Page A-2

Technical Specifications

1.1 Aim of project

1.2 Special Requirement of Works ................................................................................................4
1.3 Performance Requirements and Guarantees ......................................................................... 5
1.3.1 Schedule of Performance Requirements ................................................................................. 5
1.3.2 General Guarantees ................................................................................................................ 5
1.3.3 Guarantee Period .....................................................................................................................5
1.3.4 Guarantee Tests ...................................................................................................................... 5
1.3.5 Pump Efficiency and Pump Flow ............................................................................................. 6
1.3.6 Power Requirements ............................................................................................................... 6
1.3.7 Cavitation ................................................................................................................................. 6
1.3.8 Wear ........................................................................................................................................ 7
1.3.9 Seals ........................................................................................................................................ 7
1.3.10 Vibration ................................................................................................................................... 7
1.3.11 Noise ........................................................................................................................................ 7
1.3.12 Reverse Runway Speed Rise and Pressure Rise/Drop ...........................................................7
1.4 Design-Build Period .................................................................................................................. 8
1.4.1 Key Engineering, Procurement and Construction Tasks ......................................................... 8
1.4.2 Overview of Contractor’s Responsibilities................................................................................ 9
1.4.4 Survey and Preparatory Works .............................................................................................. 12
1.4.5 Land Acquisition..................................................................................................................... 13
1.4.6 Design and Engineering.........................................................................................................14
1.4.7 Design Drawings ....................................................................................................................15
1.4.8 Pump Stations ........................................................................................................................ 19
1.4.9 Instrumentation and Control and SCADA System ................................................................. 24
1.4.10 Valves and Piping at Pump Stations ...................................................................................... 32
1.4.11 Pump Motors .......................................................................................................................... 35
1.4.12 Electro-mechanical Equipment and Works ............................................................................ 37
1.4.13 Rising Mains and Pipeline Distribution System ...................................................................... 38
1.4.14 Earthworks and Excavation ................................................................................................. 106
1.4.15 Steel and Iron Works ........................................................................................................... 106
1.4.16 Concrete Works ................................................................................................................... 106
1.4.17 Building Works ..................................................................................................................... 106
1.4.18 Road Works .........................................................................................................................106
1.4.19 Other Facilities .....................................................................................................................106
1.4.20 Quality Control .....................................................................................................................107
1.4.21 Construction Program .......................................................................................................... 107
1.4.22 Inspections and Tests .......................................................................................................... 108
1.4.23 Commissioning ....................................................................................................................110
1.5 Operations Service Period ................................................................................................... 110
 Page A-3

1.5.1 General Requirements ......................................................................................................... 110

1.5.2 Operation and Maintenance Operator Requirements .......................................................... 112
1.5.3 Operation and Maintenance Plan ........................................................................................ 113
1.5.4 Reporting .............................................................................................................................114
1.5.5 Site Security .........................................................................................................................116
1.5.6 Environmental Requirements ............................................................................................... 116
1.5.7 Training ................................................................................................................................ 117
1.5.8 Water User Associations ...................................................................................................... 118
 Page A-4

1.1 Aim of Project:-

The ultimate aim of the scheme is to irrigate 9950 ha of land (CCA) within 12945 ha
GCA, as shown in index map attached in the tender document, which shall not be less
than 12945 ha of said GCA by drip / sprinkler system.

1.2 Special Requirement of Works

The bidders are required to submit preliminary design. Specifically, the bidder should submit his design details
as follows in absence of which the bid will be treated as non–responsive:

 Coordinates of all intake channels, pump stations and main pipeline lengths and static heads and
discharge in each stage of pumping and irrigated command shall comprise of specified CCA area within
GCA as shown in index map attached in tender document which shall not be less than as specified CCA
of the said GCA in entire system.

 The maximum power requirement shall not exceed specified 1.67 MW (including Booster pumping
wherever required) over the first 15 year life cycle of the pumping station as determined at the low voltage
side of the main station transformer based on all pumps being in operation, except stand-by units.

 The guaranteed life time of all pipelines shall not be less than 50 years.

 Layout of the main pipelines and a sample layout for a 300 ha supplied from main pipeline. The sample
layout of the distribution network for 300 ha down to 30 ha chak and 3 ha sub-chak including sample
layouts for micro irrigation systems supplied by the 1 ha outlets.

 The bidder shall provide for micro irrigation system such that sprinkler/ drip connections at the 1 ha chak
can be used in such a manner as to allow the farmers in this area to use their sprinklers and drip directly
by connecting a flexible pipe to the last pipe of the micro irrigation system provided under this bid. This
means that the bidder shall be required to provide sufficient connection outlets for sprinkler pipe on the 1
ha outlet to allow the farmer to connect his sprinkler directly at different places.

 The residual head at every outlet at 1 ha of 20 m should be suitably maintained to provide the required
exit gradient as designed for the micro irrigation systems.

 The Contractor shall prepare all documents, maps and forms required as per M.P. krishakon ki bhagedari
adhiniyam (2000) and its rules amended up to date, for formation of water users associations under the
culturable command area served by the pressurized irrigation system to be constructed under contract.

 Disposal of surplus excavated material after refilling of pipe trenches shall be spread on nearby low lying
Govt. land after due permission from competent authority.

 Construction project facility comprising of residential and non-residential buildings of specified carpet
area, which includes a fully furnished office as approved by department, the facility shall include fencing,
sanitation, water supply, electrification, approach and internal roads, garden etc.

 Necessary fire fighting arrangements, canteen, washrooms, retiring room shall be established in the
pump houses.

 Necessary safety sign boards will be displayed at work site on suitable location as per directions of the
Engineer-in-Charge.
 Page A-5

1.3 Performance Requirements and Guarantees

1.3.1 Schedule of Performance Requirements

The Contractor shall ensure that the Project meets, as a minimum, guarantees for the following parameters as
part of the Acceptance Tests as well as during the 5-year Operations Service Period:

 The irrigation system – pump station(s), pipelines, outlets and all associated facilities – shall be operable
during any period of the year for any length of time as required to meet crop water demands

 Minimum pressure at every 1 ha outlet shall be 2 kg/cm2

 The pipelines and distribution system as a whole for the complete CCA shall be designed to provide
specified duty at field including possible losses.

 Discharge capacity in the pipelines below the 30 ha chak should be 0.33 to 0.35 lit/sec/ha and discharge
at 1 ha chak shall be ten times the specified duty.

1.3.2 General Guarantees

The Contractor shall warrant that all parts of the pumping units shall be free from defects in design, material or
workmanship and shall be suited in all aspects for the purposes for which it is specified.

The Contractor shall also warrant the successful operation of all equipment supplied under this tender document.

If any equipment or system fails to meet the guaranteed values, at Acceptance Testing or anytime during the
5-year Operations Service period, all necessary modifications and/ or replacement shall be carried out by the
Contractor at his own cost and without any extra costs to the Employer so that equipment and systems comply
with the guaranteed requirements.

1.3.3 Guarantee Period

Unless otherwise specified, the guarantee period for which all requirements and guarantees of this tender shall
remain in effect, and during which the Contractor shall be responsible for the provision and maintenance of the
guarantees, shall be for the entire duration of the Defects Notification Period except with respect to the cavitation
guarantee which shall be in accordance with Cavitation section below.

1.3.4 Guarantee Tests

The responsibility of conducting the tests will be with the Contractor and the Contractor shall make all the
arrangements for carrying out tests at site and all costs associated with the above tests shall be borne by the
Contractor. The guarantee parameters must be demonstrated by the Contractor upon completion of integration,
preliminary/initial operation, trial run and commissioning of the plant and equipment.

Guarantee tests at site shall be conducted as soon as possible and preferably within thirty days after successful
completion of trial operation, commissioning, stabilization of the complete plant establishing the desired capacities
and parameters in the presence of Employer's representative. If the guarantee tests cannot be conducted within
30 days, the Contractor shall propose options for the Employer to approve. Undertaking the guarantee tests after
30 days will not relieve the Contractor of its obligation to undertake guarantee tests and demonstrate plant
performance.

All instruments used during tests shall be of adequate accuracy for the purpose in accordance with international
standards. All the instruments required for the functional guarantee test should have been calibrated by the
contractor from the client approved independent agency/ reputed laboratory /Institute prior to the start of the test,
by standard methods and valid calibration certificates shall be submitted by the contractor before executing the
test.
 Page A-6

Both parties jointly shall witness all phases of the test and record the data. The tests shall be conducted in
presence of the respective equipment supplier/manufacturer, if specified in this tender document, to monitor and
demonstrate the performance of the units and respective equipment and shall make minor adjustments to the
equipment if required, prior to the official test.

At the end of test, the Contractor shall prepare a test report and submit to the Employer. Submission of the report
and subsequent approval by Employer shall be required for completion. Test reports shall be submitted in booklet
form showing all fields tests performed to adjust each component and all field tests performed to prove
compliance with specified guarantee parameters.

During testing the readings are to be taken every two (2) hours from the field instruments as well as from the
control room panel during the test period in the field log book as well as in the log book maintained in the control
room for all necessary parameter(s), as appropriate.

The Bidder shall propose a test procedure along with the bid submission which will be agreed at Contract stage.

1.3.5 Pump Efficiency and Pump Flow

The pumps and motors shall be of a high efficiency design, which will minimize future operating costs.

Pump flow, pump power and pump efficiency shall be guaranteed. Total pump heads shall be verified by the
Contractor according to the effective pressure losses caused by the proposed valves including friction and local
losses for the pump intake, the discharge header and siphon system.

