the sensor shall be strictly as per ISO up to DN 600 mm and for other sizes
it shall be as per the manufacturer‘s standard.
All flow meters shall be offered for inspection & testing before dispatch at Manufacturers
Factory where the instrument has been manufactured. QAP shall be submitted which
shall include functional testing and calibration at the manufacturer factory.
8.10.3 Level Measuring System
8.10.3.1 Ultrasonic Level Meters
Ultrasonic level measuring devices applied for liquid level measurement shall comprise a
transducer, control unit and remote indicator.
The transducer shall be suitable for flange or bracket mounting as required and shall be
environmentally protected to IP 67. It shall have ambient temperature compensation,
adjustable datum setting facilities.
The accuracy of the sensor shall be ±0.25% or better.
It shall be programmable with an integral programming keyboard and provide a digital

display of the measured variable. It shall be provided with diagnosis facilities and shall
provide an isolated 4 to 20 mA dc output signal proportional to the range of
measurement.
The design and application of ultrasonic level meters shall take into account the vessel
or channel construction, the material, size, shape, environment, process fluid or material,
the presence of foam, granules, size etc.
The installation shall avoid any degradation of performance from spurious reflections,
absorption, sound velocity variations, sensor detection area, temperature fluctuations,
specific gravity changes and condensation. For applications where spurious reflections
are unavoidable the control unit shall be provided with facilities for spurious reflection
rejection.
If turbulence exists, shielding, stilling tubes or other measures shall be provided to avoid
effects on the measurement.
8.10.3.2 Conductivity Level Switches
The electrodes used for conductivity level switches shall be stainless steel. Single
electrode systems (one electrode per holder) shall be used (except where their use is
impractical) with insulated electrodes such that only the tip of each electrode is exposed
to the liquid at the operating level.
Relay or control units operating with level electrodes shall have adjustable sensitivity.
Electrodes for use in fluids of low or variable conductivity shall be fitted with conductivity
discs.
Where relay or control units are not mounted in control panels, they shall be provided
with surface mounting enclosures with a degree of protection to IP 52 for indoor locations
or IP 65 for outdoor locations.

8.10.4 Pressure gauges, Switches and transmitters
8.10.4.1 General
Pressure gauges shall comply with BS EN 837- Parts 1, 2 and 3. Pressure gauges,
transmitters and switches shall have over range protection up to 1.5 times the maximum
anticipated line pressure and have concentric scales. For specially arduous duty where
the gauge is subject to pressure pulsations and/or vibration, it shall be provided with a
glycerine-filled dial and line snubbers shall be used. Bourdon-tube type differential-
pressure gauges shall be capable of withstanding full line pressure on any side with the
other side vented to atmosphere without damage to or effect on the calibration. No
plastic material shall be used in their construction. Internal parts shall be of stainless
steel, bronze or approved corrosion-resistant material.
The minimum diameter for round pressure gauges shall be 100mm unless specified
otherwise or where the gauge forms part of a standard item of equipment.
Unless specified elsewhere the accuracy for pressure gauges shall be 1% of range, for
diaphragm gauges 1% of range and for differential gauges 1.5% of range or better.
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 shall be marked on the dial.
The zero and span of a pressure transmitter shall not change by more than 0.1% of the
span per Celsius degree change in ambient temperature. After application for 10 minutes
of pressure at 130% of maximum pressure, the change in zero and span shall not
exceed 0.1% of the span.
Pressure transmitters/switches shall have an accuracy typically better than 0.1% of span,
depending on the application and shall be protected to BS EN 60529: IP 65 standard or
higher standard. For transmitters installed in meter chambers liable to flooding or
underwater applications, they shall be to BS EN 60529: IP 68 standard and shall operate
up to maximum submergence of 20 metres of water.
Pressure transmitters shall provide a digital or 4mA to 20mA dc output proportional to the
pressure range.
Pressure gauges, switches and transmitters shall have primary isolating valves, 2 or 3
way valve manifold and vents, in such a way that it has the facility to calibrate the
gauges or transmitters without removal.
Pressure and differential pressure switches shall have contacts with separate ‗cut in‘ and
‗cut out‘ pressure values.
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.
Pressure monitoring shall be by a sensor suitable for the medium and pressure/level
range.
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 pipework.

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.
The transmitter shall have provision for span and zero adjustment.
8.10.4.2 Strain-gauge pressure transducers and transmitters
Strain-gauge pressure transducers shall use thin film sensors without bonding.
Each instrument housing shall be of all-welded Grade X 4 CrNiMo 17 12 2 stainless steel

or equivalent and hermetically sealed. Non-interacting, zero and span adjustments shall
be provided on each transducer. The measuring diaphragm shall be isolated from the
process fluid by a non-corrodible barrier diaphragm. The mean time between failure for
any model of strain-gauge transducer shall be not less than 15 years, and the
performance of the measurement system shall be as given below, or higher
performance:
 accuracy: ± 0.1% of calibrated span, including linearity hysteresis and repeatability;
 repeatability: ± 0.05% at maximum span;
 stability: ± 0.1% of upper range limit over 6−month period;
 over pressure: sustain a 400% over-pressure without damage;
 RFI / EMI effect: less than 1% of span with 500MHz at 5W direct contact;
 power supply variation effect: 0.01% per volt variation.
 load variation effect: ±0.0002% per ohm of loop-resistance variation.
 temperature: −29°C to +82°C range; total thermal error of ±0.75% of span over 0°C
to 50°C;
 protection: IP 65.
Strain-gauge transducers which do not have terminals for their cable connection, shall
have integral sealed-cable assemblies, installed in conduit and terminated at
weatherproof junction boxes, protected to IP 65 each mounted near to its associated
process transmitter. A digital or 4mA to 20mA dc output signal proportional to the
transducer range shall be provided.
Strain-gauge pressure transmitters shall be generally as the transducer except that it

shall incorporate a waterproof pressure transmitter producing a digital or 4mA to 20mA
output signal.
Provision for transducer venting shall be provided.
8.10.5 Temperature Instrumentation
8.10.5.1 Resistance Thermometers
Platinum resistance thermometers shall be used for temperature sensing up to 650

Degree C.
Each temperature sensor, used for process monitoring shall have a stainless steel
pocket and extension assembly, non-corrodible metal sheath and waterproof terminal
head. Pockets for steam, oil and pressurised water lines shall be welded; pockets for
other duties shall be screwed. Temperature sensors incorporated within motor winding
shall be inserted during the winding process to ensure intimacy of contact.

Platinum resistance thermometers shall be selected and used in accordance with BS

1041-3 and shall comply with BS EN 60751. Each element shall be artificially aged
during manufacture. Terminal heads and amplifiers shall be designed for three-wire
connections between head and amplifier.
Platinum resistance elements shall be fully encapsulated in ceramic, and element 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.
8.10.5.2 Thermocouples
Thermocouples shall be of the mineral insulated type and, unless otherwise specified,
shall be of the chromel-alumel (nickel chromium v nickel-aluminium) type. Wires shall not
be smaller than 1.0 mm2 and shall be selected and used in accordance with BS 1041-3
and shall comply with BS EN 60584.
8.10.6 Analytical Instrumentation
8.10.6.1 General
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.
This section covers individual elements to measure and transmit pH and ORP.
Transmitters shall convert the sensor measurement to a 4 to 20 mA dc signal capable of
transmission into at least a 500 ohm load at 50 V or less. Power supply shall be 240 Vac,
50 Hz. Reference accuracy of the output signal shall be ± 1 percent of measured span or
better. Output signal shall be electronically isolated from ground to permit connection to
a receiver with a grounded input. Transmitters shall be provided with an indicating scale
having at least a 0.1 meter calibrated length. Operating ambient temperature shall be -5
to + 50 degree C or better. Transmitted signals shall be linear with the measured variable
excepting pH which shall be linear with pH.
8.10.6.2 Sensor Measurement Principles and Features:
Each type of sensor shall use the measuring principle and incorporate the features
appropriate to it as specified below:
pH and ORP sensors shall measure hydrogen ion activity and oxidation-reduction
potential respectively in the process medium. The pH sensor shall consist of a glass
measuring electrode, a reference electrode, a solution ground and a temperature sensor
for compensation in the transmitter. The reference electrode shall be the non- flowing
type with an electrolyte diffusion rate through a non-reactive porous membrane or plug
which shall not require electrolyte refill more often than once per year. ORP sensors
shall use the same elements specified for pH sensors except that electrode shall be
platinum and no temperature compensation is required. pH and ORP sensor assemblies
shall incorporate an integrally mounted preamplifier for the measuring electrode. Sensors
shall operate over a temperature range of - 5 to + 1000 C or better.

Construction. Transmitter and sensor enclosures shall be rated NEMA 4 unless

explosion proof (XP) is specified on the Schedule. Enclosure materials and finish shall
be as specified in the Schedule. If not so specified, they may be the manufacturer's
standard which is compatible with the corrosivity of the atmosphere normally in contact
with the enclosure. All parts of sensors, their assemblies and supporting parts which are
wetted by the process medium shall be constructed of stainless steel and/or plastic
unless specified otherwise on the Schedule. When specified on the Schedule, pH and
ORP assemblies shall be provided with integrally mounted ultrasonic cleaners.
8.10.6.3 Total Dissolved Oxygen Monitoring System
The Dissolved Oxygen (D.O) monitoring system shall consist of a sensor, transmitter,
indicating converter and electrode cleaning equipment. Accuracy shall be + 0.5% full
scale for DO, barometric pressure + 0.27 kPa and temperature + 0.3C.
The sensor shall not require zero point. The transmitter shall allow the DO sensor to be
fitted without the use of tools. The transmitter shall output a signal proportional to the DO
level and measured temperature. The following alarms shall be detected and
transmitted.
1) Membrane puncture
2) Depleted or worn out DO sensor
3) System/electronic fault.
The indicating converter shall perform auto calibration of the system and compensate for
sensor age, temperature, barometric pressure, relative humidity and liquid salinity. It
shall display OD concentration, temperature, sensor lifetime remaining (mg/l x hours or
%) and rh selected for calibration.
Construction: The DO sensor shall consist of a prefabricated, disposable, sealed

cartridge that slides easily into the transmitter without special tools. Systems that require
re-generation (refill of electrolyte and membrane change) will not be acceptable. The
sensor shall use the Clark‘s principle, with a gold cathode, silver wire anode and a
nontoxic electrolyte of potassium chloride. The pre-stressed membrane shall be of Teflon
and bonded onto the DO sensor.
The transmitter shall be protected to IP 67 and supplied with 6m of cable for connection
to a junction box. The converter shall be housed in a NEMA 4 x enclosure and be
handrail or panel mounted up to 200m from the sensor without need for a pre-amplifier. It
shall be interchangeable without the need for recalibration or reprogramming of the
system by using a sensor specific storing device continuing all settings and calibration.
The sensor and transmitter shall be installed in a self- cleaning polystyrene ball float,
which shall float on the surface of the water and allow the sensor to be inserted by
approximately 125mm into the water. The ball shall be constructed to fit the sensor and
transmitter and leave a smooth surface to prevent accumulation of dirt or grease.
8.11 Installation Requirements for Instruments
8.11.1 General
The contractor is responsible for coordinating the installation, testing and commissioning
to assure proper interface and system integration. Services shall include, but not
necessarily be limited to all labour, materials, tools, equipment, supplies and services

and auxiliary devices including brackets and mounting hardware required to install the
instrumentation.
8.11.2 The following general installation guidelines shall apply:
 Transmitters and transducers shall be mounted as near as practical to the

measurement point.
 Instruments shall be readily and safely accessible from grade, permanent platforms
or fixed ladders to facilitate ease of maintenance for the equipment.
 Supply power to instrumentation from the control panel to which information is
reported for remote monitoring. Provide a separate (independent) circuit for each
analyzer (note that control panels are powered by online UPS and supplied from the
sites critical emergency power circuit).
 Unless otherwise shown or specified, mount instruments 1.4 m above finished floors,
grade or platforms. Allow for cabinet plinth/floor-pad heights when locating panel
instruments.
 Do not mount direct reading or electrical transmitters on process piping. Mount on
instrument racks or stands or in enclosures near the sensor at a level that permits
viewing from ground elevation.
 Do not mount instruments on vibrating structures (e.g. handrails), or on piping or near
equipment that may induce vibration.
 Do not mount instruments below or directly adjacent to lines conveying corrosive
chemicals or near sources of leakage or spillage.
 Install the instrumentation and auxiliary devices (including sensors) such that they
are accessible for maintenance. Provide space between instruments and other
equipment and piping for ease of removal and servicing. Install to ensure
accessibility from grade without requiring staff to enter confined spaces.
 Ensure that instrument displays are properly oriented for easy viewing.
 Any instrument that is not easily accessible for operation or maintenance, and any
indicator that is not easily and readily visible, must be relocated as directed at no
charge to the contract.
 Follow additional installation requirements as specified in the individual instrument
sections and as recommended by the manufacturer.
 Follow the Manufacturer‘s recommendations for loading resistors on digital outputs to
limit the affect of leakage currents through triac and relay outputs.
 Follow the Manufacturer‘s recommendations for surge suppression on inductive
loads.
 Unless specifically instructed otherwise, ensure installations conform to the
manufacturer's installation recommendations.
8.11.3 Analytical Instrumentation
 Physically locate the sample point so is does not contribute unnecessary dead time
in the analysis. Take care to ensure the sample point is clean, thoroughly mixed, and
representative of the process stream.
 Locate the analyzer next to a floor drain. Provide shutoff (block) and bleed valves:
size valve and select type and material for the application.
 Provide a table nearby with the necessary equipment and chemicals to perform
calibration checks.
 Provide flushing facilities for cleaning probes

8.11.4 Surge Protection Devices
Surge protection devices (SPDs) shall be suitable for withstanding the surge arising out
of high energy static discharge / lightning strikes and protect the instrument to which it is
connected against damage. SPDs shall provide protection through the use of quick
acting semiconductors like Tranzorb, Zener diodes, varistors and an automatic
disconnect and reset circuit. SPDs shall be passive and shall require negligible power for
operation. During the occurrence of a surge it shall clamp on the allowable voltage and
pass the excess voltage to the ground. The SPD shall be self- resetting to minimise the
down time of the measurement loop.
SPD shall be provided to protect devices transmitting and receiving analogue and digital
signals derived from field devices located outdoors.
The surge protection device shall be rated for surge rating of 10 KA.
8.12 Control & Automation
8.12.1 Programmable Logic Controllers
Programmable Logic Controllers (PLC) shall be provided as a Hot Stand-by Controller to

perform combinational and sequential logic functions, status monitoring, process control
and reporting functions with counter and timer facilities.
In particular, the following configuration shall be applicable across the STP.
Plant PLC system shall be a hot standby PLC linked to the plant redundant SCADA
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.
PLC shall comprise of necessary 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.
PLCs shall be microprocessor based. PLCs 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.

PLC System & all RIO 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.
8.12.1.1 Remote input/output modules (RIO)
The PLC system shall consist of field remote input/output modules (RIO) 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.
8.12.1.2 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. Provision shall be provided for future expansion of
additional 20% extra I/O modules of the installed capacity in the panel.
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.
8.12.2 Ethernet Switches
The contractor shall only provide managed industrial grade Ethernet switches under this
contract.
8.12.3 PLC Programming
The Contractor shall supply, install, program and commission the PLC using the PLC
manufacturers recommended windows based PLC coding and documentation software.
The PLC code shall be structured in the manner of the best industry standard and have
comprehensive subroutine and rung annotation.
PLC programming under this contract shall be implemented 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 & approval as an integral part
of FDS submissions.
The Contractor shall provide all required IT Hardware complete with PLC coding and
documentation software as specified in the bid document & as agreed with the Employer
representative based on the FDS submitted.
8.12.4 Supervisory Control & Data Acquisition System (SCADA) system
The SCADA shall be suitable for day to day operation by non-computer literate
personnel in the monitoring and operation of the treatment works.
SCADA shall be provided at central Monitoring Room which shall be located in

administration building.
The STP shall be provided with a Dual redundant SCADA system. The SCADA software
shall be of unlimited tags version. The SCADA System shall be designed to store,
archive and retrieve complete plant operational data for at least three (3) months. This
shall be provided in addition to the Historian software being provided.
The Historian software shall be designed and configured on a minimum to accept the
number of tags similar to the SCADA software. The Historian software and server system
shall be designed and configured to store data for a minimum of 3 years.
On a minimum, the SCADA system shall generally consist of the following:

1) SCADA software as indicated above.
2) SCADA redundant servers
3) Historian software & station as indicated above
4) Operator work station with licensed software (Latest Windows OS, Anti-Virus
software, firewall, required licensed software)
5) Engineering work station (Latest Windows OS, Anti-Virus software, firewall, required
licensed software)
6) Alarm printer & A3 size desktop printers
7) Managed industrial grade Ethernet switches
8) 65‖ LED screen which shall act as a mimic for the SCADA system

9) Industrial grade control room console
The SCADA system 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 optimisation. The system will allow operators, technicians and engineers to
issue commands to change system parameters, start and stop equipment, provide
configuration tools and operate diagnostic facilities from Operator Workstations (OW)
and Engineers workstation (EW), after successful log-on by security password.
The System shall perform all the necessary functions for the optimum monitoring,
automatic control and operation of the entire system.
The SCADA system shall be constructed to a high standard to provide a high profile
feature and focal point for visitors to the Sewage Treatment Plant (STP).
The SCADA control room shall be equipped with false flooring to provide access for all
cables. No cables shall be installed over the control room floor.
The SCADA control room shall be provided with air conditioning system. The
temperature in any area of the control room shall not exceed 22deg C.
Note: Refer particular specifications for design of SCADA control room and the particular
requirements.
8.12.5 Private Automatic Branch Exchange (PABX) System for Connection to Public
Switched Telephone Network (PSTN)
General:
The PABX system described in this specification shall have the following minimum
features and facilities integrated into the system and ancillary equipment:
Scope:
This technical specification describes requirement of Private Automatic Branch

Exchange (PABX) system connected to Public Switched Telephone Network (PSTN) and
PABX to Exchange Telephone systems of Sub Treatment plant areas for both STP.
Operating Loop Limits:
The system shall provide the following loop features:

 The extension line maximum loop resistance, including the resistance of the
telephone shall not be less than 600 ohm.
 The trunk and tie line shall be capable of detecting a signaling current from the
distant end, with the supply at a minimum of 45 volt.
Following Technical details along with Datasheets shall be submitted during detailed
engineering.
a) Whether the system can be equipped with duplicated controls and processor unit.
b) What type of main processor/s will be supplied?
c) Which components are duplicated, e.g. main memories, clock generator, switching
d) network, multibus, signal unit, conference equipment, and voice mail?
e) What the size of the main system memory is.

f) What the dynamic traffic value is as specified in Busy Hour Call Attempts (BHCA).
g) Whether the main processor can be upgraded to allow for a greater number of
BHCA.
8.12.6 Uninterruptible Power Supply (UPS)
The power for Programmable Logic Controllers (PLC) and RIO panels and Supervisory
Control and Data Acquisition (SCADA) system inclusive of all IT hardware, centrifuge
PLC & complete field Instrumentation system, Fire alarm system and EPBAX system
shall be derived from separate redundant UPS system.
The UPS provided shall be sized to provide power to maintain system functioning for a
period of minimum one hour (60 Minutes) on full load, in case of power failure.
The UPS shall be an online UPS, i.e. the status & complete operating parameters of the
UPS shall be monitored by the plant SCADA system in real time.
The above feature should be demonstrated during UPS Factory Acceptance Test (FAT)
& Site Acceptance Test (SAT).
8.13 Closed Circuit Television System
The bidder shall be responsible for the detailed design, supply, installation, testing and
commissioning and training of Employer‘s staff of Closed-Circuit Television (CCTV)
system to be installed in the SCADA control room & at various locations in the STP plant
on a minimum covering all process units and other areas of the stp
The scope shall include all necessary cabling, indoor & outdoor cameras and lenses,
camera housing, TV monitor, control and interface units, coaxial cable transmission,
video switching unit, time-lapse video recorders and tapes, junction boxes, power
supplies, mounting brackets, etc, as required to provide a cost effective and reliable and
fully operational CCTV system complying with the specification and to the approval of the
Employer‘s Representative.
The CCTV system shall incorporate all equipment necessary to enable all areas
to be viewed from the CCTV station monitor. The CCTV monitoring system shall be of
latest design incorporating all the power and signal wiring as per manufacturer‘s
standard. The system shall be complete package of one supplier of equipment, fixings,
wiring conducting and all items necessary for a complete installation.
8.13.1 Materials
Cameras
Cameras shall be digital high resolution colour cameras having 1/3 inch CCD 450 TV
lines with lens and an interlace of 2:1 in the scanning system of high excellent quality
and performance utilising latest digital technology of super colour reproduction with low
light high sensitivity down to 5 lux with electronic shutter speeds 1/50 to 1/30000
seconds.
Cameras shall be provided with a 14mm automatic lens with/without ―drive‖ (amplifier) for
1/2‖ sensors, F1.4 CS mount, 22° angle shot and a composite video output at 75 ohms
lines and the useful illumination range shall be 1.5 lux.The camera lens shall be of the

auto iris zoom type with spot filter providing automatic control throughout the iris range
from fully open F1.4, the lens shall incorporate a shutdown mechanism to protect the
camera from high light level during periods of not in use. A neutral density filter designed
to maintain image
detail and contrast shall be incorporated in the lens. The output signal shall be of PAL.
The Camera shall be suitable for the specified environmental conditions.
The camera shall be provided complete with all accessories required. The camera shall
have the following features.
1. Program modes 1.5, 3, 6 minutes;
2. Variable scan speed between 1.40° per second;
3. Programmable limit stops for auto/random/frame scan modes;
4. Series protocols BS-422 ‗P‘ series and ‗D‘ series;
5. Built-in menu system;
6. Pan movement – 360° continuous pan rotation;
7. Vertical tilt - Unobstructed +2 to +92°;
8. Variable pan/tilt speed controller;
9. Preset speeds:
Pan – 250°/sec
Tilt – 100°/sec
10. Electrical input – 24V AC.
Monitor
The monitor shall be of high resolution type suitable for CCTV system and shall comply
with the following:
1. LED Screen: 62‖;
2. Power Supply: 240V, 50Hz;
3. Resolution : 420 lines;
4. Bandwidth : 5 MHz (±3dB);
5. Video Input : 1 Vpp 75ohm;
6. Input/Output: BNC Video connector;
7. Front Controls: Power ON/OFF;
Brightness Control;
Contrast Control;
Colour Control.
Matrix Switcher
The matrix switcher shall be micro-processor based and provide switching and control
for 16 video inputs and up to 4 monitor outputs from any one keyboard.

The unit shall be remotely operated by desk-top key boards or external computer
systems. The switcher shall have on-screen menu programming. The switcher shall
support two system macros or salvo sequences to allow quick call-up of up to four
cameras to four monitors simultaneously.
The salient features of the switcher shall be as follows:

1. 16 volts inputs; 2 or 4 video outputs;
2. 20-character camera title;
3. Time (24-hour or AM/PM formats), Date (4 formats);
4. Video inputs individually detectable for terminating or looping;
5. Individual monitor sequential switching with preset cell;
6. Compatible with RS 422 protocol;
7. Camera control selection;
8. Full duplex RS485 keyboard communications;
9. Selectable data port – RS 232/RS 422/RS 425;
10. Password protected menu programming;
11. User partitioning to prevent unauthorised viewing.
Receiver
The receiver shall operate on the principle of transmitting of transferring control

information and video data on the same line. Standard control features shall include
pan/tilt control, camera power, zoom lens control (zoom, iris, and focus with adjustable
speed).The receiver shall be compatible with control systems utilizing standard 15-bit
command protocols. Auto random scan capability or preset positioning shall be possible.
The test local control module shall allow on-site testing of system functions.
The salient features of the receiver shall be as follows:
1. Input power – 240V 50Hz AC;
2. Control method – 15 pulse train superimposed on the video signal;
3. Pulse amplitude – approximately 1 Vp-p added to video signal, 333kHz nominal;
4. Connectors – two BNC connector for video input and output one 37pin
Amp CPC for control output;
5. Input video level – 1 Vp-p nominal, 2 Vp-p maximum;
6. System band width – Less that 2dB down at 10 MHz;
7. Fuse protection – 3 AG type;
8. Power chord – 3 wire grounded 18 AWG;
9. Operating distance – RG 11 at 1828 m;
10. Ambient temperature –20 to + 60°C.
The receiver shall be UL listed and shall comply with NEMA 4X and be CE compliant.

Amplifier
The video amplifier shall be of solid state circuitry and is meant for post equalization
application only. The amplifier shall provide effective means of maintaining CCTV picture
quality with RG11 coaxial cable.
The general construction of the amplifier shall consist of cover, chassis and panel.
The salient features of amplifier shall be as follows:
1. Input voltage – 240V AC;
2. Power transformer – 1.5VA (1.25 AMP) at 12 ±15% volts, 50Hz;
3. Input – Single BNC internally terminate in 75ohms;
4. Outputs – Single BNC source terminated;
5. Gain – Adjustable form 1 to 8dB;
6. Frequency response – Adjustable form flat (±1dB) at 12 MHz, greater than 18dB of
boost at 12 MHz;
7. Output dynamic range – Up to 2 volts p-p at 50% APL;
Up to 1.5 volts p-p at 90% APL.
8. Cable length – RG 11 – 1828.8M;
9. Ambient temperature – 0° to 48.89°C at 0 - 90% RH.
The amplifier shall be UL listed to standard 2044 and comply with NEMA 1 and be CE
compliant.
Time Lapse Video Cassette Recorder or Disk recorder
The time-lapse VCR/disk recorder shall be designed to suit multiple use. The recording
capability shall enable continuous coverage over a long period of time with minimum
tape changes.
Recording mode shall include standard VHS2 and 6-hour real time modes in addition to
high density 18-hour linear real time recording. SP and EP recording modes shall make
increase field recoding rate using standard high quality T120 VHS tapes.
The programming menu shall appear on the monitor output to provide easy setup of any
programme feature. A lock mode shall disable all front panel controls presenting all
changes to the unit‘s programming or operation. Playback features shall include speed
search and reverse play back. Automatic alarm search feature shall allow the operator to
go to a specific alarm index.
The salient features of disk recorder shall be as follows:

1. Standard VHS 2/6 hour recording mode;
2. 18/24/218/72/96/120/168 hour VHS compatible time-lapse modes;
3. Internal / short recording mode;
4. 24 hours real time recording mode;
5. High density record mode – triple speed time lapse recording;

6. Audio recording up to 24 hours;

7. Alarm index search;
8. Jog/shuttle for easy forward and reverse field playback and search;
9. On-screen menu programming;
10. Eight daily/weekly reading schedules.
CCTV Integration
A Close Circuit Television Camera‘s (CCTV) based on IP standard should be amenable

to be integrated with the SCADA system. The camera integration feature should be a
standard feature of SCADA in following ways –
● Web Services
● Video Viewer - ActiveX Control
● PTZ Control (Pan, Tilt, Zoom) - ActiveX Control
● Camera Manager
● Add / Edit / Remove cameras in runtime environment
● Camera configuration stored in DBF files
● Pre-built Displays:
● 1 Up
● 2 Up
● 4 Up
● 9 Up
Additional features such as pop-up displays for motion/intrusion detection and linking of
events with video functions should be made available.
Broadband internet services with high speed connectivity shall be used for data
communication from CCTV monitoring locations to the CCTV server. The most suitable
package of high speed broadband internet service provided by an Internet Service
Provider (ISP) which suits the Client‘s requirement for high speed real time monitoring
thru the CCTV shall be utilized. The contractor shall enter in to SLA agreement to
provide continuous fail safe services as required under this contract.

9 Inspection, Testing and Commissioning Requirements
9.1 Inspection and Testing During Manufacture
9.1.1 General
a) All inspection and testing shall be carried out in accordance with the Specification
and in absence of Specification relevant Indian Standard or internationally approved
equivalent standard. After award of contract, Contractor shall furnish a QA plan for
approval by Employer. QA plan shall include testing for incoming supply of raw
materials and bought out items, stage inspections and tests on finished products at
manufacturer‘s works / appropriate testing station. QA plan shall clearly indicate tests
which are intended to be witnessed by the Contractor alone and those by both
contractor and Employer.
b) Inspection and tests schedule shall be as follows;

1) Manufacture tests
2) Acceptance inspection (including Works Acceptance Testing)1 / Quantity
checking
3) Install /site inspection
4) Site acceptance test
5) Tests on Completion
6) Process Wet Tests (by Raw Sewage)
7) Operation Test (Tests After Completion)
8) Complete performance tests of Plant (Before plant handing over)
9) Test furnished as per IS Code/manufacturer QAP
c) The Contractor shall carry out at the place of manufacture tests of the Plant
/Equipment at any part of the Works as per approved QAP.
d) The Employer and/or duly authorised and designated representative(s) shall be

entitled to attend the aforesaid inspection and/or tests.
e) Notwithstanding the specific requirements of the QAP, the Employer and his duly
authorised representative shall have access to the Contractor‘s premises at all times
to inspect and examine the material and workmanship of the mechanical and
electrical plant and equipment during its manufacture there. If part of the plant and
equipment is being manufactured on other premises, the Contractor shall obtain
permission for the Employer or his duly authorised representative, to inspect as if the
plant and equipment was manufactured on the Contractors own premises. Testing
(including testing for chemical analysis and physical properties) shall be carried out
by the Contractor and certificates submitted to the Engineer who will have the right to
witness or inspect the above mentioned inspection /testing at any stage desired by
him. Where inspection or testing is to be carried out at a subcontractor‘s works, a
representative of the Contractor shall be present.
f) Contractor shall provide test procedure, pre-factory test results, and calculation
sheet, photo in advance and provide all of test result with necessary document
1 Works acceptance testing shall be required for selected items of equipment in accordance with the QAP

Part 9: Inspection, Testing and Commissioning Requirements
including its data and photo to show Engineer that test is carried out in proper
condition and the its test results. Construction material shall be tested by contractor
at the approved laboratory
g) The procedure for the testing and inspection to be carried out during or following the
manufacture of the materials to ensure the quality and workmanship of the materials
and to further ensure that they conform to the Contract in whatever place they are
specified shall be as described below.
i. The Contractor shall give the Employer at least 21 clear days notice in writing of
the date and the place at which any plant or equipment will be ready for
inspection/testing as provided in the Contract. Prior to notice, contractor should
submit pre factory test results as per clause 14.1.1(f) The Employer or his duly
authorised representative shall thereupon at his discretion notify the Contractor of
his intention either to release such part of the plant and equipment upon receipt
of works tests certificates or of his intention to inspect. The employer shall then
give notice in writing to the Contractor, and attend at the place so named the said
plant and equipment which will be ready for inspection and/or testing. As and
when any plant shall have passed the tests referred to in this section, the
Engineer shall issue to the Contractor a notification to that effect after obtaining
clearance from the consultants.
ii. The Contractor shall forward to the Employer 6 duly certified copies of the test
certificates along with characteristics performance curves/tables if any for all
equipment obtaining dispatch clearance from the consultants/Engineer
iii. If the Engineer(s) fails to attend the inspection and/or test, or if it is agreed between
the parties that the Engineer(s) shall not do so, then the Contractor may proceed
with the inspection and/or test in the absence of the Engineer and provide the
Employer with a certified report of the results thereof as per (ii) above.
iv. If any materials or any part of the works fails to pass any inspection / test, the
Contractor shall either rectify or replace such materials or part of the works and
shall repeat the inspection and/or test upon giving a notice as per (i) above. Any
fault or shortcoming found during any inspection or test shall be rectified to the
satisfaction of the Engineer before proceeding with further inspection of that item.
Any circuit previously tested, which may have been affected by the rectification
work, shall be re-tested.
v. Where the plant and equipment is a composite unit of several individual pieces
manufactured in different places, it shall be assembled and tested as one
complete working unit, at the manufacturer‘s works.
vi. Neither the execution of an inspection test of materials or any part of the works,
nor the attendance by the Engineer (s), nor the issue of any test certificate
pursuant to (iii) above shall relieve the Contractor from his responsibilities under
the Contract.
vii. The test equipment, meters, instruments etc., used for testing shall be calibrated
at recognised test laboratories at regular intervals and valid certificates shall be
made available to the Engineers at the time of testing. The calibrating instrument
used as standards shall be traceable to National/International standards.
Calibration certificates or test instruments shall be produced from a
recognised/Laboratory for the Engineer‘s consent in advance of testing and if

necessary instruments shall be recalibrated or substituted before the

commencement of the test.
viii. Items of plant or control systems not covered by standards shall be tested in
accordance with the details and program agreed between the Engineer and
Contractor‘s Representative. If such materials or works are found to be defective
or not conforming to the Contract requirements, due to the fault of the Contractor
or his sub-contractors the Contractor shall defray all the expenses of such
inspection and/or test and of satisfactory reconstruction.
ix. Tests shall also be carried out such that due consideration is given to the Site
conditions under which the equipment is required to function. The test certificates
shall give all details of such tests.
x. The Contractor shall establish and submit a detailed procedure for the inspection
of materials or any part of the works to the Employer for approval within the date
indicated in the Programme Details. The detailed procedure shall indicate or
specify, without limitation, the following :
 Applicable code, standard, and regulations.
 Fabrication sequence flow chart indicating tests and inspection points.
 Detailed tests and inspection method, indicating the measuring apparatus to
be used, items to be measured, calculation formula, etc.
 Acceptance criteria.
 Test report forms and required code certificates and data records.
 Method of sampling, if any sampling test to be conducted.
 Contractor‘s or Employer‘s witness points.
xi. The Contractor shall not pack for shipment any part of the Plant until he has
obtained from the Employer or his authorised representative his written approval
to the release of such part for shipment after any tests required by the Contract
have been completed to the Employer‘s satisfaction.
xii. The following Inspection and Testing procedures shall be carried out for the
equipment as per approved QAP.
The detailed procedure shall indicate or specify, without limitation, the following:
 Raw Material
 Visual Inspection/Appearance.
 Chemical and Mechanical property tests
 Dimension Checking
 Dynamic balancing for all rotating parts
 Stage inspection
 Hydrostatic / Leak testing for all pressure parts, Pneumatic Leak Test
wherever applicable
 Repair procedure
 Operation check
 Procedure Qualification Record (PQR); Welding Procedure Qualification
(WPQ) and Welders Qualification Report (WQR)
 Material Test
 Assembly/Connection
 Documentation

a) The Contractor shall maintain proper identification of all materials used, along with
reports for all internal / stage inspection work carried out, based on the specific job
requirement and or based on the datasheets / drawings / specifications.
b) The expenses incurred during inspection shall include, but not be limited to all
travelling, boarding, lodging and out-of- pocket expenses.
i. The Contractor shall be responsible for all expenses incurred by the Engineer or
person/s nominated by the Engineer in attending inspection and tests of Plant
carried out during manufacture within India and abroad. Normally two or three
persons from Employer side will witness the Inspection and testing along with the
contractor‘s representative.
ii. Cost of inspection when material or any part of the facilities is not ready at the
time specified by the Contractor for inspection or when re-inspection is
necessitated by prior rejection shall also be borne by the Contractor.
c) Witnessed testing will normally be waived on standard types of equipment such as

small motors made by approved manufacturers, individual standardised instruments,
small mass produced components used in the manufacture of Plant items, small bore
pipework and fittings, minor installation materials and low voltage cable. In order to
remove doubt this shall not relieve the Contractor of his obligation under the Contract
to ensure that all Plant is tested at the manufacturer's works prior to delivery to Site.
d) As a guide to the Contractor the Employer reserves the right to witness testing of the
following but not limited to the following Plant items:
a) Electrical:
i. Transformers
ii. 22/11 kV Switchgear and Controlgear Assembly or Switchboards.
iii. 415 V Switchgear and Controlgear Assembly or Switchboard (PCC)/(PMCC)/
(MCC)
iv. 415 V Power capacitor and APFC panel and Harmonic Mitigation System
v. Battery, battery charger and DC Distribution Board
vi. Variable Frequency Drives
vii. Non-Segregated Bus Duct
viii. High Voltage and Low Voltage Power Cables & control cables
ix. Lighting System
x. PABX and PA system
xi. Fire Detection and Alarm System
xii. Earthing and Lightning Protection System
b) Mechanical:
i. Storage and process vessels
ii. Clarifier and thickener bridges, drives, and sludge/scum mechanisms
iii. Chemical dosing systems complete with pumps, valves & tanks
iv. Mixers, pumps and blowers including their motors, Valve and penstock
actuators
v. Valves
vi. Pipes
vii. Sluice Gates
viii. Expansion/Dismantling Joints.
ix. Weir Gates
x. ISPS/TSPS Coarse Screens and STP Medium/Fine Screens
xi. Dewatering Unit and associated plant

xii. Fine Bubble Diffuser systems

xiii. Chlorination system and Cl2-Gas Scrubbers
xiv. H2S Gas Scrubber
xv. Process Air Blowers
xvi. EOT Cranes and Hoists
xvii. Decanter (if applicable)
xviii. Bio-gas engine / turbine and associated electrical generator
c) Instrumentation and Control:

i. Level Measuring System
ii. Pressure Gauges
iii. Pressure Transmitter
iv. Flow Measuring System
v. DO analyzer
vi. ORP analyzer
vii. Temperature Measuring System
viii. Residual Chlorine Measuring System
ix. Real time effluent monitoring system, Auto Samplers
x. Laboratory equipment‘s
xi. Instrumentation and Control Cables
xii. Instrument Control Panel
xiii. Programmable Logic Controller (PLC)
xiv. Vendor PLC system being tested at vendor supplied package works
xv. SCADA System
xvi. Uninterruptible Power Supply System
xvii. Wireless GPRS gateway testing
xviii. FAT & SAT for complete ICA system
d) All destructively tested samples shall be replaced with new.
e) The Employer reserves the right to be present during the testing and inspection
of all Plant items.
9.1.2 Materials, Plant, and Equipment
The Contractor shall place orders for the material and the equipment only after approval
QAP by the Engineer. The Contractor shall submit the detailed technical and its drawings
from the approved manufacturer and the procedure of submission, review and revision
shall be as specified herein below.
The Contractor shall inform the Employer about the likely dates of manufacturing,
testing, and dispatching of any material and equipment to be incorporated into the
Permanent Works. The Contractor shall notify the Employer for inspection and testing, at
least twenty-eight (28) days prior to packing and shipping and shall supply the
manufacturer's test results and quality control certificates.
The following inspection and test categories shall be applied prior to delivery of the
equipment, of various categories as indicated in the technical specifications for each type
of the equipment:
Category A: -The drawings or documents have to be approved by the Engineer before

manufacture and testing. The material and/or equipment has to be inspected by the
Engineer or a third party inspecting agency approved by the Employer at the
manufacturer‘s premise before packing and dispatching.