The Contractor shall conduct a model/prototype efficiency tests to demonstrate that the installed pumps have
achieved the guaranteed performance. If as a result of the efficiency tests it is found that the efficiency of pumps
and motors is less than that quoted by the Contractor in its bid.

1.3.6 Power Requirements

The Bidder agrees to design and build the Works to achieve energy efficient operation over the lifetime of the
Project. The total maximum power requirement of the pump station(s) shall not be more than as specified. The
Bidder shall submit a preliminary design capable of producing the required performance at the guaranteed
maximum power level.

The Contractor must demonstrate ongoing compliance with this requirement throughout the full Contract period,
including the 5-year Operations Service period, and at regular intervals in accordance with the O&M Plan.

1.3.7 Cavitation

The Contractor shall guarantee that the amount of metal removed by cavitation, erosion and corrosion from the
pump impeller after either 8000 operating hours, or 2 years of operation, whichever occurs later, during which
the pump has been operating within the guaranteed range of operating conditions, does not exceed a given
value. The cavitation guarantee is evaluated according to IEC 60909 – "Hydraulic Turbines, Storage Pumps
and Pump-turbines - Cavitation pitting evaluation - Part 1: Evaluation in reaction turbines, storage pumps and
pump-turbines”.

Excessive cavitation on the impeller shall be defined as being when the weight of metal removed from the impeller
exceeds W [kg], where:

W Limit = 0.8 x D2 x (t A / 8000) [kg]

and where D is the impeller inlet diameter (in metres) and tA the reference duration of operation hours.

If the pump impeller exceeds this material loss limit, the Contractor shall repair all damaged areas by welding and
grinding in a manner satisfactory to the Employer. The Contractor shall be responsible for all costs of the repairs
including any necessary dismantling and/or transport. Subsequent to any such repair, the impeller shall be
subjected to a renewal of the guarantee for another period of not less than an additional 8000 operating hours.
 Page A-7

Each cavitation guarantee shall be automatically fully renewed each time the impeller fails to meet these
cavitation limit requirements.

During the cavitation guarantee period, the Contractor shall be permitted to inspect the pump. The inspection of
parts subject to cavitation shall be conducted at the end of the Trial Operation Period and at the end of the
guarantee period.

Further inspections will be decided by the Employer if deemed necessary. If the pump parts become excessively
pitted or eroded during the above guarantee period, the Contractor shall repair the affected spots in a manner
satisfactory to the Employer using stainless steel welding.

1.3.8 Wear

The Contractor shall be fully acquainted with the properties of the pumped water to be pumped and any effects
such properties may have on the pumps and the parts or equipment to be supplied, and shall therefore warrant
that the pumps and other equipment will not suffer any abnormal degree of wear during operation.

1.3.9 Seals

All bearings, pipework for oil, water or air, and all related equipment shall be perfectly leak-proof, and no water, oil
or air leaks will be permitted. Condensate shall be trapped and drained. The Contractor shall also guarantee that
none of the electrical circuits as designed will be exposed to oil splash or vapour, and in his design and
manufacture he shall state precautions to ensure this.

1.3.10 Vibration

Limit values for shaft vibrations in accordance with ISO 7919-5, and for bearing vibrations in accordance with ISO
10816-5 and VDI 3839.

1.3.11 Noise

The Contractor shall guarantee that airborne noise under pump operating conditions will not exceed the values
defined in both the following standards:

 ISO 1999 – "Acoustics: Determination of occupational noise exposure and estimation of noise-induced
hearing impairment"

 ISO 2204 – "Acoustics: Guide to International Standards on the measurement of airborne acoustical
noise and evaluation of its effects on human beings".

In particular, the noise level caused by the pumping unit shall not exceed 85 dB(A) at any place up to 1.0 meter
distance from the operating equipment. If this noise level is exceeded, the Contractor shall, at his own cost,
provide sound absorber hoods, doors, etc. to the extent necessary to meet the requirement.

As a part of the scope of work, the Contractor shall supply and deliver to the Employer one calibrated manual
measuring instrument for the pump station personnel to be able to perform regular noise control monitoring.

1.3.12 Reverse Runway Speed Rise and Pressure Rise/Drop

A hydraulic transients analysis shall provide the principal characteristics of the pump station including transient
speed rise and pressure rise/drop of the pumps in case of a sudden electrical disconnection of the electrical motor
from the network. The corresponding closing time and closing characteristics of the discharge main butterfly valve
presented.

The maximum dynamic reverse runaway speed and pressure rise/drop shall be guaranteed by the Contractor in
the appropriate Technical Data Sheet and subject to the agreement of the Employer. Compliance with the
guarantee shall be proved by model tests.
 Page A-8

1.4 Design-Build Period

The Contractor shall consult with the Employer throughout the design, procurement and construction activities
involving the entire Project, access to the sites, provision of new power supplies, and other facilities in and around
the pump stations and pipeline distribution system.

1.4.1 Key Engineering, Procurement and Construction Tasks

The overall project implementation consists of the following general tasks:

 Engineering and design; preparation of all engineering studies and activities needed to complete project
design, including but not limited to topographical survey and geotechnical survey for construction any
other relevant studies;

 Preparation of design review submittals as required to achieve implementation progress, along with
overall plant performance, durability and quality as specified

 Mobilization and demobilization for project construction

 Preparation of the project site for construction

 Removal and/or relocation of existing above and underground structures, piping and other facilities,
equipment, debris, vegetation and other physical obstacles to execution of Project construction located at
the site designated by the Employer for the pump stations and pipelines or any construction of
associated facilities including power supplies and access roads.

 Identification and removal or alleviation of surface and subsurface obstacles along the route of the intake
and discharge piping and on or above the pump station, the electrical interconnection facilities and the
access roads.

 Construction of electrical supply facilities for the pump stations’ electrical systems from the dedicated
132/33 kV electrical lines and interconnecting with the electrical switchgear of the substation as required
for complete turnkey operation

 Specification of equipment (aligned with Employer performance requirements)

 Selection of vendors for all mechanical, electrical and instrumentation equipment and other high value
items and consumables with the approval of the Employer. Managing of all vendors to ensure highest
quality and defect-free products as well as on-time delivery.

 Ensuring timely procurement, manufacture, delivery, unloading, unpacking, inspection, installation and
testing of equipment

 Completion of final detailed design

 Obtaining design, procurement and construction related licenses and permits ensuring that any
assistance or support required from the Employer is identified as soon as possible.

 Integrate construction of all Works to ensure safety of personnel, assets and environment.

 Pre-commissioning and commissioning of individual equipment, items of plant and entire systems using a
consistent step-by-step methodology, prioritizing early operation of the pump stations – so that each
system is reliable and can support uninterrupted operation of the entire system in a safe and reliable
manner to produce irrigation water.

 Regular performance testing of Works to demonstrate the performance requirements are being achieved
 Page A-9

 Training of plant operating personnel

 Preparation of Works operation and maintenance systems and manuals

 Preparation of Works “as-built” construction drawings

 Provision of construction, commissioning and operation and maintenance spare parts for all items of
plant.

1.4.2 Overview of Contractor’s Responsibilities

An indicative list of Contractor’s Key Responsibilities is summarized in the following table. Other items (where
noted in other parts of this document or in the Contract) may be added to this list to make it comprehensive.

The Employer shall have the right to seek information, updates and right to inspect works listed works in this table
or other works that are part of the DBO package. The Contractor shall consult and coordinate with the Employer
to ensure ongoing approvals (as required to progress all works).

Contractor’s Responsibilities

Project Management and Administration

Overall project coordination and management

Initial and ongoing design project deliverables
Daily, weekly, monthly, quarterly or annual progress reporting to Employer
Any other services required to achieve best Practices in Project Management in accordance with Project
Management Standards

Engineering and Design

Updates on the compliance with environmental obligations listed in the Environmental Impact Assessment
(current report attached to the tender documents, but always refer to the final report that shall be provided by
the Employer)
Implementation of Environmental Monitoring Plan
General layout, site layout, plant layouts and layouts of key areas of work or interfaces
Roadway improvements and construction
Civil and site work (grading, paving, drainage, fencing, security, access control and facilities)
Utility installations and connections (electrical, water, sewer)
Connecting pipelines and utilities
Architectural
Structural
Power consumption for entire system
Site landscaping
Plumbing and drainage
Fire protection
Heating, ventilation and air conditioning systems (including exhaust systems) and linkage to fire detection and
protection systems.
Electrical systems
Instrumentation and Controls (I&C) systems including local plant control system and overall Supervisory
Control and Data Acquisition (SCADA) system, servers, IT infrastructure
Process instruments and hard-wired control systems for all systems including main pump sets
 Page A-10

Communications
Process equipment layouts
Process equipment design integration
Equipment utility connections
Signage for the construction site
Pumps
Chemical unloading, handling, feed and monitoring systems
Potable water supply and associated works
Process control panels (Local Panels and Remote Terminal Units)
Valves and piping
Spare parts (including start-up/construction spares, commissioning spares and O&M spares)
Hoists and cranes
Electrical metering equipment
Transformers
Standby Generator (emergency power supply)
Electrical switchgear
Electrical control panels
Cables, conduits and trays
Power and control wiring
Indoor and outdoor lighting
Grounding/Earthing (including visible earthing provision) for all items of plant
Lightning and corrosion protection systems
Fire protection/detection/alarm systems; early smoke detection and alarm systems
Approach channel, trash removal system, track racks (intake system)
Service water and air
Valves and instruments
Annunciation panels
Desktop computers, printers, and scanner
Laboratory equipment
Furnishings and office equipment
Any other Engineering and Design effort to achieve highest standards of safety, environmental compliance,
equipment and plant guarantees, Plant Performance, Plant Availability and Durability (Design Life)

Construction Services

Supply of power, water and other utilities, services, chemicals, and consumables during the time of works
construction, pre-commissioning and acceptance testing through final completion
Relocation of existing utilities and piping
Building erection
Equipment installation
Temporary ground access
Outdoor lighting
Fencing and access control gates and system
Any other Construction Services to achieve highest standards of safety, environmental compliance,
equipment and plant guarantees, Plant Performance, Plant Availability and Durability (Design Life)

Equipment Procurement
 Page A-11

Equipment selection, specification preparation, purchase and delivery and installation

Review and analysis for compliance with specifications
Placement of purchase orders and issuance of sub-contracts
Packing, marking, shipping, expediting, inspecting, shipping, international shipping, customs, inland and air
transport and all required services to ensure equipment is delivered to site timely and in the best possible
condition
Processing of invoices for payment
Construction materials such as concrete, rebar, piping, etc., supplied by the Bidder
Initial set of equipment spare parts (for start-up, commissioning and operation)
All other items that are included in the Engineering & Design

Site Work

Site preparation including demolition and relocation of existing facilities and piping
Roadway improvements and construction of access roads
Civil / site work (grading, paving, drainage, fencing)
Utility installations and connections (electric, water, sewer, telephone)
Foundation and slab installation
Building installation
Plumbing installation
HVAC installation
Fire protection equipment installation
Electrical power, grounding, and lighting installation
Instrumentation and control system installation, point-to-point checks and any required calibration and
installation of field instruments
Communications work
Equipment installation
Landscaping
Signage installation
Any other Site Works to achieve highest standards of safety, environmental compliance, equipment and plant
guarantees, Plant Performance, Plant Availability and Durability (Design Life)

Construction Management

Construction supervision
Construction inspection, Quality Assurance (inspection and test plans) and Quality Control
Shop drawing reviews
Coordination of field requests for information
Employer liaison
Progress reporting
Cost and scheduling
Records and document maintenance
Equipment receipt
Bulk receipt

Commissioning and Acceptance Testing

Pre-commissioning planning and detailed commissioning plan

Supply of consumables (power, water, chemicals, etc.) during commissioning and Acceptance Testing and all
 Page A-12

required spares
Training to all operators, supervisors, sub-Contractor and employer staffs
Providing temporary O&M staff during commissioning and Acceptance Testing and assisting the Employer
with retaining and training of permanent O&M staff
Preparation of O&M Manuals
Start-up and commissioning of process and non-process systems of both full-scale plant
Final Acceptance Testing, data analysis and reporting to Employer
Punch listing and rectification of all defects
Final project documentation
Transfer of all Plant to the Employer upon completion of 3-year O&M contract

Plant Operation

One-Year Engineering Support to Employer after the Completion of the 3-year O&M contract
Personnel
Operation and Maintenance
Chemicals and consumables
Insurance
Operations Licenses/Regulatory Compliance
All Required Facilities and Services for the full O&M Scope

1.4.4 Survey and Preparatory Works

Review of survey and investigation data available with WRD, carrying additional survey and investigation
required: survey for structures having catchment area survey less than 2.50 sq. km. and grid survey, levelling
along the nalla/river to determine the bed slope of the nalla/river, cross section of nalla/river for cross drainage
works; grid survey for all structures, taking trial pits/drilling for foundation investigation of structures; preparing
combined village map on tracing cloth for each piped canal system separately, survey of whole command area,
plotting the same on combined village map, contouring the village map, marking ridges by red dotted lines and
valleys by blue arrow lines, survey for fixing alignment, taking trial pits, drilling along the alignments wherever
necessary, and investigation. Marking the approved alignments, chak boundaries (up toone hectare), in position
“Outlets” and other structures on the village maps, preparing chak statements, outlet register, cut-off/design
statement, design-drawing of the piped canal system as per design criteria of WRD, relevant IS code and IRC
publication issued from time to time, preparing detailed estimate as per UCSR (w.e.f. 01.09.2017) of the
Department on the basis of approved design-drawing, clubbing of items for record measurement and basis of
payment, getting approval from competent authorities.

All additional survey, investigation and testing data and any other data relevant to design shall be collected by the
Contractor without any financial burden to the Employer.

The relevant specification for irrigation projects (November 1991) Volume I, Section I, Chapter 2 of Engineer in
Chief, WRD Bhopal shall be strictly followed for carrying out the survey for fixing the alignment of rising
main/gravity main/main piped canal along with distribution network complete) including survey for construction of
intake well / pump houses, various structures, buildings, roads and transmission line etc.

In addition to above the relevant IS codes (updated) / IRC specifications (updated) / MPPKVVCL/CPHEEO
specifications will also be followed for the above work and as directed by Engineer-in-Charge.

In addition to above the agency can also submit survey for alignment marked on Google earth map to department
for approval purpose.
 Page A-13

1.4.5 Land Acquisition

After the alignment and locations of the various work components of the project are finalized by the competent
authority, the Contractor will start the process of temporary land acquisition for underground pipelines, rising
mains, piped distribution network up to 1.0 ha sub-chak and permanent land acquisition for intake well cum pump
houses, distribution tanks and residential and non-residential buildings required and for approved spoil bank and
dumping yards. The work components requiring permanent land acquisition should preferably be constructed on
available government land and permanent acquisition of the private land should be minimized.

In case the permanent acquisition of private land is unavoidable, then private land shall be purchased at the first
instant by the Contractor for which he shall be reimbursed the cost as per actual subject to the ceilings imposed
by land acquisition act/ purchase policy of M.P. in force at that time. Such land shall be handed over to M.P. under
provisions of the MPLRC after completion of the work along with other assets. In case Contractor fails to procure
land on his own, on his request the state government would procure land as per the prevailing provisions of the
land acquisition act/purchase policy of M.P. but the delay in this process, if any, shall not be attributable to M.P.

The cost of forest land, if any, required permanently for the construction of different components of the scheme,
shall be borne by the Government. The turnkey Contractor has to prepare the proposals for forest land and will be
responsible to get the clearance in scheduled time from M.P., as the case may be. WRD will only help the turnkey
Contractor in getting the clearance from the competent authority. The delay in clearance of the forest land will be
attributable to the turnkey Contractor. Costs incurred in preparing proposals and getting clearances shall be borne
by the agency other than the costs of forest land and the cost of compensatory reforestation if any.

Preparing temporary land acquisition cases for borrow area required, underground pipeline, haul road, diversion,
camp office etc., if any, the cost of such temporary land acquisition and crop compensation, if any, etc., shall be
borne by the Contractor.

After approval of GAD, the detail alignment and locations of the various work components of the project shall be
submitted for finalization by the competent authority. After due approval of location and alignments, the
turnkey agency shall start the process of land acquisition for underground pipelines such as, main branches and
disnet up to 1 hectares, the L. A. cases shall be prepared as per MP Underground pipe line, cables and duct act
2012 (number 5 of 2013). However, state government will bear the cost of land and shall reimburse, for a strip
equal to two times the diameter of pipe laid. Cost of additional land, if any acquired for the execution of work, shall
be borne by the contractor. For pump houses, distribution chambers, other permanent arrangements/accessories
and residential & non-residential buildings, permanent land acquisition cases shall be prepared. The work
components requiring permanent land acquisition should preferably be constructed on govt. land available to
minimize acquisition of private land. In case the permanent acquisition of private land is unavoidable, then private
Land acquisitions is to be carried out by the contractor with the help of department. Necessary proposals\letters to
concern department will be issued by the Engineer in charge; further follow-up for timely acquisition is to be done
by the contractor. The department shall make payments for acquiring permanent land and property as per LA
act/LA package. Such land shall be handed over to the State Govt. under provisions of MPLRC after completion
of the work along with other assets. Pursuing the land and property acquisition cases, getting the award\approval
from competent authority within the time shall be the whole responsibility of the contractor. The land required for
Construction before award will be arranged by the contractor to ensure timely completion of the scheme for which
no claim shall be entertained from the contractor. The delay in this process of land acquisition, if any shall not be
attributable to the State/WRD.

The contractor shall pay cost of temporary land acquisition apart from a strip equal to two times the
diameter of pipe laid and the entire crop compensation (including 2 times dia of pipe laid) or any other
compensation to complete the project as per MP Underground pipe line, cables and duct act 2012
(number 5 of 2013).

The Contractor shall furnish ten (10) copies of land plan schedules and land acquisition proposals for obtaining
approval of competent authorities.

Wherever the pipe network irrigation system is passing through or by the side of villages, towns and other
habitations, suitable cattle ramps in each village shall be provided by the Contractor duly getting the design
 Page A-14

drawing / proposals approved by the Engineer-in-Charge and cost of these structures are deemed to be included
in the contract price quoted.

1.4.6 Design and Engineering

The Contractor's Scope of Services shall include the following activities:

1.4.6.1 Review and Assessment of Data Requirement

Identification of survey and investigation requirement considered necessary for design, execution, commissioning
and operation of the project.

Review of technical and design parameters for rising mains, electro-mechanical and underground pipeline works.

Preparation and submission of reports on the above for the information to the Engineer-in-Charge.

Preparation of work program for carrying out additional investigations and studies for the information of the
Engineer-in-Charge.

The Contractor shall submit a review report after carrying out the above activities for acceptance of the Engineer-
in-Charge.

1.4.6.2 Additional Investigations, Observations and Studies

Carrying out additional surveys, geo-technical investigations and laboratory tests, analysis and studies including
collection of other relevant data as necessary.

Evaluation of results of additional investigations, carrying out studies and analysis for the design of the Project
components.

Finalisation of preliminary design based upon the Base Design and planning of the Employer, the works to be
executed for the pump station(s) and pipeline network of the scheme. The conceptual plan shall be on whole to
the part principle.