Category B: - The drawings or documents of the material and or equipment have to be

submitted and approved by the Engineer prior to manufacture. The material and or
equipment has to be tested by the manufacturer and the manufacturer‘s test certificates
are to be submitted and approved by the Engineer before dispatching of the equipment.
Notwithstanding the above, the Employer, after examination of the test certificates,
reserves the right to instruct the Contractor for retesting, if required, in the presence of
the Contractor‘s representative.
Category C: - Samples of the materials and/or equipment shall be submitted to the

Engineer for pre-construction review and approval, in accordance with the provisions of
Sub-Clause 5.5, Section 2. Following approval by the Employer, the material may be
manufactured as per the approved standards and delivered to the Site.
For material/equipment under Category ―A‖ and ―B‖, the Employer will provide an
authorization for packing and shipping after inspection or after approval of
Manufacturer‘s test certificates.
The testing and approval for dispatching shall not absolve the Contractor from his
obligations for satisfactory performance of the plant.
Dispatch Clearance
All mechanical/electrical/instrumentation, control and automation equipment shall be

tested at their respective factory which will be witnessed by tri parties (Contractor,
Employer /Consultant) in line with approved QAP and Equipment Data sheet.
The test observation sheets, material tests certificates (chemical and mechanical test at
laboratory) and joint inspection report shall be signed by the Contractor, Employer/
Consultant officials after successfully completion of tests.
Contractor shall forward all original reports to Employer and copy to Consultant for
verification and issuances of Dispatch Clearance Certificates as per clause 14.1.1 g (ii).
No Dispatch Clearance Certificate will be issued at the factory itself by the inspecting
agency
9.1.3 Factory Acceptance Test (FAT) Document
Fifty Six (56) days prior to commencement of inspection of each Plant item / equipment
the Contractor shall supply a Factory Acceptance Test (FAT) Document for approval.
This shall comprise four copies of the following:
 Unpriced copy of the Contractors order for the Plant item / equipment concerned:
 Details of the inspection and test procedures to be carried out.
 Pre-factory test results and its photos.
The FAT Plan shall provide comprehensive details of the tests to be carried out, the
purpose of each test, the equipment to be used in carrying out the test and the methods
to be adopted in carrying out the tests. The FAT shall provide space within the
documentation for results of the tests to be added and for each test and for the FAT as a
whole to be signed off by the Contractor and the Engineer.
On completion of the tests the Contractor shall provide four copies of all test certificates,
curves etc. for the inspected Plant item. To remove doubt test certificates shall be

provided for the Plant item as a whole plus certificates for the relevant component parts
such as:
 Motors;
 Mixers, pumps and Blowers;
 Instruments;
 Gear boxes;
 Electrical switchgear
 Integral control and switchgear panels;
 Valve gear;
 Castings.
 Actuators
 Cranes and Hoists
 Screens
 Girt removal mechanisms
 Diffusers
 Storage and process vessels
 Pumps /blowers
 Air blowers
 Centrifuge Decanters
 Disinfection equipment
 Anaerobic Digester mixing system
 Anaerobic Digester heating system
 Bio-gas scrubbers
 Bio-gas blowers
 Bio-gas storage units
 Bio-gas Engine and associated electric Generator set
 SBR Equipment and associated Plant (if awarded contract is on SBR process)
9.1.4 Inspection and Testing Programme
The Contractor shall submit to the Engineer not later than 56 days prior to the
commencement of the first inspection and test during manufacture a programme
detailing the inspection dates for all Plant. Those items of Plant that the Engineer has
specifically identified for witness testing test shall be highlighted in the programme.
The Contractor shall keep the Engineer informed of any changes to the programme.
The Engineer shall not be requested to inspect an item of Plant until the Contractor has
satisfied himself that the equipment meets all requirements of the Employer‘s
Requirements.
The Contractor shall inform the Engineer in writing at least 21 days in advance regarding
readiness for carrying out inspection of equipment/material etc. at manufacturer's works
or at places of inspection. The programme for inspection shall be finalised by the
Engineer after the receipt of the above case equipment/material etc. is found not to
comply with the specification, dates for re-inspection shall be finalised and expenses
incurred by the Employer for such visits shall also be recovered from the Contractor.
Contractor's Representatives shall essentially be present during all inspections of Plant
items. The following information shall be given in the inspection call letter mentioned
above:
a) Name of manufacturer/supplier;
b) Address of place where inspection is to be carried out;
c) Proposed date/s and equipment to be inspected;

d) Name/s of contact personnel at manufacturer's/ supplier/s works with their telephone

and fax numbers.
e) Name of Contractor's Representative who will be present during the inspection.
f) Confirmation that internal testing has been completed. Submission of internal testing
report for review before visiting the plant
The Contractor shall provide all the necessary instruments, test facility, water / electric
power, test piece, samples, engineers/ workers, all cost and others to carry out the tests
after assembly. All instruments used for such tests shall be calibrated and certified by
and approved by an independent testing authority not more than one month prior to the
tests in which they are used. Calibration certificates with expire date and name of
authorization agency for instruments used for such tests shall be produced for the
approval of the Engineer and if necessary, instruments shall be recalibrated before the
commencement of the tests.
No material shall be delivered to the Site without Dispatch clearance certificate having
been carried out or waived in writing by the Engineer.
If during or after testing, any item of plant fails to achieve its intended duty or otherwise
proves defective, it shall be modified or altered as necessary and retested and re-
inspected as required by the Engineer.
9.1.5 Tests at Manufacturer's Premises – Mechanical Equipment
9.1.5.1 Sewage / Sludge Pumps
a) All pumps shall be assembled completely in the shop to ensure correct fitting of all
parts and shall be match-marked before shipment.
b) All pumps shall undergo witness performance tests at the pump manufacturer‘s
Works. Testing shall be undertaken with the respective job motor for all the pumps
being supplied under the Contract.
c) All tests such as Q/H curve, efficiency of pumps, power consumption, vibration and
noise level shall be conducted, and NPSH tests one for each pumping station shall
be undertaken to verify that the pumps meet the specified criteria. The pumps shall
be run at constant flow capacity and speed.
d) Pump casings shall be subject to hydrostatic pressure testing as an assembly at
150% of the pump shut-off head or 200% of the pump rated head whichever is
higher. The hydrostatic pressure shall be held for not less than 30 minutes after all
leaks have been stopped between attachments.
e) Impeller and pump rotating assembly shall be dynamically balanced as per ISO 1940
/ Gr. 6.3 / VDI 2060.
f) Standard running test shall be conducted as per BS 5316 Part 2 Class B / ISO 3555
at the rated speed at manufacturer‘s works to measure the capacity, total head,
efficiency and power. These tests shall form the basis for pump acceptance except
for vibration and noise. The pump shall be tested over a range comprising shut off
head to maximum flow. Minimum seven readings approximately equidistant shall be
taken for plotting the performance curve.
g) The following formula shall be taken for computing the power input to the pump:
Power input to the Pump in kW: Q x Hx1.02

367.2 x p
Where, Q = Discharge in cum/hr

H = Total head in mwc

p = Efficiency of pump
h) If the vibration, noise level readings taken during performance test show higher than
that permitted, vendor shall guarantee to show that the values shall be maintained at
site after erection. Any cost of rectification needed on this count shall be borne by the
Contractor.
i) Stage inspection for pumps shall be carried out as per approved QAP/ The
Contractor has to make all necessary arrangement for witnessing the same.
9.1.5.2 Motors
a) Routine Tests
All routine tests shall be carried out on all motors as per the latest edition of IS 325.
b) Acceptance Tests
Full load test to determine efficiency, power factor and slip shall be conducted on all
the motors.
c) Type tests
The following type tests certificates shall be submitted on one motor of each rating
above 18.5 kW.
i. Temperature rise test
ii. Momentary overload test
iii. Vibration measurement test
iv. Noise level test
v. Over speed /over load test
vi. Starting current, starting torque, and pull out torque at reduced voltage
9.1.5.3 Valves and Expansion Joints
a) During testing there shall be no visible evidence of structural damage to any of the
valve component.
b) Motorized valves shall be tested with their job actuator, with a differential head
equivalent to their maximum working pressure, to prove that the actuators are
capable of opening and closing the valves under maximum unbalanced head
condition within the specified opening or closing period.
c) Hydrostatically tested shall be as per relevant IS/BS standard for each type of valve.
d) The following test shall be carried out for sluice valves, Knife Gate valves:
i. Seat leakage test.
ii. Body hydrostatic test.
iii. Valve operation.
iv. Dimensional Check.
v. Visual Inspection.
e) The following test shall be carried out for non-return valves:

i. Seat leakage test.
iii. Valve operation
f) The following test shall be carried out for Expansion Joints:

i. Leakage test.

iii. Displacement range.

9.1.5.4 Pipe-work
Testing of pipes and fitting shall be carried out in accordance with relevant Indian
Standard and internationally approved standard. Pipes, fittings and expansion bellows
shall be hydrostatically tested for 1.5 times the rated pressure.
The following test shall be carried out for pipelines:

i. Pressure test
ii. Leakage test
iii. LP test for welding pipeline
iv. Welding beat check
v. Dimensional Check
vi. Visual Inspection
9.1.5.5 Compressors and Blowers
Tests shall be carried out in accordance with the relevant international standard. All
compressors and blowers shall be tested with their ancillaries to confirm design
performance particularly in respect of flow and pressure. The test shall demonstrate that
vibration and noise are within the specified limits and that the pressure relief valve
operates correctly.
Air receiver shall be tested in accordance with the relevant section of B.S. 5169.
All pressure vessels shall be inspected and hydro water tightness tested. Test will be
conducted with Job Motors at Compressors/Blowers manufactures place
9.1.5.6 Process Plant Items
All process plant items shall be tested to ensure they meet the Employer‘s Requirements
for quality of workmanship, construction, and performance at the place desired by client
9.1.5.7 Crane & Hoists
The cranes shall be completely assembled in the Contractor‘s or subcontractor‘s Works

and shall be subjected to the tests as specified in IS 807/IS 3177 or relevant
internationally approved standard. The Contractor shall provide the test weights.
Hoists and lifting equipment shall be assembled and tested at the place of manufacture
in accordance with IS 3938.
Each and every rotating part/assembly/sub-assembly shall be dynamically balanced as

per grade G16 of ISO 1940/1 - 1986.
9.1.5.8 Sluice Gates
a) Seat Clearance Check
With the gate fully closed, the clearance between seating faces when checked with
the filler gauge, shall not exceed 0.1 mm.

b) Movement Tests
Each gate shall be shop operated Manually/Electrically three times from the fully
open position to the fully closed position and return to fully open, under no flow
conditions to demonstrate that the assembly is workable.
c) Leakage Tests
With the gate in closed position design pressure shall be applied for a period not
lesser than 5 minutes to the unseating side of the sluice gate and the leakage shall
not exceed the maximum leakage permissible as per IS 13349.
d) Hydrostatic Tests
Finally a differential of one and a half times the design pressure shall be applied to
the unseating side of the gate. Under these tests no part shall show any deflection of
deformation.
9.1.5.9 Medium and Fine Screens
a) All screens shall be checked for overall dimensions, assembly, and clearance
between the bars / space between a rake and bar surface / aperture size and its
material as well as painting works. Moreover, motion of rake/drum and wiper/self
cleaning arrangement shall also be tested at works
b) Conveyor shall be checked for dimensions and physical conditions, belt joint portion,
travelling accuracy of belt, motors and its power consumption, performance of safety
device.
c) At least one screen of each type shall be tested for efficiency and operation by
employing screenings. For the screen having depth of channel more than 3 metres,
testing with reduced depth is acceptable.
9.1.5.10 Fine Bubble Diffusers
a) Clean water Standard Oxygen Transfer Efficiency (SOTE) tests shall be performed
for each different diffuser grid geometry/arrangement proposed in the design. These
tests shall be performed by the diffuser Manufacturer at the Manufacturer‘s testing
facility or an equivalent facility appropriately equipped with an adequately sized
testing tank and other required appurtenances. The testing shall be performed in full
compliance with the latest version of the applicable standard testing protocol. These
tests shall be witnessed by Engineer per procedures set forth for witnessing
elsewhere in this document.
b) All diffusers including 5 % spares shall be thoroughly inspected by Contractor for

physical damage to the membrane or any other part of the diffuser and results of the
inspection shall be reported to Engineer.

9.1.5.11 SBR Equipment :
a) The Decanter and its accessory shall be checked by the Engineer for overall
dimensions, fabrication accuracy, pipe connection, material and pipe line, and a test
to confirm design performance particularly in respect of flow, pressure inspected and
hydro water tightness tested shall be carried out in accordance with the relevant
international standard or an acceptable manufacture test procedure.
b) The check or/and test shall demonstrate that Assembly‘s vibration and noise during
the test is within the specified limits and that operates correctly.
c) The overflow weir shall be checked the level of V-notch, maximum flow rate and
smooth operational movement.
d) All accessory including flow control valves, mooring facilities, discharge pipe, transfer
pumps, bubbling diffuser, blowers, air supply pipe and mixers, which shall be
checked and tested according to the testing procedure shown above respectively.
e) The testing shall be performed in full compliance with the latest version of the
applicable standard testing protocol. These tests shall be witnessed by Engineer per
procedures set forth for witnessing elsewhere in this document.
f) SBR Mixers: The tests shall include but not limited to Dimensional and appearance
check, Motor tests, Vibration and Noise level test, Performance test including
pressure test and sensor test.
9.2 Field test
The test 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.
Levelling tests:
1) Introduce clear water into each tank to the top of the diffuser elements.
2) Check the level of the diffusers to verify that all element horizontal surfaces are within
10 mm of a common horizontal plane and at the specified elevation.
Leakage and distribution of flow tests:

1) After successful completion of the levelling tests, raise the water level to 50mm
above the manifold.
2) Visually inspect the water surface to ensure that the airflow is uniformly distributed
across the tank.
3) Repair any leaks in the elements holders, elements, pipes or the like.
4) Repeat the test until the installation is essentially void of air leaks.
a) SBR Field Testing

b) The test will be verified any damage/missing part, No. of equipment to be
installed, material, location as specified in drawing, levelling including overflow
weir centreline, stable/solid installation and condition of installation to be fit in
levelling of decanter/overflow-weir/drain pipeline/ valves and their supports,
control valves, pumps, mooring facilities, mixers, Air-diffuser facilities/blowers,
etc.
c) Testing run will be conducted for verifying rotation direction, vibration, noise,
smooth motion/overflow weir performance and stability of installation and any
leakage, if possible.
d) The test will be verified to check maintenance space and ease of equipment
maintenance work.

9.3 Reinforced Cement Concrete Pipes
9.3.1 Testing
1) All pipes for testing purposes shall be selected at random from the stock of the
manufacturer and shall be such as would not otherwise be rejected under the criteria
of tolerances as mentioned in IS: 458.
2) Contractor shall provide laboratory test /analysis results of cement and aggregate
component and cement vs. aggregate vs. water mixing ratio and concrete mixing time
and mixing method.
3) During manufacture, tests on concrete shall be carried out as per IS:456. The
manufacturer shall supply, when required to do so by the Engineer the results of
compressive tests of concrete cubes and split tensile tests of concrete cylinders
made from the concrete used for the pipes. The manufacturer shall supply cylinders
or cubes for test purposes required by the Engineer and such cylinders or cubes shall
withstand the tests prescribed as per IS:458. Every pressure pipe shall be tested by
the manufacturer for the hydrostatic test pressure. For non-pressure pipes, 2 percent
of the pipes shall be tested for hydrostatic test pressure.
4) The specimen of pipes for the following tests shall be selected in accordance with
relevant clause of IS:458 and tests in accordance with the methods described in
IS:3597.
a) Hydrostatic test
b) Three edge bearing test
c) Absorption test
d) Dimension and colour of surface
e) Damage
9.3.2 Sampling and Inspection
1) In any consignment, all the pipes of same class and size and manufactured under
similar conditions of production shall be grouped together to constitute a lot. The
conformity of a lot to the requirements of this Employer‘s Requirements shall be
ascertained on the basis of tests on pipes selected from it.
2) The number of pipes to be selected from the lot for testing shall be in accordance
with Table 15 of IS:458.
3) Pipes shall be selected at random. In order to ensure randomness, all the pipes in
the lot may be arranged in a serial order and starting from any pipe, every r-th pipe
be selected till the requisite number is obtained, r being the integral part of N/n where
N is the lot size and n is the sample size.
4) All pipes selected shall be inspected for dimensional requirements, finish and
deviation from straight. A pipe failing to satisfy one or more of these requirements
shall be considered as defective.
5) The number of pipes to be tested shall be in accordance with column 4 of Table 15 of

IS:458. These pipes shall be selected from pipes that have satisfied the requirements
mentioned in the above clause.

6) A lot shall be considered as conforming to the requirements of IS:458 if the following

conditions are satisfied.
7) The number of defective pipes shall not be more than the permissible number given
in column 3 of Table 15 of IS:458.
8) All the pipes tested for various tests shall satisfy corresponding requirements of the
tests.
9) In case the number of pipes not satisfying requirements of any one or more tests,
one or two further samples of same size shall be selected and tested for the test or
tests in which the failure has occurred. All these pipes shall satisfy the corresponding
requirements of the test.
10) All destructively tested samples shall be replaced to new.
9.4 Steel Cylinders Pipes and Specials
9.4.1 Testing
a) Welding beat check Remove all scale on the welding points and welding beat and its
thickness shall be checked by the Engineer.
b) Penetration Test
A suitable penetrating liquid (kerosene oil/Dye) is applied to the surface of the

portion under examination and is permitted to remain there for sufficient time to allow
the liquid to penetrate into any defects open at the surface. After the penetrating
time, the excess penetrant, which remains on the surface is removed. Then a light
coloured powder absorbent called a developer is applied to the surface. This
developer acts as a blotter and draws out a portion of the penetrant which had
previously seeped into the surface openings. As the penetrant is drawn out it
diffuses into the coating of the developer, forming indication of the surface
discontinuities or flaws.
c) Each steel cylinder shall be subjected before lining/coating to a hydrostatic test under
a water pressure equivalent to the test pressure in accordance with Clause 10 of
IS:1916 and relevant provisions of IS:3597, provided that the whole of the area of the
calculated reinforcement is used in the steel cylinder. In the case of pipes where a
part of the principal reinforcement is provided in the cage, the steel cylinder shall be
subjected to proportionately less hydrostatic test pressure.
d) Manufacturer's standard specials shall be hydrostatically tested before lining/coating.

Where feasible, other specials shall be hydrostatically tested (before lining/coating) at
factory. However, when this is not practicable, at the discretion of the Engineer, the
unlined specials shall be tested by penetration test as per IS:3658 or other approved
means.
e) The contractor has to submit QA/QC and methodology for welding works
f) Approval of welding rods
g) Welders qualification Test

9.5 Cast Iron / Ductile Iron Pipes
9.5.1 Mechanical Tests
Mechanical chemical tests shall be carried out during manufacture of pipes and fittings
as specified in relevant IS codes. The results so obtained shall be considered to
represent all the pipes and fittings of different sizes manufactured during that period and
the same shall be submitted to the Engineer. The method for tensile tests and the
minimum tensile strength requirement for pipes and fittings shall be as per relevant IS
codes.
9.5.2 Brinell hardness Test
For checking the Brinell hardness, the test shall be carried out on the test ring or bars cut
from the pipes used for the ring test and tensile test in accordance with IS 1500.
9.5.3 Retests
If any test piece representing a lot fails in the first instance, two additional tests shall be
made on test pieces selected from two other pipes from the same lot. If both the test
results satisfy the specified requirements, the lot shall be accepted. Should either of
these additional test pieces fail to pass the test, the lot shall be liable for rejection.
9.5.4 Hydrostatic Test
For hydrostatic test at works, the pipes and fittings shall be kept under test pressure as
specified in relevant IS codes they may be struck moderately with a 700 g hammer. They
shall withstand the pressure test without showing any leakage, sweating or other defect
of any kind. The hydrostatic test shall be conducted before coating the pipes and fittings.
9.6 Chlorination and Gas Pipeline System
a) All items of plant shall be tested at manufacturer's works and test certificates shall be
provided.
b) All chlorine gas piping from chlorine drums to chlorinator shall be pressure tested with
dry air/nitrogen to a pressure of 15 kg/sq.cm.
c) The chlorine gas piping from the chlorinators up to injectors shall be pressure/vacuum
tested with dry air/nitrogen to a pressure/vacuum equal to 1.5 times the maximum
pressure/vacuum to be encountered during operation.
d) The motive water piping shall be hydrostatically tested for a pressure of 1.5 times the
operating pressure or the maximum pump discharge pressure at pump shut off
whichever is higher.
e) After the chlorine system has been completely tested as above leak tests shall be
conducted admitting chlorine gas. Leakages if any shall be identified using ammonia
stick. During this test all chlorine leak detectors shall be in place and all safety
procedures shall be adhered to.
f) Gas cylinder shall provide the pressure test certificate issued by authority and
manufacture year.
g) Chorine gas detector sensors shall be tested, and results shall provide to the Engineer.

h) Ventilation System :
The ventilation fans shall be tested at manufacturer's works to verify the design flow and
pressure.
i) Process Plant Items;
All process plant items shall be tested to ensure they meet the Employer‘s Requirements
for inlet and outlet quality of workmanship, construction and system performance.
9.7 Bio Gas Engine and Power Generator (for contracts that include power generation)
9.7.1 Bio Gas Engine
The engine shall be tested with biogas or natural gas at manufacturer works assembled with
power generator. Test shall be carried on after at least 10 hrs in a continuous Engine running
time under normal operation including idling adjustment.
Contractor shall provide the test procedure in advance for review and approval.
The results shall be evaluated by calculated and measurement data to verify weather all data is
cover the specification or not at manufacture.
Works shall include but not necessary be limited to the following;

a. Normal: 90%-100% load.
b. Load change test:115%
c. No load test: 0%
Work shall include but not necessarily be limited to the following;

i. Quantity checking
(1) Engine model /Type
(2) Appurtenances
(3) Level of humidity (room)
(4) Spare parts
a) Appearance test
b) Dimensions.
c) Weight (Engine and Cogeneration)
d) Performance test
i. Starter (Auto/Manual)
ii. Main piston speed (rpm)
iii. Fuel consumption
iv. Specific fuel consumption (Fuel Vs. output HP)
v. Efficiency of Engine out put
vi. Time for Engine stability.

vii. Quick over load test.

viii. Acceleration test
ix. Safety performance (Emergency stop etc)
x. Fluctuation of engine temperature.( room air and engine)
xi. Noise level (db)
xii. Vibration
xiii. Emission test (Suspended Particulate Matter, Sulphur Dioxide, Nitrogen
Dioxide, Photochemical Oxidants as Ozone, Carbon Monoxide, Lead, Carbon
dioxide)
xiv. Jacket Water ( Flow, inlet outlet water temperature)
xv. Exhaust gas (Flow, Temperature)
xvi. Performance of Appurtenances (Oil pumps, water pumps, heat exchangers,
cooling tower, pressure relief valves, valves, gauges, expansion joints, muffler)
9.7.2 Power Generator (50Hz)
The power generator shall be tested by assembled system with engines. Test shall be carried
on after at least 10 hrs in a continuous Engine and Power Generator operating time under
normal operation including idling adjustment.
Contractor shall provide the test procedure in advance.
The results shall be evaluated by calculated and measurement data to verify weather all data is
cover the specification or not at manufacture.
Work shall include but not necessary be limited to the following;

(1) Normal: 90%-100% load.
(2) Load change test:115%
(3) No load test: 0%
Scope of supply shall include Generator set and cogeneration system.
Inspection Work shall include but not necessarily be limited to the following;
a) Quantity checking
b) Power generator model /Type
c) Isolation method
d) Level of humidity (room)
e) Appurtenances
f) Spare parts
e) Appearance test
f) Dimensions.
g) Weight
h) Performance test
(1) Fluctuation of motor temperature.( room air and motor)

(2) Motor speed (rpm)

(3) Power factor
(4) Voltage drop(Max, Total)
(5) Insulation resistance
(6) Power generation efficiency
(7) Amount of generated electric.
(8) Performance of follow suit and stability.
(9) Over load test
(10) Acceleration test
(11) Wavelength stability.
(12) Performance of Quick over load test.
i) Emergency stop
j) Noise level (db)
k) Vibration
l) Control panel
m) Performance of Appurtenances (Battery, solenoid valves)
9.8 Mechanical Equipment
All mechanical equipment shall be tested at site as following items in bellow,
a) The test will be verified any damage/missing part, No. of equipment to be installed,
material, location as specified in drawing, levelling, centreline, solid installation and
condition of installation to be fit in levelling of pipeline and valves.
b) Testing run will be conducted for verifying rotation direction, vibration, noise, and
stability and any leakage, if possible.
c) The test will be verified to check maintenance space and ease of equipment
maintenance work.
d) The testing shall be performed in full compliance with the latest version of the
applicable standard testing protocol. These tests shall be witnessed by Engineer per
procedures set forth for witnessing elsewhere in this document.
9.9 Tests at Site
a) In addition to the progressive supervision and inspection by Engineer, the Contractor

shall offer for inspection to Engineer, the completely erected plant/part of Plant on
which tests are to be carried out. After such inspection, each equipment/sub-system
shall be tested by the Contractor in accordance with the applicable standards in the
presence of Engineer. Such tests shall include but not be limited to the tests
specified in following clauses.
b) The Contractor shall possess during the entire working period the Electrical
Contractor's licence of appropriate class from the concerned statutory authorities
governing the area of work place. The Contractor shall fully comply with the relevant
statutory rules and regulations. On completion of the installation or at intermediate

stages, if required by the statutory authorities, the Contractor shall arrange for
inspection and obtain the approval from the concerned statutory authorities. If any
fees are to be paid to statutory authorities for testing, inspection and calibration these
shall be paid by the Contractor and shall be included in his erection and
commissioning charges.
9.10 Pumps, Piping and Valves
a) The erected pipe work shall be subjected to a hydraulic test at 1.5 times the
maximum pressure or twice the working pressure whichever is higher to test the
soundness of the joints. Provision of the necessary pumps, gauges, blank flanges,
tappings etc. for carrying out these tests shall be included in the Contract. All gas
piping shall be air tested to twice normal working pressure.
b) Leakage tests shall be carried out on all erected pipework, pumps and valves
immediately after erection and where possible before being built in.
c) Operating tests shall be conducted on valves.
d) The pump set shall be tested for satisfactory operation. The vibration and noise level
shall be checked to be within the specified limits.
9.11 Motors
Condition of winding insulation be tested and insulation values shall be restored to

required level by suitable heating arrangements locally.
9.12 Cranes
The crane and lifting tackle shall be tested to 125% of the safe working load. The
Contractor shall arrange the test load. The contractor shall also arrange for the
appropriate certificates from the concerned authorities before regular use of the cranes
and other lifting equipment.
9.13 Screens
After erection, all screens screen shall be tested for smooth operation and capability to
handle typical wastewater solids including stringy materials. Clearance between the
dead plate and tines shall be checked as applicable.
9.14 Gates
a) Leakage test shall be performed by the Contractor after installation of all Gates.
b) Under the design seating head and unseating head the leakage shall not exceed the
limit specified in IS:13349, for shop testing.
9.15 Reinforced Cement Concrete Pipes
a) After laying and jointing of RCC pipes is completed the pipe line shall be washing out
with sufficient water and be tested at work site as per the Employer‘s Requirements
and as directed by the Engineer. All equipment for testing at work site shall be
supplied and erected by contractor. Water for testing of pipes shall be arranged by
him. Damage during testing shall be contractor's responsibility and shall be rectified

by him to full satisfaction of the Engineer. Water used for the test shall be removed
from pipes and not released to the excavated trenches.
b) After the joints have thoroughly set and have been checked by the Engineer and
before back filling the trenches, the entire section of the sewer or storm water drain
shall be proved by the contractor to be water tight by filling in pipes with water to the
level of 1.50m above the top of the highest pipe in the stretch and heading the water
up for a period of one hour.
c) The apparatus used for the purpose of testing shall be approved by the Engineer.
Contractor if required by the Engineer shall dewater the excavated pit and keep it dry
during the period of testing. The loss of water over a period of 30 minutes should be
measured by adding water from a measuring vessel at regular 10 minutes intervals
and noting the quantity required to maintain the original water level. For the approval
of this test the average quantity added should not exceed 1 litre/ hour/100 linear
metres / 10mm of nominal internal diameter. Any leakage including excessive
sweating which causes a drop in the test water level will be visible and the defective
part of the work should be removed and made good.
d) In case of pressure pipeline, the completed stretch of pipeline shall be tested for site
test pressure. The site test pressure should not be less than the maximum operating
pressure plus the calculated surge pressure, but in no case should it exceed the
hydrostatic test pressure as specified in IS: 458.
9.16 Steel Cylinder Pipes and Specials
a) After laying and jointing of steel cylinder pipes and specials with concrete lining and
coating is completed the pipeline shall be washing out with sufficient water and be
tested at work site as per the following Employer‘s Requirements and as directed by
the Engineer. All equipment for testing at work site shall be supplied and erected by
Contractor. Water for testing of pipes shall be arranged by him. Damage during
testing shall be Contractor‘s responsibility and shall be rectified by him to the full
satisfaction of the Engineer. Water used for test shall be removed from pipes and not
released to the excavated trenches.
b) Each section of the pipe line shall be slowly filled with clean water and all air shall be
expelled from the pipeline. The pressure in the pipeline should then be raised and
maintained by means of pump to the test pressure. The test pressure should not be
less than 1 1/2 times the working pressure at the lowest point or the static head
pressure, whichever is higher. Under the test pressure no leak or sweating shall be
visible at the welded joints. The duration of test shall be not less than 24 hours. The
exposed joints shall be carefully examined and all such joints showing visible leaks
shall be rewelded. Any cracked or defective pipes and specials in consequences of
this pressure test shall be removed and replaced by sound material by Contractor
and the test shall be repeated to the satisfaction of the Engineer.
c) Hydrostatic shop test for pipes and fittings shall be as per code/standard
requirement. After erection at site, complete pipes and fittings shall be hydrostatically
tested for a pressure of 1.5 times operating pressure.
d) Where directed by the Engineer welded joints on pipes larger than 675 mm diameter
shall be subject to a nitrogen gas test after welding.

e) A tapped hole (approximately 6 mm diameter) shall be made in the socket end of

each pipe by the Contractor and shall be fitted with a suitable non-return valve.
Nitrogen, at 400 kPa pressure, shall then be pumped into the annular space between
the spigot and socket and the pump disconnected.
f) If no drop in pressure occurs over the ensuing period of 30 minutes the test shall be
deemed to be successful. If the test pressure cannot be maintained for 30 minutes all
defects in the weld shall be cut back and rewelded and the test reapplied until
successful. The cost of initial and subsequent testing of defective welds shall be at
the Contractor's own expense.
g) The Contractor shall provide all items necessary for the nitrogen tests including
compressor, valves, gauges and tubing.
9.17 Cast Iron, Ductile Iron Pipes and Fittings
a) After the pipes and fittings are laid, jointed and the trench partially backfilled except
at the joints the stretch of pipe line as directed by Engineer shall be subjected to
pressure test and leakage test after washing the pipe line out with sufficient water.
Where any section of the pipeline is provided with concrete thrust blocks or
anchorages, the pressure test shall not be made until at least five days have elapsed
after the concrete was cast. If rapid hardening cement has been used in these blocks
or anchorages, the tests shall not be made until at least two days have elapsed.
b) Each section of the pipe line shall be slowly filled with water and all air shall be
expelled from the pipe by tapping at points of highest elevation before the test is
made and plugs inserted after the tests have been completed. The specified test
pressure based on the elevation of the lowest point of the line or section under test
and corrected to the elevation of the test gauge shall be applied by means of a pump
connected to the pipe as directed by the Engineer.
c) The duration of test shall not be less than 5 minutes. The exposed joints hall be
carefully examined and all such joints showing visible leaks shall be recaulked until
water tight. Any cracked or defective pipes and fittings in consequence of this
pressure test shall be removed and replaced by sound material by Contractor at no
extra cost to the Engineer and the test shall be repeated to the satisfaction of the
Engineer.
d) After the satisfactory completion of pressure test, the section of pipe line shall be
subjected to leakage test. The duration of test shall be 2 hours. No pipe installation
shall be accepted until the leakage is less than the number of cm3 /h as determined
by the formula:
NDP
qL = ___________
3.3
Where,
qL = The allowable leakage in cm3/hr
N = Number of joints in the length of the pipeline
D = Diameter in mm, and
P = The average test pressure during the leakage test in Kg/cm2

Should any test of pipe laid indicate leakage greater than that specified above, the
defective joints shall be repaired by Contractor at no extra cost to the Engineer until the
leakage is within the specified allowance.
e) Necessary equipment and water used for testing shall be arranged by Contractor at
his own cost. Damage during testing shall be Contractor's responsibility and shall be
rectified by him at no extra cost to the Engineer. Water used for testing shall be
removed from the pipe and not released in the excavated trenches.
f) After the tests mentioned above are completed to the satisfaction of the Engineer,
the backfilling of trenches shall be done as per the Employer‘s Requirements
specified elsewhere.
9.18 Manufacturer's Works Acceptance Tests on Electrical Equipment
The Electrical equipments / items/systems as referred in clause number 14.1.1.k shall be

subjected to inspection, routine /acceptance tests as per latest edition of relevant Indian /
International standards in the presence of Employer/ his Engineer
All the routine tests on respective electrical equipment‘s and systems shall be performed
as mentioned in the General Technical Specification in compliance with the latest Indian
Standard (IS) and International Electro-Technical Commission(IEC) standards.
Copies of test Certificates for the Type tests and Special tests conducted not before 10
years as per relevant Indian / International Electrotechnical Commission (IEC) Standards
for all the equipment /items/Systems of above shall be furnished for the perusal of
Employer / his Engineer. If type tests and special tests have not been conducted on any
of these items, the same shall be carried out in the presence of Engineer at no extra
cost.
9.19 Manufacturer's Works Acceptance Tests on Instrumentation, PLC, SCADA and

Associated Equipment
A) Instrumentation:
Inspection, Testing and Setting to Work:
General
Each item of plant shall be subjected to the manufacturer‘s own tests which shall be
certified.
Each item of plant and its installation shall be subject to inspection and testing at the
place of manufacture.
The Contractor shall be responsible for the provision of all necessary test equipment.
The Contractor shall demonstrate to the Engineer, the correct operation of any item of
plant and the Engineer may witness any test. Tests which, in the opinion of the Engineer,
were failed or not performed correctly shall be repeated.
Calibration tests for field instruments and analytical instruments should be conducted on
site after installation and the same should be witnessed by the Engineer.