1.4.6.3 Detailed Engineering Design

Preparation of design memorandum indicating design criteria, design parameters, design assumptions, method of
analysis on all components of the Work (pumps, civil works, rising mains, structure, electro-mechanical and
underground pipelines).These design briefs shall be submitted to the Engineer-in-Charge for approval by Chief
Engineer before carrying out detailed design and construction drawings.

Detailed design for the Civil Works i.e., pump houses, distribution chambers, electro-mechanical and underground
pipeline works i.e. pump related electrical components including drawings required for the execution and the
calculations performed and the construction drawings issued shall be submitted to Engineer-in-Charge for
approval by Chief Engineer.

Detailed design of gates, hoisting arrangement and electro-mechanical parts including drawings required for the
execution of the Works and all calculations performed and the construction drawings issued shall be submitted to
Engineer-in-Charge for his approval.

Detailed design of pumps, electro-mechanical and underground pipeline including drawings required for the
execution of the Works and all calculations performed and the construction drawings issued shall be submitted to
Engineer-in-Charge for approval by the Chief Engineer.

Details of control arrangement including drawings required for the execution of the Work shall be submitted to
Engineer-in-Charge for his approval.
 Page A-15

Additional designs and modifications, as needed, during construction.

The Contractor shall adopt modern methodology and state of the art technologies in the design of pump stations
and pipeline systems.All software used shall also be loaded in Engineer and his Representative’s computers for
design verification and subsequent use at no additional cost.

Submission of methodology for commissioning of entire scheme.

No separate payment shall be made for any of the design and engineering works indicated above and needed for
the completion of the project and shall deemed to be included in the quoted price.

1.4.6.4 Design Liaison

Design liaison with Engineer and his representative, Consultant(s) of the Employer, etc.

Preparation of Monthly Reports on the progress of the project work as a whole for information of the Engineer-in-
Charge, in respect of:

 Investigation and Surveys

 Design and engineering

 Civil construction

 Pumps, gates and electro-mechanical parts

 Control arrangements

 Technical status (present status and future program)

 Project status (time schedule, achievement of milestones, slippage in time schedule with specific
reference to activities and acceleration measures proposed)

 Financial status (present status and future projection)

 Deployment of manpower, labour, expatriates staff and construction equipment

 Furthermore the Report shall include necessary photographs and sketches showing the previous month's
progress

1.4.7 Design Drawings

The design and drawings of all pump houses, electrical systems, rising mains, pipeline distribution network,
SCADA system and all associated structures, residential and non-residential buildings, etc. will be as per design
criteria of WRD, relevant I. Codes, CPHEEO Manual, I.R.C. Publications, design parameters and circulars issued
by the WRD from time to time and getting ITS approval from competent authorities. Preparation of detailed
estimate on the basis of approved design drawings and obtaining approval from competent authorities as per
UCSR of WRD (W.E.F. 01.09.2017), other department CSR or market rates for items not covered in above CSRs.

Construction Documents means all designs, drawings, calculations, methodology and any other related data
provided by the Contractor to the Engineer’s Representative under the Contract including all samples, patterns,
models, operation and maintenance manuals and other technical information of alike nature submitted by the
Contractor and approved by the Engineer’s Representative. However such approval will not relieve the Contractor
of any of his obligations, responsibilities under the Contract.
 Page A-16

The Contractor shall prepare Construction Documents in sufficient detail to satisfy all regulatory approvals, to
provide suppliers and Construction personnel sufficient instruction to execute the Works, and to describe the
operation of the completed Works. The Employer's Representative shall have the right to review and inspect the
Construction Documents. The Contractor shall prepare and submit, with reasonable promptness and in such
sequence as is consistent with the Project Completion Schedule, three copies each of the design and drawings,
duly certified by the "Design Consultant", to the Engineer.

The Contractor shall furnish to the Engineer-in-Charge the following number of copies of drawings, reports and
other technical documents:

Electronic
Type Hard Copies REMARKS
(CD/DVD)
Drawings for information 6 sets 1
Drawings for approval 6 sets 1 One hard copy shall be
returned to the Contractor
with approval or
comments.
Approved drawings 1+ 10 sets 1
As-built document 1 + 10 sets 1 In soft copy also.
Review Report/ Design 3 sets 1 One hard copy shall be
Briefs/Design Memo/ returned to the Contractor
Design Reports (Draft) with approval or
comments.
Review Report/ Design 1 + 10 sets 1 In soft copy along with
Briefs/Design Memo/ licensed software used for
Design Reports (Final) design and drawing.
Progress Reports 6 (Six) sets Also through e-mail to
(monthly) respective authority
Final design computations 6 (six) sets 1 In soft copy also.
Detailed Project 10 sets 1 In soft copy also.
Completion Report

By submitting the Design Drawings for approval, the Contractor shall be deemed to have represented that it
has determined and verified that the design and engineering, including field construction criteria related thereto,
are in conformity with the Scope of the Project, the Specifications and Standards and the Applicable Laws.

Within 30 (thirty) days of the receipt of the Design and Drawings, the Engineer or his authorized Design
Organization shall review the same and convey its observations to the Contractor with particular reference to their
conformity or otherwise with the Scope of the Project and the Specifications and Standards. All communication
and or notices pertaining to works and concerning matters, such as passing and approving of foundation,
reinforcement, and form work, measurements, mark outs, etc. shall not be addressed by the Contractor to an
officer not below the rank of Executive Engineer. All such notices communications, etc. shall be addressed in
good time so as not to hold up the work.

If the aforesaid observations of the Engineer indicate that the Design and Drawings are not in conformity with
the Scope of the Project or the Specifications and Standards, such Drawings shall be promptly revised by the
Contractor in conformity with the provisions of this Agreement and resubmitted to the Engineer or his
authorized Design Organization, for review. Design Consultant or his representative shall regularly attend
Engineer's office or the design organization authorized by him and seeks approval within 10 days.

In the event the Contractor fails to revise and resubmit such Design and Drawings to the Engineer, for review
as aforesaid, then he may direct the Engineer-in-Charge to withhold the payment for the affected works, till
observations are compiled and design and drawing are found acceptable.

However, no review and/or observation of the Engineer, and/or its failure to review and/or convey its
observations on any Drawings shall relieve the Contractor of its obligations and liabilities under this Agreement
in any manner nor shall the MPWRD be liable for the same in any manner; and if errors, omissions,
 Page A-17

ambiguities, inconsistencies, inadequacies or other Defects are found in the Design and Drawings, they and
the construction works shall be corrected at the Contractor's cost.

The Contractor shall be responsible for delays in submitting the Design and Drawing as set forth, caused by
reason of delays in surveys and field investigations, and shall not be entitled to seek any relief in that regard under
this agreement.

Each of the Construction Documents shall be submitted to the Employer's Representative for review. If the
Employer's Representative, notifies the Contractor that such Construction Document fails (to the extent stated) to
comply with the Employer's Requirements, it shall be rectified, resubmitted and reviewed in accordance with this
Sub-Clause, at the Contractor's cost.

The Contractor shall have to submit detailed plan to the Engineer-in-Charge showing the layout of the work site,
roads and approach roads proposed by him, before he starts the actual work. Such a road layout road plan will be
scrutinized by the Engineer-in-Charge and any modifications suggested by him shall be binding on the Contractor.
If it is decided by the Engineer-in-Charge to have some of the roads proposed by the Contractor as common road
for common use of WRD and other Contractors or convenient and for compact and planned layout of work site,
the Contractor will be bound to construct them and allow them to be used simultaneously by other Contractors
and departments. In case of disputes, the decision of the Engineer-in-Charge shall be final and the binding on the
Contractor.

For each part of the Works, and except to the extent that the prior consent of the Employer's Representative shall
have been obtained:

 Construction shall not commence prior to the approval of Construction Document which are relevant to
the design and Construction of such part

 Construction shall be in accordance with such Construction Documents

 If the Contractor wishes to modify any design or document which has previously been submitted, the
Contractor shall immediately notify the Employer's Representative, and shall subsequently submit
revised documents to the Employer's Representative for approval.

Works shall only be executed in accordance with the Drawings approved by the Engineer, and such Drawings
shall not be amended or altered without prior written notice to the Engineer. If the Employer's Representative
instructs that further Construction Documents are necessary for carrying out the Works, the Contractor shall
prepare such Construction Documents.

Any cost or delay in construction arising from review by the Engineer or his authorized design organization shall
be borne by the Contractor. Errors, omissions, ambiguities, inconsistencies, inadequacies and other defects shall
be rectified by the Contractor at his cost.

In general the drawings shall contain the following basic information in the nameplate:

 Project name

 Name and number of the Contract

 Contractor's name

 Number and title of the drawing

 Date and scale

 Draftsman's name and signature

 Name of the designer responsible and signature

 Page A-18

­ Revision Number (R0 for drawing submitted initially and R1, R2, etc., for drawings submitted
subsequently).

­ Name and designation of checking official and space for signature.

­ Approving authorities name and designation as specified by the Engineer-in-Charge and space for
the signature.

A blank space 90 x 50 mm shall be provided immediately above the title block for the approval stamp. If required,
the detailed design and the execution drawings shall be submitted only after verification by the Consultant(s)
approved by the Engineer-in-Charge.

The Contractor shall be responsible for preparation of working drawings and the Construction documents for
works, as specified in the Contract. The procedure for submission and approval of drawings shall be as stated in
these tender documents, and the Contractor’s work program shall include such submission and approval
procedure.

Drawings given, listed are indicative, but will form part of the Contract.

The Contractor shall carry out alignment studies including cost economics by examining all possible alternatives
to prepare detailed layout, designs and drawings of all components of the work stated in scope of work.

The Contractor shall use guidelines in the relevant IS codes, IRC publications and circulars issued by the WRD
from time to time for various components of the works.

All the studies, layout drawings and modifications if required to be prepared for taking up execution of the work,
shall be prepared by the Contractor and shall be got approved from the competent authority.

The Contractor will have to submit detailed drawings of each component with appropriate scales, measurements,
RL’s, full dimensions, index map locations of components such as go-down, dumping area, internal roads, etc.

For the pump station(s) the Contractor shall furnish six (6) sets of assembly drawings, wiring diagrams, etc., for
approval. The drawings shall include but not be limited to:

 Layout drawings indicating the location of various equipment

 Detailed foundation drawings to withstand hydraulic thrust, magnitude of forces due to unbalanced
rotating parts, mass of rotating parts, etc., in a complete manner

 Loads on foundation for civil structure designs

 Drawings showing ducts, openings, pipe routings, etc.

 Drawings showing embedment of pipes and foundation parts

 Assembly and sub-assembly drawings of all assemblies/ components showing elevations, plans and
sections for the pump, controller/governor parts, control panels, etc.

 Control gear diagrams for pump, controller/governor oil system, CW system, DD system, compressed air
system, etc.

 Detailed drawings showing draft tube profiles, controller/governor, guide bearing, shaft gland, etc.

 Wiring and schematic diagram for control, protection and indication, etc.

 Drawing showing parts to be welded at site, method of welding with details of type and quantity of
electrodes and capacity of welding sets
 Page A-19

 Schematic and detailed drawing for all piping, lubrication and cooling arrangement

 Drawings indicating lifting arrangement of important components/ assemblies with crane clearances

 Part list of all the components with details viz. part numbers, quantity, reference drawing numbers,
packing list, weight and dimensions etc.

 The assembly/sub assembly drawings of Pump guide bearing, shaft gland, Impeller, volute casing, draft
tube, air valve, test equipment’s for Impeller, metallic volute etc.,

 Drawing of the main cross-section of the pump showing the various components/parts/assemblies for the
pump to the extent possible.

 Drawing showing combined cross section of pump and motor.

 Schematic drawings of piping system.

 Efficiency curves and hill chart

 Curve showing areas and velocities at different sections of the draft tube.

The Contractor is expected to organize his work to the best of his knowledge so that final draft of various types of
designs and layouts will be submitted to competent authority within stipulated time period.

All the studies layouts, drawings, design notes, which have been submitted to the department, shall become the
absolute property of department under the copy right act and the Contractor shall not use the same in whole or
part thereof elsewhere for any purpose without explicit written permission from the WRD.

In all difference of opinion on technical matters between the Contractor and the Engineer-in-Charge, the decision
given by the Engineer shall be final and binding on the Contractor.

No later than 60 (sixty) days prior to the end of the design build period of the construction works under contract or
in case of partial completion and start of operation of system within contract period, the Contractor shall, in
consultation with the Engineer, evolve an operation and maintenance manual (the “Operation and Maintenance
Manual”) for the regular and preventive maintenance of the pressurized irrigation system in conformity with the
Specifications and Standards, safety requirements and good industry practice, and shall provide five (5) copies
thereof to the Engineer-in-Charge. The Engineer-in-Charge shall review the manual within fifteen (15) days and
communicate its comments to the Contractor for necessary modifications, if any.

Within 90 (ninety) days of the commissioning of major components the Contractor shall furnish to the Engineer-in-
Charge a complete set of as built drawings, in two (2) hard copies and the electronic files on CD/DVD or in such
other medium as directed by Engineer-in-Charge, reflecting the works as actually designed, engineered and
constructed, including an as built survey illustrating the layout of the completed system.

1.4.8 Pump Stations

System head curves shall be furnished by the Bidder. The Bidder shall furnish characteristic curves of bowl
assembly and also pump after deducting column losses etc. The Bidder shall furnish along with his tender the
characteristic curves superimposed on system head curves for single and multi-pump operation. The pumps shall
have stable characteristics over the entire range of working head. The pump shall be suitable for starting against
closed valve i.e. shut off condition. The efficiency curve shall be reasonably flatter between designed head range.

The design, manufacture and performance of pumps shall comply with all currently applicable standards,
regulations and safety codes applicable in the locality here the equipment will be installed. The equipment shall
also confirm to the latest applicable Indian Standards. In particular the equipment shall confirm to the latest
revisions of relevant IS. Where IS standards are in conflict with the stipulation of this specification, these
specifications will supersede.
 Page A-20

The pump equipment shall be capable of developing the required total head at rated capacity for continuous
operation. The total head discharge curve shall be continuously rising towards the shut off. Pumps shall be
suitable for parallel operation with equal load division. Pumps shall run smooth without undue noise and
vibrations.

Approach channels, distribution chambers, pump stations and electrical power supplies at suitable locations as
approved by competent authorities to supply water at specified duty for irrigation by pressurized irrigation system
for irrigation from pump station(s) at a suitable location approved by the competent authority. Asphalt approach
roads have to be constructed for access to each pump station as directed by the Engineer-in-Charge. The
installed standby capacity of 25%should be provided in each pump house, with the minimum being at least a
single pump of sufficient capacity. In no case will more than one number of pump stations shall be permitted
without approval of the Engineer-in-Charge.

Type and capacity of pumps has to be decided by bidder and as may be approved by Engineer-in-Charge which
shall be as per approved duty and operating conditions.

Typical Technical Data Sheet for Vertical Line-shaft Pumps

Description Particulars
Type of pump Vertical line-shaft pump or any other as adopted by
bidder.
Make As per approved make
Impeller Closed type
Pump arrangement The pump is either mounted on the discharge elbow or the
motor stool
No. of stages One or multistage
Quantity As per approved design
Liquid handled River water
Strainer type Basket type
Discharge head type Above floor
Shaft seal Asbestos-free soft packing. Removable sleeves.
Impeller material Stainless steel
Discharge head, Bellmouth and motor M.S. fabricated
stool
Shaft sleeve Stainless steel
Impeller shaft High grade carbon steel/ stainless
steel AISI 410/416
Column pipes Heavy duty fabricated
Nut and bolts Stainless steel AISI 410
Wearing ring Stainless steel
Line shaft Stainless steel AISI 410/416
Type of lubrication and cooling for Self water for line shaft bearing and oil lubricated for thrust
bearing bearing
Drive Electrical motor with VFD, direct coupled
Ambient temperature 46degrees c.
Location Indoor
Hazardous area division N.A.
Atmosphere Humid, Dusty at a time
Shaft orientation vertical
Type of Couplings Flexible type
Type of bearings Antifriction Ball /Roller Bearing
Thermisters / RTD’s / required for For trip, alarming and indicating
bearings
Bearing temp. Detectors Required for alarm / trip.
Standard to be followed IS 1710, IS 5120,IS 9137, IS 5120or equivalent
international standards. Flanges acc. to IS, DIN (EN),
ASME (AWWA)
 Page A-21

1.4.8.1 Model Test

After the award of contract, the Contractor shall build a model of the pump. The water passages of the model shall
be fully homologous with those of the prototype from the pump intake chambers to the pump discharge valve
arrangement. The column pipe and suction bell mouth shall be transparent to permit observation and for taking
photographs of the vertex flow pattern and cavitation phenomenon. The Contractor shall submit to the Owner,
drawings, description covering details of the proposed model, testing equipment, instrumentation, and test
procedures for individual tests, method of interpretation and computation of test results for approval of Owner.

The model tests shall be performed in accordance with the International Code for Model Acceptance Tests [IEC
Publication 60193 (1999)], and with the IEC International Standard No. 60995 (1991) "Determination of the
prototype performance from model acceptance tests of hydraulic machines with consideration of scale effects".

The final model test series shall include the following tests: Pump performance (efficiency) tests under various
conditions. Cavitation tests. Reverse runaway speed test. Pressure fluctuation tests. Hydraulic thrust test.

The model test shall simulate all possible normal operating conditions of the prototype for the entire range of
reservoir and delivery levels.

After completion of the model test studies, the Contractor shall furnish the model test reports to the Employer
within one month from date of completion of model test for owners review and approval. The test report shall
include but not necessarily be limited to the following:

 Complete pump performance diagram showing efficiency, head, NPSHrequired shaft power; the diagrams
shall include the cavitation limits and shall be extended in a wide range of heads and flows.

 Pump performance diagrams for single and parallel operation including guaranteed pump flows;

 Curves of predicted pump efficiency vs. output for each value of net head given in the guaranteed data;
guaranteed data and inaccuracies shall also be indicated;

 Pump hydraulic thrust;

 Predicted reverse runaway speed for different values of head

 Photographs and sketches of the cavitation phenomenon.

 A sample calculation for each computation in a complete manner.

 Record of calibration of all test instruments and equipment.

 Description of test equipment and test procedures.

The charges for the Model test shall be deemed to be included in the Contract price.

The Contractor shall notify to the Employer, at least one month in advance, the readiness of the model for
witnessing the test and to carry out the dimensional checks of the model.

Should the model fail to meet the guarantees and requirements, it shall be optional for the Employer to
conditionally accept the model and direct the Contractor to modify the model unit to comply with the requirements.
All expenses involved for the modifications and subsequent model tests shall be borne by the Contractor.

The Employer reserves the right to get the model tested in an independent laboratory or suggest the laboratory
where the model testing is to be conducted from among the pre-approved labs indicated by the supplier.
 Page A-22

The Contractor shall also furnish detailed calculations for impeller setting, the basis for selected plant NPSHavailable.
The Contractor shall guarantee the operation of the pumps without undue cavitation under the above conditions.