Before any test is made, the Contractor shall submit to the Engineer a full list of test
equipment & test procedures (method statements) to be used. Each item of test
equipment shall have a standard of accuracy better than that stated by the manufacturer
of the item to be tested. The Contractor shall provide evidence of the condition and
performance of any item of test equipment, in the form of test certificates issued by an
appropriate authority independent of the Contractor and manufacturer, or as otherwise
directed by the Engineer. Test equipment shall be checked frequently during the period
of the tests.
The Contractor‘s staff responsible for supervising and carrying out tests shall be fully
conversant with the various items of equipment of other manufacturers and if necessary
the Contractor shall arrange for his personnel to attend suitable training courses on his
own expense.
Any fault or shortcoming found during any inspection or test shall be rectified to the
satisfaction of the Engineer before proceeding with further inspection or testing of that
item. Any circuit previously tested, which may have been affected by the rectification
work, shall be re-tested.
Preliminary Inspection and Testing at the Place of Manufacture
Field-mounted instruments
After the successful completion of the manufacturer‘s own inspection and testing of
instruments supplied under the Contract, similar tests shall be carried out in the
presence of the Engineer and the Contractor. Such tests shall include a demonstration
that an increase or decrease of the measured value at several points over the full range
of the instrument produces a corresponding increase or decrease in the instrument
output signal. These tests shall include checks on the specified accuracy of the
instrument at all points.
Instrument panels, enclosures and mounting boards
The manufacturer shall not present instrument panels, enclosures and mounting boards
(assemblies) for inspection and testing until the manufacturer‘s own tests and inspection
has been completed. A preliminary inspection and test of these assemblies may then be
witnessed by the Engineer. The Contractor shall give not less than 7 days‘ Prior notice in
writing that he has completed.
His tests and inspection and is ready for the witnessed tests and inspection. Where this
notice period is different in the Conditions of Contract this shall take precedent.
The witnessed inspection and testing shall include the following:

a) A visual inspection of the panel assembly to show that the design, construction and
finish are satisfactory and in accordance with the Specification;
b) A check that equipment is securely mounted, accessible for removal or calibration
without damage to or undue disturbance of other components, wiring or piping;
c) That all engraving and labels are correctly positioned, fixed and designated in
accordance with the Specification;
d) Panel power-distribution circuits have the correct breaker/fuse rating coordination
and designation;
e) Power-isolation facilities meet the Specification;

f) The main incoming supply voltage, frequency and/or pneumatic supply pressure is
within the required limits, these being checked at the beginning and end of the test
and the results recorded on test certificates;
g) The output of all power supply units again at the beginning and end of the testing
with results being recorded;
h) The power supply voltage or air pressure of all component instruments of the
assembly(s), these voltages/pressures being recorded on the test certificate;
i) The insulation resistance of all circuits except sensitive electronic equipment which is
liable to damage by application of the test voltage, such circuits being disconnected
before making the insulation resistance tests and these tests being carried out in
accordance with IEE Wiring Regulations;
j) That the clean earth bar is isolated from main frame of the panel.
Internal lighting and anti-condensation heaters and associated thermostats, isolators,

limit switches and wiring shall be checked for compliance with the Specification.
Spare capacity within the panel(s) shall be checked to see that it complies with the
Specification. This shall include future equipment space, spare terminals, space in wiring
trunkings and provision for additional cable entry.
Functional Testing at the Place of Manufacture
General requirements
Once the preliminary inspection and testing is complete to the satisfaction of the
Engineer, functional testing shall commence. The purpose of the functional tests are to
demonstrate that instrument panels enclosures and mounting boards (assemblies)
conform with requirements of the Specification.
Not less than 30 days before the commencement of functional tests, the Contractor shall
submit to the Engineer, for approval, two copies of comprehensive test procedural
documents detailing each test to be carried out. The document shall include results
forms on which the results of each test will be entered. The forms shall include spaces
for numerical values, where necessary, and witness signatures.
All applicable drawings and data shall be provided at the place of inspection by the
Contractor.
The Contractor shall provide all test instruments and equipment necessary to test the
assemblies in their entirety.
The following is a typical list of the equipment required:

 Switch boxes;
 Indicator light boxes;
 Analogue signal sources;
 Dummy loads;
 Meters;
 Simulators;
 Desk-top computers;
 Programmers for DCS or outstations;
 Insulation test equipment
B) Programmable Logic Controller (PLC) and SCADA

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 control panel containing the PLC
and associated equipment in order to demonstrate correct functional operation of the
hardware and software systems.
Factory Acceptance Test (FAT)
The Contractor shall conduct a full programme of tests of the PLC & SCADA system at
the Contractor‘s testing facility in the presence of the Engineer to verify that all features
of the system have been provided, are operating correctly and are in full compliance with
the Specification. FAT shall include PLC based SCADA system for STP and PLC based
control system with panel mounted HMI for ISPSs/TSPS(s) with wireless communication
system for the all of the above. Unless otherwise specified or agreed by the Engineer,
the entire PLC & SCADA system shall be assembled and tested together as an
integrated system, including all master station equipment, all operators‘ consoles, all
outstations and telemetry equipment all instrumentation panels and uninterruptible power
supplies included in this Specification. The scheduled date for the factory acceptance
test shall be as agreed by the Contractor and the Engineer at least four weeks before the
test. FAT shall be conducted with a hardwired simulation panel connected to the PLC
based SCADA system. Contractor shall note the importance of the requirement. No
software based simulation testing shall be accepted or allowed.
Not less than one month before the scheduled factory acceptance test, the Contractor
shall submit to the Engineer for approval two copies of a comprehensive manual
detailing each test to be conducted. The manual shall include a results form on which the
results of each test will be entered, including spaces for numerical values where
appropriate and witness signatures.
Not less than 7 days before the scheduled factory acceptance test, the Contractor shall
give written notification to the Engineer that a complete dry-run of the factory acceptance
test has been performed successfully and that, in the opinion of the Contractor, the
system exhibits stable operation and is ready for the formal factory acceptance test.
The factory acceptance test will be considered successfully completed only when the
system has successfully passed all factory tests. The system shall not be delivered to
Site until the successful completion of the factory acceptance test is certified by the
Engineer or unless otherwise approved by the Engineer. Delay in the delivery of the
system due to failure of the factory acceptance test shall not constitute an unavoidable
delay. If the system fails the factory acceptance test, the test shall be extended or
rescheduled at the discretion of the Engineer.
All hardware to be used in the testing of the system shall have passed an agreed
preliminary hardware performance test to ensure known hardware operability before
software testing begins.
After successful completion of the factory acceptance test, no software changes shall be
made to the system without written authorisation by the Engineer. Any changes to the
system which effect the system software documentation, such as input scale
modifications or changes to the control logic, shall be entered into the system
documentation before delivery of the system to Site. All instruments under IC&A scope
has to be tested 100%.
Factory Acceptance Test Procedures

General
The scope of the tests shall include the proving of every aspect of hardware and
software operation and functions as detailed below.
Hardware tests
a) Verify the correct inventory of hardware including cables and printed circuit boards;
b) Demonstrate that all spare-memory, disk-capacity and system-expansion
requirements have been met;
c) Demonstrate all hardware and software diagnostics;
d) Verify all power supply voltages are within tolerance;
e) Verify proper earth connections and isolation of instrumentation earth for all
equipment;
f) Demonstrate operation of test simulation and indication equipment and its Suitability
for adequate functional testing of all system functions.
Software Tests
a) Demonstrate the editing of all system parameters including set-points, timers and the
like;
b) Demonstrate system configuration capabilities including the addition and deletion of
input and output points, outstations, and all data base parameters;
c) Demonstrate the addition, deletion and modification of mimic displays and report
formats;
Functional Tests
The functional tests shall verify proper operation of every specified system function as an
integrated system. These tests shall be conducted in conjunction with functional tests of
instrumentation and control panels as specified elsewhere. All failures or discrepancies
found shall be documented in the test manual.
Following a failure of any functional test, should software or hardware modifications be
required it shall be the decision of the Engineer whether the factory acceptance test is to
continue, re-start or be aborted. If testing is allowed to continue, any changes which are
required shall be described in a system modification document, signed by both
Contractor and Engineer and be incorporated into the final factory acceptance test
documentation. The failed test shall be re-conducted and the Engineer may require the
retest of functions which may be affected by the modification.
The functional tests shall include, as a minimum, the following:
a) Demonstration that the system meets the requirements of the Specification for
response time and speed of screen update;
b) Verification of the accuracy of all analogue input points in the system. The procedure
shall include applying the appropriate signal to each analogue input at a minimum of
three points within the range of the input, checking for expected numerical results,
and verifying appropriate update of related mimic displays. Proper sensing and action
by the system to high and low out-of-range inputs shall also be verified;
c) Verification of the proper logic sense, pulse accumulation and rate computation
where appropriate, of all digital inputs and verifying appropriate update of related
mimic displays;
d) Verification of all control and sequencing operations and proper operation of all digital
and analogue outputs. The procedure shall include simulation of all related process

variables for both normal and abnormal conditions, including instrument and
component failure, and demonstration of fail-safe response of the system. System
outputs shall be indicated with appropriate lamps and indicators;
e) Simulation of outstation communications errors and failures and demonstration of
error detection and handling, failure detection and handling, and appropriate changes
to control actions as designed and specified;
f) Verification of fault detection and diagnostics by inducing a sufficient variety of fault
conditions in the system to ensure that detection processes and fail-safe operation
are adequately tested;
g) Demonstration of proper operation of all mimic displays, help pages, reports,
operator procedures and historical data accumulation;
h) Demonstration of proper operation of all outstations following a simulated master
station central processor failure;
i) Demonstration of proper operation of all equipment during both a system wide or
isolated power failure, and following power restoration. The procedure shall include
the demonstration of battery backup of both master station and outstation for the full
length of time specified, and proper operation of power fail, low voltage warning and
all associated alarms.
Reliability Test
After successful completion of the functional tests a 48-hour continuous run of the
system shall be performed. The test shall be passed if no system function is lost or no
hardware or software failure occurs. Hardware failure is defined for this test as the loss
of a major component such as the computer, an outstation, a VDU or a peripheral
device. Non-repetitive mechanical failures of loggers, push-buttons and the like are
excluded.
During this test, the system shall be exercised with simulated inputs and conditions in a
manner which approximates the on-site operational environment. Unstructured testing by
the Engineer shall be included during this test. Upon any system failure during this
period, it shall be the decision of the Engineer whether the reliability test is to continue or
be aborted. If testing is allowed to continue any changes to the system which are
required shall be described in a system-modification document, signed by both
Contractor and Engineer and the document shall be incorporated into the final factory
acceptance test documentation.
Factory Acceptance Test Documentation
As a minimum, the following information shall be included in the factory Acceptance test
manual for each test:
 Test identification number;
 Test name and description;
 List of all equipment to be tested including any special test equipment required;
 Description of the test procedure broken down into logical steps;
 Description of the expected system response verifying the completion of each logical
step;
 Space for recording the results of the test and the time and date of the test;
 Space for signatures of the Contractor and the Engineer.
In addition, the Contractor shall provide a method for recording and tracing all problems,
discrepancies, queries and suggestions regarding the system and software, and for
formalised control of any modifications to the system.

Pre-commissioning Tests
The Contractor shall perform pre-commissioning, or preliminary, testing of the SCADA

system in accordance with that specified for instrumentation. The purpose of pre-
commissioning tests is to confirm readiness of the system for commissioning.
The scope of pre-commissioning tests shall be generally as specified for factory

acceptance tests but real field inputs and final control elements shall be used wherever
practical to provide inputs to the system and to confirm proper outputs.
Where this is impractical, simulation signals shall be injected as near as possible to their
ultimate sources so as to include in the tests as much of the cabling system as possible.
Each process system shall be set to work under manual control and the system tested to
confirm proper operation. After proper operation of manual control mode has to be
verified, tests of automatic controls of each process system shall be conducted wherever
practical.
Commissioning
Site Acceptance Tests (SAT)
The Contractor shall submit all relevant draft operating manuals for the PLC & SCADA
System to the Engineer for approval prior to commissioning tests.
Any faults or failures of the system detected during the previous tests shall be noted and
corrected to the satisfaction of the Engineer before commissioning is allowed to
commence.
As part of commissioning, the PLC & SCADA system shall be tested for availability for a
continuous period of 60 days. During this period, the system will perform the normal
functions according to the procedures described in the SAT documentation approved by
the Engineer.
The system shall have passed the SAT if all major components have been free from fault
or failure and exhibit full error-free functionality for 100 % of the total duration of the test,
unless otherwise agreed by the Engineer. Major components include all master station
equipment, outstations, communications facilities and instrument panel components,
excluding push-buttons, switches and lamps and any equipment not supplied by the
Contractor.
During SAT, no modifications to the system shall be made by the Contractor without the
written approval of the Engineer. Erroneous functioning which requires software
modifications or re-configuration to correct, other than set-point or parameter changes,
shall constitute a failure of the availability test. Any changes to the system which are
required and approved shall be described in a system-modification document, signed by
both Contractor and Engineer and the document shall be incorporated into the final test
documentation. The test shall be restarted after corrections have been made.
9.20 Manufacturer's Works Acceptance Tests on Uninterruptible Power Supplies
The Contractor shall carry out further 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:

1) Change-over from full load with mains present to full load on battery supply
2) Carry out a discharge test on the system at full load and for the specified duty
bridging time period.
3) 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.
9.21 Inspection at Site
During erection of the Plant the Engineer will inspect the installation from time to time in
the presence of the Contractor's Supervisor to establish conformity with the requirements
of the Specification. Any deviations found shall be corrected as instructed by the
Engineer.
9.22 Plant Protection on Site
Factory finished plant shall be adequately protected both before and during installation
against damage to finished surfaces, fitted components, and the ingress of dust. It may
be necessary for structural finishing operations to be carried out in the vicinity of installed
plant before it is taken over and the Contractor shall take this into consideration in
complying with the requirement of this clause.
9.23 Erection staff
The Contractor shall provide at least two approved senior English speaking working
erectors to supervise the erection of all Plant in the Contract and in each case to act as
the Contractor's Representative as set out in Clause 13 of the general conditions of
contract.
In the case of a foreign firm based overseas the Contractor's Representative shall be
thoroughly conversant with the manufacturer's Plant and equipment, and its erection and
shall be an expatriate.
The Contractor shall also provide sufficient erectors skilled in electrical, mechanical and
instrument engineering, with such skilled, semi-skilled and unskilled labor as are
necessary to ensure completion of the various sections of the Contract in the time
required. The Contractor shall not remove any supervisory staff or labor from the site
without the prior approval of the Engineer.
The Engineer will give the Contractor at least one month's notice in writing of the date on
which the erection staff will be required on site, and the Contractor shall confirm the date
of arrival in writing to the Engineer. The Contractor shall make all the necessary
arrangements to ensure that sufficient plant has been or is about to be delivered to site,
so that there shall be no delay to the start of erection.
It shall be the responsibility of the contractor to obtain necessary License / Authorization

n/Permit for work from the Licensing Boards of the Locality/State where the work is to be
carried out. The persons deputed by the Contractor‘s firm should also hold valid permits
issued or recognized by the Licensing Board of the Locality/State where the work is to be
carried out.

9.24 Erection and Building-in
The installation work shall comply with the latest applicable Standards, Regulations,
Electricity Rules and Safety Codes of the locality where the installation is to be carried
out. Nothing in this specification shall be construed to relieve the Contractor of this
responsibility.
It will be the Contractor‘s responsibility to obtain approval/clearance from local statutory
authorities including Electrical Inspector, wherever applicable for conducting of any work
or for installation carried out which comes under the purview of such authorities.
The Contractor shall carry out the complete erection of all plant, including the provision
of all necessary skilled and unskilled labor, material, transportation, supplies, power and
fuel, Contractor's Equipment and appurtenances necessary, for the complete and
satisfactory erection of the Plant.
The Contractor shall have a separate cleaning gang to clean all equipment under
erection and as well as the work area and the project site at regular intervals to the
satisfaction of the employer. In case the cleaning is not up to the employer‘s satisfaction,
he will have the right to carry out the cleaning operations and any expenditure incurred
by the employer in this regard will be to the Contractor‘s account.
Erectors
The Contractor's employees shall include skilled erection staff in sufficient number, who
shall arrive on the site on or before the respective dates set out in the approved work
programmed and prior to delivery of any item of Plant to the Site. The Engineer will not
entertain any claim by the Contractor in respect of delayed erection due to a delay in the
delivery of any items of Plant to the site.
Contractor's Equipment, Materials and Appurtenances
The Contractor shall have available on the Site sufficient suitable equipment and
machinery, as well as all other materials and appurtenances required by him, of ample
capacity to ensure the proper erection of Plant and to handle any emergencies such as
may normally be expected in work of this character.
The Contractor shall be responsible if any installation materials are lost or damaged
during installation. All damages and thefts of equipment/component parts, after takeover
by the Contractor, till the installation is taken over by Employer shall be made good by
the Contractor to the satisfaction of Engineer.
Workmanship
Plant shall be erected in a neat and workmanlike manner on the foundation and at the
locations and elevations shown on the approved drawings and other Engineering
documents. Unless otherwise directed by the Engineer the Contractor shall adhere
strictly to the aforesaid drawings and no departures there from will be permitted.
All plant shall be correctly aligned, leveled and adjusted for satisfactory operation and
shall be installed so that the proper and satisfactory connection can be made readily
between the various units and pipe work and equipment installed under the Contract.
The mounting arrangements for pumpsets and blowers shall be such that the alignment
offset between motors and the driven equipment shall be well within 0.1 mm.
Building-in

Erection of Plant shall be phased in such a manner so as not to obstruct the work being
done by other contractors. Before commencing any erection work, the Contractor shall
check the dimensions of structures where the various items of plant are to be installed,
and shall bring any deviations from the required positions, lined or dimensions to the
notice of the Engineer and shall take such measures as are necessary for their
correction.
The Contractor shall take particular care for the correct positioning and alignment of all
puddle pipes which are required through concrete structures prior to, and during the
pouring of concrete.
The Contractor shall pin and plug in the holes prepared, all small clips, plugs, screws,
nails, sleeves, inserts, etc., required for fixing electric wires and conduits, small pipe
work and all other apparatus.
The Contractor shall align all equipment and holding down bolts and shall inform the
Engineer before proceeding with grouting-in the item or item concerned. The Contractor
shall ensure that all equipment is securely held and remain in correct alignment before,
during and after grouting-in.
The Contractor shall properly bed in cement grout each item of plant or its supporting
base resting on foundations, and shall grout-in where required holding down bolts placed
in the holes prepared in the foundations. The materials and workmanship used in
grouting shall be such as will result in a solid anchoring of foundation bolts and complete
filling of the gaps between the Plant or its base and the foundations, without shrinkage or
cracking.
During erection of the Plant the Employer will inspect the installation from time to time in
the presence of the Contractor‘s Site representative to establish conformity with the
requirements of the Specification. Any deviations and deficiencies found or evidence of
unsatisfactory workmanship shall be corrected as instructed by the Employer.
All plant shall be installed in accordance with the recommendations or instructions of the
manufacturer, for the particular application. Each mounting position shall be chosen to
give correct operation of the equipment, ease of operation, access for maintenance and
servicing and freedom from any condition which could have adverse affects.
Precautions
The approval by the Engineer of the Contractor's proposals for rigging and hoisting of
any item of plant into its final position shall not relieve the Contractor from his
responsibility for avoiding damage to completed structures, parts or members thereof or
other installed equipment. He shall at his own cost make good, repair or replace any
damaged or injured items whether structural, mechanical, electrical, architectural, or of
any other description, promptly and effectively to the satisfaction of the Engineer.
No plant or other loads shall be moved across the floors of structures without first
covering the floors with timber of sufficient size so that applied loads will be transferred
to floor beams and girders of steel or concrete. If it is required to reduce bending
stresses or deflection, the beam and girders shall be provided with temporary supports.
Any movement of Plant and other loads over the floor structures shall be subject to the
prior approval of the Engineer.

9.25 Civil Inspection (Water Leakage Test)
9.25.1 Tanks and basins
Refer to Part 10B – Particular Civil and Structural Works Requirements of the Bid
Document
9.25.2 Field Control Inspection
Contractor shall be conduct periodic field control inspection to prevent any field accident.
The Engineer shall joint field inspect or conduct unannounced inspections.
9.25.3 Inspection after Erection
After the erection of any item of Plant and its associated equipment has been completed,
it shall be offered to the Engineer for inspection in its static state prior to commissioning
the item.
Completion of erection and procedure prior to setting to work.
The mechanical completion of plant under erection shall be deemed to occur if all the
units/systems of the Works are structurally and mechanically complete as noted below:
All rotary, static, structural equipment, piping, electrical/instrumentation and other

equipment under the scope of the Contract have been erected, installed and grouted and
are as per the specifications.
All systems have been washed/flushed/drained/boxed up where necessary.
All system testing including pressure, vacuum and non-destructive tests, no load tests
and such other tests are completed with safety valves/relief valves set to operating
conditions installed in position.
All panels, local control desks erected with power/control cable terminations with all
continuity checks, insulation checks and other installation checks are carried out.
Prior to pre-commissioning checks, the Contractor shall erect the entire Plant and ensure
readiness of civil works to the satisfaction of Employer, so that the Works are physically
ready to undergo pre-commissioning checks. Pre-commissioning checks will include
checks like no-load running of machinery, checks on instruments and electrical including
calibration and loop checks, functional checks, inter-lock checks etc.
At the stage of mechanical completion of erection, the Contractor shall ensure that all the
physical, aesthetic and workmanship aspects are totally complete and the Plant is fit and
sound to undergo pre-commissioning checks.
The following documentation shall be completed before the Contractor notifies

Mechanical Completion of Erection to the Employer
a) All shop inspection records compiled and bound in 4 (four) copies.

b) All erection and commissioning procedures duly approved.
c) All instruction manuals in draft form - with each sheet bearing a stamp to indicate
"DRAFT FOR REVIEW ONLY" submitted in 4 (four) copies.

Upon achieving mechanical completion, the Contractor shall notify the Employer of such
completion of section/units/systems and readiness for inspection for acceptance of
mechanical completion of erection. The Employer/ Engineer shall proceed with
inspection of such sections/units/systems within 10 days of such notice.
Consequent to inspection, the Employer will inform the Contractor a list of deficiencies
for rectification and the Contractor shall complete the rectification work within a jointly
agreed period prior to start of pre- commissioning tests. The erection period allowed by
the Contractor shall include all activities of mechanical completion as noted above.
9.26 Site Acceptance Test Document
Fifty Six (56) days prior to commencement of Tests on Completion the Contractor shall
supply a Site Acceptance Test (SAT) Document for approval. This shall comprise four
copies of the details of the inspection and test procedures to be carried out in testing the
Works.
The SAT Plan shall provide comprehensive details of the tests to be carried out, the
purpose of each test, the equipment to be used in carrying out the test and the methods
to be adopted in carrying out the tests. The SAT shall provide space within the
documentation for results of the tests to be added and for each test and for the SAT as a
whole to be signed off by the Contractor and the Engineer.
The SAT shall categorise tests as follows:
a) Dry tests
Dry tests are those tests carried out without process fluid being present.
b) Wet tests which can be further sub-divided into

1) Hydraulic tests
Hydraulic wet tests are those tests carried out with potable water in order to prove the
hydraulic capability of the Works.
2) Process tests /System tests
Process wet tests are those tests carried out with raw Sewage as the feed stock to prove
the process capability of the Works.
The Contractor shall make his own arrangements for water supply, chemical, electric
power, fuel, instrument and labour during hydraulic wet tests.
It shall be assumed that the co-operation of other contractors in the carrying out of Tests
on Completion will not be unreasonably withheld.
9.27 Tests on Completion
9.27.1 General
Prior to the commencement of Tests on Completion the Contractor shall submit for
approval the following:
1) Site Acceptance Test Documents
2) As-Built Drawings

3) Operation and Maintenance Manuals

4) Site test results / data sheet and photo
Tests on Completion shall not be commenced until the aforementioned documents are
approved.
The initial charges of oil, grease, electrolyte, generator fuel / oil, chemical, disposal of
cake, etc. necessary for Tests on Completion shall be provided by the Contractor. Raw
Sewage and electricity required for Tests on Completion will be provided by the
Employer free of charge. If necessary, Contractor shall create design loading conditions
for testing purposes by testing fewer than the total number of installed units of process
tanks or equipment at a time. In such cases, multiple tests shall be conducted to ensure
that all installed units are tested. In the event that raw sewage/influent wastewater is not
available at the plant, the Contractor shall defer testing until such time as sewage
becomes available for treatment as described elsewhere in these Bid Documents. The
Contractor shall provide adequate notice (this notice period shall be determined by the
normal lead time for locally purchased chemicals plus at least 28 days) of his chemical
requirements prior to commencement of the Tests on Completion involving their use.
The cost of chemicals used for the Tests on Completion shall be met by the Contractor.
The inspection and tests procedure which will be carried out are provided under the
general conditions of contract and shall also consist of the following:
a) Manual Commissioning Tests (Clause i)
Manual Commissioning Tests shall be such preliminary trials, tests and retests on
individual items of Plant or complete systems as are required by the Engineer in
order to demonstrate that the Plant as a whole is ready to undergo the Manual
Operation Tests (Clause 3.11) and that these will take place with a minimum of
interruption.
The Manual Commissioning Tests shall demonstrate not only the items of Plant
under normal operation, but also their response to abnormal and emergency
conditions.
The Engineer will notify to the Contractor which items of Plant will be tested and the
extent to which they will be tested in order to fulfill the requirements of the
Specification.
Leakage tests at 1.5 maximum working pressure shall be carried out on all erected
pipe work prior to the Manual Commissioning Tests.
Pump curves shall be available for the Manual Commissioning Tests and all
instruments essential for the tests shall have been calibrated.
b) Manual Operation Tests (Clause ii)
When the Manual Commissioning Tests have been completed so that the items of
Plant have been demonstrated to the satisfaction of the Employer Representative,
the Contractor shall commence the Manual Operation Tests.
The Plant will be required to demonstrate satisfactory operation at all design flow
rates.

The tests shall be of seven consecutive days' duration; if the supply of sewage
should fail or other matters interfere outside the Contractor's control, the tests may
be of such number of broken days as the Engineer considers is the equivalent.
The exact date of commencement shall be subject to the approval of the Engineer
and shall be dependent on the following conditions having been met
1) All relevant items of Plant in approved working order
2) All items of Plant correctly identified with labels
c) Automatic Commissioning Tests (Clause iii)
The Automatic Commissioning Tests shall be such preliminary trials, tests and
retests on individual items of Plant or complete system as are required by the
Engineer in order to demonstrate that the Plant as a whole is ready to undergo the
Tests of Completion (Clause 3.13) and that these will take place with a minimum of
interruption.
At least one week before the commencement of these tests, the Engineer will notify
the Contractor which items of Plant will be tested and the extent to which they will be
tested in order to fulfill the requirements of the specification.
The Tests on Completion (Clause 3.13) as provided under the general conditions of
contract-clause 37 shall not be carried out until the completion of the above tests.
1) All pipe work shall be hydrostatically tested at site to a pressure equal to 1.5
times the maximum working pressure likely to be encountered in the system.
2) The Contractor shall carry out all tests on the Plant and shall supply four copies
of all test results to the Engineer.
3) All tests shall be to the approval of the Engineer who may require them to be
repeated, prolonged or modified as may be necessary to ensure that any or all
items of Plant conform to the Contract.
4) The Engineer shall be permitted to inspect all Plant which is undergoing tests and
may himself conduct tests.
Where it is necessary for the Engineer to make arrangements for the supply of water,
chemicals, power, etc., for any testing, the Contractor shall not commence the tests
until after these arrangements have been made on or after a date agreed by the
Engineer and the Contractor shall make no claim for delay to such testing on this
account except as provided for under Clauses 44 of the General Conditions of
contract.
If any item of plant fails during or after testing to achieve its intended duty or
otherwise proves defective, it shall be modified or altered as necessary and re-tested
and re-inspected as required by the Engineer.
Vibration/noise level tests shall be carried out at site which will form basis for
acceptance of the equipment. If the Contractor is not in a position to meet the
requirements given below as per ISO 10816 – 1995, the equipment may either be
rejected or the Contractor shall carry out all necessary modifications to keep
vibrations within the acceptable limits specified.
Noise Level Velocity of

Equipment (dBA at 1.86 m from vibration
equipment) (mm/sec)

Noise Level Velocity of

Equipment (dBA at 1.86 m from vibration
equipment) (mm/sec)
All rotating equipment not having
85 1.12
reciprocating parts with motor kW less
than or equal to 15 kW
reciprocating parts with motor kW
85 1.8
more than 15 kW and less than or
equal to 75 kW
reciprocating parts with motor kW 85 2.8
greater than 75 kW
All equipment having reciprocating
parts viz. compressors, dosing pumps 85 -
sampling pumps
The Contractor shall have a minimum of three commissioning engineers, one for process
and plant and the other for mechanical/electrical/instrumentation works on site during all
tests in order to both demonstrate the Plant and to correct any faults which may occur.
9.28 Dry Test Requirements
As a minimum requirement the following dry tests shall be carried out as a general
requirement:
1) A general inspection to check for correct assembly and quality of workmanship
2) A check on the presence of lubricant, cooling medium, electrolyte, etc.
3) A check on adequacy and security of Plant fixing arrangements.
4) A general check to ensure that all covers, access ladders, water proofing, guard
railings etc are in place.
5) A check on damp-proofing, rust-proofing and vermin-proofing and particularly the
sealing of apertures between building structures, chambers etc and the outside.
a) Civil and Building Works
As a minimum requirement the following dry tests shall be carried out on the civil
engineering and building works:
 Check for the presence of foreign bodies in pipe work and structures.
b) Mechanical Works
As a minimum requirement the following dry tests shall be carried out on the
mechanical systems:
 Carry out preliminary running checks as far is permitted by circumstances in
order to ensure smooth operation of Plant.
c) Electrical Works

Contractor shall submit Pre-Commissioning Dry checks programme based on

process requirement and recommendation of the Original Equipment Manufacturer
(OEM) for Engineer‘s approval.
Pre-commissioning Dry checks shall comprise pre-power and power tests pertaining
to Electrical Power Distribution System, as applicable. As a minimum requirement the
following pre-power dry tests shall be carried out on the electrical systems:
 Check that the earth electrode system is secure and providing the correct earth
electrode resistance
 Check that main equipotential and supplementary equipotential bonding is
completed and all fixings are secure
 Check cables are secured, glanded, terminated and identity tagged
 Carry out dielectric checks on cables core to core and core to earth
 Check conductor and earth continuity
 Check all ducts are sealed where required to be
 Check switchgear and motor controlgear assemblies and control panels are free
from foreign bodies and secure
 Carry out dielectric test on switchgear and motor controlgear assemblies and
control panels
 Check fuse setting against the schematic drawing and motor overload setting
against the schematic drawing and motor nameplate details
 Check paint and corrosion protective finishes are intact
 Check instruments and switching devices are correctly fitted and secured
 Carry out those tests required by CEA Regulations to prove the integrity of the
electrical installation prior to energisation.
 Check fuse/MCB setting against the schematic drawing
 Check operation of fire alarm and security systems
The satisfactory completion of Pre-Power Tests is an essential prerequisite for the

commencement of Power Tests.
Prior to the commencement of Power Tests a Permit to Work Certificate shall be issued
by the Contractor for the part of the Works concerned with the Power Tests. This part of
the Works shall remain under the control of a Permit to Work until Take-Over.
Power Tests shall include the following:

 check phasing and polarity
 carry out those tests required by CEA Regulations and Indian standard to prove the
integrity of the electrical installation necessary after energisation
 check operation of main circuit breakers by secondary injection methods
 check rotational direction of Plant
 check instrument loop integrity, functionality and calibration where possible
 check functionality of the HMIs
 check the control system power supply.
 balance out current between phases
 check operation of switching devices.
 Check operation of standby generator installation and mains / generator changeover
procedures; a 4-hour load test (using the normal load of the Works) shall be carried
out on the generator when the load is available.
Contractor shall perform the pre-commissioning tests, as per approved test programme,
to the satisfaction of the Engineer.

Contractor shall maintain the documentation of all the procedures and results obtained
for each of the pre-commissioning checks using appropriate proforma and customised
test sheets.
9.29 Process Plant Item / Equipment
All process plant items / equipment shall be tested to ensure they meet the Employer‘s
Requirements for quality of workmanship, construction and performance.
9.30 Hydraulic Wet Test Requirements
Hydraulic wet tests shall be carried out on completion of dry tests.
Clear Water shall be used for hydraulic wet tests. The purpose of the tests is to prove the
hydraulic performance of the Works. In order to demonstrate this, the Contractor shall
ensure that each part of the Works is hydraulically loaded to its rated throughput for a
period of at least four hours.
In order to ensure a sufficient supply of water to carry out these tests the Contractor shall
provide all required facilities, including but not limited to any temporary facilities that may
be required for storage and recycle of Clear Water or facilities for the disposal of the
water off Site in an approved manner.
The following tests inter alia shall be carried out:

1) Pressure testing of all piped systems laid direct in ground in accordance with the
relevant standards.
2) Fill all structures and check for leaks.
3) Filling of all storage vessels to check for leaks and distortion.
4) Running of all pumped systems in order to check for.
a) Correct functionality.
b) Absence of leaks.
c) Correct running temperatures.
d) Smoothness of running and the absence of undue vibration or stress.
e) Check drive running currents.
5) Carry out calibration of instruments where appropriate.
6) Carry out valve operation, diversions etc. to fully hydraulically load each process
element (or where there is a requirement to withstand an over load), overload each
process element.
7) Demonstrate correct functionality of electrical, control and instrumentation systems.
The Contractor shall simulate the conditions that will prevail when operating as a process
in order to demonstrate the correct functionality of process control loops etc.
During these tests a check on the performance of Plant shall be made to compare its site
performance with the factory test data and to identify any constraints on performance
due to site conditions.
9.31 Safety Audit
After satisfactory completion of hydraulic wet tests and prior to introduction of process
fluid to the plant a safety audit shall be carried out to ensure compliance with the
necessary requirement for safety and for operation of Plant. The safety audit shall be
documented. The safety audit document shall be approved by the Engineer prior to
commencement of Plant commissioning.

9.32 Process Wet Tests (with Raw Sewage)
On approval by the Engineer the Contractor shall carry out process wet tests.
Raw Sewage shall be used as the main feed stock for process wet tests. These tests
shall be carried out to demonstrate the process performance of the Works. In order to
demonstrate this, the Contractor shall ensure that each part of the Works is loaded to its
rated throughput (including a period of overload if required in order to demonstrate
compliance with the Employer‘s Requirements) for a continuous stable operating period
of not less than fifteen (15) continuous calendar days. If necessary, Contractor shall
create design loading conditions for testing purposes by testing fewer than the total
number of installed units of process tanks or equipment at a time. In such cases, multiple
tests shall be conducted to ensure that all installed units are tested.
The Contractor shall provide all required facilities for the disposal off Site in an approved
manner.
The following tests inter alia shall be carried out:

1) Check for leaks on vessels, structures, pumps and pipe work.
2) Running of all pumped systems in order to check for.
 Correct functionality.
 Absence of leaks.
 Correct running temperatures.
 Smoothness of running and the absence of undue vibration or stress.
 Check drive running currents where the solution pumped is different from that
pumped during hydraulic wet tests.
3) Carry out calibration of instruments.
4) Carry out valve operation, diversions etc. to fully hydraulically load each process
element (or where there is a requirement to withstand an over load), overload each
process element.
5) Demonstrate correct functionality of electrical, control and instrumentation systems
not checked during dry or hydraulic wet tests or which may have changed as a result
of the different operating conditions now prevailing.
On completion of the tests on the various parts of the works the Contractor shall run the
plant as a whole in order to demonstrate the full functionality and performance of the
Works at various throughput rates for a continuous period of not less than 30 days.
During the various process tests the Contractor shall perform sampling and analysis of
all the process streams (locations) and parameters listed in the ―Sampling/Analysis
Locations and Frequencies‖ table provided in the ―Tests after Completion‖ Section
below. The frequencies listed in this table shall be followed for the Tests After
Completion. However, for the Process Wet Tests performed as part of the Tests On
Completion, the sampling frequency for all locations and all parameters shall not be less
than once every hour. The Contractor shall demonstrate to the Engineer that the Works
is functioning in accordance with the Employer‘s Requirements. Each sample shall
comprise two 1 litre (minimum) quantities and shall be labelled to identify the contents,
where taken and time and date. The flow recorded at the time of sampling shall also be
indicated in the log book or record. One sample shall be used by the Contractor for his
analysis; the other shall be handed over to the Engineer.
The Engineer reserves the right to take additional samples and to carry out his own tests
or to check the samples taken by the Contractor.

The Engineer shall be given reasonable access to the premises where analysis is taking
place in order to check on working practices and the procedures being adopted.
9.33 Effluent Quality Criteria for Passing the Tests on Completion
The Works shall be considered to have achieved the required effluent quality standards
for passing Tests on Completion if all samples taken during a 30 day continuous
operational period comply with the criteria set down for passing the Tests After
Completion. This includes criteria relating to the reliability of the plant.
The Effluent quality Tests On Completion shall not be commenced until all tests
associated with the civil/building, electrical and mechanical works and individual process
tests have been completed to the satisfaction of the Engineer.
9.34 Co-operation with other Contractors in the Execution of their Tests
The Contractor shall, where required, assist other contractors in carrying out their tests
on completion and or tests after completion.
Where this assistance does not constitute part of the Contractors own work associated
with Tests on Completion or Tests after Completion the Contractor shall be reimbursed
at the rates approved by the Engineer.
9.35 Tests After Completion
General
On successful completion of ―Test on Completion‖ the Contractor shall carry out over a
period of time not exceeding twelve months two separate 30 days operational tests.
These tests shall be used to prove the operation of the Works at varying flows and with
varying raw Sewage quality. During these tests Effluent produced by the Works will be
entering the disposal system. These tests after completion shall be undertaken in
accordance with Clause 11 of the General Conditions of Contract.
The timing of the tests shall be determined by the Employer who shall give notice to the
Contractor in accordance with Sub-clause 11.1 of the General Conditions of Contract.
The total time for carrying out the tests shall not be less than six calendar months. One
of the tests for each part shall be carried out in a period of high raw Sewage BOD and
suspended solids.
On commencement of each 30-Days test the Employer shall allocate a continuous

period of not greater than 60 days to complete the test. Any failure to perform during the
60 days period shall restart the ‗30 day clock‘. If the part of the Works fails to pass the
test in the 60 days period the test shall be deemed as a failure and the Contractor shall
carry out any necessary remedial work to the satisfaction of the Engineer before the
Contractor restarts the test.
During the tests the Contractor shall take samples to demonstrate that the part of the
Works is performing in accordance with the Employer‘s Requirements. The procedure for
taking the samples shall follow the pattern adopted for Test on Completion. Samples
shall be taken at locations and intervals detailed below. The results of the Tests after
Completion shall be compared and evaluated by the Employer and Contractor.

The Contractor will not be held responsible for interruptions to the sewage treatment
process as a result of Grid power failures (unless as a result of a Plant failure)
interruptions in the raw Sewage supply etc. which are out of his control. However, the
Contractor shall be required to demonstrate that the Works can cope with these
inevitable interruptions in an orderly fashion and recover to a normal operational state
with the minimum of manual intervention.
All consumables except power needed for operation of the Works shall be provided by
the Contractor.
The Contractor shall provide all facilities and equipment not supplied under the contract
and which are deemed necessary for the Contractor to carry out and monitor the Tests
after Completion.
Tests are required on the Process Air Blowers, and diffusers within the Aeration tanks,
showing air flow distribution patterns, and efficiency of oxygen transfer. Power
measurements of the Air Blowers shall also be carried-out and efficiency ratios for all
relevant parameters calculated.
Tests are required on the Bio-Gas engine and gen set, to prove power generated, and
criteria set at Works Acceptance Tests has been achieved in the field.
Sampling and Analysis
Sampling and analysis shall be performed to measure the parameters indicated in the
table below, at the locations and frequencies indicated in the table. In case of multiple
units (such as multiple aeration basins or clarifiers), the indicated sampling and analyses
shall be performed for each individual module.
Table 9-1 Sampling/Analysis Locations and Frequencies
Sampling
Sample Location and Parameters to be Measured Frequency
Method
Plant Effluent (outlet of chlorine contact tank): Daily Flow-weighted
All parameters specified under the ―Effluent Quality 24-hour
Requirements‖ sub-section of Volume 2, Section 4, composite
Part 5.
Dewatered Sludge: Daily Composite of
All parameters specified under the ―Dewatered Sludge samples from
Quality Requirements‖ sub-section of Volume 2, each container
Section 4, Part 5. or vehicle filled
during the day
Raw Sewage Influent, Plant Effluent, MLR, RAS, Continuous Continuous
WAS, Thickened Sludge, Dewatering Influent, Plant instantaneous
Recycles: flow from
Flow recorder
Raw Sewage Influent, and Secondary Effluent: Daily Flow-weighted
TSS, VSS, Temperature, pH 24-hour
composite
Raw Sewage Influent, and Secondary Effluent: 3 times per Flow-weighted
BOD, COD, TKN, Ammonia-N, Nitrite-N, Nitrate-N, week 24-hour
Alkalinity, Total Phosphorus, Soluble Phosphorus composite

Sampling
Sample Location and Parameters to be Measured Frequency
Method
Aeration/ SBR Basins: MLSS, MLVSS, Temperature, Daily Grab
SVI
Aeration Basin Zone Profiles (Anaerobic, Anoxic, 3 times per Grab
Aerobic): week
Ammonia-N, Nitrite-N, Nitrate-N, pH, Soluble
Phosphorus, VFAs, rbCOD
RAS, WAS, Thickened Sludge, Dewatered Sludge: Daily Grab
TSS, VSS
Chemicals/ Scum/ Screenings/ Grit: 3 times per Grab
Specific weight, volume, weight, Chemical week
consumption
All costs associated with the taking and analysis of samples shall be met by the
Contractor.
The analysis shall be carried out by certified laboratory approved by the Engineer, and
shall be performed in strict compliance with appropriate analytical methods published in
Indian Standards, or in ―Standard Methods for the Examination of Water and
Wastewater‖ published by the American Public Health Association, or as published by
the US Environmental Protection Agency. The Contractor shall submit to the Engineer a
comprehensive report of the above sampling and analysis, including details of each
analytical test as well as a summary of all the data and results in a Microsoft Excel
spreadsheet.
Criteria for Passing the Test After Completion
1) Treated Effluent and Dewatered Sludge Quality Criteria
The Works shall be deemed to have met the Treated Effluent and Dewatered Sludge
Quality Criteria if:
i. at least 95 percent of the plant effluent samples described above meet the
requirements specified under the ―Effluent Quality Requirements‖ sub-section of
Volume 2, Section 4, Part 5, and
ii. at least 95 percent of the dewatered sludge samples described above meet the
requirements specified under the ―Dewatered Sludge Quality Requirements‖ sub-
section of Volume 2, Section 4, Part 5.
2) Operational Cost Criteria
The plants shall have fulfilled the operating cost criteria if the operating costs
determined during the Tests After Completion are in agreement with or less than
those detailed in the Contractor‘s Functional Guarantee or an amount of liquidated
damages are agreed by the Contractor and the Engineer to compensate for any short
fall in performance up to an agreed maximum amount if stated.
3) Plant Reliability Criteria
A part of the Works shall be deemed to have failed its test if:
1) A single item of Plant / equipment fails more than twice during the test.
2) More than four individual Plant items / equipment fail.

An item of Plant / equipment shall be deemed to have failed if manual intervention is

required in order to restore the Plant / equipment to its fully operational state: i.e. the
failure of a duty drive will be considered as one failure, if the standby drive fails to start
that will be considered as a second failure.
9.36 Performance Certificate
The conditions for issuance of a Performance Certificate as detailed in Clause 12 of the

Conditions of Contract shall inter alia comprise:
a) The completion of the six months operation of the Works (Tests after Completion) to
the satisfaction of the Engineer.
b) The O & M Manuals have been updated following one year‘s operational experience
and approved by the Engineer.
c) All defects identified prior to Taking Over and defects identified during one year
operation of the Works have been rectified.
d) All Tests ―After Completion‖ have been completed to the satisfaction of the Engineer.
e) All training detailed in the Employer‘s Requirements has been completed.

10 Training Requirements
10.1 General
The Contractor shall provide comprehensive training for the different categories of the
Employers operation and maintenance staff. Training shall fall into two main types which
are ‗off the job‘ and ‗on the job‘. Off the job training shall take place in the class room and
on the job training shall be carried out on the running plant(s).
10.2 Off the Job Training
The Contractor shall prepare formal training documentation for distribution to the
trainees. Visual aids shall be used to illustrate the points being made and to make the
training programme interesting and enjoyable for the participants. Off the job training
shall comprise the following:
1) Off the Job Training Programme for all Trainees
To provide training:
a) on the simple physical-chemical and biological process principles involved in the

operation of the Works;
b) regarding basic features of the electro-mechanical and instrumentation
equipment to be installed
c) health and safety;
d) plant safety procedures;
e) on the use of the local and central HMIs and SCADA.
f) Monitoring devices;
g) Operational performance index.
2) Off the Job Process Training Programme for Operators
a) on the operation of individual items of plant and sections of the Works including
automatic operation and manual operation;
b) on the day to day operation of the Works and procedures;
c) on a comprehensive list of ‗what if‘ scenarios dealing with the actions to be taken
in the event of potential process problems, alarms, plant failures, overflows,
power failures etc.;
d) on first line mechanical maintenance;
e) safe work practices;
f) on safety procedures to be followed in operating, maintaining, and cleaning the
plant;
g) special procedures to be followed in the event of a chlorine leak.
h) Creation of O&M forms;
i) Troubleshooting.
3) Off the Job Training Programme for Electrical Maintenance Staff
a) on the configuration, construction and operation of the electrical Plant;
b) on the electrical maintenance requirements of the Works;
c) on the switching and safety procedures to be followed;

Part 10: Training Requirements
d) safe methods of working;

e) on fault finding and repair procedures.
f) Creation of O&M forms;
g) Troubleshooting.
4) Off the Job Training Programme for Instrumentation, Control & Automation (ICA)
Maintenance Staff (Refer 15.6)
5) Off the Job Training Programme for Mechanical Maintenance Staff
a) On the routine mechanical maintenance requirements of the Works;
b) On lubrication requirements of the Works;
c) On fault finding, repair and overhaul procedures;
d) Cleaning & maintenance method ;
e) Safe methods of working
f) Creation of O&M forms;
g) Troubleshooting.
6) Off the Job Training Programme for Sewage Treatment Plant Staff
a) Sewage treatment process management techniques;
b) Sewage treatment plant cost management;
c) Sewage treatment plant laboratory management;
d) Safe methods of work general;
e) On safety procedures to be followed in operating, maintaining and cleaning the
plant;
f) Creation of O&M Management Index;
g) Creation of Asset/Property ledger and Management method;
7) Off the Job Training Programme for Intermediate Sewage Pumping Station
(Kalyaninagar IPSs) Staff
a) Process management techniques;
b) Plant cost management;
c) Safe methods of work general;
d) On safety procedures to be followed in operating, maintaining and cleaning the
plant
e) Cleaning & Maintenance method;
f) Creation of O/M forms;
g) Troubleshooting.
10.3 On The Job Training
The Contractor shall utilise the Operation and Maintenance Manuals as the primary
training aid in carrying out the on the job training. Shortcomings, omissions and errors
identified in the O&M Manuals during the training shall be rectified prior to final
acceptance of the O&M Manuals.
1) On the Job Training Programme for all Trainees

a) Plant familiarisation tour;

b) On the use of the local and central HMI/SCADA;
c) Health and safety;
d) Identify areas where special safety precautions are necessary.
2) On the Job Process Training Programme for Operators
a) under operational conditions on the operation of individual items of plant and
sections of the Works including automatic operation and manual operation;
b) illustrate by example the day to day operation of the Works and procedures;
c) illustrate by example the actions to be taken in the event of potential process
problems, alarms, plant failures overflows, power failures etc. (as identified in the
‗what if‘ scenario off the job training);
d) illustrate by example the first line mechanical maintenance;
e) illustrate by example safety procedures to be followed in operation, maintenance
and cleaning of the Works;
f) Operation at the time of change of inflow load;
g) Measure against sludge bulking;
h) Proper management method of a sludge treatment facilities;
i) Evaluation of Process Monitoring;
j) Water quality testing;
k) Entry and evaluation of everyday performance data ;
l) Creation of various types of a report of a day, monthly, and a fiscal year using
PC.
3) On the Job Training Programme for Electrical Maintenance Staff
a) Carry out detail tour of the electrical plant;
b) Illustrate by example the operation of the electrical plant;
c) Illustrate by example the electrical isolation and maintenance procedures;
d) Illustrate by example fault finding and repair procedures;
e) Illustrate by example switching and safety procedures to be followed;
f) Illustrate by example safe systems of work;
g) Entry and evaluation of everyday performance data;
h) Creation of various types of a report of a day, the monthly, and a fiscal year.
4) On the Job Training Programme for Instrumentation, Control & Automation (ICA)
Maintenance Staff (Refer 15.6)
5) On the Job Training Programme for Mechanical Maintenance Staff
a) Illustrate by example the routine mechanical maintenance requirements of the
Works;
b) Illustrate by example lubrication procedures;
c) Illustrate by example fault finding, repair and overhaul procedures.
d) Illustrate by example safe systems of work;
e) Entry and evaluation of everyday performance data;
f) Creation of various types of a report of a day, the monthly, and a fiscal year.

10.4 Training Programme
Off the job training shall be carried out prior to Taking Over of the Works or any section
of the Works.
Off the Job training shall be carried out prior to On the Job training. On the Job training
shall be completed as a condition for acceptance of the Works following completion of
the Tests after Completion.
10.4.1 Prior to Operation Service Period
The Employer will not operate the Works but he will require relevant staff to become
familiar with and capable of operating the STP, during the Tests on Completion of
Design-Build and the Operation Service Period, in order to adequately administer the
Contract.
The Contractor shall provide a training plan for each category of staff. The training plan
shall detail the content and duration of each course. The training plan shall be submitted
for the approval of the Engineer at least 120 days prior to the commencement of the
Tests on Completion. The duration of training offered for each category of staff shall not
be less than that detailed in the following table.
Off the Job On the Job

Category of Staff (minimum days duration (minimum days duration
for each course) for each course)
All staff 1 1
Operator 3 5
Electrical technician/
2 2
electrician
Control/instrument technician 10 5
Mechanical technician/fitter 2 2
STP/ISPS management 3 (see note)
Note: It is assumed that STP/ISPS managers on the job training will be continuous
throughout 12 months in a calendar year when the plant(s) is operated by the Contractor.
The training day shall be assumed to be not less than 8 (eight) hours split into two
sessions. The Contractor shall provide facilities for training which shall include inter alia
the training rooms/locations, tables and chairs, projectors, white/black boards, training
aids, training manuals etc.
Where trainees of a given category can all be released from their Works operational
duties simultaneously they may be trained together. Where this is not possible the
Contractor shall repeat the complete course for those who could not attend.
10.4.2 Prior to Contract Completion
The Contractor shall provide formal training and hands-on experience to the Employer‘s
operators during the last twelve months of the Operation Service Period such that they
are capable of operating the Works successfully and safely at the time of Contract
Completion.

The number of Employer‘s operators to be trained shall be 50% more than the number
employed by the Contractor in the operation and maintenance of the Works. The
Contractor shall assume that the operatives are skilled in their relative disciplines (i.e.,
electrician, fitter, laboratory technician, instrumentation technician, painter, stock
controllers, etc) but are unfamiliar with the Plant and Materials at the Site and, with the
exception of the process controllers and works manager, are unfamiliar with the
operation of a sewage treatment plant.
10.5 Training Personnel
The Contractor shall provide suitably qualified trainers to carry out the off the job and on
the job training.
The trainers are to be experienced in sewage treatment plant and sewage pumping
station management, operation and maintenance in their relevant discipline and in the
training of skilled and unskilled staff.
The Contractor shall submit the curriculum vitae of the trainer nominee's to the Engineer
for approval 120 days prior to the commencement of the Tests on Completion. The
training expert shall be fluent in English, Hindi and Marathi Languages or the Contractor
shall provide the services of an interpreter during the training periods.
10.6 Instrumentation, Control & Automation Training requirements
The Contractor/ system supplier shall conduct training courses for personnel selected by
the Employer. Training shall be conducted by personnel employed by the Contractor/
system supplier familiar with the system supplied and who have experience and training
in developing and implementing instructional courses.
The contractor shall arrange training for the Employer personnel for 5 days before the
conduction of FAT. This training shall be separate from the training for Employer (2
sessions of 5 days each) which shall be conducted during SAT. Training shall be
provided separately for each STP and ISPSs
The entire cost of the complete training programme, including reasonable per diem
expenses to cover meals, lodging, transport and similar expenses for all Employer
personnel and the consultants attending the training program, shall be the responsibility
of the Contractor/ system supplier and shall be included in the contract price.
The Contractor/ system supplier shall submit information on the training programme for
approval, prior to shipment of the equipment. This submittal shall include a course
outline; time required, course schedule, sample workbook and instructor qualification
information for each level.
The Contractor/ system supplier shall make a workbook on each course available to
every person taking the courses listed herein. The workbook shall be of sufficient detail
so that, at a later date, a trainee could review in detail the major topics of the course.
The training times shall be scheduled by the Employer in advance with the Contractor/
system supplier so as not to disrupt the Employer‘s ability to operate the plant.

Operations and Maintenance Training
Training shall be provided for ten (10) of the Employer personnel at the Contractor/
system supplier facility on operations and maintenance of all system components
separately for each STP and ISPSs. The training program shall be divided into two
segments and shall consist of at least 5 (five) working days, each of 8 (eight) hours
duration.
The maintenance training program shall be developed for personnel that have
electronics maintenance and repair experience and a general knowledge of computer
systems, but shall not assume any familiarity with the specific hardware furnished.
 As a minimum, the following subjects shall be covered:
 System Architecture and Layout
 Hardware Components
 Module Switch Settings (Configuration Switches)
 I/O Modules
 Power Supplies
 Data Highway:
 Programmer connection
 IOP programming and diagnostic techniques
 Battery replacement and recharging
 PC and workstation familiarization and maintenance:
 Troubleshooting
 Disassembly
 Cleaning
 Component Replacement
 Re-assembly
 The operation training programme shall include the following topics:
 Power-up, bootstrapping and shutdown of all hardware devices
 Interpretation of all standard displays
 Appropriate actions for software and hardware error occurrences
 Use of operator interface displays and keyboards
 Use of printer including replenishment of supplies
 Manual data entries
 Creation and editing of graphic operator display screens.
 Loading of any required software into the system
 Data base creation and editing.
10.7 Training Assessment
At the conclusion of off-job and on-job training, all the trainees shall be asked to undergo
a simple assessment / test to examine the level of understanding of the working of an
STP and the effectiveness of the training program. The feedback gathered from the
assessment / test shall be used by the Managers to make a decision whether some of
the trainees need to be re-trained.
The contractor shall prepare the proposed assessment / testing questionnaire and
submit for approval before commencement of the training program.

11 Operation and Maintenance
11.1 Operation Service Performance Requirements
11.1.1 General
In this section, the required performance of the Works during the Operation Service is
described. The Contractor shall be obliged to receive and accept all wastewater
delivered to the Sewage Treatment Works during the Contract Period. The Contractor
shall not stop or reduce the delivery of flows from the sewerage network to the
wastewater treatment works. The Contractor shall not discharge any flows through an
emergency bypass, except in an emergency and with the express permission of the
Employer for each overflow event.
11.1.2 Measurement of Qualitative and Quantitative Performance
The minimum requirements for monitoring, sampling and analysis during normal
operation are specified in Appendix 2.
The main monitoring and measurement requirements for the purposes of compliance
and payment during the O&M Period are set out in Appendix 2, however additional
measurement points may be required to comply with the Contract. Any additional
measurement points shall be installed by the Contractor at his cost.
11.1.3 Performance Standards
11.1.3.1 Treated Effluent Standards
The Contractor shall ensure that the Works produce treated effluent meeting the
standards specified in Appendix 2.
Compliance with the above standards shall be assessed on a Daily basis in conjunction
with the Monthly payments (including performance damages) and in accordance with the
programme of analyses for compliance purposes
The Engineer may instruct additional sampling over and above that is specified herein
Appendix 2.
The sampling specified herein and the additional sampling instructed by the Engineer
shall be included in the assessment of compliance and the associated application of
performance damages.
11.1.3.2 Treated Sludge Standards
The sludge at the time of its transportation off the Site, shall meet the specific quality
standards specified in Part 4 Process Requirements.
11.1.3.3 Noise Standards
The Works shall be designed and operated and maintained by the Contractor to ensure
that the noise emanating from the Works does not exceed the limits set out in Table 16.2
below during operation, when measured at any position on the Site boundary.

Part 11: Operation and Maintenance
Table 11-1 Noise Performance Levels Outside of the Site
Time Standard (15 minute Leq)

06:00 – 22:00 75 dB(A)
22:00 – 06:00 70 dB(A)
The noise level 2m in a perpendicular direction from any point on any item of equipment
(if unprotected) or the shell of a building or enclosure shall be continuously less than
80dBA.
The Noise measurements shall be carried out as per MPCB / Indian Standard
Noise measurements shall be carried out whenever there is a complaint and in any event
shall be monitored following any change in the plant design or operation of the Works
affecting noise levels.
Noise levels shall be measured using a calibrated sound level meter complying with BS
EN 60651. Sound levels shall be monitored in accordance with ISO Recommendations
R1996, ‗Assessment of Noise with Respect to Community Response‘ as amended by
ISO Recommendations, R1996/1, 2 and 3 ‗Description and Measurement of
Environmental Noise‘ as appropriate.
11.1.4 General Performance Requirements and Standards
In addition to the performance requirements and standards specified in Part 4 Process

Requirements, the Works shall also comply with the performance requirements specified
in Table 11-2.
Table 11-2 General Performance Requirements for the Works
Description Parameter Value

Screens and Dry solids content of screenings ≥ 30% DS (w/w)
screenings Organic solids content of screenings <30% of DS
system
Reliability (downtime) <4%
Grit Particles removal > 95%
separation Organic solids content of cleaned grit < 10% of DS
and grit
Handling Reliability (downtime) <4%
Primary Reliability (downtime) ≤ 2%
settlement
Aeration plant Ability of aeration system to continuously ≥ 2 mg/l
maintain the DO concentration
Reliability (downtime) of aeration system ≤ 2%
Secondary Reliability (downtime) ≤ 2%
Primary Dry solids content of thickened sludge ≥ 5% DS (w/w)
sludge Reliability (downtime) ≤ 2%
thickening
Secondary Thickened dry solids content ≥ 5% DS (w/w)

Description Parameter Value

sludge Reliability (downtime) ≤4%
thickening
Sludge Temperature of the sludge in the The average daily set
digestion digesters point temperature of the
sludge in the digesters
shall be between 35 to 39
C, but not be outside the
set point by a range
1.00C.
Retention time in the digesters (based on >15 days
ADWF x 1.3)
VSS destruction >45 %
Reliability (downtime) ≤4%
Sludge Reliability (downtime) ≤4%
dewatering
11.1.5 Monitoring, Sampling and Analysis
11.1.5.1 General
Prior to the commencement of the O&M Period, the Contractor shall submit to the
Engineer for approval a ‗schedule of tests and procedures‘ that will allow the Contractor
to:
 demonstrate effective Works operation;
 demonstrate compliance with the Employer‘s Requirements;
 provide a basis for determination of payment.
The required minimum frequencies for sampling and measurement for normal operation
and reporting purposes, for compliance with performance standards and for payment
purposes are set out in separate tables in Appendix 2.
The Contractor shall arrange sampling to be undertaken by suitably trained personnel.

Sample lines shall be continuously purged.
Analyses shall be carried out in accordance with;
 The latest edition of ―Standard Methods for the Examination of Water and
Wastewater‖ (APHA, AWWA, WEF)
 IS 2488: Methods of Sampling and Testing For Industrial Effluents
 Noise levels shall be measured using a calibrated sound level meter complying with
BSEN 60651.
The Contractor shall provide all the equipment necessary, and shall undertake all
sampling, and shall pay for all the testing and analysis unless expressly stated
otherwise. The monitoring facilities shall be linked into the central control and monitoring
system for the Works.
The Contractor shall take all samples as agreed in ‗schedule of tests and procedures‘ to
demonstrate compliance with the Employer‘s Requirements, including those required for
payment purposes. The Contractor shall deliver all such samples to be tested/analysed
to a certified/accredited laboratory jointly agreed between the Employer and the
Contractor.

In the case of breakdown of the automatic sampling equipment, sampling shall be

undertaken manually at three-hourly intervals and the results will be weighted according
to flow in order to establish the equivalent daily total load.
The location of all the sampling and monitoring points required during the Contract shall
be proposed by the Contractor, and shall be submitted to the Engineer for approval.
Where appropriate samples shall be representative of the wastewater, liquor or sludge
that has passed through that point over the period since the last sample was taken.
The Contractor shall adjust and expand on the testing and monitoring procedures,
described here to suit his proposed process design arrangement, if necessary. In the
course of the Operation & Maintenance, the Contractor shall update the tests and
procedures according to the operational experience and any alterations to the treatment
process.
Appendix 2 presents the minimum requirements for flow monitoring, sampling and
recording facilities, and identify the measurement points to be used for monitoring and
measurement for compliance.
The instrumentation associated with the flow measurement for the main process streams
shall record the flow rates in terms of both daily and 15-minute averages.
Flow meters and other in-line meters shall be calibrated by the Contractor on a regular
basis, in accordance with the manufacturer‘s recommendations.. The Contractor shall
submit a detailed methodology of this calibration to the Engineer for approval.
For Plant Influent and Plant Effluent Composite samples, a reserve sample shall be kept
refrigerated for 7 days in order that the Engineer may order further analysis if he so
requires. At all times, the samples shall be stored in the dark and at a temperature of 1°C
to 4°C. The samples shall not be allowed to freeze.
Where sampling is to be undertaken on a weekly basis the day(s) selected shall vary
each week unless agreed otherwise.
Samples of liquid sludge or sludge cake, shall be composite samples comprising at least
three spot sub-samples, each of equal volume. The sub-samples shall be collected
manually at 30-minute intervals over at least one hour or, in case of intermittent
processes, over the period of sludge flow. In the case of assessment of polyelectrolyte
consumption, the sludge samples shall be collected over a two-hour period at 30-minute
intervals. The analysis of dry solids content shall commence within a maximum of 24
hours from the end of the sampling period.
Sludge samples shall be taken at the outlet to the process unit (thickener/dewaterer etc).
Samples containers shall be polyethylene, polypropylene, Teflon, non-etched Pyrex
glass or equivalent or stainless steel.
The three samples shall also be used to determine the dry solids content.
All samples taken by the Contractor that are required to be analysed to demonstrate
compliance with the performance criteria shall be split into two equal parts. The samples
shall be labelled with the name of the sampling point and date and time of collection. The
Contractor shall analyse the first sample and store the second sample in accordance
with industry best practice to preserve its status for further analysis for a minimum of 7
days.