1.4.8.2 Factory Acceptance Test and Inspection

For the Factory Test a review of raw materials test certificates and quality control procedure shall consist of:

 Hydrostatic Test:

 Performance Test:

The test shall generally be carried out as per relevant IS. The test shall cover minimum 6 points, i.e.:

1) Duty point

2) 2 points above duty point

3) 2 points below duty point

4) Shut off head

5) Power consumption at all above points

6) Zero reading confirmation for V. notch.

The test shall be carried out only by the job motor which will be supplied under this contract. Any tests done only
at reduced speed and reduced load will not be acceptable.

Material Test Certificate of the various pump components shall be furnished by contractor.

The test to be conducted at Works shall include the following:

 All the static parts of the pump shall be completely assembled in the manufacturer's shop and properly
match marked and doweled to ensure correct assembly and alignment at site. Dowels required for
insertion after erection at site shall also be supplied.

 Shaft Seal: assembly of ring with static seal, check function of the static seal.

 Static balancing of impeller.

 All pipes, fittings, pressure tanks and other components of the controlling/governing system shall be
tested under a pressure equal to 150% of the maximum operating pressure maintained for not less than
half an hour and the equipment shall withstand this pressure without any signs of leakage, distortion, and
failure.

 Functional tests of all equipment wherever applicable.

 In addition to the above, each mechanical and electrical sub-assembly shall be tested for proper
functioning and continuity of electrical circuits.

 Testing of auxiliaries including cooling water system, air compressor system, dewatering and drainage
system, oil pressure system, etc.

 Testing of controllers/governors, both hydro mechanical and electrical cubicle jointly for functional
checks.
 Page A-23

 Inspection of flow metering equipment at works for calibration, performance and discharge measurement.
The Owner reserves the right to be present during the above tests and also for the inspection of the
equipment at the Contractor/manufacturer’s works/sub-supplier's works unless waived in writing. The
Contractor shall furnish detailed testing procedures for all the above tests and routine tests on all the
equipment’s to be conducted as per international standards for the review and approval of the Owner
well before witnessing the tests.

1.4.8.3 Field Performance Test

Field Performance Test shall be carried out as relevant IS.

The inspection of the pump at factory site will be carried by the Employer and or inspection agency appointed by
the Employer, in the manufacture's workshop. All the tests as required as per IS shall be carried out in presence
of inspecting agency. The pump shall be dispatched only after issue of test certificate by the inspecting agency for
satisfactory performance of test pump. The inspection charges for such tests shall be borne by the Contractor.

Surge Control System for Pumping Main shall be as approved after surge analysis from expert of IISc or IIT.

Following types of control systems are acceptable for control of water hammer pressures in the pumping mains.

 Zero Velocity Valves

 Air Cushion Valves (only for pumping main)

 Bladder vessel

 As may recommended by the expert from IISc or IIT for surge analysis.

The requirements given are tentative.

1.4.8.4 Hydraulic Transient Analysis

The Contractor, after award of contract, must carry out the surge analysis based on the longitudinal section, pump
and motor characteristics of the selected pumps by the contractor. Surge analysis along with the selected system.

During detailed engineering following information must be submitted based on the Surge Control System selected
by the contractor. For design of surge control system limits will be adhered to (the surge pressures will be
estimated after all working pumps at designed discharge, trip simultaneously) as may be approved after the surge
analysis report from the expert.

The specification of surge control services shall be as approved by Chief Engineer after getting report of Expert
from IISc or IIT or any other expert appointed by department.

Necessary safety measures and fire fighting arrangements shall be established in the pump houses. Necessary
safety sign boards shall be displayed at work site on suitable location as per directions of the Engineer-in-Charge.

The Contractor must, at its own cost, provide Employer’s Representative with:

 Office space and facilities at the pumps station (in the administration/control building overlooking the
main pump /motor gallery) to the reasonable satisfaction of the Employer. As a minimum requirement this
must include air conditioned office space equipped with phone connections, desks, chairs and storage or
filing cabinets; and

 Two computer workstations equivalent to those used by the Contractor, each with Plant Control
System/SCADA access, internet access to a level equal to that used by the Contractor. Plant Control
System/SCADA access must be password protected and must provide visual level access to all areas of
the pump station i.e. no ability to control or change process set points.
 Page A-24

1.4.9 Instrumentation and Control and SCADA System

1.4.9.1 General Requirements

The Contractor shall provide a state of the art control system, comprising a pumping station local instrumentation
and control for all electro-mechanical equipment and a Supervisory Control and Data Acquisition (SCADA)
System distributed over the entire pipeline distribution network, in the following referred to as 'Computerized
Control System’ (CCS).

The objectives of providing Instrumentation and Control and SCADA for each pumping station and the entire
irrigation system network in general are as follows.

 Hydraulic parameters monitoring and control

 Electrical energy monitoring

 Equipment monitoring i.e. pump, motors, etc.

 Emergency response for stopping pumping station

 Optimization of pumping system operation

 Monitoring and measurements in the distribution network up to 30ha chak

 Pumping system efficiency monitoring

 Minimization of human errors

 Logging, reporting, preventive maintenance, safety, etc.

 In case of sabotage/pilferage/ leakage in any distribution network the SCADA should be able to
automatically shut down the valve one level above.

The entire SCADA system is required to receive and store the information from the following systems and takes
desired computerized actions including alarm and automatic actions. The design details and standards of the
SCADA system shall be such as may be approved by the Chief Engineer (BODHI) WRD.

The scope of work shall include all required studies, calculations, design, engineering, manufacturing, supply,
submission of drawings and documents, shop and site testing, erection, adaptation to related equipment,
commissioning and training services for the CCS and its components.

The CCS hard- and software shall be fully developed, installed, debugged, commissioned and tested for manual
and fully automatic control of the pumping station.

The central control room equipment for the CCS shall be composed of the following systems, components and
ancillaries not being limited to:

 Two (2) operator stations with dual screens and alarm printers (color and black/white)

 One (1) large screen with controller (64” or 70”)

 One (1) fire detection and alarm panel

 One (1) metering station with two monitors and printer

 One (1) archiving system for long term and spontaneous data archiving as integrated ports on the CCS
 Page A-25

 One (1) engineering station with two monitors and laser color printer

 Two (2) redundant main servers in hot-standby

 One (1) interface with firewall to Office LAN and Web Client for remote access

 One (1) GPS master clock system with interface to secondary system

The CCS shall be characterized by an innovative system concept, powerful communication capabilities and a
scheme-wide unique engineering and configuration tool. The CCS shall consist of state-of-the art equipment and
components, applying the latest knowledge and achievements in the industrial process automation technology,
such as:

 Client-Server/ Master-Slave concepts

 Object-oriented processing of data

 Re-usable automation software objects and program modules

 High-level of hardware modularity and scalability

 System-wide data management and data access with single data entry and storage

 Central engineering system to program and configure all system components

 Long-term availability of components

 Expandability

 Standard-based communication from field to management level

 Standardized 10/100/1000 BASE FX Gigabit-Ethernet bus system

 Application of IEC 60870-5-104 protocol

 Distributed redundant concept

 Integrated alarming

 Time correct processing

 Effective and ergonomic human-machine interfaces

 Window-based operation system, process diagrams and sequential controls

 Total plant efficiency optimization modules and diagnosis functions

Expansion or software updates of the CCS shall be enabled based on an open system architecture concept and
by strictly applying international communication standards for the main-, process- and field-bus applications.

The CCS shall be designed in consistent hierarchical and decentralized structure. Dividing the total scheme
automation system into autonomous functional areas shall increase the availability and guarantee all time pre-
defined and safe operating modes in case of emergency situations.

The CCS shall be designed to ensure maximum availability by the inclusion of built-in redundancy for both
hardware and software. This shall include duplicated control processors, I7O cards, sensors, actuators where
 Page A-26

applicable, bus systems and power supplies with automatic bumpless change-over within one execution cycle to
the standby device upon detection of a fault or failure.

The system shall be designed for industrial use and withstand permanently the climatic and electro-magnetic
environmental conditions in a pumping station (EMC and ESD).

The CCS shall contain self-monitoring hard- and software functions. Software self-supervisory and fault diagnosis
functions and plausibility checks shall lead to an early detection of abnormalities and therefore to a high
availability of the plant. Comprehensive system diagnostic facilities shall be incorporated also to assist in
maintenance and trouble-shooting.

A failure of any single element shall not affect the operation of any main system of the power plant in operation. In
particular, the redundancy concept shall enable a failure tolerance in order not to affect the plant operation or any
control sequences.

All process signals shall be managed without multiple engineering (single data-entry).

The two operator stations with dal screens, keyboards, printers and peripheral devices and their associated
control desks shall allow monitoring, operating and adjustment of all relevant plant operation tasks via high
resolution window-based graphic displays.

The process bus system shall be arranged as a dual fibre optic ring network and realise the data transfer between
the redundant main servers, the unit controllers, and all other related controllers according to the system
architecture drawing.

The CCS shall be connected to a GPS master clock system to guarantee synchronisation of all CCS components.

The CCS shall be designed to ensure maximum pumping station availability and efficiency. In its final
configuration, the CCS shall be capable of controlling and monitoring the operation of the entire power scheme,
the pumping systems and individual sub-systems and auxiliary equipment.

Open system standards and international software protocols shall facilitate interconnectivity to a wide range of
optimization and diagnosis applications as well as asset management systems. A high level of modularity and
system scalability shall allow optimum process adaptation. The use of standard industrial components shall
assure long-term availability and reduce spare part costs.