The Employer may, at his discretion, have the second sample analysed at an
independent laboratory, and associated costs will be paid by the Employer.
The Employer or the Engineer reserves the right to enter the Works, to take samples or
undertake tests at any location and at any time without the requirement to give prior
notice to the Contractor. However, the Employer shall notify the Contractor immediately
prior to entering the Site to comply with health and safety requirements. If the results of
these tests indicate a discrepancy with Contractor‘s records, further investigation shall be
agreed between the parties to ensure that the Contractor‘s monitoring procedures meet
the requirements of the Contract. If it is established that the Contractor‘s procedures do
not meet the requirements of the Contract then the cost of these investigations shall be
borne by the Contractor.
The Contractor shall undertake sampling, testing for all process stages to provide
reliable data for quality control and for use in interpreting the performance of the Works.
11.1.5.2 On Site Analysis
In addition to the services provided by a Nominated Laboratory, the Contractor shall

provide on-site analytical services to allow for routine and non-routine monitoring,
analysis and control of the treatment facility processes in respect of all wastes, whether
liquid, solid or gas. The scope of measurements conducted in the on-site laboratory is as
given below.
a) temperature of air, sewage and sludge ;
b) pH;
c) Chemical Oxygen Demand (COD);
d) Biochemical Oxygen Demand (BOD);
e) Suspended Solids (SS) concentration;
f) Dry solids content in sludge (total dry solids);
g) Stirred Sludge Volume Index (SSVI);
h) Microscopic examination of the biomass in the aeration tank;
i) Dissolved oxygen (DO) concentration.
The on-site laboratory shall be provided in accordance with:

 the references as noted in Clause 11.1.5
The on-site laboratory facility shall be located at grade level floor with a separate
entrance and not be housed in a building or near a building that has vibratory equipment.
11.1.6 Failure to Meet Performance Requirements
11.1.6.1 General
If it is determined by the Contractor that the Works are failing to meet the performance
requirements specified in this Volume for any reason, the Contractor shall take
immediate remedial action and advise the Engineer in writing of the specific cause for
the failure and report the actions taken or the proposal to correct the deficiency.
If it is determined by the Engineer that the Works are failing to meet the performance
requirements specified in this Volume for any reason, the Engineer will advise the
Contractor in writing and the Contractor shall determine the specific cause for the failure
and report to the Engineer within 7 days on actions to correct the deficiency.

Where the Contractor is unable to meet the specified contractual performance standards
for whatever reason, and irrespective of whether the penalties described in the
Conditions of Contract are applied, the Contractor shall use his best endeavours to
maintain the performance standards as close to the specified levels as possible, at all
times. Failure to do so will be deemed to be a failure of his contractual obligations.
Unless the following conflicts with more specific requirements relating to specific Failure
Event types set out below, on the occurrence of a Failure Event, the Contractor shall:
 as soon as possible and not more than 24 hours after the Failure Event is apparent
notify the Employer of the location and extent of the Failure Event;
 within 3 days of the Failure Event submit a report to the Employer identifying and
explaining the cause of the Failure Event and the Contractor‘s plans for preventing a
recurrence of the Failure Event;
 implement the Contractor‘s plans for preventing recurrence of the Failure Event; and
 report monthly on progress of implementation of the Contractor‘s plans for preventing
recurrence of the Failure Event measured against the Contractor‘s plans until the
Contractor‘s plans have been effected.
11.1.6.2 Failure Events
In the event of a failure where an allowable exception cannot be identified, payment to

the Contractor will be adjusted in accordance with the terms of the Particular Conditions
of Contract.
Table 11-3 Failure Events and Allowable Exceptions
Failure Monitoring
Failure Event Description Allowable Exception
Event Aspect
1 Treated Treated Effluent exceedances Influent parameters greater
effluent are greater than the allowable than Design Flows and
number Loads specified in Part 4
2 Sludge Dry solids content in any Influent parameters greater
product – composite sample less than the than Flows or Loads
solids value specified in Part 4 specified in Part 4
content
3 Noise levels Noise levels exceed None
performance requirements or
complaints are received
In the event that the measurement and monitoring of the Works indicates persistent
problems as evidenced by frequent failures in terms of the Failure Events identified, the
Contractor shall promptly submit to the Engineer detailed proposals for remedying the
problems. Once the Engineer has approved such proposals, the Contractor shall
proceed to implement the proposed modifications, at his own cost.
11.2 Operation Management Requirements
11.2.1 General
The Contractor shall operate and maintain the Works in accordance with the Contract
until the end of the Operation Service Period and during this period shall be responsible

for all aspects of the wastewater treatment and sludge treatment and disposal of all
screenings, grit, and sludge. The Contractor shall ensure that the wastewater treatment
facility achieves the required treated effluent and sludge quality. The treatment,
transportation, and disposal of sludge shall be carried out by the Contractor in an
efficient and cost- effective manner in compliance with statutory requirements.
The Contractor shall be responsible for identifying off site location/land and route(s) for
disposing all screenings, grit and sludge arising from the Works and for paying all tipping
& transportation charges and other associated costs including that for location/land. The
Contractor shall dispose of all hazardous materials in accordance with existing laws and
regulations. All permissions and consents from respective authorities shall be obtained
by the contractor.
11.2.2 Employer’s Communication
The Operation Service requirements shall apply to the whole of the Works. The
Employer shall keep the Contractor informed of proposed alterations to major
infrastructure which may in the Employer‘s opinion have a material impact on the
Sewage Treatment works. The Employer shall, except in the case of emergency, inform
the Contractor where it intends to carry out any repair, maintenance or upgrading of any
part of the any of the collection system which could have a material impact on the
Contractor‘s ability to deliver the services.
The Employer shall also advise of any proposed discharges to the collection system
which may in the Employer‘s opinion have a material impact on the Sewage Treatment
works.
11.2.3 General Requirements
During the Operation Service Period, the Contractor shall take total responsibility for the
operation and maintenance of the Works. As part of these general obligations, the
Contractor shall undertake the following tasks.
a) Provide all the staff for the managerial, technical, supervisory and administrative
responsibilities, and provide labour necessary to operate and maintain the Works,
safely and efficiently.
b) Develop and implement the necessary procedures and information systems required
for the Operation Service.
c) Carry out all flow measurement, sampling and laboratory analyses for the wastewater
treatment and sludge treatment and disposal throughout the Operation Service
Period.
d) Operate and maintain the Works and ensure that all the Plant is able to operate at all
times to its maximum installed capacity. The Operation Service shall achieve the
performance criteria specified in these documents. The Contractor shall satisfy all
legal and environmental requirements for disposal of treated effluent and sludge and
other waste products for each day of the Operation Service Period.
e) Provide all necessary services to the site including electricity, water, gas,
telecommunications and any other services necessary for the provision of the
Operation Service.
f) Utilise information gathered as a result of monitoring to determine what
improvements can be made to optimise the operation of the treatment facility.
g) Implement all systems required and record and make available to the Engineer all
necessary operation and maintenance information.
h) Keep and update the Operational Cost Model for the Operation Service.
i) Transport all waste by-products and sludge arising at the Site .

j) Operate the Works in the most economic manner with respect to the consumption of
energy and other resources. (e.g. take in to consideration Time of the Day (TOD)
tariff made applicable by MSEDCL)
k) Carry out the Tests Prior to Contract Completion.
l) Maintain the Works such that they remain in a visually and aesthetically pleasing
condition at all times.
m) Monitor all changes in legislation, codes or standards and bring these to the attention
of the Engineer.
n) Operate the Works to minimize the total long term life cycle cost of the facility,
supported by establishing the optimal timing and strategy to replace assets based on
the historical operating and maintenance records.
11.2.4 Management, Operation and Maintenance Personnel
The Contractor shall provide suitably qualified personnel for the management, operation
and maintenance of the works. The personnel shall have skills in the areas of, but not
confined to:
 Operations management;
 Maintenance management;
 Asset Management;
 Treatment process operation and management;
 Analytical chemistry and laboratory procedure management;
 Mechanical and electrical plant and equipment operation and maintenance;
 ICA operation and maintenance;
 Software, communications and IT systems programming and configuration;
 Facilities operation and maintenance;
 Administration;
 Quality Management Systems planning, implementation, management and auditing;
 Health and safety planning, implementation, management and auditing.
During Operation and Maintenance period, the Contractor shall appoint a full time Plant
Manager and a Plant Chemist. In addition, the Contractor shall appoint suitable number
of operators, fitters, electricians, helpers, gardeners, office peons, security guards,
labourers as required for the operation and maintenance of the plants for three shifts and
adequate other staff / supporting personnel during general shift.
Key O&M personnel shall have minimum qualification and experience as given below:

Table 11-4 Minimum Staff and Qualification Requirements for O&M of the STP
Sr. Designation Qualifications No. Experience

No. in Years
1 Plant Manager Graduate/ Post Graduate in Civil, 1 8
Public Health, or Environmental
Engineering with specialization in
wastewater collection and treatment
and having experience in STP and
Sewage Pumping Stations Testing,
Commissioning, Operation &
Maintenance, Liaison with
Government, Pollution Control
Authorities. Shall have completed at
least one CPHEEO advanced
Wastewater Operations course or
equivalent.
2 Plant Graduate in Civil, Public Health, or 1 5
Supervisor/ Environmental Engineering with
Superintendent specialization in wastewater collection
and treatment. Shall have completed at
equivalent.
3 Shift-in-charge Diploma in Civil, Public Health, or 3 5
Environmental Engineering with
specialization in wastewater collection
equivalent.
4 A) Operators for Diploma in Civil, Public Health, or 4 3
STP Environmental Engineering with
specialization in wastewater collection
least one CPHEEO basic Wastewater
Operations course or equivalent.
B) Operators for Diploma in Mechanical/Electrical 4 3

ISPS Engineering
5 Plant Chemist Graduate in Environmental Science / 1 3

Chemistry having experience in STP
laboratory (sampling / analysis)/
operation and maintenance.
6 Electrician Diploma/ ITI Certification in Electrical 3 3
Engineering with experience in
WTP/STP Erection, Testing,
Maintenance.

Sr. Designation Qualifications No. Experience

No. in Years
7 Instrumentation Diploma/ ITI Certification in 3 3
and Control Instrumentation and Control
Technician Engineering with experience in
WTP/STP & ISPS Erection, Testing,
Maintenance.
8 Fitter/Mechanic Diploma/ ITI Certification in Mechanical 3 3
Engineering with experience in STP &
ISPS Erection, Testing,
Maintenance.
9 Peon 10th Pass 6 2
10 A) Security 8th Pass 6 3
Guards for STP
B) Security 8th Pass 6 3

Guards for ISPS
11 Gardener 8th Pass 3 1

12 Helpers for - 6 -
Sludge Handling
Note:
a. The above requirement is minimum only. The Contractor will arrange extra work
force, as and when required, so as to smoothly run the operation and
maintenance including preventive maintenance, repairs etc. and general
cleanliness of the installations at no extra cost to Employer.
b. The above staff strength is exclusive of leave reserve required for different
category of staff. The Contractor shall ensure availability of the personnel given in
the above table for all seven days in a week.
c. All above staff shall be dedicatedly assigned to Bhairoba STP and Kalyaninagar
IPS only.
d. The Contractor shall make appropriate arrangements for maintenance of items
like road work, buildings, patrolling and maintenance of civil structures, vehicle
operations and other activities defined to fulfil its obligations under O&M
Contract.
The Contractor shall furnish complete resumes/biodata for all personnel proposed two
months before the start of Operation and Maintenance period to the Engineer for
approval.
All personnel employed by the Contractor shall be suitably qualified and have an
appropriate level of training and experience in the area to which they are allocated. Prior
to the commencement date, the Contractor shall submit details of the key personnel he
proposes in each of the above areas to the Engineer for approval.
The Contractor shall develop and maintain the competencies of personnel through yearly
evaluations and encourage employee development and reward throughout the Operation
Service Period.
All key personnel employed by the Contractor in the delivery of the service shall remain
at all times the employees of the Contractor. The Contractor shall not subcontract or

assign any part of this obligation without the prior written consent of the Engineer, which
shall not be unreasonably withheld.
Should the Employer or the Engineer be reasonably dissatisfied with the performance of
any of the Contractor‘s personnel, the Contractor shall, at the Engineer‘s written request,
remove the said person(s) from the service. Any such personnel shall be immediately
replaced by staff of equivalent or greater qualification and experience, and this shall be
subject to approval by the Engineer.
The Contractor shall ensure that there is a suitable level of continuity of key personnel.
Should the Contractor wish to change any personnel engaged directly in the
management and operation of the service, then the Engineer shall be informed at least
two months in advance, wherever practical.
The names, status, qualifications, years of experience and record of training of all
personnel engaged in the operation service shall be provided as part of the Operation
and Maintenance Plan. This shall include details of individual ongoing staff-training
programmes. These programmes shall be updated and maintained regularly by the
Contractor. Updates shall show evidence of the training carried out each year and
training proposed for the following year.
Any new personnel or personnel reallocated to different duties shall be supervised by

experienced staff until they are properly trained and have a level of experience deemed
necessary for the service tasks being undertaken. This shall be deemed to be for a
minimum of two months. The Contractor shall provide details, as part of the Operation
and Maintenance Plan, of the measures to be taken to cater for these changes.
11.2.5 Health and Safety Requirements during Operation Service
The Contractor shall be responsible for all aspects of health and safety during the
Operation Service Period and shall comply with all national and regional legislation and
regulations.
The Contractor shall be responsible for the security of the Site and shall provide
adequate security staff at all times to maintain site security and check incoming and
outgoing traffic and persons for the duration of the Operation Service.
The Contractor shall maintain throughout the Operation Service Period a set of
‗Emergency Procedures‘. The procedures shall identify the potential accidents and
emergencies which could occur on the Works and set out a clear plan of action to be
followed should any of these occur. The Contractor shall ensure that employees are
aware of these procedures and display, in prominent positions, posters stating these
procedures with emergency telephone contacts.
The Contractor shall agree emergency procedures with the emergency services and
carry out emergency drills in accordance with statutory requirements and when
recommended by the emergency services.
With respect to health and safety, the Contractor shall:

a) implement safe working and reporting procedures and promote safety awareness in
every element of operation and maintenance;
b) ensure adequate regard to site safety including:
 safe working procedures in all Works operation and maintenance activities;
 cleanliness and care of the facility;
 reporting accidents and hazards;

 safe practice in sewers, tanks, and all other elements within the wastewater
treatment facility;
11.2.6 Suppliers and Subcontractors
The Contractor shall be permitted to enter into contracts and agreements with
Subcontractors and suppliers for the delivery of non-critical parts of the Operation
Service and/or for the supply of goods or services relevant to the Operation Service.
Before entering into such arrangements, the Contractor shall submit details of the
Subcontractors and suppliers he proposes to use to the Engineer for approval. He shall
provide and update these details, as part of the O&M Plan.
11.2.7 Operation Service Monitoring Group
An Operation Service Monitoring Group (OSMG) will be formed for this Contract. The
purpose of the OSMG is to provide a forum for regular discussion by representatives of
the Employer and Contractor of relevant ongoing matters relating to the Contract.
Meetings of the OSMG will normally take place at monthly intervals, or at such longer
intervals as may be agreed by the OSMG from time to time (such intervals not to exceed
three months). A special meeting of the OSMG may be convened to address abnormal
circumstances.
The Monthly Status Report (MSR) and in particular the Executive Summary of that report
will provide the basis for much of the discussion at the OSMG meetings.
The primary role of the OSMG is to facilitate the harmonious implementation of the
Contract and to provide comfort to the main stakeholders that the interests of all parties
are protected. The Employer and Contractor will be kept informed by their
representatives on the OSMG of relevant operational aspects of the Contract. However,
the Engineer, as defined in the Contract Documents, will be solely responsible for the
issuing of instructions under the Contract.
It is proposed that the Employer be represented on the OSMG by one senior member of
the Employer‘s organisation and by the Engineer. It is proposed that the Contractor be
represented on the OSMG by one senior member of the Contractor‘s organisation
(operations manager) and by the most senior member of the Contractor‘s personnel on
site, the Plant Manager.
One of the Employer‘s nominees will normally chair the meetings of the OSMG and one
of the representatives of the Contractor will normally minute the proceedings. In certain
circumstances, a special meeting of the OSMG may be held, to which an external
stakeholder, such as a major local industry, may be invited, at the discretion of the
Employer and Contractor.
The meeting agenda shall be generally based on the following generic headings, which
may be changed as the Contract progresses and circumstances may change:
1) Minutes of last meeting;
2) Monthly Status Report(s);
3) Complaints;
4) Plant Maintenance Plan;
5) Facility Maintenance Plan;
Operational changes;
1) Compliance monitoring;

2) Third party interfaces;

3) Any other business.
11.2.8 Records and Reporting
A) Archiving of SCADA and CMMS Data
The Contractor shall maintain all operation and maintenance records, including the
SCADA and CMMS data, throughout the Operation Period in a safe and secure
manner. No record shall be discarded without prior consent of the Employer. Any
amendment to the records shall only be made in accordance with proper checking
and authorization procedures, which shall be included as part of the Operation Plan
submitted to the Employer for consent.
The Engineer shall be allowed to check the abovementioned data and records
described at any time.
As far as possible, all records shall be kept electronically utilizing the Contractor‘s
Site computer facilities with backup security. If the computer facilities fail, then
appropriate paper records shall be produced and filed.
The records shall be filed electronically and the electronic files shall be submitted to
the Employer and/ or the Engineer upon request. Copies of any paper record shall
also be submitted at the same time. The Contractor shall submit formats of electronic
and paper records to the Employer for consent.
For the purpose of retrieving SCADA and CMMS data under this Clause, the
Contractor shall provide and maintain workstations at the Employer‘s offices,
including an on-site office and an off-site office, the location of which shall be
determined by the Employer. The requirements of these workstations shall be in
accordance with the Specification. The workstations shall be complete with all
necessary hardware and software. All cost, including for the avoidance of doubt
application and subscription fees for licences and communication services, are
deemed to be included in the fixed Operation Fees.
B) Site Diary
The Contractor shall maintain a Site Diary which shall include, as a minimum, the
following information on a daily basis:
 Date and weather;
 Operation hours;
 Labour on the Site;
 Flow and quality records of influent and effluent;
 Disposal records of treatment by-products;
 Accidents and incidents;
 Instructions to the Contractor;
 Comments by the Contractor;
 Complaints received and action taken;
 Authorized visitors to the Site; and
 The exact scope, form and layout of the Site Diary shall be agreed with the
Employer from time to time.
The Site Diary shall be in a printed proforma completed with one original and three
copies:

a) Employer (Original);
b) Engineer;
c) Contractor; and
d) File copy.
 The Site Diary shall be checked and signed by authorized personnel of the
Contractor in accordance with the consented Operation Plan. The completed Site
Diary shall be made available to Engineer for inspection not later than noon time on
the following day.
 The Contractor shall keep appropriate records of all personnel employed at the Site.
These records shall be available for inspection by the Engineer at any reasonable
time. These records shall be kept available for inspection throughout the Operation
Period.
 The Contractor shall retain at the Facility a Construction Site Safety Manual or
approved equivalent. All accidents occurring to personnel during the Operation
Period shall be recorded and reported to the Engineer within two hours of the
occurrences of the accidents.
C) Safety and Health Records
The Contractor shall keep records on all safety and health matters and update such
records daily for inspection by the Engineer. The exact records to be maintained shall
be agreed as part of the Operation Plan.
D) Monthly Report
The Contractor shall provide and present details, in the form of Monthly Reports, of
operational data and information in relation to the Operation of the Facility to the
Employer in a systematic and concise manner. Monthly Reports shall be submitted in
duplicate to the Employer and the Engineer by the 14th day of the month following
the month to which the report relates. Typical required information and data shall
include, but not be limited to the following:-
Project Management
 An updated organization chart which includes details such as number of
employees in the Facility by trades;
 Change of staffing;
 Summary of visits to the Facility;
 Performance Tests or Condition Surveys carried out and scheduled in the
following month;
 Meetings held with the Employer, and other related authorities, etc;
 Scheduled meeting in the following month; and
 Quantity and quality of influent and effluent, and a summary of problems
encountered during the month.
Energy Consumption, Energy Recovery and Power Generation Data

 Summary of energy consumption (fuel and electricity) of the Facility,;
 Quantity of biogas produced and power generated;
Inventory and Consumables Data

 Quantities of chemicals, reagents, fuel and spare parts consumed;
 Stock level of chemicals, reagents, fuel and spare parts;

 A list of current suppliers for chemicals, reagents and additives and their contact
details;
 Delivery records of all consumables.
Environmental Monitoring Data

 Records and document concerning the disposal of treatment by-products.
Maintenance Records
 Summary of all preventive and corrective maintenance, plant alteration, renewal
and replacement activities with descriptions, photos and drawings as appropriate;
 Summary of the CMMS database for ongoing maintenance / repair work carried
forward to the next month;
 Summary generated from CMMS database for backlog of outstanding preventive
maintenance work orders for 30 days and more (counting from the CMMS preset
work order completion date), with reasons of delay and measures taken / plan to
rectify;
 Summary generated from CMMS database for backlog of outstanding corrective
maintenance work orders for 3 days and more, with reasons of delay and
measures taken / plan to rectify; and
 Programme showing the scheduled maintenance (including planned and
ongoing) work in the following month.
Incident Report
 Covering injury of any staff or members of the public / fire / property damage, etc.
and their corresponding statistical analysis;
 Covering any fatal incidents of any staff or members of the public;
 Details of incidents and recommendation on prevention of re-occurrence;
 Comparison with relevant statistics in the past; and
 Safety and security issues.
Complaint Record
 Detailed account of each complaint including complainant, time, nature, issue of
complaint and action taken; and
 Statistical analysis of all complaint records.
 The Contractor shall supplement and present any additional operational data and
information, in form of Monthly Reports or in ad-hoc manner, as requested by the
Engineer from time to time.
 Details of report formats shall be approved by the Employer.
E) Annual Report
The Contractor shall submit Annual Reports to the Employer and the Engineer before
the last day of the anniversary month following the year to which the report relates.
 summaries of quantities and characteristics of sewage received and treated at
the Facility during the reporting year;
 overall performance of the Facility with highlights on non-compliance with
Operational Performance and Environmental Performance Requirements;
 summary of expiry dates for licences, permits and certificates for the Operation;
 summary of major equipment breakdown, repair, overhaul, renewal, replacement,
modification, Performance Tests, Condition Surveys carried out, with CMMS
reports;
 summary of incidents related to safety and health, environmental issues, security
and complaints;

 scheduled maintenance, overhaul, renewal, replacement, modification of major

plant and equipment, Performance Tests and Condition Surveys in the
forthcoming 12 months;
 list of Changes ordered by the Employer, with details and status;
 summary of payments of Operation Fees; and
 records of the Contractor‘s financial performance including audited accounts with
balance sheets and profit/loss statements.
Details of report formats shall be approved by the Employer.
F) Monthly Environmental Monitoring Report
The Contractor shall submit Monthly Environmental Monitoring Reports to the

Employer and the Engineer by the 14th day of the month following the month to
which the report relates. Typical required information and data shall include, but not
be limited to the following:-
 results of environmental monitoring undertaken during the reporting period;
 actions and mitigation measures adopted or to be adopted to redress
unacceptable, consequential or unanticipated environmental impacts, together
with an assessment of their likely effectiveness;
 comparison with both statutory and contractual compliance limits; and
 details of response in the event of any omissions or failures.
Details of report formats shall be approved by the Employer.
G) Annual Environmental Audit Report
The Contractor shall submit Annual Environmental Audit Reports to the Employer
and the Engineer before the last day of the anniversary month following the year to
which the report relates.
The Annual Environmental Audit Report shall include review on environmental

monitoring data and operational data obtained in the reporting year, with particular
reference to the effectiveness of mitigation measures identified in the previous
Environmental Monitoring/Audit Reports and measures that the Contractor proposes
to adopt in overcoming any shortcoming.
11.2.9 Spares
The Contractor shall during the Operation Service Period, replenish the stock of spares
to maintain at all times an equivalent stock of spares as required at the commencement
of the Operation Service Period.
The minimum stock of spare parts held shall be the comprehensive spares required for a
two- year period of Operation Service and shall be detailed in the Operation &
Maintenance Plan. The Contractor shall monitor the use of spare parts and make
recommendations to the Engineer to vary the stock in accordance with the experience
gained during the Operation Service Period.
A two year stock of spare parts shall be provided by the Contractor with the Works
handed back to the Employer on completion of the Contract.

11.2.10 Public Liaison
The Contractor acknowledges that the Employer shall be the sole point of contact for
dealing with comments or complaints from customers of the Employer or members of the
public relating to the provision of the Operation Services.
Where a customer of the Employer or member of the public makes a complaint to the
Contractor, whether written or oral, in relation to any aspect of the Contractor‘s provision
of the Operation Services, the Contractor shall notify the Engineer as soon as practically
possible.
Where any complaint or an enquiry has been received directly by the Contractor or
received by the Employer and notified by the Employer to the Contractor, the Contractor
shall report to the Engineer within 24 hours in such a way that the Engineer can respond
prudently to the complaint in accordance with the good customer service expected.
Where a customer or member of the public has made repeated or ongoing complaints,
the Contractor shall manage such complaints on a case by case basis, prepare an action
plan, keep records of meetings and discussions with the customer and submit regular
progress reports at least monthly to the Employer until such time as an agreed resolution
or outcome is made with the customer or member of the public.
11.3 Operation and Maintenance Plan
11.3.1 Overview of Requirements
The Operation and Maintenance Plan (O&M Plan) shall be agreed between the
Employer and the Contractor as a fundamental part of the Contract for service delivery.
The O&M Plan shall then become an evolving plan, agreed on an annual basis, which
will include all aspects of the Operation Service as they are developed and applied within
the Contract.
The Contractor‘s O&M Plan for the Works shall comprise three main sections, as follows:-
 O&M Manual
 Operation Management Plan
 Maintenance Management Plan
The general structure of the O&M Plan shall be as highlighted in Figure 11-1 below.
O&M Plan
OSMG
Operation O&M Manual Maintenance

Management Management Plan
Plan
Plant Facility Asset

Maintenance Plan Maintenance Management
Plan Database
Figure 11-1 General structure of O&M Plan

The Contractor shall submit the O&M Plan to the Engineer by the times stated in Part 3.
The O&M Plan shall ensure that the operation of the service consistently complies with
the output quality and quantity sections of this document. In addition the O&M Plan shall
ensure that the treatment and transportation and disposal of sludge shall be carried out
in an efficient and cost-effective manner in compliance with Contract.
The O&M Plan shall also ensure that the maintenance aspects of the service will be in
compliance with all requirements on a continuous basis. It shall include systems for the
safe, efficient and effective operation and maintenance of the Works, together with safe
systems of work and safe working procedures in compliance with current legislation.
The O&M Plan shall contain procedures for quality control which shall be contained in a
separate section, together with procedures for compliance auditing and quality auditing.
These shall confirm service delivery and compliance with technical, regulatory and
performance requirements.
The O&M Plan shall contain, amongst other matters:

 Staffing and details – responsibilities, qualifications and training;
 Plant replacement plan;
 Design information;
 Operation and maintenance systems;
 Health and safety;
 Quality control;
 Monitoring;
 Reporting requirements and links to other documents;
 O&M Manual (Standalone).
11.3.2 Preparation and implementation of the O&M Plan
The Contractor shall issue the O&M Plan in a ‗manual‘ form, with covering document
control sheet to denote document status and date of issue. The O&M Plan shall be
divided into sections, as per the structure outlined in Figure 16.1, with appendices where
necessary for additional data. Three original copies of the O&M Plan shall be issued at a
minimum. One copy shall be held at the treatment facility at all times and controlled
copies shall be issued to the Employer and the Engineer (one each). Should other
copies be required, up to 3 additional copies shall be issued to the Employer, upon
request.
The O&M Plan shall be a central point of reference for the Contractor in the delivery of
the service and shall be compiled and issued to the satisfaction of the Engineer prior to
the commencement of the Operation Service Period. The O&M Plan shall be
implemented in accordance with the time limits in Part 3. To achieve this, the Contractor
shall ensure that all resources and fully qualified and trained personnel are in place and
that service requirements are being consistently met in accordance with the plan. The
Contractor shall demonstrate this fully to Engineer.
The Contractor shall update the O&M Plan as appropriate, following the Service Delivery
Review Report or at the intervals stated in Part 3.

11.3.3 Auditing the O&M Plan
The Engineer can, at his own discretion, or at the behest of the Employer, audit the
Contractor‘s Operation Service performance against that required under the service as
set out in the Contract and O&M Plan. The Engineer and/or a third party specified by the
Engineer can carry out the audits. The audits are described in Part 1 of this document.
Any remedial actions to the O&M Plan or its implementation that are deemed necessary
shall be discussed with the Contractor and the appropriate initiatives shall be agreed and
issued to him, in writing, by the Engineer. This shall include a specific timeframe for
remedial actions to be taken.
Where there is a failure, on the part of the Contractor, to implement such initiatives within
the specified timeframe, the Conditions of Contract provide that the Employer shall have
the right to withhold payment until such time as the failure(s) are remedied. Should this
measure fail, the Employer shall retain the right to terminate the Contract and shall
recover all costs associated with the employment of replacement staff or Contractors.
11.3.4 Operation and Maintenance Manual
The Contractor shall provide an Operation and Maintenance Manual (O&M Manual) to
the Employer and the Engineer in a ‗manual‘ form, with covering document control sheet
to denote document status and date of issue.
The manual shall be provided under the O&M Plan, but as a separate standalone
document, which shall form a hard copy technical reference for the Works. The manual
shall apply specifically to the functional and technical aspects of existing and new
installations, processes, equipment and components.
The manual shall commence with an introduction and general section comprising
contents, description of the whole installation and relevant addresses and phone
numbers of manufacturers and suppliers. This shall be followed by a description of the
Works and its design, operation, control and protection. Following this, it shall contain
clear, factual descriptions, instructions, diagrams, drawings and explanations of all
installations, processes, plant and equipment. These shall be free from such irrelevant
matters as might be contained in contractors‘, manufacturers‘ or suppliers‘ general or
promotional literature.
Three original copies of the O&M Manual shall be issued at a minimum. One copy shall
be held at the Site at all times and controlled copies shall be issued to the Employer and
the Engineer (one each). Should other copies be required, up to 3 additional copies shall
be issued to the Employer, upon request.
The O&M Manual shall read such that it has been written specifically for the Works by
the Contractor and shall not refer to Plant or Materials that are irrelevant. It shall be
divided and sub-divided logically into a series of volumes to ease their use on a day to
day basis and to ease the location of plant details, reporting procedures and policies.
The preparation of the O&M Manual shall be to a programme to be agreed with the
Engineer which shall indicate the delivery schedules, draft submissions, collection and
submission of suitable asset and maintenance data, collection and submission of the
supplier‘s operation and maintenance manuals and a system for vetting and approving
the manual. The O&M Manual shall be provided within the time shown in Part 3.

For all installations and processes, the manual shall contain at a minimum:
 Introduction;
 Safety, health and welfare information;
 Overview of the Works;
 Description of the operation of processes;
 Design information and relevant calculations;
 Routine tasks and staff duties & task check lists;
 Functional descriptions of plant elements;
 Details, charts and calibrations for chemical systems;
 Calibration procedures for chemical systems;
 Routine wastewater sampling and analysis instructions;
 Chemicals and chemical systems type, quantities, storage, safety and safe use
information;
 As-built documentation;
 Calibration procedures and reports for instrumentation, control and analogue circuits;
 Fault finding instructions;
 Maintenance instructions stating maintenance routines and intervals
 Procedures for disassembly, repair and assembly;
 List of components indicating manufacture, type, component number, ordering
numbers, position and other data;
 Manufacturer‘s or supplier‘s literature and data leaflets;
 Lists of spare parts (including order references and part numbers);
 Lists of tools;
 Lists of consumables
11.3.5 Plant Manager
No later than six months before the anticipated start of the Process Commissioning, the
Contractor shall nominate a Plant Manager. The Plant Manager shall have at a
minimum:
 10 years‘ experience in the O&M of municipal Treatment Plants;
 Bachelor Degree in Engineering;
 Operations Manager for at least two municipal STW‘s which included sludge
handling, and energy recovery facilities of similar size, process technologies,
complexity and capacity in the last five years.
The submission shall include details of the nominee‘s experience and qualification (CV).
If a plant manager was identified in the prequalification process and if a different person
is nominated during the Contract Period, the appointment of the Plant Manager shall be
subject to approval by the Engineer.
The Plant Manager shall be appointed before the commencement of the Tests on
Completion of Design-Build for the whole of the Works (including pre-commissioning
tests) and shall be a full time appointment.
 The Plant Manager shall be involved in the development of:
 Operations management plan including the organisation chart;
 Compile a full asset register of the facility and set up an asset maintenance system
and operations systems;
 Put in place necessary training plan and hire staff ahead of operations as necessary.
Whenever the Contractor wishes to replace the Plant Manager, a nomination shall be
submitted to the Engineer for approval at least one month prior to the intended
replacement date. The Contractor shall use best endeavours to ensure that the

replacement Plant Manager shall have a working overlap of at least two weeks with the
current Plant Manager.
11.4 Operation Management Plan
11.4.1 General
The Operation Management Plan shall be one of the main parts of the O&M Plan and in
itself shall comprise the procedures for the operation of the treatment facility.
The Operation Management Plan shall be capable of demonstrating in an easily

identifiable schedule that the Works are and have continued to comply with the terms of
all relevant licenses and legislation.
11.4.2 Procedures for the Operation Service
The Operation Management Plan shall contain detailed procedures for the operation of
the Works, including equipment and processes, which the Contractor proposes to use in
delivering the service. A detailed control philosophy shall be provided for the overall
process and for each process stage, which shall be accompanied by a procedure for the
operation of each individual item of plant and/or system. This shall form a set of clear
instructions to operators and management in the STP.
The treatment facility control system shall be capable of continuous automatic

operations. The treatment facility shall be capable of running under manual control,
although normal operation shall be in automatic mode.
Optimum performance of the Works is an important requirement of the control system.
11.4.3 Non-Compliant Operation
Notwithstanding the requirements given herein, whenever the Employer is dissatisfied

with test results, he may instruct the Contractor to carry out additional tests, at no
additional cost to the Employer, for investigation of non-compliance. If, as a result of the
examination, inspection, measurement, analysis or testing, any Plant, Materials, design
or workmanship is found to be defective or otherwise not in accordance with this
document, the Contractor shall promptly make good the defect at his own expense and
ensure that the item complies with the appropriate standards.
Notwithstanding any previous test or certification, the Contractor shall, if so instructed by

the Employer: -
 Remove and replace any Plant or Materials, which is not in accordance with this
Contract.
 Remove and re-execute any other work which is not in accordance with this Contract.
 Execute work which is urgently required for the safety of the Works, whether because
of an accident, unforeseeable event or otherwise.
Non-compliance determined by the Engineer will be communicated to the Contractor by

the most appropriate means and confirmed in writing. The Contractor shall determine the
cause of non-compliance, identify the corrective measures and report in writing within
five days.

11.5 Maintenance Management Plan
11.5.1 General
The Maintenance Management Plan shall provide for production of the following:
 Operational maintenance issues;
 Equipment calibration records;
 Equipment service records;
 Plant maintenance records;
 Emergency event records.
The Contractor shall also develop and implement a comprehensive computer-based

maintenance management system (CMMS), which shall include data on each of the
above sections. The computerised system shall address all Plant and Materials. It shall
be capable of developing readily available historical data, including an inventory of spare
parts and provision for enforcing warranties on Plant or Materials purchased. The
Contractor shall incorporate the computerised system into the Contractor‘s SCADA
system, thus enabling all operational and maintenance details of Plant to be accessed by
the Contractor, the Employer and the Engineer. The Contractor shall also develop an
Asset Management Database that includes every component of the Works. The
database shall be structured to have "parent/child" relationships for each component.
The requirements of this Database are provided in clause 11.6.4
All maintenance activities and Plant usage shall be logged through the SCADA system to
provide the necessary input to the computerised Maintenance Management Plan and
Asset Management Database. The system shall be capable of generating details for
work orders and asset lifecycle information that are specific to any items of equipment.
These work orders shall outline the required maintenance, describing previous history
and the work to be undertaken. The asset management database and software
applicable shall be capable of deriving the requirements as prescribed in clause 16.5,
based on the real time monitoring of assets by SCADA system.
The resultant maintenance work shall be logged as to when the work order was issued,
when completed, by whom, duration of work, and listing of parts and consumables used
in expediting the work. This information shall be continuously updated for all equipment
and presented on an annual basis to the Employer to confirm that work is being
undertaken as required to protect investment in the infrastructure. The Employer,
however, may request to review records more frequently.
The Contractor shall provide a periodic inspection (at least once a month) to detect any
significant variance from the baseline condition. Corrective action shall be taken by the
Contractor to prevent major damage to equipment, as well as protect warranties on new
equipment.
11.5.2 Plant Maintenance Plan
The Plant Maintenance Plan shall provide for the routine, planned, breakdown and repair
maintenance of mechanical, electrical, instrumentation and electronic plant, equipment
and infrastructure (the STW assets) contained within the STW. The plan shall be for the
duration of the Operation Service Period and shall be continually evolving, including all
new equipment as it is installed.
The Plant Maintenance Plan shall reflect procedures and standards for a modern
wastewater treatment facility. All routine and preventative maintenance activities shall, as

a minimum, meet the requirements of manufacturers and shall be based on the premise
than in no event shall maintenance be less frequent and less comprehensive than that
specified in manufacturers‘ warranties and instruction manuals.
The Plant Maintenance Plan shall serve as the framework for developing the detailed
maintenance plans for each item to be included in the O&M Manual. It shall therefore be
based on a recognised quality maintenance methodology, for example the Reliability
Centred Maintenance (RCM) approach. It shall also serve as a record of maintenance
carried out on an ongoing basis, with reference to the O&M Manual where appropriate.
The Contractor shall provide a statement of the methodology he proposes to the
Engineer for review before developing it in detail.
At a minimum, the Plant Maintenance Plan shall include:
i. Schedules for the maintenance of the Works to include but not be limited to:
 A complete list of the STP assets to be maintained
 The frequency and type of routine and planned maintenance for each STP asset
 Calibration of all instrumentation
 A listing of all essential spare parts to be carried
ii. Methods for dealing with breakdown and repair of STP assets to include:
 Callout response times for each STP asset
 Communication with the Engineer when breakdowns occur
iii. Procedures for the maintenance of the STP assets;
iv. Methods for the planned replacement of minor STP assets;
v. Records of all maintenance carried out at the STP. These are to be kept up to date
and held electronically and in paper format at the Site at all times.
Plant and Materials shall meet the residual life requirements specified in Part 12 and
shall be replaced as determined by the manufacturer‘s life warranties or earlier.
11.5.3 Facility Maintenance Plan
The Facility Maintenance Plan shall provide for the routine, planned, and repair
maintenance of all buildings, structures, roads, paths, accesses, green areas, gardens,
shrub and tree areas, etc., contained within the Site. All routine and preventative
maintenance activities shall, as a minimum, meet the requirements of suppliers.
The Contractor‘s facilities maintenance plan shall include procedures and standards for a
modern wastewater treatment facility. It shall be based on the premise that in no event
shall maintenance be less frequent and less comprehensive than that specified in
suppliers‘ or manufacturers‘ warranties and manuals.
The plan shall ensure that maintenance is carried out at a level adequate for the efficient,
long-term reliability and preservation of the Employer‘s capital investment. It shall also
ensure that buildings, grounds, and landscaping are kept in an aesthetically attractive
and clean condition and are in compliance with all national regulations.
The Contractor shall carry out grounds maintenance so that all areas of the Site are kept
neat and tidy and free of any item which could constitute a nuisance or pose a threat to
the safety of any person, property or the environment or to the provision of the Operation
Services.
In the plan, the Contractor shall at a minimum include for the following activities relevant
to the buildings and grounds:

Buildings and Structures

 Repairing/ replacing all worn out items, breakages and leaks immediately;
 Cleaning roof guttering and drainage, windows and doors at six monthly intervals;
 Cleaning and maintaining ventilation systems at six monthly intervals;
 Washing down walls and wall tiles at least every six months, or more frequently, as
appropriate;
 Painting internal and external surfaces regularly (every 3 years as a guideline) and
as detailed in maintenance schedules.
Grounds and Site

 Mowing the grass once per week in the growing season and once per month
otherwise, including trimming of any edges, cutting hedges, shrubs, weeding and
applying weed killer to maintain an attractive appearance of the Works;
 Pruning trees once per annum to minimise interference with or damage to the STW
and Site work;
 Cleaning paths and roadways on a monthly basis, including freeing surface water
drainage systems, gulleys and manholes;
 Inspect and repair, as required, cracks, erosions, depressions, and potholes and slab
shifts on paved areas, sidewalls and other areas on a monthly basis;
 Inspect and repair, as required, security fencing, access gates and secure accesses
to all Site areas on a monthly basis;
 Resurfacing to paved areas when required.
11.5.4 Asset Management
11.5.4.1 General
The Contractor shall submit a draft Asset Management Plan to the Engineer for
certification. The draft Asset Management Plan shall be developed based on and shall
not differ in any material respect from the Outline Asset Management Plan submitted by
the Contractor. The Asset Management Plan shall include, but shall not be restricted to,
the following sections: -
Asset Overview
 classification and registry of assets of the Facility;
 significance of assets to the performance of the Facility;
 dependencies between the assets;
 asset management strategy;
Performance and Standards

 design lives of Plant, buildings and structures;
 benchmarks, standards and guidelines adopted for Performance Tests, Condition
Surveys and Residual Life Assessments;
Asset Performance Monitoring

 plans, scopes, arrangements and reporting for Condition Surveys and Residual Life
Assessments in accordance with the Specification;
 plans, scopes, arrangements and reporting for Performance Tests in accordance with
of the Specification;
Asset Remediation Plans

The Contractor shall obtain the Employer‘s consent on the certified draft Asset
Management Plan, which will then be construed as the Asset Management Plan. The
Contractor shall review and update the Asset Management Plan annually.
 The Contractor shall carry out all corrective and preventive maintenance
programmes for the Facility in accordance with the consented Operation Plan and
Asset Management Plan.
 The Contractor shall carry out or cause to be carried out repair, replacement and
rehabilitation of the Facility and the Site as required for the ongoing operation of the
Facility in accordance with the design performance and standards.
 The Contractor shall note that all reports prepared by the Contractor under this
Specification will be made available for inspection by the Contractor for any follow-on
contracts.
 All costs associated with works and services pursuant to this Specification shall be
borne by the Contractor and deemed to be included in the Operation Fees.
11.5.4.2 Asset Remediation Plans
The Contractor shall develop and implement asset remediation plans which shall include,
as a minimum, the following:-
 schedules for overhaul and replacement of Plant;
 schedules for refurbishment and renewal of buildings and structures;
 planned actions to bring or keep the assets above their minimum conditions required
under the Contract;
 criteria for acquisition and disposal of assets; and
 means and arrangements to demonstrate to the Employer that the Plant, buildings
and structures have the respective residual lives specified in the Specification at the
expiry of the Operation Period;
If the design life of any Plant, buildings or structures stated in the Asset Management
Plan or otherwise established during Residual Life Assessments in accordance with the
Specification expires during the Operation Period, the Contractor shall before such
expiry renew, rehabilitate or replace such Plant, buildings or structures. The cost of such
renewal, rehabilitation or replacement shall be deemed to be included in the Operation
Fees provided that with respect to the design life of any Plant, buildings or structures
which is due to expire but which Plant, buildings or structures still performs safely and
efficiently and in accordance with the Contract requirements, the Contractor may at the
option of the Engineer defer such renewal, rehabilitation or replacement so long as the
said performance continues but the Contractor shall in any event complete the said
renewal, rehabilitation or replacement before expiry of the Operation Period.
11.5.4.3 Condition Surveys
The Employer shall engage with the Engineer to carry out Condition Surveys of the
Facility in the presence of the Contractor and the Engineer. The surveys shall be carried
out in the seventh month of the 3rd, 6th and 8th year of the Operation Period.
 The scope of the Condition Survey shall include:
o Inspection and auditing of manuals, schedules, reports, SCADA and CMMS
records for compliance;
o Visual inspection of all components, including Plant, buildings and structures for
state of maintenance and repairs;
o Inspection of performance records and performance evaluation of the plant and
equipment in operating condition;

o Witness testing of the plant and equipment in operating condition, including the
Performance Tests specified in the Specification;
o Based on the above information, forming a view as to the general operation and
maintenance condition of the Plant, buildings and structures, with due regard to
their service hours and/or age; and
o Making recommendation on enhancement of the operation and maintenance of
the Facility, where applicable.
 The Contractor shall compile and submit a condition survey plan to the Employer for
approval at least 45 days prior to commencement of the Condition Survey. The
condition survey plan shall be prepared in consultation with the Engineer to
demonstrate uninterrupted Operation of the Facility. The condition survey plan shall
include the following information, as a minimum:
o a programme showing the systems, equipment, structures, etc. which are
included in the Condition Survey;
o detailed descriptions of precautionary measures, methodologies, procedures,
timing for the inspections, audits, measurements or tests to be carried out on
each survey item;
o effect on normal operation of the Facility including any reduction in redundancy or
standby capacity, with mitigation measures or temporary arrangements clearly
stated;
o any safety, health and environmental related issues;
o details of any temporary work for the Condition Survey; and
o contingency plan for emergency situations that may arise during the Condition
Survey.
 The Condition Survey shall not commence until the condition survey plan has been
approved by the Employer. The entire condition survey shall be completed within 1
calendar month.
 The Contractor shall prepare and submit to the Employer and the Engineer, a
detailed condition survey report within 28 days of the completion of the Condition
Survey. The report shall include:-
o methodologies and findings of the survey;
o identification of any damage or defects;
o recommendation of rectification work required to satisfy requirements of the
Contract; and
o recommendation of enhancement to the operation and maintenance of the
Facility.
 In the event that the Employer considers, as a result of the Condition Survey and the
Residual Life Assessment, that any part or parts of the Facility require repair,
maintenance, rectification or replacement to satisfy the requirements of the Contract,
if appropriate, the Employer will serve notice under the Conditions of Contract, on the
Contractor of the work necessary to be carried out. The Contractor shall ensure that
all such repair, maintenance, rectification or replacement are completed within
reasonable time and in any case not more than 90 days after receipt of the
Employer‘s notice, unless otherwise consented to by the Employer.
 Prior to the handing over of the Facility, the Contractor shall conduct an End-of-
Contract Condition Survey.
 The Condition Surveys in the 6th and 8th years of the Operation Period shall include
the Residual Life Assessment.
 For the avoidance of doubt, all costs associated with the carrying out and reporting of
the Condition Surveys shall be borne by the Contractor deemed to be included in the
Operation Fees.

11.5.4.4 Residual Life Assessments
 The Condition Surveys in the 6th and 8th years of the Operation Period and the End-
of Contract Condition Survey shall include a Residual Life Assessment. The Residual
Life Assessment shall be carried out as part of the Condition Surveys by a Third
Party.
 The Residual Life Assessment shall benchmark the Facility against relevant
international standards / guidelines, and performance of similar facilities on a
worldwide basis.
 The Contractor shall include a separate section in the survey report for the Residual
Life Assessment, to record the following:-
o Residual life assessment methodology;
o Standards, guidelines and references adopted;
o Detailed descriptions of assessment carried out;
o Findings of assessment; and
o Recommendation of work required for the upkeep of the Facility in satisfactory
conditions.
11.5.4.5 End-of-Contract Condition Survey
 All requirements for Condition Surveys and those for Residual Life Assessments
shall apply to the End-of-Contract Condition Survey unless otherwise specified.
 The End-of-Contract Condition Survey shall be carried out at least six months but not
more than nine months prior to the expiry of the Operation Period to verify conditions
of the Facility and ascertain the residual life of the Facility.
 For the avoidance of doubt, the End-of-Contract Condition Survey shall include a
Residual Life Assessment.
 As part of the End-of-Contract Condition Survey, the Contractor shall carry out tests
and provide all necessary assistance to the Engineer to determine whether the
Facility to be handed over to the Employer is in good and serviceable condition
suitable for continual use and meets the residual life requirements.
 The Contractor shall compile and submit an End-of-Contract Condition Survey Plan
to the Employer for consent at least 60 days prior to commencement of the End-of-
Contract Condition Survey. The plan shall include tests and inspections requested by
the Employer.
 The Contractor shall prepare and submit to the Employer, and the Engineer, a
detailed End-of-Contract Condition Survey report within 28 days of the completion of
the End-of-Contract Condition Survey. The report shall include recommendation of
work required to meet the residual life requirements specified in the Specification.
 In the event that the Employer considers, as a result of the End-of-Contract Condition
Survey, that any part or parts of the Facility require repair, maintenance, rectification
or replacement to satisfy the requirements of the Contract, the Employer will serve
notice under the Conditions of Contract on the Contractor for the work necessary and
the work that becomes necessary during the remainder of the Contract to be carried
out and completed to the satisfaction of the Employer no later than 60 days prior to
the expiry of the Operation Period. In the interpretation of the End-of-Contract
Condition Survey, the Employer will have due regard for the obligation under this
Contract on the Contractor to fully maintain the Facility that is to be handed over to
the Employer in good and serviceable condition suitable for continual use to the
performance requirements of the Facility.
 After the remedial works carried out according to the notice served by the Employer
after the End-of-Contract Condition Survey, the Contractor shall carry out joint
inspections with the Engineer on the plant and equipment that has been maintained

or replaced, including all necessary tests to demonstrate that the requirements of the
Contract have been met.
 If in the opinion of the Employer, the Contractor has failed to carry out any work to
hand over the Facility in good and serviceable condition to the Employer for continual
use at the expiry of the Operation Period, the Employer may order such defects to be
made good and recover the costs as per the provisions of Conditions of Contract.

12 Handing Over
12.1 General
At the end of the Operation Service Period the Contractor shall handback the Works to
the Employer.
Immediately prior to the end of the Operation Service Period the Contractor shall carry
out final repairs to the Works. These shall include repainting as necessary and making
good any defects or damage. The Contractor shall handover all spare parts, tools and
tackles and consumables used in the Works and top up all fuel, oil and water tanks.
The Works shall be handed back in a condition which would permit the Works to receive
influent, treat and dispose of effluent after handback in accordance with the standards
required by the performance requirements (assuming that the Works are operated and
maintained in accordance with the Operational Specifications and Maintenance
Specifications).
The whole of the Works shall be handed back in a clean and maintained state and in full
operation and good working order.
The Plant and Materials shall have been maintained in accordance with the Maintenance
Management Plan.
At the end of 9 year of operation and maintenance, contractor shall carry out structural
audit of all civil structures and submit report.
12.2 Residual Life and Planned Asset Replacement at Handback
At the time of Handback all Permanent Works shall be in a condition in which the
components of the Works identified in the table below shall satisfy the remaining useful
life specified in the table.
Table 12-1 Residual life at handback
Minimum Remaining
Item
Useful Life (in years)
Civil engineering and building works (including underground
40
services and pipes)
External pipework 40
Roads 15
Steel tanks 15
Mechanical – Internal pipework and valves 15
Mechanical – Rotating machines and complex equipment 3
Electrical – Cables 15
Electrical - HT Electrical, Transformers & Switchgear 10
Electrical - LT Electrical and Switchgear 3
Instrumentation 4
Diffuser Membrane 4

Part 12: Handing Over
The Contractor shall manage the scheduling of the replacement of assets such that there
are no planned replacements during the 5 years following Contract Completion.
12.3 Expiry of the Operation Service Period and Joint Inspection
Two years before expiry of the Operation Service Period, the Contractor and the
Engineer shall carry out a joint inspection of the Works to identify any defects, damage
and plant replacements that may be necessary prior to the expiry of the Operation
Service Period.
The Contractor shall provide a programme for making good the defects and damage and
replacing items of plant, all as identified in the joint inspection, for approval by the
Engineer.
The Contractor and the Engineer will carry out further joint inspections at intervals not
exceeding 6 months. They will assess the Works condition and operation, progress with
the implementation of the above measures and identification of any further measures to
be implemented.
12.4 Tests Prior to Contract Completion
12.4.1 Procedure
The Contractor shall carry out Tests Prior to Contract Completion in accordance with the
Employer‘s Requirements.
The Contractor shall prepare a detailed method statement for carrying out Tests Prior to
Contract Completion and submit it to the Engineer for review. The Tests Prior to Contract
Completion shall be similar to the procedures for the Tests on Completion of Design-
Build described in Volume 2 Part 9, including sampling and analysis, developed to
include new elements of the Works added since the Tests on Completion of Design-Build
were carried out and modified to include procedures and methods appropriate at the end
of the Operation Service Period.
As a minimum these Tests Prior to Contract Completion shall demonstrate to the

satisfaction of the Engineer that:
a) the Works are meeting the required performance, current at the time of testing and all
other outputs conform with current legislation and regulations under all operating
conditions that can be expected;
b) the Works comply with the Contractor‘s design and the Engineer;
c) the capacity and efficiency of all Plant and process units are within the design limits;
d) disposal of site products, by-products, sludge and waste is in accordance with
current legislation;
e) all Plant and the Works remain fit for their intended purposes.
The inspections, tests, monitoring and analysis shall be witnessed by persons nominated
by the Engineer.
The Tests Prior to Contract Completion shall be deemed to have been completed when
the Works have been operated without breakdown of any item of Plant for a continuous
period of one month and compliance with all the criteria stated above has been
demonstrated to the Engineer‘s satisfaction and the results of the tests have been
submitted to the Engineer as stated below.

The Contractor shall be responsible for any remedial measures necessary to achieve the
above criteria.
No inspection, or approval or failure to give approval/consent to or response by the

Engineer or his staff of the Works, Plant and Materials shall release the Contractor from
any of his obligations under the Contract.
It is a requirement of the Contract that all Plant and Material shall be suitable for ongoing
use to the benefit of the Employer at the conclusion of the Operation Service Period.
Accordingly, they shall comply with the residual life requirements. This shall be assessed
by the Engineer by reference to the Works condition and where relevant to the history of
its performance, breakdown, maintenance etc.
Where residual life expectancy does not meet the Contract requirements the Employer
shall have the option to deduct monies from the final payment due to the Contractor or
seek damages in lieu of the Plant being replaced.
Inspection of the Works for the purposes of assessing the residual life of the Works shall
be part of the Tests Prior to Contract Completion.
12.5 Handback of the Works to the Employer
The Works shall be transferred to the Employer at the date stated in the Contract
Completion Certificate in accordance with Conditions of Contract.
Shortly before Handback of the Works the Contractor and the Engineer shall carry out a
final joint survey of the Works. A schedule of minor defects shall be compiled by the
Contractor and submitted to the Engineer. Upon the Engineer being satisfied regarding
such final inspection, and subject to the Contractor having successfully completed the
Tests Prior to Contract Completion, the Engineer shall issue to the Employer and the
Contractor a Contract Completion Certificate stating any minor works remaining to be
completed. The Employer shall thereafter be responsible for the care, safety, operation,
servicing and maintenance of the Works.
12.6 Training of the Employer’s Operators
The Contractor shall provide formal training and hands-on experience to the Employer‘s
operators as required by Volume 2 Part 10 during the last twelve months of the
Operation Service Period.
12.7 Final Documentation
Prior to the commencement of the Tests Prior to Contract Completion the Contractor
shall submit to the Engineer one original plus three copies of a final version of all the
documentation utilised and required for the operation and maintenance of the Works.
This shall as a minimum be the documentation required stated herein the Employer‘s
Requirements and health and safety documentation required by legislation. It shall
include inter alia up to date records of:
 Updated as-built drawings of the Works (hard and soft copy);
 design details (calculations, etc);
 operation and maintenance manual including standard procedures, emergency
procedures and environmental management procedures;
 plant inventory and data sheets for each item of plant;
 software for all programmable devices (PLC, SCADA etc);

 maintenance management plan including the Modified Asset Replacement Schedule;

 records of test results, inspections, surveys, investigations, monitoring, sampling,
analysis (if not included elsewhere);
 control system functional design specification;
 monthly maintenance reports for the previous six months;
 the last two annual maintenance reports;
 schedule of outstanding repair orders.
Any changes arising from the Tests Prior to Contract Completion shall be made prior to
Handback of the Works.

APPENDIX 1 – DESIGN STAGE CONTRACTOR’S DOCUMENTS

The following are typical minimum design stage details that shall be submitted as part
of the Contractor’s Documents.
1. Civil
1.1. General
 site layouts providing information on levels and detailing the location of:
o buildings
o storage tanks
o process plant
o roadways
o drainage
o buried pipelines
o cable routes for direct in ground and ducted systems;
 plans, elevations and main sections of all structures and buildings
 general arrangements and main sections of all facility areas
 drainage provisions
 general arrangement drawings showing the location of each Plant item
 detail drawings of:
o cable and pipework chambers
o buried pipework
o pipework connections
o contract interfaces
1.2. Structural
1.2.1. Design Philosophy
Following are the details which are to be included in the general design philosophy
document submission:
1) Design assumptions/philosophy for Liquid Retaining Structures with various
boundary conditions as applicable, softwares to be used for analysis etc.
2) Design assumptions/philosophy for buildings
3) Design assumptions/philosophy for all other structures
4) Standard General Notes shall include material properties (grade, strength, unit
weight etc.), development lengths, lap/splice lengths, Anchorage lengths under
tension and compression, clear cover, water proofing specifications, legend used etc.
1.2.2. Standard Details

Following typical details shall also be submitted for approval prior to proceeding with
detailed design:
1) Reinforcement detail showing the development length at Column/ Footing
intersection, Column and Roof beam intersections, Walls and Base slab
intersections; Walls and cover slab intersections
2) Detailing of the reinforcement for columns, beams, beam/column intersection,
footing/column intersection, and Slabs as per relevant code provisions/requirements
depending upon the assumptions made in the designs
3) Reinforcement detail for cut-outs in slabs and walls with maximum size of cut-outs
4) Reinforcement detail at top of RCC trench walls showing edge/seating angles
5) Pouring sequence of concrete and standard details for construction joints, expansion
joints, contraction joints, etc.
Section 6: Employer‘s Requirement 307 Bid Document

Appendix
6) Details of Manholes and Rungs to be placed in the tanks

7) Detail for rain water drainage down takes at terrace slab and water proofing at
roof/sunken slabs
8) Detail for storm water drain, plinth protection and entrance ramps to buildings
9) Detail for Handrails and fixing detail of handrail to concrete, Steel Ladders and fixing
detail of ladders to walls/concrete, cage ladders, Boundary walls, Fencing and Gates,
etc.,
10) Material Specifications and application methodology for Anti-Corrosive Internal Lining
protection of Concrete Surfaces
Contractor shall not submit the detailed design and drawings until items mentioned in
under clauses 1.2.1 and 1.2.2 are approved.
Complete detailed design calculations of foundations and superstructure together with

general arrangement drawings and explanatory sketches shall be submitted by the
Contractor to the Engineer. Separate design calculations for foundations or
superstructures submitted independent of each other shall be deemed to be incomplete
and will not be accepted by the Engineer.
Submissions of detailed design calculations and Good for Construction drawings shall
include the following as a minimum:
A) Detailed Design Calculations
1) One (1) Copy of a Compact Disc (CD) containing electronic files relevant to the
structure‘s modelling, analysis and design calculations (Microsoft Excel, Staad
Pro, etc.). Files submitted shall be in editable format.
2) Print copy (6 Copies) of the contents as submitted in the Compact Disc / USB.
B) Good for Construction Drawings

1) One (1) Copy of a Compact Disc (CD) containing Autocad files (Civil General
Arrangement, Structural Dimensions and Reinforcement Details) pertaining to the
structure. Files submitted shall be in editable format.
2) Print copy (6 Copies) of the contents as submitted in the Compact Disc. Prints to
be submitted on A1 Size Sheet as a minimum or A0 Size Sheet when required by
the employer.
3) Bar-bending schedule indicating the number, shape and size of the rebars shall
be submitted as part of the Reinforcement Details
4) Detailed drawing showing the location, number and depth of inserts shall be
included for any structural steel inserts/Metal inserts in the structure such as
rungs, bolted connections for ladders/railings, etc.
5) Location of Construction Joints and pour sequence shall be included on the
drawing for base slabs, walls and top slabs.
6) Revised drawings shall be submitted by clouding at the location with the latest
revision number and also show the history of revisions in a table format just
above the title block.
The design considerations described hereunder establish the minimum basic
requirements of plain and reinforced concrete structures, masonry structures and
structural steel works. However, any particular structure shall be designed for the
satisfactory performance of the functions for which the same is being constructed. The
Contractor shall also take care to check the stability of partly completed structures.
2. Process
 drawings:
 process flow and mass balance diagrams
 comprehensive P&IDs including details of:

Appendix
o pipeline sizes and materials valve size and type

o instrumentation
o identification of controlling PLC
 calculations for:
o process mass balance
 pumping hydraulic calculations (including surge analyses if appropriate)
o plant hydraulic flows
o chemical process
o washwater recovery
o electrical
o dynamic simulation of process modelling using BioWin®
 electrical documents
o Works phasing plans
o Electrical changeover/ construction schemes and plan
o Operation and control philosophy
o Guaranteed technical particulars and Technical data sheets
o Specifications
o Original Equipment Manufacturer‘s Technical catalogues.
o Original Equipment Manufacturer‘s Technical catalogues covering Erection,
Testing, Commissioning, Operation & Maintenance recommendations
o Routine and Type test certificates for all the equipment‘s.
o functional design specification (FDS)
o factory acceptance test document (FAT)
o site acceptance document (SAT)
 drawings:
o Single Line Diagrams showing proposed metering, indications and protection
scheme
o Control Schematic drawings for each module of HV and LV switchgear and
Control Gear Assembly
o Wiring diagrams HV/LV switchgear and Control Gear Assembly, Transformer
Marshalling Box, APFC, Battery charger, Local push button stations,
OLTC/RTCC panels etc.
o General Arrangement drawings of...
o Metering kiosk, HV Switchgear and Control Gear Assembly, RMU,
o Transformers and its accessories
o LV Switchgear and Control Gear Assembly
o APFC and Harmonic mitigation system, DC Battery charger & battery bank
o with DCDB
o LV Bus Duct
o Distribution Boards
o Control Panels
o Local Push Button Station
o Substation layout
o General Arrangement drawings of...
o Bio Gas Power Generation System Electrical equipment.
o Cable containment layout
o Earthing and Lightning protection system layout
o Illumination (Indoor and Outdoor) Layout
o Hazardous area zone layout
o Bill of material for each switchgear and control gear covering type, make, quantity
of each component

Appendix
 electrical schedules and calculations

o Earthing or protective conductor design calculation and schedule
o Lighting design calculation along with coefficient of utilization chart and schedule
o Lightning protection design calculation and schedule
o Reactive power compensation and Harmonic mitigation design calculation
o Cable sizing calculation and Cable schedule
o Power and control cable termination schedule
o Cable containment system sizing calculation and schedule
o Load sizing and Load schedule
o Drive schedule
o Distribution board schedule
o Protection relay setting coordinated protection study
3. Electrical Building Services

 drawings:
o single line schematic for each distribution and sub-distribution board
o general drawings showing the location of each luminaire, socket outlet, fan etc,
including details of mounting height
o fixing details
o schedule:
o luminaire data sheets socket outlets data sheets
o fans data sheets
o calculations for:
o cable sizing lighting levels
4. Control and Instrumentation
 drawings:
o power supply distribution single line and schematic diagrams (see note 1) for
each control panel
o internal and external (see note 2) general arrangement for each control panel
(dimensional)
o control and instrumentation loop drawings (see note 3)
o instrument installation detail drawing (hook up, see note 4)
o cable block diagrams
o cable routing / installation drawings
o foundation and fixing details and trench drawings
o mimic general arrangement
 schedules:
o cable schedule
o cable interconnection schedule
o control and instrumentation load schedule for each control panel
o I/O schedule
o junction box schedule instrument schedule
o instrumentation, process control set point schedule instrument data sheets
 documentation:
o functional design specification (FDS)
o factory acceptance test document (FAT)
o site acceptance test document (SAT)
Notes:
1) Schematic drawings shall include a comprehensive schedule of the components
used in each switchboard, MCC and control panel, including details of the type,
manufacturer and rating of each component.

Appendix
2) The external arrangement of each switchboard, MCC and control panel shall show
the arrangement of all components, including details of panel section, switch and
instrument labels.
3) Control and instrumentation loop drawings shall show on a single drawing the
complete circuit associated with an instrument or device including details and
location of power supplies, cabling and terminations.
4) Hook up drawings shall detail how an instrument or device is installed. Electrical
control schematics, loop diagrams and schedules shall, where practical, be A3 size
drawings, all other drawings shall be A1 size.
5. Mechanical
 drawings:
o general arrangement of plant, pipework and ducting, including sections
o isometric views of pipework and ducting systems
o detail drawings of proprietary and fabricated plant items.
 schedules:
o pump curves
o plant performance details pipeline schedules
o valve schedules
o pumps pipelines
6. Mechanical Building Services
 drawings:
o single line schematics for hot and cold water system and drainage systems
o general drawings showing the location of each mechanical building service plant
item fixing details
 schedule:
o plant data sheets pipeline schedules
o valve schedules
o system sizing

Appendix
APPENDIX 2.1 – DESIGN EFFLUENT QUALITY DURING OPERATION AND MAINTENANCE
Effluent Parameters
Table 2.1.1 – Treated Wastewater Quality (for discharge to river)
Parameters Unit Limits Compliance basis

6.5 –
pH 95%ile
9.0
BOD5 at 20OC mg/L 10 95%ile
Total Suspended Solids (TSS) mg/L 10 95%ile
Total Nitrogen (TN) mg/L 10 95%ile
Total PO4-P (TP) mg/L 2 95%ile
Faecal Coliforms (MPN/100ml) <230 30 day geometric mean
Table 2.1.2 – Performance Requirement for the Plant (effluent for discharge to river)
Performance Requirements
Parameter Maximum Admissible
Compliance as above
Concentration (MAC)
BOD5 at 20OC 10 20
TSS 10 30
Total Nitrogen (TN) mg/L 15
Total PO4-P (TP) mg/L 2.5
Faecal Coliform <230 (MPN/100ml) <1000 (MPN/100ml)

Appendix
APPENDIX 2.2 – PERFORMANCE TESTS DURING PLANT PROVING PERIOD
During the Plant Proving Period it is likely that the flows and loads will be less than the
maximum values. In order to replicate the loading conditions that would be experienced at
maximum plant capacity the plant shall be configured to achieve these conditions. This is likely
to include the plant to be operated with only some lanes or units receiving flow. The exact
configuration is to be agreed with the Employer prior to testing.
During the Plant Proving Period daily samples of Influent and Effluent shall be taken in
accordance with the following requirements:
Samples shall be 24 hour composite flow proportional samples taken using an automatic
sampler and kept in a refrigerated enclosure.
Samples of Influent shall be taken from sample point 1 as shown in Appendix 2.3.
Samples of Effluent shall be taken from sample point 25 as shown in Appendix 2.3.
The sampling method for Influent shall aim to exclude debris, floating grease and grit from the
sample.
The daily Influent and Effluent samples shall be analysed for the parameters shown in table
2.2.1 Analysis of sewage and treated effluent shall be commenced as soon as possible and in
any case within a maximum of 24 hours from the end of the sampling period and completed
without delay.
Influent and Effluent shall also be continuously monitored for the parameters indicated in table
2.2.2
Data shall be collected by the SCADA system and shall be capable of being transferred to office
personal computer (PC) networks via Windows Direct Data Exchange (DDE), or other equal
database exchange software. The data shall be in a format which permits it to be automatically
uploaded into Microsoft Access or Excel tables, and other proprietary software packages, to
permit data graphing and analysis.
Table 2.2.1 – Suite of analyses for Influent and Effluent
Parameter Unit Influent Effluent**

Biological Oxygen Demand (BOD5) mg/l X X
*
Chemical Oxygen Demand (COD) mg/l X X
Total Suspended Solids (TSS) mg/l X X
Ammonia Nitrogen (NH3)* mg/l X X
*
Phosphorus mg/l X
Total Kjeldahl Nitrogen (TKN) mg/l X X
Sulphate (SO4)* mg/l X
Nitrate (NO3)* mg/l X
Nitrite (NO2)* mg/l X
Alkalinity (as CaCO3)* mg/l X X
Total Dissolved Solids (TDS)* mg/l X

Appendix
Parameter Unit Influent Effluent**

pH N/A X X
Note: all other parameters as mentioned in the License to Establish and License to
Operate from the regulator.
* Analysis for Reference Only
** Effluent monitoring to take place after secondary/biological treatment and after
disinfection
Table 2.2.2 – Parameters for which continuous monitoring and recording is required
Parameter Unit Influent Effluent*

o
Temperature C X
pH N/A X
-1
Conductivity μS.cm X
3
Flow rate m /s X X
Dissolved Oxygen mg/l X
* Effluent monitoring to take place after secondary/biological treatment and after
disinfection.
Table 2.2.3 – Performance during plant proving period (Effluent Discharge to River)
This is to be the same as specified in Appendix 2.1.