The following installations and essential equipment shall be monitored and operated by the CCS:

 Pumps and pumping equipment

 Flow meters and pressure sensors in the pipeline network

 Synchronous Motors including ancillary equipment

 MV switchgears

 Station auxiliaries (station service transformers, LV switchgear, DC / UPS systems, diesel generating
sets)

 Common services (cooling water system, drainage and dewatering system, HVAC, compressed air
system, fire protection system, potable water system)

 Any water control system e.g. valves, gates

 Any system for removing sediment/weeds

The CCS shall cover the following functions:

 Page A-27

 Fully automatic control and monitoring to provide safe start-up and shut-down of all pumps

 Monitoring of flow rates and water levels at the distribution chambers

 Loss of mains and start-up of the emergency diesel generator(s) running.

 Plant operation forecast schedule module

 Plant optimization software module

 Provision of facilities for comprehensive monitoring, storage and presentation of information concerning
plant conditions and performance and historical archive

 Energy metering

 GPS master clock systems to generate signals to the secondary clock system

The system shall be able to monitor the flow meters installed in the pipeline distribution system at 30 ha levels, as
well as be able to remote monitor valve positions at 300 ha and remotely close the valves from the central control
room. The pressure on the upstream and downstream side of the 30 ha chak outlets shall be measured and
reported in the SCADA system.

The central control room server shall poll the data from all remote stations at regular interval, at least every 10
minutes. The latest version of the manufacturer’s systems software packages shall be provided fully developed
and tested. All software licenses necessary for the plant operation and maintenance shall be included. This shall
lead to unrestricted use of all operator-level applications required for the safe and reliable operation of the plant
and its components. Access to software and application programs at various levels shall be possible by operating
or engineering personnel using passwords. This shall protect the software from unauthorised access.

The software and associated displays, reports, databases, etc. shall be fully debugged in the shop before testing
and commissioning at site. The modification of displays, reports, databases or control strategies shall be possible
on-line by the engineering personnel without affecting the plant operation. Modifications to the software shall be
done in straightforward and logical steps using, wherever possible, graphic displays. The HMI software
applications shall enable the operator to carry out the necessary actions in a safe and efficient manner.

Unless otherwise stated hereafter, ratings, characteristics, tests etc. of the control equipment shall comply with the
provisions and requirements of the latest issues of the following IEC publications as applicable:

IEC 60051 Direct acting indicating analogue measuring instruments and accessories

IEC 60255 Electrical relays

IEC 60439 Low voltage switchgear and control gear assemblies

IEC 60473 Dimensions for panel mounted indicating and recording measuring instruments

IEC 60521 Class 0.5, 1 and 2 alternating-current watt-hour meters

IEC 60687 AC static watt-hour meters for active energy (classes 0.2 S and 0.5 S)

IEC 60688 Electrical measuring transducers for converting AC electrical quantities

IEC 60751 Industrial platinum resistance thermometer sensors

IEC 60801 EMC for industrial-process measurement and control equipment

IEC 60870 Tele-control equipment and systems

 Page A-28

IEC 60947 Low voltage switchgear and control gear

IEC 61000 Electromagnetic compatibility (EMC)

IEC 61082 Preparing documents used in electro-technology, Part 1; Part 2, Part 3

IEC 61131 Programmable controllers

IEC 61158 Field-bus standard for use in industrial control systems

IEC 60617 Graphical symbols for diagrams

IEC 60625 Programmable measuring instruments – Interface system

IEC 60381 Analogue signals for process control systems

IEC 60044-1 Instrument transformer

IEC 60186 Voltage transformer

IEC 8802 Information technology

The following international standards shall be applied for the automation and control systems:

 IEEE 802.3 (Ethernet) network access layer

 OPC (Object Linking and Embedding for Process Control)

1.4.9.2 System Monitoring, Display, Logging and Archiving

The monitoring up to outlet of 30 ha from rising main shall be done by SCADA through a single control room at
suitable location at the pump station and equipped the same shall be established by Contractor for each scheme.

For this purpose, the SCADA unit shall be established at 30 ha chak with one flow meter and pressure monitoring
for 30 ha outlet (downstream side of the filter) and minimum three manual on/off valves for each rotation area. At
the 3 ha sub-chak outlet the bidder will provide connections for pipes up to 1 ha. The outlet for every 1 ha shall be
provided with a manual on and off valve.

The power supply arrangement for operation of SCADA and valves, flow meter shall be made by providing
suitable power arrangement or alternatively by solar power with 3 days backup capacity. The Contractor will
obtain necessary permissions from concerned authorities for use of required frequency for operation of SCADA
and the cost on this account shall be borne by the Contractor. The complete SCADA system shall be protected
against sabotage in RCC box with door, lock and key.

The equipment in the CCR shall acquire and save to the database automatically and periodically the process
parameters such as analogue quantities, on-off event quantities, statuses, etc. from the CCR via the data bus, it
also receives, threshold overshoot of analogue measurements, the trend of temperature changes, etc. and shall
refer them into the buffer area. The information acquired and received shall be used for updating the data base,
for controlling and adjusting, for record retrieving, for operation guide, fault analysing and repair advice etc.

The data acquisition of the CCS shall also be possible to be carried out by the operator or by the instructions of an
application program. It shall realise the function of acquiring a part or whole of the parameters from the pumping
station or the entire boards connected to the bus, at any time.

The fault alarm signal shall have first priority to transmit and the time at which the fault occurs shall be referred at
the lowest level before entering the bus or field-bus system. The distinguishing time shall be less than 5 ms for
 Page A-29

important alarms. The A/D conversion precision of data acquisition of the CCS shall be 12 bits or more, the total
measurement error shall be not more than ± 0.15%.

The CCS shall process the following:

 Check of plausibility, analysis of faulty codes and control transmission errors.

 Update the real time database of the CCS, distribute the real time data to relative stations, modify the
foreseen data and the equipment states in the views to be displayed on the screens, alert the operator by
displays about data with abnormal trend changes.

 Analyses of the trend of changes of some important quantities being supervised, forecast the probability
of incidents, provide the operation guide. The sampling period of trend analysis may be distinct for
different equipment; the number of parameters acquired in distinct sampling period shall also be different.
A trend record file shall be compiled by sampling points from the real time database according to the
requirement of trend recording. It shall be possible to show the trend curve on the display automatically
or at demand. When several measuring points shall be displayed at the same time, they shall be
distinguished by different colours.

 Supervising bearing temperatures of the units and the trend of temperature change of the pump motor
bearing, upper guide bearing, lower guide bearing and the guide bearing in the starting up process. The
supervising points shall be the points with highest temperature and points with maximum temperature
change rate which shall be chosen by an application program or the points designated by the operator.
The CCS shall collect and save the temperature-time curve T°C = f (t) and compare them with the stored
maximum permissible temperature rise curves. An alarm signal shall be initiated when the permissible
limit is surpassed.

 Supervising the rate of temperature change of the unit bearings with the view to discover early the
abnormality of equipment. The method of choosing the points are the same as mentioned above.

 Supervising the temperature difference between different thrust bearing pads, compare periodically the
temperature of every thrust bearing pad and compute the difference between them (or the change rate of
the difference) Alarm signal shall be initiated to indicate the abnormality of thrust bearing pads, when the
permissible limit is surpassed.

Dual screens shall be provided for each operator station in the plant control room for man-machine
communication and to display dynamically the views of the more important operation parameters, fault and
abnormality states in figure, letter, graph and table.

The diagrams shall be built up with symbols according to CENELEC, IEC and ISO standards. All text shall be in
English.

The following process diagrams shall be available as a minimum:

 Process overview diagrams, showing the main data:

- Speed

- Active and reactive output

- Water levels

 Overview of the pumping station control systems.

 Overall single line diagram of the plant, showing status and electrical data.

 Single line diagram of the MV switchgear, showing status and electrical data.
 Page A-30

 Single line diagram of the station auxiliary LV system, showing status and electrical data.

 Process diagrams of the station drainage and dewatering systems.

 Total discharge calculation module.

 Process diagram for the gates and discharge control.

 Diagram for the cooling system of each unit and overall supply, showing status and data.

 Threshold overshoot alarming.

 Failure in the CCS: inform and alarm immediately when following failures occur:

- CCS unit control device failure

- CCS communication link failure

- CCS control room system failure

 EDG in standby or running mode

 Periodic recording tables display the tables to be printed out periodically, including the tables of the
pumping station, the unit and other systems.

 Table of threshold setting values of supervised quantities: the dead zone for refreshing the display of
each measuring point shall be able to be modified on views individually or in batches, switching on/off of
each kind of measuring point (on/off inputs, analogue inputs, etc.) shall be able to be chosen on the
views individually or in batches. It shall be possible to set the state or the value of the measuring points
taken from the real time supervision manually, but the display format shall be different from that of real
time measuring points. At this time, the CCS shall take effective measures to ensure the safety of
equipment.

 Maintenance record.

 Statistical table of number of operations of each equipment.

 Block diagram of computer system.

 Daily load curve of pumping station and individual units.

 AGC and AVC views, it shall be possible to select the functions, to assign the real time values, etc. on
the view, the unit shall not be disturbed when the selected function changes.

 Statistical tables of faults, abnormalities of the pump motors

For the events of change in state, threshold overshoot, etc. the time of event occurrence, content of the event,
name of the equipment and permissible operating parameters, the overshoot parameters of the equipment, etc.
shall be displayed in time sequence.

Images shall attract the attention of the operator by way of a change in colour or change of symbols or flashing.

 Mechanical protection

 Electrical protection
 Page A-31

 Aux transformers

 MV switchgear

 Interface with the CCS

Long term archive functions shall be implemented. The data storage can either be event related or periodic.