Appendix
Table 2.2.4 – Performance tests concerning sewage screening and screenings handling
Test background and

Parameter Performance criteria
procedure
Dry solids content in the Not more than one spot sample There will be no formal
washed and dewatered of screenings taken over seven sampling programme.
screenings consecutive days shall have the Measurements may be made
dry solids content lower than the at the request of the
designed value Employer‘s Representative.
Organics content in the Not more than one spot sample There will be no formal
washed and dewatered of screenings taken over seven sampling programme.
screenings consecutive days shall have the Measurements may be made
concentration of organic solids at the request of the
content higher than the specified Employer‘s Representative.
performance standard.
Screenings removal There shall be minimal carryover The carry over shall be
efficiency and quality of screenings during the test assessed visually at random
period. The screenings shall be by the Employer‘s
sufficiently clean at all times for Representative.
disposal at the Designated
Landfill Site.
Continuous operation and The downtime of any unit over The Contractor shall keep an
reliability of screens, the test period shall not be operation and maintenance
washing and dewatering greater than 4%. log for each unit.
plant.

Appendix
Table 2.2.5 – Performance Tests Concerning Grit Separation and Handling
Test background and

procedure
Removal of grit from Grit removal shall be sufficient The Contractor shall report any
sewage to prevent blockages and blockages and grit
significant amounts of grit accumulations.
accumulating in pipes and
treatment units.
Dry solids content in the Not more than one spot sample
washed and dewatered of grit taken daily over any 7
grit consecutive days shall have a
value lower than the specified The quality of grit shall be
performance standard. assessed visually at random by
the Employer‘s Representative,
Organic content of Not more than 10% of dry measurements may be made
washed and dewatered/ solids in any one spot sample at the request of the
classified grit of grit taken daily over any 7 Employer‘s Representative.
consecutive days shall be of
organic nature.
reliability of grit the test period shall not be operation and maintenance log
separators and grit greater than 4%. for each unit.
classifiers.
Table 2.2.6 – Performance Tests Concerning Primary Settlement
Test Background and

Procedure
The scum removal system The system shall be The Contractor shall observe
effective. visually, and report daily
Continuous operation and The downtime of any unit The Contractor shall keep an
reliability of the primary over the test period shall not operation and maintenance
settlement units (including be greater than 2%. log for each unit.
de-sludging plant).
BOD and TSS removal As per the approved design Primary influent and effluent
sampling and testing for BOD
and TSS

Appendix
Table 2.2.7 – Performance Tests concerning Biological Treatment
Test background and

Parameter Performance Criteria
procedure
Aeration system shall be capable
It may be necessary to
of producing continuously (for
disable the automatic DO
continuous systems) during the
Aeration System control system to assess the
operation the dissolved oxygen
Capacity compliance with this
concentration required by the
requirement during the test
design in any location of the
period.
aeration tanks.
Continuous operation
The downtime of any unit over the The Contractor shall keep an
and reliability of aeration
test period shall not be greater operation and maintenance
blowers, mixers, valves
than 2%. log for each unit.
and distribution system.
Nitrate concentration at As per the approved design within Sampling and testing of the
the outlet of the last 30 – 45 days of start of process mixed liquor at the outlet of
anoxic zone commissioning the last anoxic zone
Dissolved phosphorous
concentration at the As per the approved design within Sampling and testing of the
outlet of the last 30 – 45 days of start of process mixed liquor at the outlet of
anaerobic zone (if commissioning the last anaerobic zone
provided)
Table 2.2.8 – Performance Tests concerning Final Settlement System
Test background and

procedure
Capacity of return activated Minimum and maximum 1. The capacity is to be
sludge system capacity shall be as the values demonstrated on one
specified in the Contract. occasion over a short
period during the tests.
2. It may be necessary to
disable the automatic
control system to assess
the compliance with this
requirement during the
test period.
reliability of the secondary the test period shall not be operation and maintenance
settlement units (including greater than 2%. log for each unit.
scraper systems and
desludging plant).
The scum removal system The system shall be effective. The Contractor shall observe
visually, and report daily.

Appendix
Table 2.2.9 – Performance Tests Concerning Thickening of Sludge (Primary and

Secondary)
Test Background and

Procedure
Dry-solids (DS) The average DS content over the 1. The Contractor shall take
concentration of thickened entire test period shall not be daily samples (one
sludges less than the specified values. composite comprising 3
sub-samples collected
over one hour) of the
thickened sludges and
measure DS content.
2. Sampling and analysis
shall be in accordance
with Section 17.
Solids recovery by the Solids recovery over any 1. Samples of sludge liquor
sludge thickening system from the thickening plant
consecutive 14 days shall be
shall be taken daily over
greater than the specified value.
any 14 consecutive days.
2. On each sampling day,
three sub-samples of
liquor of an equal volume
shall be collected
manually (simultaneously
with the thickened sludge
sub-samples) and
combined into one
sample which shall be
analysed for DS and SS
concentration.
3. Alternatively, solids
recovery may be
estimated based on the
DS content in the feed
and in the thickened
sludge.
reliability of thickening the test period shall not be operation and maintenance
units greater than 4%. log for each unit.

Appendix
Table 2.2.10 – Performance Tests Concerning Dewatering of Sludge
Parameter Performance Criteria Test Background and Procedure

Dry-solids The daily DS content 1. During the performance test, the Contractor
concentration of over the entire test shall take daily samples (one composite
dewatered sludge period shall not be comprising 3 sub-samples collected over
less than the specified one hour) of the dewatered sludges.
performance standard. 2. Sampling and analysis shall be in
accordance with Section 17.
Solids recovery by Solids recovery over 1. Samples of sludge liquor from the
the sludge any consecutive 14 thickening plant shall be taken daily over
dewatering system days shall be greater any 14 consecutive days.
than the specified 2. On each sampling day, three sub-samples
value. of liquor with an equal volume shall be
collected manually (simultaneously with the
sludge cake sub-samples) and combined
into one composite sample which shall be
analysed for DS and SS concentration.
3. Alternatively, solids recovery may be
estimated based on the DS content in the
feed and in the sludge cake.
Continuous The downtime of any The Contractor shall keep an operation and
operation and unit over the test maintenance log for each unit.
reliability of period shall not be
dewatering units, greater than 4%.
including pumping,
polymer, and
washing systems.
Table 2.2.11 – Performance Tests Concerning Digestion of Sludge
Test Background and

Procedure
Temperature of the sludge in The average setpoint Temperature in the digesters
the digesters temperature of the sludge in shall be continuously
the digesters shall be recorded. The temperature
between 35 OC to 39 OC, and shall be measured at a
the measured sludge minimum of two positions in
temperature shall not be each digester.
outside the setpoint by a
range of 1.0 OC on any day
during the test period.
Minimum retention time in the The sludge retention time The Contractor shall record
digesters shall never be less than 15 the daily flow of the sludge to
days. the digesters in order to
estimate the retention time.
Continuous operation and The downtime of any unit The Contractor shall keep an
reliability of the digestion plant over the test period shall not operation and maintenance
be greater than 4%. log for each unit.

Appendix
Table 2.2.12 – Performance Tests Concerning Sludge Generally
Parameter Performance Criteria Test Background and Procedure

Consumption of For each particular sludge 1. On at least three occasions
polyelectrolyte treatment process (thickening/ during the performance tests,
dewatering) requiring addition of agreed with the Employer‘s
polyelectrolytes (or polymers), Representative, the Contractor
the consumption of shall measure consumption of
polyelectrolyte shall not be polyelectrolyte for each particular
greater than the stated value sludge treatment process over a
expressed in gram of solid minimum period of two hours.
polyelectrolyte per kg of sludge 2. On each occasion, a two hour
dry solids. test shall be conducted. During
the test the amount of
polyelectrolyte used shall be
measured.
3. The volume of the sludge feed to
the process during the test shall
be measured.
4. The samples of the sludge feed
to the particular sludge process
unit shall be taken at minimum
20 minutes intervals during the
test. The samples shall be
analysed for dry solids and the
mean value shall be used for
assessment of dry solids load
during the test.
5. The Contractor shall provide a
detailed test procedure for
Employer‘s Representative‘s
approval.
Sludge storage at Blended Primary sludge + The Contractor shall demonstrate
design load thickened WAS sludge – all for the available storage.
Digester Feed: As per
Contractor‘s approved design
Digested sludge: As per
Dewatered sludge: As per

Appendix
Table 2.2.13– Performance Tests concerning the Whole STP
Test Background and

Procedure
Peak Flow for preliminary treatment. 1. Flows shall be measured

continuously during the
Minimum hydraulic Diurnal peak flow plus the return and/or test period.
capacity of the recycle flows which would normally be 2. Compliance shall be
Works: applied to the unit under test for demonstrated to the
primary, biological and further Employer‘s
treatment. Representative.
Sampling and testing as per

Treatment capacity Effluent quality as per the Design
the requirements given in
of the Works Effluent Quality stated in Part 4
Part 9 and Appendix 2.

Appendix
Table 2.2.14– Performance Tests Concerning Noise
Test background and

procedure
The noise level of equipment The noise level 2m in a 1. Noise levels shall be
perpendicular direction from measured by the
any point on any item of Contractor using a
equipment (if unprotected) or suitable hand held
the shell of a building or instrument.
enclosure shall be 2. Noise measurement shall
continuously less than be carried out to ISO
80dBA. Recommendations R1996
& 1996/1, 2 and 3 as
appropriate.
Noise levels at Site boundary Noise levels from the Works
between 22:00hrs and shall be continuously less
06:00hrs than 45dBA (15 min Leq) at
the Site boundary.
oise levels at Site boundary Noise levels from the Works
between 06:00hrs and shall be continuously less
22:00hrs than 55dBA (15 min Leq) at
the Site boundary.

Appendix
Construction of 75 MLD Bhairoba STP on DBO Basis, Including Rehabilitation of Kalyaninagar Intermediate Pumping Stations (IPS)
APPENDIX 2.3 – Monitoring, Sampling and Analysis

Appendix
Table 2.3.1a – Minimum Monitoring, Sampling and Analysis During Normal Operation
Thickener: Primary Sludge Thickener: Secondary Sludge Digesters Combined

Settled Mixed
Parameter Influent Bypass Feed Thickened RAS Feed Thickened Return
Sewage Liquor Liquor Liquor Feed Contents Biogas
(WAS) Sludge (WAS) Sludge Liquors
1 25 2 17 4 7 13A 5 6 8 13B 9 10 22 13D
Type of sample CF CF CF S S S S S S S S CF/S S C S
Flow rate/ volume/ weight C C C/I C/I C C/I C/I C/I C/I C C
BOD (mg/l) 7X 2X 1X
COD (mg/l) 2X 2X 2X
pH C 1X 1X M 1X 1X
SS (mg/l) 7X 2X 3X M 2X 2X 2X
VSS (mg/l) 3X 2X 2X
SVI (ml/g) 5X
DO (mg/l O2) C
% TDS (% W/W) 2X
% VS (% W/W) 2X
Alkalinity (mg CaCO3/l) 7X M 2X
Conductivity C C
Temperature (°C) C C
Faecal Coliforms 1X
Hydrogen Sulphide
Methane (% W/W)
Microscopic Examination 1X
Sulphide and REDOX Potential C 1X
Total Kjedahl Nitrogen (TKN) 2X 1X 2X
Ammoniacal Nitrogen
2X
(NH4-N)
Total Phosphorus (TP) 2X 1X 2X
Soluble Phosphorus(P) 2X

Appendix
Table 2.3.1b – Minimum monitoring, sampling and analysis during normal operation
Dewatered Secondary Site Energy Treated

Polymer Potable Energy Effluent Wash
Parameter Dewatered Treated Screenings Grit Boundary Generated
Feed Liquor Usage Water Imported water
Sludge Effluent Receptors on site
Measurement Point 11 12 13C 3 14 15 19A,19B20,21 18 23 24 25 26
Type of Sample S S S CF CF CF S CF CF
Flowrate/Volume/Weight C C I I C C C
BOD (mg/l) 2X 7X
COD (mg/l) 7X
pH M C
SS (mg/l) M 2X 7X 7X
DO (mg/l O2) C C
% TDS (% W/W) 1X 1X
% VS (% W/W) 1X
Faecal Coliforms 7X
Hydrogen Sulphide O
Total Kjedahl Nitrogen(TKN) 2X 7X
Ammoniacal Nitrogen (NH4-N) 2X 7X
Total Phosphorus (TP) 2X 7X
Soluble Phosphorus(P) 2X 7X
Odour O
Noise O
Energy (kWhrs) C C
Notes
1. Measurement point references refer to Figure 2.3 and are indicative. To be confirmed following confirmation of process design.
2. Monitor to be installed on Emergency overflow in order to identify flow event, but flow measurement not required.
CF 24 hour composite, flow proportional. nX n times a week

CT 24 hour composite time proportional, or composite time proportional collected during discharge. M Monthly
S Spot, or composite comprising three spot sub-samples. O Occasional and when complaints or problems encountered.
C Continuous measurement and recording.
I Intermittent measurement (whenever discharged or transported on or off site).

Appendix
APPENDIX 3 – MONTHLY STATUS REPORT IN OPERATIONS PERIOD
Minimum requirements of Monthly Status Report (MSR)
Section Minimum Requirements

1 Introduction A brief summary, including:
 The date on which the Operation Service Period commenced, in
accordance with the Commissioning Certificate
 The number of MSRs produced since the Operation Service
commenced
 The period covered by the report
 Confirmation that all issues relevant to the Site activities and Works
performance during the reporting period covered are included in the
body of this report
2 Executive A clear, concise summary of the main events that occurred and the
Summary significant aspects of Works performance during the reporting period.
This Section shall include, where applicable, descriptions of:
 analysis results for the reporting period and whether the results were
within the specification of the Contract
 any reasons why the analysis results are not within the required
specification
 recommendations to improve the efficiency of the treatment process
and quality of the outputs of the facility
 any complaints that were received and how they were dealt with
 any alarm callouts
 any new procedures that were implemented and when they
commenced
 any health and safety issues raised since the last report
 any equipment that was taken out of / put into service
 Planned Vs Actual Operation & Maintenance activities and Target
ratios
 other issues of relevance (e.g. utilization of Asset Replacement
Fund, implementation of Independent Compliance Audit, as
encountered)
3 Graphical Flow data and analysis results shall be tabulated and graphed for each
Presentation of process parameter listed using a proprietary computer package:
Data
 Total daily inlet flows
 Total daily outlet flow
 BOD, Suspended Solids and other parameters of final effluent as per
the consent.
The permissible flow and effluent limits, as defined by the Contract, are
to be indicated on all graphs.
4 Comments on The analysis results shall be discussed in sufficient detail to allow the
Analysis Results performance of the Works to be assessed thoroughly in comparison to
the requirements of the Contract. During any problematic period of
service delivery, all aspects of the Site results shall be commented on in
detail. Specific reference shall be made to the following:
 the final effluent quality compared to discharge standard

Appendix

requirements
 the mixed liquor figures
 the microscopic analysis results
 the raw influent figures
 the thickened sludge figures
 any major change in results since the previous reporting period
 the digester contents results
 the activated sludge figures
 the figures for the dewatering equipment
 any other issues of relevance
5 Process Table showing any process operational changes made with the following
Operational headings:
Changes
 description of the change made to the operational process
 the purpose of the change
 the date the change was implemented
 the name and position of the person who carried out the change
6 Health and Health and safety issues that have arisen on Site during the reporting
Safety Issues period are commented on in this section. It shall include details of any
Site inductions or training undertaken. Also, any accidents or incidents
shall be reported in full together with statistical results.
7 Operational The snags, listed in tabular format, that are dealt with on Site during the
Maintenance Issues reporting period are taken from the previous MSR. Table to include:
 the snag number
 the nature of the snag, i.e. mechanical, controls, electrical, etc.
 a description of the snag
 the priority status of the snag
 any comments relevant to any corrective action already taken
 the date the snag was first reported
8 Complaints Complaints shall be logged in a standard, systematic fashion and shall
Register be dealt with appropriately in accordance with the Contract and reported
in this Section of the MSR. The information required to complete the
complaints register is:
 the complainant‘s name and address
 the date and nature of the complaint
 the date of acknowledgement to the complainant and author
 the action taken to eliminate or mitigate the cause of the complaint
 the cause of the complaint
 the author of the final outcome report
 the date the final outcome report was forwarded to the Employer
9 Alarm The details of all alarm call-outs (events outside of normal working
Callouts and hours) and Site incidents (events occurring during normal working
Site Incidents hours).
10 Analysis The results of sampling and laboratory analysis required in accordance
Results with the Contract.
11 Site Visit A record of all visitors shall be kept on Site and presented in each MSR.
Records The record shall include:
 the date the Site visit occurred

Appendix

 the name, company and position of the person(s) that visited
 arrival and departure time
 the purpose of the visit
12 Weather A log briefly describing the weather for each day during the reporting
Records period.
13 Equipment Site equipment shall be calibrated regularly, in accordance with the
Calibration Records manufacturer‘s instructions, and based on the calibration schedule
available from the Site database or when a piece of equipment is put
back into service. If Site equipment is calibrated during the reporting
period the details are entered into the equipment calibrations record and
included in this section of the MSR. The data to be included, in tabular
format, is as follows:
 the date the calibration occurred
 a description of the equipment that was calibrated
 the serial number of the equipment that was calibrated
 by whom the equipment was calibrated (name and company)
 when the next calibration is due
 whether a calibration certificate was produced
 any relevant comments
14 Equipment Site equipment shall be serviced as frequently as stated in the suppliers
Service Records literature or the operations and maintenance manual or if a fault occurs
with the equipment and it needs repair. The equipment service record
shall present, in tabular format, the details of each service, including:
 the date the service occurred
 a description of the serviced equipment
 the serial number of the serviced equipment
 by whom the equipment was serviced (name and company)
 when the next service is due
 any relevant comments in relation to the service
15 Plant The Contractor shall undertake examination and maintenance of all plant
Maintenance and equipment in accordance with the frequency recommended by the
Records manufacturer, the O&M Manual and in accordance with the Contract.
The examinations and maintenance activities shall be recorded in a plant
maintenance schedule and presented in this section of the MSR. The
information required to complete the plant maintenance schedule report,
which shall be in tabular format, is as follows:
 a description of the equipment
 the serial number of the equipment
 the section the maintenance schedule was taken from in the O&M
Manual
 the items that need to be checked every week, month, 3 months,
6 months or year for that piece of equipment
As the item of work is checked for each piece of equipment, it is
marked on the Table and initialled to indicate that it has been examined.
16 Non-sludge Any non-sludge waste that is removed from Site shall be documented in
Waste Disposal the Site database and the information is transferred to the non-sludge
Records waste disposal record for inclusion in the MSR.
The information required for the non-sludge waste disposal record is as

Appendix

follows:
 the date the waste was removed
 a description of the waste
 the amount of waste removed at that time
 by whom the waste was removed (name and company)
 the intended destination of the waste
 receipt for acceptance of the waste
17 Sludge Any sludge that is disposed of from Site shall be transported for disposal
Disposal Records in accordance with the Contract. A record is kept on Site of all sludge
that is taken from the Site. The following information is
required for completing the outgoing sludge record which shall be
presented in tabular format in this section of the MSR:
 Batch number - Each load of outgoing product is allocated a batch
number to have a record and facilitate traceability of the product
 Date - The date the product is exported
 Destination of the product - Where the product is to be delivered,
 Type of product - A description of the type of product being
exported, i.e. liquid, cake, other
 Quantity of the product - The quantity of the product being
exported to the destination facility is recorded in kg or m3 depending
on the consistency of the final product
 Certificate of origin/delivery - A certificate of origin or delivery
docket for the outgoing product must be given to the driver delivering
the load.
 Receipt returned from destination - A receipt is returned to the
Contractor from the facility that receives the product, to verify that the
delivery was completed
 Contact at destination
18 Analysis Samples of the raw influent, settled sewage and mixed liquor shall be
results for raw analysed and results presented in clear tabular format for the specific
influent, parameters required and the frequencies specified in the Contract. The
settled sewage Food/Mass Ratio shall be calculated and presented on the right hand
and mixed liquor side of the table for each date.
The Contractor shall also monitor, and report on, any further parameters
necessary for proper and efficient operation and maintenance of the
Works such as:
 Flow, level and performance monitoring throughout the WwTF
 Raw, inter-stage and treated wastewater quality monitoring
 Flow and quality sampling on sludge stream
 Flow and pressure monitoring on pumping mains
19 Analysis Results Samples of the sludge feed and digester contents shall be analysed and
for Anaerobic results presented in clear tabular format for the specific parameters
Digester required and the frequencies specified in the Contract. The details of the
biogas composition and efficiency of the digester shall be included in the
table.
20 Analysis results Samples of the final effluent shall be analysed and results presented in
for final effluent clear tabular format for the specific parameters required and the
frequencies specified in the Contract. Additional samples taken for
independent analysis by the Employer shall be recorded in this section of

Appendix

the MSR.
21 Analysis results Samples from the sludge thickeners and dewatering units shall be
for sludge analysed and results presented in clear tabular format for the specific
dewatering parameters required and the frequencies specified in the Contract.
22 Analysis results The Contractor shall carry out microscopic analysis on the activated
for microscopic sludge as frequently as the Contract requires, or if there are problems
analysis with the sludge or settlement. The following characteristics of the sludge
are to be commented on in this section of the MSR:
 floc size
 floc shape
 floc form and strength
 the presence of colonies, dispersed bacteria, fungi, protozoa and
higher organisms
 the presence of filaments and their effect
23 Analysis results The Employer may collect as many of the split samples as desired and
of random sampling may analyse the samples in accordance with the Contract. The analysis
by Employer results are forwarded to the Contractor by the Employer and are
presented in this section of the MSR for comparison with the results
obtained by the Contractor for the same sample.
24 Facility Certain aspects of the site must be checked regularly to ensure that the
maintenance facility is maintained in good order. A record in tabular format shall be
records presented in this section of the MSR together with any relevant
comments. The aspects that must be kept under constant surveillance
shall be established and agreed and shall include as a minimum:
 Lawn Maintenance
 Shrub Maintenance
 Hard Surfaces
 Exterior Painting
 Housekeeping
 Buildings
 Interior Painting
 Welfare & Sanitation
Each of the listed aspects of site maintenance are examined and
deemed to be in ―excellent‖ condition, ―acceptable‖ condition or
―unacceptable‖ condition. When an item is in an unacceptable condition,
steps must be taken to improve the condition of that item.
25 Emergency Any emergency events that occur during the reporting period must be
event records reported in this section of the MSR and must include the following
information:
 the date the emergency occurred
 how the emergency was noticed
 the location of the emergency
 a description of the emergency
 how the emergency was dealt with
 the person(s) involved in dealing with the emergency
 the duration of the emergency situation
 the date of the Emergency Response Review Meeting
 the attendees at the Emergency Response Review Meeting

Appendix

 the action(s) taken to prevent such an emergency occurring again
A separate sub-section shall be compiled for each emergency event that
occurred during the reporting period.
26 Plant breakdown A detailed record shall be kept and presented here of any failure of any
records
element of the Works or of the Works itself.
27 Analysis for The analysis and measurement for payment, including any deductions
payment for failures, and including the calculations for payment of the variable
charges shall be included in this section of the MSR.
28 Plant A record of all plant or asset replacements undertaken during the
replacements reporting period.
29 Record of A record of the laboratory analysis undertaken.
laboratory services
30 Training record Records of all personnel training that took place in relation to the
operation and maintenance of the Works during the reporting period.
31 Employee Any absence from the works due to illness or otherwise of members of
sickness and the Contractor‘s personnel together with the details of temporary
absence records replacement personnel.
32 Use of energy, The Contractor shall keep records of the hours of operation of each item
utilities and of electrical plant and the total energy usage on a daily, weekly and
chemicals monthly basis as part of the procedures for operation of the facility.
Total energy usage records shall include day, night and total kWhrs,
wattless units and maximum demand usage. The records shall clearly
define energy used from the energy generation facilities on Site and that
energy taken from the external supply
The Contractor shall also report on the Renewable Energy Certificate
process under this section.
The Contractor shall keep records of all chemicals used for the treatment
of wastewater or sludge as part of the procedures for operation of the
facility. This shall include weekly records of bulk storage and deliveries
and daily use of all treatment associated chemicals.
33 Process The details of any process stoppages or unit cleaning undertaken are to
stoppages & unit be presented in this section of the MSR.
cleaning
34 Vermin control The Contractor shall employ a recognised vermin control company to
provide and maintain bait points at the Works. The Contractor shall also
ensure that the Works is kept in good condition and free of any organic
waste material that could attract vermin. All the vermin control measures
shall be incorporated into the procedures for operation of the facility.
35 Unusual or Unusual circumstances arising from industrial disputes, accidental
abnormal spillage, mechanical breakdown, power failure, stoppage for essential
conditions maintenance or abnormal weather conditions shall be noted by the
Contractor in detail and taken into consideration when interpreting the
analytical data from the Works.

Appendix
APPENDIX 4 – SAMPLE ASSET HIERARCHY

Appendix
APPENDIX 5 – TYPICAL PLC INPUT/OUTPUT (I/O) SCHEDULE
Minimum I/O Requirements for Auto mode Control operation of the Plant:
On a minimum, the control design shall incorporate the I/O requirements which are indicated in
the table below.
All process & Instrumentation Diagrams (P&ID) shall incorporate & depict the minimum I/O
requirements.
Design shall include complete auto mode of operation of the entire STP and associated
plants/stations with all necessary interlocks and safety mechanisms.
The detailed I/O list shall be finalized during FDS finalization. Design shall include complete auto
mode of operation of the entire STP with all necessary interlocks.
Sr.
Type Minimum I/O’s to be Considered
No.
1. Pump, Motor Start, Stop, Auto, Off, Manual, Run, Emergency Stop,
Fault, available.
2. Valve Auto, Off, Manual, Open, Close, Travelling Indication,

Fault
3. Drives Start, Stop, Auto, Off, Manual, Run, Emergency Stop,
Fault
4. Blower : Start, Stop, Auto, Off, Manual, Run, Emergency Stop,
Fault
5. Level Indicator HH, H, L, LL, Analog value,
6. Level Switch HH, H, L, LL,
7. Analytical Instruments Analog Value,
8. Pressure (in addition to individual pumps, blowers, at common
Indicator/transmitters discharge end of pumps, blowers, dosing pumps
etc...): Analog Value,
9. Flow Indicator/Transmitters in addition to other plant flows, at common discharge
end of pumps, blowers, dosing pumps etc...): Analog
value, totalizer,

Appendix
Typical Drive Control Philosophy to be provided on a minimum shall be as follows:
Sr.
Description Type Of I/O No Of I/O
No.
PLC Interface for Unidirectional HT Drive / LT Breaker Control Drive (Signal Exchange
1.
has Been Envisaged Between PLC And Switchgear)
A. Start Command DO 1
B. Stop Command DO 1
C. On Feedback DI 1
D. Off Feedback DI 1
Auto, Off, Manual DI 3
E. Switchgear. Disturbance (Overload Relay Operated/ DI 1
Control Supply Fail/
Emergency LPBS Stop) DI 1
F. Electrical Trip (Motor Protection Relay) DI 1
G. Switchgear Available (Breaker in Service Position, DI 1
Switchgear in Remote & Breaker Spring Charged)
H. Pump Bearing Temperature Measurement AI 2
I. Motor Bearing Temperature Measurement AI 2
J. Motor Winding Temperature Measurement AI 6
K. Current Transducer Input AI 1
PLC Interface for Unidirectional Lt Drive (Signal Exchange Has Been Envisaged
2.
Between PLC And PCC/MCC)
A. Start Command DO 1
B. Stop Command DO 1
C. On Feedback DI 1
D. Off Feedback DI 1
E. Switchgear/MCC Disturbance (Overload Relay DI 1
Operated/ Control Supply Fail/
Emergency Lpbs Stop) DI 1
F. Switchgear/MCC Available (Switchgear/MCC In DI 1
Remote)
PLC Interface for Bidirectional LT Drive- For Integral Starters (Signal Exchange Has
3.
Been Envisaged Between Actuator and PLC.)
A. Open Command DO 1
B. Close Command DO 1
C. Integral Starters Fault DI 1
D. Open Limit Switch Feedback DI 1
E. Close Limit Switch Feedback DI 1
F. Position Transmitter (For Inching Type Drive) AI 1
G. Command AO 1

Appendix
Sr.
Description Type Of I/O No Of I/O
No.
PLC Interface for Bidirectional LT Drive-For Non-Integral Starters (Signal Exchange
4.
Has Been Envisaged Between Actuator and PLC.)
A. Open Command DO 1
B. Close Command DO 1
C. Switchgear/MCC Disturbance (Overload Relay DI 1
Operated/ Control Supply Fail/
Emergency LPBS Stop) DI 1
D. Switchgear/MCC Available (Switchgear/MCC In DI 1
Remote)
E. Open Limit Switch Feedback DI 1
F. Close Limit Switch Feedback DI 1
G. Position Transmitter (For Inching Type Drive) AI 1
5. PLC Interface for Solenoid Drive (Single Coil)
A. Energise or Deenergise DO 1
B. Open Limit Switch Feedback DI 1
C. Close Limit Switch Feedback DI 1
6. PLC Interface for Solenoid Drive (Double Coil)
A. Energise DO 1
B. Deenergise DO 1
C. Open Limit Switch Feedback DI 1
D. Close Limit Switch Feedback DI 1
7. PLC Interface for Pneumatic Drive
A. Command to I/P Converter AO 1
B. Position Transmitter AI 1
C. Open Limit Switch Feedback DI 1
D. Close Limit Switch Feedback DI 1
E. Command to Solenoid Valve DO 1
(Wherever Applicable)

Appendix
APPENDIX 6 – LIST OF PREFFERED SUPPLIERS
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.
In the event that the contractor wishes to propose alternate makes, 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.
Preferred Vendor/Manufacturer/Make List
MECHANICAL ITEMS
Sr. No. Equipment Name Manufacturer Name

Jash Engg
Johnson Screen
EIMCO
1 Bar Screen
Huber Technology
Estruagua
Technofangi
Huber Technology
Estruagua
2 Drum screen
Johnson Screen
Technofangi
Jash Engg
Johnson Screen
Screening Conveyance Compaction
3 EIMCO KCP
and Dewatering
Huber Technology
Estruagua
Smith & Loveless

4 Vortex Type Grit Separator Huber Technology
EIMCO KCP

Appendix
Fluiteco
Ovivo
Bilfinger
Smith & Loveless

Huber Technology
Geo Miller
5 Degritter
Triveni
Voltas
EIMCO KCP
Triveni
Geo Miller
Primary and secondary Clarifier Filsep (Chennai)
6
Mechanisms EIMCO KCP
Finnchain
Shivpad Engineers
Triveni
Geo Miller
7 Gravity Thickener Filsep
EIMCO
Shivpad Engineers
Krofta
Infilco
8 DAF Thickener
World Water Works
OVIVO
Siemens
Huber
9 Mechanical thickener (Gravity belt))
Andritz
Technofangi
Alfa Laval
Technofangi
Mechanical thickener (Rotary drum
10 WesTech
thickener)
Huber
Estruagua
11 Mechanical thickener (Filter /Screw Technofangi

Appendix
press)
AMCON
Kay International
Everest
Ingersoll Rand
Positive displacement blower
12 Gardener Denver
(Twin /Tri lobe type)
Swam pneumatics
Kulkarni power tools Ltd.
TMVT (Ahmedabad)
Siemens
Howden
Swam
GL Turbo
13 Centrifugal Turbo Air Blower
ABS
Arzener
Sulzer
Hoffman and Lamson
Kirloskar Brothers Limited

KSB
Grundfos
14 Horizontal Centrifugal Pumps Wilo - Mather & Platt

WPIL
Flowserve
Jyoti
Kishore Pumps
Wilo - Mather & Platt
KSB
Aqua Machinery
Falcon
15 Submersible Pumps for Sewage
Waterman
Jesco
Mody
ABS
Grundfos

Appendix
Flyght/Xylem
Ebara pumps
Mody
BS
ABS
16 Submersible Pumps for Tube well
KSB
LUBI
Mody
Grundfos
Johnson
Sump Pumps / Dewatering Pumps Kishore Pumps
17
and Pit Pumps KSB
ABS
KBL
Aqua Machineries
Roto pumps
Netzsch
18 Screw Pumps
ABS
UT Pumps
Asia LMI /Milton Roy

Prominent
Toshcon
Dosing System / Dosing Pump / Grundfos (Aldos)
19
Metering Pump
Swelore
V.K.Pumps
Eagle Burgmann
Flowserve Sanmar
20 Mechanical seal
Prestige
Jayyashri

Appendix
Grundfos
ABS
21 Kishore
Xylem / Flyght
Submersible Mixer Sulzer
Utile Engineering
Gardner Denver
Anaerobic Digester Gas Mixing Siemens

22
System Infilco
VA Tech
Triveni
REMI
Rathi Lightning
23 Agitator Cum Mixer Fibre & Fibre

Voltas
Johnson
Milton Roy / Acuadyne
SSI
EDI
OTT
REHAU
Eurotech
24 Diffuser
Flyght / Xylem
ABS
Grundfos
Ovivo
C-Tech / SFC
UEM / Toshiba
Metawater / Aqua Aerobics
25 SBR Decanter system
Evoqua / Siemens
Xylem
Waterleau (Belgium)
26 Centrifuge Humbolt Wedag

Appendix
Alfa Laval
Hiller
Pennwalt
Andritz
GEA Westfalia
Toshcon Jescon
Pennwalt
Metito
Perfect Chloro System (Baroda)
27 Chlorinator
Industrial devices (Chennai)
Evoqua / Siemens
Capital controls
Trojan
28 UV system Calgon
Wedeco
SWAM Pneumatics
Kirloskar Pneumatic
Ingersoll Rand
Chicago Pneumatic
29 BiogGas Compressor
KAY
Elgi
USHA
MAPRO
Essen Pro
Radicon
Elecon
30 Gear Reducers
Greaves
Bonfiglioli
Allen Beri
Bonfiglioli
31 Geared Motors SEW
REMI
32 Membrane Filtration (vacuum/ Kubota

Appendix
pressure) Norit
Mitsubishi
Siemens
GE / Suez
HyFlux
Toray
Hydranautics (Nitto Denko)
Pilani
Eurotech
Innovative Environmental Technology
Green Power
33 Scrubber
Deutz
Praj Industries
United Engineers
GGE
GE Jenbacher
Bio-Gas Power Generation System Caterpillar
34
MANN
MTU
MWM
Kay
Swam
35 Biogas blower Everest
Kulkarni Power Tools (KPT)
MAPRO
36 GGE
Biogas membrane type storage Biogas Equipment LLC
W2E Engineering
Alfa Laval
37 Heat exchanger (For sludge heating) HRS
Tranter
Evoqua
38 Disc filter
Aqua Aerobics

Appendix
Hydrotec (Veolia)
Estruagua
Huber
Nordic
Kirloskar Brothers Ltd.

39 Sluice Gates Indian Valve Company
Jash Engineering
VAG
AVK
Indian Valve International (IVI)

Avishkar
40 Gate Valves/Sluice Valves
Indian Valves Company
Dorot
Jash Engineering
VAG
41 DI sluice Valve glandless
AVK
VAG
Fouress
42 Knife Gate Valves Infilco
Veolia
Jash Engineering
R&D multiples
Dynamics
43 Butterfly valve Kirloskar
BDK
Intervalve
VAG
AVK
Indian Valve International (IVI)
44 Non-Return Valve Avishkar
Kirloskar Brothers Ltd.
Indian Valve Company
Dorot

Appendix
BDK
Intervalve
Kirloskar Brothers Limited (KBL)

45 Air Valve Indian Valve Company (IVC)
VAG
Audco
46 Gas Valves
Combustion Research Associates (CRA)

47 Tamper proof air valve AVK
VAG
The Indian Iron & Steel Company Ltd.

Jindal Saw Ltd.
48
Cast Iron / Ductile Iron Pipes & Electro Steel Castings
Fittings and Dismantling Joints Tata Iron & Steel Co.
Auma india
Limitorque
Rotork
49 Valve Actuator-Electric Marsh
L&T
SDTORQUE
L Bernard
Bettis
D Torque
50 Valve Actuator- Pneumatic
Elomatic
FESTO
Stahl
Vedant
Street Crane
EMH
HOT and EOT crane & Electrical
51 United Crane
hoist
W.H.Brady & Co. Ltd.

Appendix
Electro Fab
Indef Engg.
Hercules Hoists Ltd.
Reva Engineering
52 Chain Pulley Block Demag
Electro fab
Electro mech
W.H.Brady & Co. Ltd.
Steelage Industries (MINIMAX)

Kooverji Devshi & Co. Ltd. (FIREX)
Vijay Fire Protection System Pvt. Ltd.
53 Fire Extinguisher
(VIJAY)
VSP Aqua Mist
Ahluwalia
Combustion Research Associates

Flame Arrestor Moisture Trap PVRV PROTEGO India Pvt. Ltd.
54
/ Flare System Innovative Environmental Technology
United Engineers
Perfect Chloro System

SS Engineers & Safety Consultant
55 Safety Equipment Medical Engineers
Super Safety Services
Capital control
ELECTRICAL ITEMS
Sr. No. Description Vendor/Manufacturer/Make

1 Compact Substation ABB
Crompton Greaves Limited
Schneider Electric
Siemens
2 Distribution Transformer-ONAN ABB
Crompton Greaves Limited
ESENNAR
Kirloskar Electric Company Ltd.

Appendix

CAHOR
Schneider Electric
Telawne Power Equipment
Voltamp Transformers Limited
3 Transformer - Dry Type (Cast ABB
Resin) Crompton Greaves Limited
EMCO
ESENNAR
Kirloskar Electric Company Ltd.
Schneider Electric
Telawne Power Equipment
Voltamp Transformers Limited
4 11/22 kV Switchgear and ABB
Controlgear Assembly/Switchboard Crompton Greaves Limited
Larsen and Toubro
Schneider Electric
Siemens
5 11/22 kV Switchgear and ABB
Controlgear - Indoor (VCB) Larsen and Toubro
Schneider Electric
Siemens
6 Protective relays (Numerical Type) ABB
ASHIDA
Eaton
GE
Larsen & Toubro
Schneider Electric
Siemens
7 Protective Relays ABB
(Electromechanical Type) GE
Schneider Electric
Siemens
Omron
PLA
8 Control and Relay Panel ABB
Alstom
Easun Reyrolle
Schneider Electric

Appendix

Siemens
9 Instrument Transformers (CT/PT) ABB
Automatic Electric
Crompton Greaves
ECS
Gilbert and Maxwell
Huphen
Indcoil
Jyoti
Pragati
Precise Electricals
Kappa
Schneider Electric
Siemens
Voltas
10 415 V Switchgear and Controlgear ABB
Assembly/Switchboard L&T
(PCC/MCC/PMCC/MLDB/MPDB/
MOVDB) EATON
Schneider Electric
Siemens
11 Air circuit breakers ABB
Crompton Greaves Ltd.
Eaton
L&T
Schneider Electric
Siemens
12 MCCB‘s ABB
C& S
Crompton
English Electric
L&T
Legrand
Schneider Electric (M&G)
Siemens
13 Switch Disconnector Fuse Unit L&T
(SDF) Schneider Electric
And Switch Disconnector Isolator
Siemens
14 Change-over switch BCH

Appendix

C&S
GE Power
Havells (euroload)
L&T
Schneider Electric
Siemens
15 V F Drives / Electronic ABB Danfoss
Soft starter Allen Bradley (Rockwell Automation)
Schneider Electric
Siemens
Yaskawa
16 LV capacitors (MPP)/ Series ABB
Reactors for Capacitors/ APFC Epcos
Panel/ APFC Relay / Controller
L&T
Madhav capacitors
Manohar Brothers
Prabodhan capacitors
Schneider Electric
Siemens
Shreem Electric Ltd.
Subodhan
17 AC Power Contactor, DC Power ABB
Contactor, Auxiliary contactors BCH
C&S
L&T
Schneider Electric
Siemens
18 Electronic / Microprocessor based ABB
overload relay, Bi-metal / Overload minilec
Relay, Thermistor relay
Schneider Electric
Siemens
19 Single Phasing Preventer Alstom
L&T
Minilec
Schneider Electric
Siemens
20 Timers, Time Delay Relay, Time BCH
switch GIC

Appendix

L&T
Legrand
Minilec
PLA
OMRON
Schneider Electric
Siemens
Theben
21 Motors ABB
Bharat Bijlee
Crompton Greaves
Kirloskar
Siemens
22 Battery Charger & DCDB Amara Raja
Automatic Electric
Caldyne Automatics
Chhabi Electricals
HBL Power Systems
Hitachi
Mass-tech Controls
Universal Instruments
23 Luminaire/ Lamps Bajaj
Crompton Greaves
GE
Osram
Philips
Polycab
Surya
WIPRO
24 11/22 kV XLPE Insulated FRLS Cable Corporation of India Ltd
Cables KEC International Ltd
KEI
Finolex
Havells
Polycab
25 LV Power FRLS Cables/ Earthing Cable Corporation of India Ltd
Cable Finolex
Havells

Appendix

INCAB
KEC International Ltd
KEI
LAPP
NICCO
Polycab
RR Kabel
Universal Cables Ltd.
26 LV Control Cables Cable Corporation of India Ltd
Finolex
INCAB KEI
KEC International Ltd
LAPP
NICCO
Polycab
Universal Cables Ltd.
27 Earthing Materials Bharat Wires & Ropes
Diamond Cables
Gupta Industrial Corporation (Vasai,
Palghar)
28 Distribution Boards (other than ABB
MLDB, MPDB, MOVDB) / Panels / BCH
Enclosures / JB / Marshalling Panel
C&S
Eldon
Enclotek
Hensel
Legrand
Manshu Comtel
Pentair
President
Rittal
Schneider Electric
Siemens
29 MPCB, MCB, RCCB, RCBO / MCB ABB
Isolators Klockner Siemens
Legrand
Moeller
L&T

Appendix

Schneider Electric
30 Alarm Annunciators (solid state type Alstom
with LED illumination) / Facia Digicont
Annunciator
ICA
IDECIZUMI
IICP
Industrial Instruments & Controls
Minilec
MTL India Pvt. Ltd.
Procon Inst. (P) Ltd
Proton Electronics
Rochester Instruments System Ltd.
Ronan (Waree)
Yashmun
Havells (Crabtree)
Honeywell (MK Electric)
31 Decorative switches, sockets and ABB
metal boxes (single plate Anchor (Panasonic)
arrangement) Modular switch &
socket (wraparound) (twin plate Anchor (Roma / Ave)
arrangement) Gewiss
Havells (Crabtree)
Honeywell (MK Electric)
Legrand
Schneider Electric (Clipsal)
Siemens
32 Ceiling Wall Mounting Exhaust Fan / Almonard
Ventilation Fan/ Air Circulators/ Bajaj
Man Coolers (Pedestal/Wall
Mounted) Crompton Greaves
Khaitan
Orient
Havells
Usha
33 Cable termination/jointing kits ABB Kabeldon
3M(Cold Shrink/Push-on)
Raychem (Tyco Electronics / RPG)
34 Control / selector switch ABB
GE Power controls
Kaycee

Appendix

L&T
Schneider Electric
Siemens
35 Indicating Lamps (Multi-chip LED) BCH
Binay
Concord
L&T
Schneider Electric
Siemens
Teknic Controls
Vaishno
36 Terminal Block / Connectors Connectwell
Elmex
Pheonix
SELEC
Wago
37 Control transformer Gauss Electricals
Indcoil
Precise Silkaans NEC
38 Semiconductor Fuse Eaton (Cooper Bussmann)
GE
Schneider Electric (Ferraz Shawmut)
Siemens
39 HRC fuse (Power & Control) Eaton (Cooper Bussmann)
GE
L&T
Schneider Electric (Ferraz Shawmut)
Siemens
40 Push button station Bals
Gewiss
Hensel
R Stahl
Schneider Electric
Siemens
41 Non-metallic enclosures (including Bals
Industrial Receptacles) BCH
Gewiss
Hensel

Appendix

Legrand
Menekkes
PCE
Rittal
SCAME
Schneider Electric
Siemens
42 Digital Meter – Ammeter & Automatic Electric
Voltmeter Circutor
Industrial Meters
Havells private limited
L&T
Masibus
Meco Instruments
Rishabh
Schneider Electric (Conzerv)
Schneider Electric (Power Measurement/
ION)
Siemens
43 Electromechanical – Ammeter & Automatic Electric
Voltmeter IMP
MECO
Rishabh
SELEC
44 Load Manager / Multi Function ABB
Meter / kWh Rishabh
Schneider Electric
Schlumberger
Secure Meters
45 Power quality analyser A-eberle
Chino – Laxsons
Fluke
Hioki
Rishabh
Schneider Electric (Conzerv)
Schneider Electric (Power Measurement/
ION)
Yokogawa
46 Cable lugs Comet

Appendix

Dowells
3D (Billets Elektro Werke Pvt. Ltd)
47 Cable Glands (safe area - double Baliga
seal cone grip type) Braco
Comet
Cosmos
Crouse Hinds
Hex (Brass Copper & Alloy(I))
Jainson
R.Stahl
Siemens
48 Polyamide Cable Glands Fibox
Gewiss
Hensel
Lapp
49 Lightning Arrestors Crompton Greaves
DEHN
Elpro
Jayshree
Oblum
OBO
WS
50 Surge Suppressors ABB
Dehn
Emerson
Erico
Furse
MTL
OBO
Pepperl+Fuchs
Phoenix Contact
Schneider Electric
Siemens
51 Floor trunking system (GI trays, Honeywell Patny
troughs & pull boxes) and GI Cable Indiana
trays
Jenco/Pentax Ferro Incorporate
Legrand
OBO

Appendix

Profab
Reliance
Sadhana
Sterlite
Cable management System Eubiq
52 Honeywell
Legrand
Panduit
Rittal
Schneider Electric
53 UPVC Conduit/JB/flexible AKG
conduit/tees/ Bevels, elbow & Polycab
accessories/fittings/ Casing Capping
Precision
Astral
George Fisthner
54 GI Conduit / MS Conduit / Pipes BEC Industries
Jindal
JK Tube Company (AKG)
SAIL
TATA Steel
Zenith
55 Lighting Controller / Lighting Lutron
Management System Philips
Tridonic Atco
Zumtobel
56 Lead Acid Battery (Plante / Tubular) Amara Raja Batteries Ltd.
Exide
HBL Power Systems Ltd.
GS Yuasa
57 SMF/VRLA battery Amara Raja Batteries Ltd.
Exide
Furukuwa
58 Ni – Cd Battery Amco Saft
GS Yuasa
59 Lighting Poles Bajaj
Bombay Tubes and Poles

Appendix

Valmont
60 High mast lighting system Bajaj
Skipper
Crompton Greaves
Philips
Bombay Tubes and Poles
61 Fire Barriers / Sealing Brattberg
CTR Manufacturing Industries Ltd.
HILTI
Roxtec
Signum
Navell
Multikil
62 Fire detection and alarm system Arman Fire
(Automatic clean agent system Fire trace
using linear heat detection tubing)
Reactan
VARAD ENTERPRISES
63 Water barriers/sealing system Rayflate (Tyco Electronics)
Roxtec
64 Safety Equipments Dozz
3M
Electromat
Joseph Leslie & Company
KARAM
Raychem RPG
VARAD ENTERPRISES
65 Emergency Light / Conversion Legrand
module / Battery Pack Philips
Prolite
Tridonic Atco
Zumtobel
66 Busduct C&S
Godrej
Schneider Electric
Siemens
Stardrive
67 Voltage / Power / Current / ABB
Frequency / Energy Transducer/ AE

Appendix

Encoders Masibus
Rishabh
Schneider Electric
Siemens
68 Test and Measuring Instruments Aplab
CATU
Fluke
Kusum Meco
Meco
Megger
Motwane
Rishabh

Appendix
Instrumentation, Control & Automation:
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 Tethys Instruments-France
system M/s Process Instruments U.K
M/s DKK (Japan)
12 Laboratory Equipment M/s Machery –Nagel
M/s DKK (Japan)
M/s Savant

Appendix
Sr.
No.
M/s Idexx
M/s In-Situ
M/s Shimadzu (Japan)
UPS M/s APC
M/s DB & ELECTRONICS
M/s HI-REL
M/s NUMERIC POWER SYSTEMS
M/s Aplab
Batteries M/s AMAR RAJA
M/s HBL NIFE
M/s AMCO
M/s EXIDE
Cables M/s Universal Cables
M/s Havell‘s
M/s CCI
M/s Finolex
M/s NICCO
M/s Delton Cables Limited
Panels M/s Rittal
M/s ECIL
1 Workstations, Servers, Laptop (17‖) Dell
HP
IBM
2 Programmable Logic Controllers & IO Make CPU IO Series
Modules Series
Schneider Quantum Quantum 140
Electric Series Series
Siemens S7-400H ET-200M
Series
Allen Bradley Control Control Logix
Logix 1756 1756 Series
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
5 CCTV systems M/s Sony

Appendix
Sr.
No.
M/s Philips
M/s D-Link
M/s Axis
M/s Pelco
M/s Fujifilm

Appendix
APPENDIX 7A – ENVIRONMENTAL MONITORING PLAN

Environmental consideration shall be conducted based upon EMoP given below,
At Construction Phase
Impacts to Methods and Monitoring Frequency Actor of

be Parameter Monitoring
Assessed
Existing  Prior contact and approval from Occasionally Contractor
Social relevant authorities
Infrastructure  Socialization activity and close
and Social communication with society
Service  Announcement through TV,
Radio, Newspaper, Internet
media, etc.
 Implementation of the survey of
underground utilities /pipes.
Infection  Allotment of safety supervisor Every 2 or 3 Contractor
Diseases and safety officer months
such as  Conduction of safety and
HIV/AIDS hygiene education at
employment of construction
workers
Occupational  Appointment of safety supervisor Every week Contractor
health and and safety officer
safety  Holding safety Meeting
 Visual inspection of dust  Daily Contractor
Air pollution  Performance of mitigation
measures for generation of dust
 Visual inspection of turbid water  Daily Contractor
Water  Performance of mitigation
Pollution measures for turbid water
 Inspection of Contractor‘s  Daily Contractor
practice on treating excavated
soil including its backfill  Daily
Waste  Management through manifest
on the transport route and
amount of excavated soil  Monthly
 Contractor‘s monthly report on
construction
Noise /  Sound level survey  Monthly Contractor
Vibration  Acceptance of complaints from  Occasionally
residents
Accident  Contractor‘s practice of safety  Daily Contractor
measures of using helmet,
safety belt and safety shoes
 Contractor‘s practice of safety  Monthly
training
 Contractor‘s preparation and  Monthly
submission of monthly report
including safety meeting
Source : JICA Survey Team

Appendix
At Operation
Impacts to be Actor of
Methods and Monitoring Parameter Frequency
Assessed Monitoring
Occupational  Performance of preparation of  Occasionally 3 PMC
health and Organization structure and training months after
safety programme operation
 Compliance with relevant regulation  Monthly
 Performance of holding periodical  Monthly
meetings
Air pollution  Preparation of appropriate allocation /  Monthly PMC
dispatching plans of cars
 Visual inspection of operator‘s practice of  Monthly
mitigation measures of idling reduction and
water sparkling
Water  Water quality analysis (pH, BOD, COD, DO,  Monthly PMC
Pollution NH3-N, total coli and E. coli)
 Water quantity analysis on the parameters of  Monthly
WHO guideline (intestinal nematode, fecal
coli,) and the parameters of FAO guideline
(electrical conductivity, Na+, Ca+, CI-) if the
treated wastewater is actually is reused
Waste  Operator‘s performance of management  Monthly PMC
system by manifest
Soil  Acceptance of complaints from resident  Monthly PMC
Contamination  Sewage flow volume monitoring  Daily
 Regular monitoring through visual  Daily
inspection or smelling at the trunk sewers,
relay pump station and WWTP
 Soil quality analysis on the parameters  Monthly
required in EU guideline (Cd, Cu, Ni, Pb, Hg,
Cr) if the related sludge is actually is reused
Noise /  Acceptance of complaints from residents  Occasionally PMC
Vibration and quick response to it
 Noise level survey at the relay pumping  Occasionally 3
station and WWTP months after
operation
Offensive Odor  Odor level monitoring (ammonia, methyl  Occasionally 3 PMC
mercaptan, hydrogen sulphide, methhyle months after
sulphide, styrene) at the facility boundary operation
of the WWTP.
 Acceptance of complaints from resident  Occasionally
and its quick response.
Accident  Operator‘s practice on holding safety  Monthly PMC
meetings
 Training through OJT  Occasionally
 Initial training by contactor at the test  Once at test
operation operation
Others (Climate  Monthly report of operation including  Monthly PMC
Change) mitigation of energy consumption and
recycling of digestion gas (e.g. methane
gas)
Source : JICA Survey Team

Appendix

Appendix
APPENDIX 7B – ENVIRONMENTAL MANAGEMENT PLAN
Environmental consideration shall be conducted based upon EMP given below,
(1) Potential Impacts and Management plan

The potential adverse impacts and the environmental management plan for mitigation
these impacts are shown in the table below,
Potential Adverse Impact and Environmental Management Plan
At Construction Phase
No. Environmental Potential Source Management to be Actors of
Items taken Environment
al
1. Geology  Excavation work  Geological survey at  Contractor

(Ground at STPs, IPSs and detail design (D/D)
collapse) Collection System  Stability check of
and Main/Sub retaining wall at D/D
Mains  Construction plan
prepared by
Contractor
 Regular inspection of
excavation works
 Emergency response
plan for the incident of
ground collapse
2. Existing Social Work lots close to  Adaptation of  Contractor
Infrastructure  Traffic construction method at
 Underground D/D minimizing
Utilities adverse impacts on
 Railway traffic
 Implementation of
underground utilities
survey at D/D
 Preparation of
construction plan
covering minimization
of adverse impacts on
traffic and railways
 Placement of traffic
guide at construction
work lots
3. HIV / AIDS Employment of  Hygiene education for  Contractor
(Infectious foreign workers for construction workers
diseases) construction works  Regular medical check
4. Occupational Construction Works  Contractors proposal  Contractor
Health and on occupational health
Safety and safety plan
 Allocation of health
and safety supervisors
 Regular meetings on

Appendix

al
occupational health
and safety
 Preparation of
organisation structure
on occupational health
and safety
5. Air Pollution Construction Works  Contractor‘s  Contractor
 Travelling of construction plan on
construction air pollution prevention
vehicles and such as water
equipment sprinkling for dust
 Idling of  Regular inspection on
construction Contractors‘ work
vehicles practice towards air
pollution
6. Water Pollution Construction work  Contractor‘s  Contractor
Construction plan on
prevention of water
pollution such as
sedimentation
 Regular inspection on
Contractor‘s work
practice towards water
pollution
7. Waste  Generation of  Contractor‘s  Contractor
excavated soil, construction plan on
construction handling or recycling
debris of excavated soil or
 Generation of construction debris
general waste  Preparation of
manifest system of
general waste
Contractor‘s work
practice towards
handling on excavated
soil or construction
debris
8. Noise/ Vibration Construction  Contractor‘s  Contractor
machineries construction plan on
handling for
minimizing noise
generation
Contractor‘s work
practice toward
minimization of noise
generation
 Environmental

Appendix

al
monitoring
9. Accident Contractor‘s  Contractor‘s proposal  Contractor
construction on safety management
practice.  Regular inspection on  Contractor
Contractor‘s safety
management
 Formulation of  Contractor
organization structure
for emergency
response  Consultants/
 Regular inspection on Contractor
Contractor‘s practice
on safety
management.
Source JICA Survey Team
AT Operation Phase:
No Potential Potential Management to be taken Actors for
Impacts Source Environmental
Management
1 Occupational Operator‘s  Preparation of Operation &  PMC
Health and operation & Maintenance manual by a
Safety maintenance Contractor at
practice commissioning
 Training on occupational
health and safety at
commissioning
 Preparation of emergency
response plan
 Regular meeting on
occupational health and
safety
2 Air Pollution Travelling of  Manifest system of  PMC
Dump truck treated sludge
conveying
treated sludge
3. Water  Influent flow  Environmental monitoring  PMC
Pollution  Treated of influent flow and
effluent treated effluent
 Compliance with relevant
guidelines and
regulations if the treated
effluent is reused
4. Waste  Treated  Manifest system of  PMC
Sludge treated sludge
 Compliance with relevant
guidelines and

Appendix
No Potential Potential Management to be taken Actors for

Impacts Source Environmental
Management
regulations if the treated
sludge is reused
5. Soil  Leakage of  Regular maintenance  PMC
contamination sewage at works through visual and
STPs, IPSs odor inspection
and main  Handling of local
/Sub Mains residents‘ information on
occurrence of leakage or
odor
 Close cooperation with
relevant authorities of
monitoring rivers and
groundwater
6. Noise/  STPs  Sound proof design at  Contractor
Vibration  IPSs D/D
 Environmental monitoring  PMC
7. Offensive  STPs  Environmental monitoring  Contract
odor  IPSs of odor level at facility
boundaries
 Handling of residents‘
complaints toward odor  PMC
8. Accidents  Operation &  Preparation of Operation  Contractor
maintenance & Maintenance manual by  PMC
of trunk a Contractor at
sewers, commissioning
replay  Training on occupational
pumping health and safety at
station and commissioning
WTTP  Preparation of emergency
response plan
 Regular meetings on
occupational health and
safety
9. Climate Generation of  Designing of STPs and  Contractor
Change GHG IPSs for energy reduction  Contractor
 STPs at D/D  PMC
 Preparation of O & M
manual toward energy
reduction
 Regular operation toward
energy reduction
Source: JICS Survey Team
(2) Complaints Handling
1) Setup of Contact System
Relevant Concerned parties at construction and operation phase should take appropriate
response for the residents‘ complaints on pollution related matters such as noise, offensive
odor, dust and traffic. The contact departments will be officially announced with the names of
the departments address, telephone number and e-mail address through newspapers,

Appendix
television, radio, radio and internets. The schematic diagram of the proposed contact system
for complaints handling is shown in below,
The contact points of each actors are shown below;
 Project proponent: Sewerage department of PMC
 Inspection of environmental management: Environmental department of PMC or
Regional office/ Technical Wing of MPCB (Maharashtra State Pollution Control Board)
 Contractor: A set up of contact point for complaints handling for the contractors will be
provided in the tender documents or construction contract documents.
Contact System for Complaints Handling
2) Complaints Response Process

All complaints received shall be recorded.
The Following data shall recorded.
 Data, time and place of the complaints
 Method how the complaint was received (e.g. telephone, e-mail)?
 Details of the complaint
Actions to be taken by the site

Appendix
APPENDIX 7C – MONITORING FORM (during Construction Phase)
1. Responses/Actions to Comments and Guidance from Government Authorities and

the Public
Monitoring Item Monitoring Results during Report
Period
Project Proponent‘s obtaining of
environmental approval from MPCB
Project proponent handling on the complaints
of residents and stakeholders
Dissemination of information on project work
through media
2. Mitigation Measures
 Air Quality
Monitoring Monitoring Method of Environmental Monitoring
Item Results management & monitoring
Dust  Visual inspection of Construction work
contractor‘s work practice lots and
 Prevention measures surrounding areas
toward dust control such as
water sprinkling
 Water Quality
Monitoring Monitoring Method of Environmental Monitoring
Item Results management & monitoring
Turbid  Visual inspection of Construction work
water contractor‘s work practice lots and
 Prevention measures toward surrounding areas
dust control such as turbid
water
 Waste
Monitoring Monitoring Method of Monitoring
Item Results Environmental
management &
monitoring
Waste  Generation of  Visual inspection of Construction work
(Excavated excavated soil contractor‘s work lots
soil) (Monthly) practice (Daily)
 Treatment  Collection and
 Location of final confirmation of monthly
disposal report (Monthly)

Appendix
 Noise / Vibration
Monitoring Measured Measured Standards Remarks
Item Value Value (Measurement Point,
(Mean) (Max) Frequency, Method,
etc.)
Noise level Indian Boundary at

Standard* construction work lots,
monthly
 Maximum allowable noise level at construction works
Time Industrial Commercial Residential Silence Zone

Area Area Area
Day Time 75 dB 65 dB 55 dB 45 dB
Night Time 70 dB 55 dB 45 dB 40 dB

Period
Project Proponent‘s Contractor‘s handling
resident‘s information and complaints
 Accident

Period
Contractor‘s monthly report
3. Social Environment
 Social Infrastructure and Service
Monitoring Item Monitoring Method of Monitoring points
Results Environmental
Management &
Monitoring
Traffic flow around  Visual inspection of Construction work
construction work lots traffic jam lots and surrounding
areas
Public notice on construction
plan and work lots through
TV, radio, newspaper and
internet
Project proponent / Contractor‘s monthly Construction work

Contractor‘s report lots and surrounding
Implementation of areas
underground utilities survey

Appendix

Appendix
APPENDIX 7D – MONITORING FORM (during Operation Phase)

1. Responses /Actions to Comments and Guidance from Government Authorities and
the public

Period
2. Mitigation Measures
(1) Water Quality Monitoring
1) Water quality Measurement 1 for 11 STPs in monthly basis and after operation (Water
quality of inflow sewage to STP, water quality after treatment at STP)
Parameters: Water Temperature, pH value(H+), Dissolved Oxygen (DO), ―Biochemical
Oxygen Demand (BOD)3, ―Chemical Oxygen Demand (COD)‖, Total Suspended Solids
(TSS)‖, Ammonia (NH3), Total Nitrogen(T-N), Total Kjeldahl Nitorgen, Nitrates (NO3-N),
Nitrites (NO2-N), Total Phosphorus (T-P), Coliforms, Air Temperature.
2) Water Quality Measurement for Public Water Body in Monthly basis before and after
operation (2 points for Mula River, 2 points for Mutha River,1 Point for Mula-Mutha River
and 4 Nallas)
Parameters: Water Temperature, pH value(H+), Dissolved Oxygen (DO), ―Biochemical
Oxygen Demand (BOD)3, ―Chemical Oxygen Demand (COD)‖, Total Suspended Solids
(TSS)‖, Ammonia (NH3), Total Nitrogen(T-N), Total Kjeldahl Nitorgen, Nitrates (NO3-N),
Nitrites (NO2-N), Total Phosphorus (T-P), Coliforms, Air Temperature
(2) Waste
Amount of treated sludge at 11 STPs
Monitoring Item Monitoring Results Method of Monitoring

Environmental
Management
& Monitoring
 Generation amount of  Visual Inside and Outside
Waste (Treated treated sludge (monthly) inspection STPs
Sludge)  Treatment method  Monthly
 Final disposal report
(3) Soil contamination
Monitoring Item Monitoring Results during Report Period

Project Proponent‘s or Operator‘s handling
on resident‘s information and complaints
Sewage inflow amount at STPs
Chemical analysis* of treated sludge for 11

Appendix
STPs
Notes: Parameters: Volatile Solids(VS), Moisture Contents, Cadmium(Cd), Arsenic (As),
Nickel(Ni), Lead(Pb), Mercury(Hg), Chromium (Cr), Selenium (Se), Flourine (F),
Cyanogen(CN), Total Nitrogen(T-N), Nitrates(NO3-N), Nitrites(NO2-N), Total Phosphorus (T-P)
(4) Noise/Vibration
1) Noise Level
Monitoring Measured Measured Standards Remarks

Item Value Value (Measurement Point,
(Mean) (Max) Frequency, Method, etc.)
Noise level Indian  Facility boundary (11 STPs,

Standard* 4 Intermediate Pump
Stations)
 3 months after commissioning
*Maximum allowable noise level as shown in the monitoring plan for construction stage
2) Handling on resident‘s complaints
Monitoring Item Monitoring Results during Report Period

Operator‘s handling on resident‘s information
and complaints
(5) Offensive odour
1) Measurement of offensive odor
Monitoring Item Measured Measured Standards Remarks

Value Value (Measurement Point,
(Mean) (Max) Frequency, Method,
etc.)
Ammonia 1.0 ppm  11 Steps: 22 (windward

Methyl Mercaptan 0.002 ppm side: 1, leeward side:1), 4
intermediate pumping
Hydrogen 0.02 ppm station: 8 (windward side:
Sulfide(H2S) 1 leeward side: 1) total: 30
Methyl Sulfide 0.01 ppm points
Styrne 0.4 ppm  3 months after
commissioning
Notes:
Japanese Offensive Odour Control Law, Law No.91/1971 or latest amendment by Law
No.71/1995

Appendix
2) Handling on resident‘s complaints

Period
3. Social Environment
 Occupational health and safety

Period
Regular meetings on operation and
maintenance works

period
Implementation of Operator‘s training at
commissioning
 Accidents

Appendix
APPENDIX 8 – LOGO FOR THE PUBLIC RELATIONS

Appendix

Volume 2 - PK 5 - Bhairoba STP To Biddders-Min PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Volume 2 - PK 5 - Bhairoba STP To Biddders-Min PDF

Uploaded by

Copyright:

Available Formats

ŽŶƐƚƌƵĐƟŽŶŽĨ75D>Bhairoba^dWŽŶKĂƐŝƐ

/ŶĐůƵĚŝŶŐZĞŚĂďŝůŝƚĂƟŽŶŽĨKalyani Nagar IPS

1 Project Requirements ......................................................................................................... 1

Section VI-A: Employer‘s Requirement i Bid Document

3.2 General Design ........................................................................................................... 23

Section VI-A: Employer‘s Requirement ii Bid Document

Section VI-A: Employer‘s Requirement iii Bid Document

Section VI-A: Employer‘s Requirement iv Bid Document

9.14 Gates ........................................................................................................................ 244

Section VI-A: Employer‘s Requirement v Bid Document

11.4 Operation Management Plan .................................................................................... 295

Section VI-A: Employer‘s Requirement vi Bid Document

1.1 Background to the Project

MOEF&CC is supplementing the efforts of the State Governments in abatement of

Package 1 : (LCB with Single Stage Two Envelope): Construction of Main/Sub-

Section VI-A: Employer‘s Requirement 1-1 Bid Document

Package 6 : (ICB with PQ followed by Single Stage Two Envelope): Construction

1.1 Objective of this Package

The main objectives of this package include:

1.2 Funding Agency

Section VI-A: Employer‘s Requirement 1-2 Bid Document

1.3 Description of Scope of Work

1.4 Scope of Work

1.4.1 Bhairoba Sewage Treatment Works

 Construction of STP at Bhairoba with the treatment capacity of 75 MLD and

The Works shall be constructed in 2 Stages as follows:

 Emptying the redundant tanks (including desludging where required), demolishing

 Construction of the 75 MLD sewage treatment facilities including preliminary

1.4.2 Intermediate Pumping Station (Kalyani Nagar)

 Rehabilitation of Kalyani Nagar Intermediate Pumping Station (IPS) and Operation

Section VI-A: Employer‘s Requirement 1-3 Bid Document

1.6 Provision of Utilities

1.6.1 Water Supply at Site

1.6.2 Electricity for Contractor's Use on Site

Section VI-A: Employer‘s Requirement 1-4 Bid Document

No payment on account of electricity charges is admissible to the Contractor.

c) Defect Liability Period, O&M period:

1.7 Independent Compliance Auditing

Section VI-A: Employer‘s Requirement 1-5 Bid Document

The annual inspection shall also review:

Section VI-A: Employer‘s Requirement 1-6 Bid Document

2.1 Location of the Site

Location Latitude Longitude

2.2 Access to the Sites

2.2.2 STP at Bhairoba

Construction of STP at Bhairoba with the treatment capacity of 75 MLD

2.2.3 IPS’s for Kalyani nagar

i. Rehabilitation of Kalyani Nagar IPS.

Section VI-A: Employer‘s Requirement 2-7 Bid Document

2.2.4 Access for the Employer and Engineer

2.3 Site Constraints

i. A sites constraint drawing PF-D-PARMM-5-43-400-Y-003 is included for information

2.3.2 Tree Cutting:

2.4 Demolition of Existing Structures at Site

Section VI-A: Employer‘s Requirement 2-8 Bid Document

2.4.2 Existing Services, Utilities and Structures

i. Where information is provided concerning existing services, this information must be

Section VI-A: Employer‘s Requirement 2-9 Bid Document

2.4.4 Demolition and Reinstatement

2.4.5 Removal of Debris

2.4.6 Asbestos Based Materials

i. Asbestos based materials may be present in buildings to be demolished under this

2.5 Maintenance of the Site

ŽŶƐƚƌƵĐƟŽŶŽĨ75D>Bhairoba^dWŽŶKĂƐŝƐ