After a change of any object configured for archiving, the software shall store the current value into a buffer for
transfer to the archive. The archiving server shall also be used for long-term storage of data (process values and
messages) of the CCS.

The archiving server shall be capable of presenting pre-defined reports to the operator. The information on the
reports may be either in tabular form or in a pre-formatted report form and may be automatic at specific times or
on request. Reports shall include periodic logs, daily logs and group logs for the plant and logs of hydraulic
conditions. All report formats and the quantity of available different logs shall be subject to approval by the
Engineer-in-Charge.

Peripheral devices for the storage/recording of plant data for long term data storage shall be provided. These
storage devices shall be based on high capacity magnetic media with facilities to copy their contents to and from
an exchangeable medium.

The archiving server shall incorporate long-term data logging facilities for all analogue, digital, serial data and
other internally generated points including the overall extension capacity specified. All signals shall either be
scanned periodically or reported by exception, and updated values or digital status changes shall be stored. Data
shall be stored for up to 3months on a suitable storage medium. An alarm shall be created well before the storage
medium approaches its maximum capacity. All data shall be automatically archived and retained for future
reference in either optical or magnetic medium.

The operator shall have the facility to present real time data, recall data held in the data logger memory or from
archives over a specified period of time. The requested information shall be presented on the operator stations
either in tabular form or as selected variables on a trend display. It shall be possible to compare on the same
display, multiple trends of real-time data or historical data from the data logger or archives.

All operation events, all events of alarming and all tables shall be displayed on the monitors, printed out and
stored on DVD. The printed logs shall be divided into several kinds, such as periodic logs, fault and abnormality
logs, operation logs and logs on request.

The most notable contents shall be:

 Operation log: record each and every operation in the pump station automatically in the sequence of
occurrence, including the equipment operated, operating instruction, operating time, process of
execution, result of execution and the time of operation completion.

 Alarm event log: record automatically each alarm/event in time sequence, including the time at which the
event occurred, contents and items, create a summary table for alarms and separate for events.

 Tables: create various hourly, daily and monthly statistic tables; create also any kind of tables as directed
by the operator.

 Trend log: record the tendency of changes of important supervised quantities.

 Plotting trends, actual load curves, etc. by printer or plotter. The Contractor shall prepare contents and
forms of the logs based on the requirement of the pump station.
 Page A-32

1.4.9.3 Local Instrumentation

The following electrical system data shall be displayed on Panel Mounted Graphical User Interface (GUI) at each
location, pumping station as well as the same shall be displayed at the master control room.

 Power consumption (kW-hr), and power factor of system, auxiliary transformers and all HT motors

 Status of breakers

 Status of all HT motors and all LT motors (on/off/Trip / Local / remote) and all parameters

 Winding temperatures and bearing temperature of HT motors

 Any modification required in electrical MCC to facilitate for SCADA system

The following mechanical equipment data shall be displayed on Panel Mounted GUI at each location, pumping
station as well as the same shall be displayed at the master control room.

 Status of all pumps, dewatering pumps and pumps used for circulation/cooling pumps and all discharges.

 Status (open/close/Local/Remote) of all Butterfly, on individual pumps (delivery & Suction), manifold pipe,
etc.

 Temperature of HT motor/ pump Thrust /shaft Bearing

The following instrumentation data shall be displayed on Panel Mounted GUI at each location, pumping station as
well as the same shall be displayed at master control room.

 Flow data (instantaneous flow rates and total flow) from the pump house (through flow meter installed on
discharge header main), inlet channel of the reservoirs / pump house, pipeline distribution pipeline up to
30 ha chak

 Level of water in the sump (intake)

 Pressures at delivery of each main pump

 Flow switch at inlet cooling water line/ lubricating water line

 Differential pressure switch across the pressure filters at the discharge of lubricating water pumps

 Portable vibration meter

 Portable sound level meter

 Portable speed meter

1.4.10 Valves and Piping at Pump Stations

Each pump shall be equipped with a main butterfly shut-off valve and a maintenance butterfly discharge valve.
The main butterfly valves are designed for shutting off the discharge pipe before starting the main pumps and also
after stopping of the main pumps to prevent backflow.

Each pump shall be provided with hydraulically operated discharge valve - oil pressure operated butterfly valve,
and electrically-operated bypass valve with guard valve for equalizing the pressure on the valve door before
opening, and a maintenance valve. The maintenance valves will be closed to enable repair and maintenance
 Page A-33

works on the main valves without interrupting the operation of other pumps by dewatering a complete main raiser
pipe.

The discharge control valve shall have maximum capacity to allow maximum flow of pump discharge. The valve
shall be designed to withstand the maximum transient pressure and shall be free from vibration and abnormality
under the whole operating range of pump including any transient conditions of operations. The inside diameter of
the valve shall be decided by the bidder considering the maximum permissible discharge of the pump and velocity
limits permissible. The valve shall be so designed as to be capable of closing from fully open position under the
condition of maximum flow at every head with minimum oil pressure supplied to servomotor. Alternatively the
bidder may choose closing by counter weight.

The opening and closing time of the valve shall be selected depending on the pump characteristics including the
operating time of bypass valve with normal operating pressure. All valve oil piping and valves complete with
flanges, bolting materials, gaskets, packing etc., required for inter-connections between the various equipment
shall be included in the offer. All piping shall be steel, suitable for maximum oil working pressure. All valves shall
be ductile iron or fabricated steel valves having flanged ends.

It shall be of cast ductile iron or fabricated welded steel construction accurately bored, reinforced with heavy ribs
and flanges on both ends with rubber seals for connection to the upstream make up piece and downstream
dismantling joint and hubs for trunnions. The body shall be provided with self-lubricating bearings without any
external greasing at both ends where the shaft is horizontally in contact. The bearings shall be provided with
necessary packing cup seals inside to prevent inflow of sand or other foreign matter contained in the water and
also at the outside end to prevent water leaking. The trunnion bearings shall be designed to take full load exerted
because of maximum hydraulic pressure including the full weight of the valve disc and trunnion and smooth
opening/closing operations. The bearings shall be self-lubricated without external greasing.

The body shall be provided with weld deposited or separately fixed and accurately bored/ machined stainless
steel seating/contacting ring while the disc shall be fitted with rubber ring to have drop tight sealing under all
working conditions.

The valve body shall incorporate the bracket feet supports suitable for anchoring against maximum servomotor
and hydraulic forces. All necessary foundation plates and anchor bolts shall be provided.

Lattice/Bi-plane/flow through type, cast ductile iron or fabricated steel construction with integral trunnions
designed with sufficient strength not causing any distortion/deformation or any abnormal vibration when the disc is
in open position or during operation shall be provided. The valve disc shall be in one piece with integral high
strength spindles and streamlined/shaped to minimise flow disturbance and head loss. A peripheral rubber seal
shall be provided on the disc to seal the leakages, seating against stainless steel seal ring welded on the inner
surface of the valve body. The rubber seal ring shall be firmly fixed in position to the disc by removable rust
resistant steel rings fixed by stainless steel screws and stainless steel nuts.

The sealing shall be of reinforced rubber to metal in one length to be joined at site and shall definitely not involve
inflation or other similar forms of relative movement of elements in the seals or seats. It shall be possible to adjust
the sealing contact without dismantling the valve.

One bypass valve of suitable diameter shall be provided directly on the upstream pipe along with a guard valve.
The bypass valve which is required for balancing the pressure across the BF valve shall be designed for vibration
and noise free operations and shall have stainless steel or bronze parts (those coming in contact with water), thus
preventing corrosion.

Metal sealing shall be provided to have leak proof seal when the valve is closed. The bypass valve shall be
electrically operated with the provision of manual operation. All wearing parts of the bypass valve shall be
renewable and of bronze or stainless steel.

A bypass steel pipe of suitable diameter and length joining upstream to downstream of valve with necessary
flanges, fasteners and packings shall be provided.
 Page A-34

The delivery pipe shall be of suitable diameter (nominal inside diameter) considering the permissible velocity limits
and shall conform to IS-3589 and of mild steel fabricated construction using required thickness plates (IS 2062).
The pipeline shall be complete with required specials (Viz. manholes, bends, connections etc., as per
requirement) fabricated and erected by the contractor. Sufficient No. of manholes and air valves shall be provided
by the bidder along the raising main at locations to be decided after award of contract.

Pipes shall be provided with stiffener rings at regular intervals of every 3 meters to retain the shape of pipes after
fabrication. Pipes shall also be provided with anchor rods, thermal expansion joints, etc., by the bidder as per the
requirement.

Low hydrogen electrodes conforming to AWS-E7018 class only shall be used during fabrication/erection.

Hydraulic testing shall be conducted.

During erection, line and level shall be ensured by the contractor. The bidder shall indicate the location of
supports anchor blocks, thrust block required to hold the pipes in position and accordingly include the supply and
erection of clamps and anchoring bolts, nuts in the scope.

The operating mechanism to open and close the valve and the bypass valve shall be capable of being controlled
from the control panel of the Pump house and also from the valve chamber. The operating mechanism shall be
such that the speed retards as the valve approaches the end of each operation. Necessary dampers shall be
provided to regulate the speed of operation and to arrest the travel of the valve exactly at the fully closed or open
positions controlled by the necessary pilot valve operated distributing valve as well as diaphragm so as to allow
for an easy adjustment of the closing time compatible with the upstream allowable pressure rise.

The valve shall be operated by means of oil operated servomotor attached to the door of the valve through a
lever. The oil to the servomotor shall be supplied under pressure by means of an oil pump. After balancing the
pressure on the upstream and downstream sides of valve by means of bypass, the oil pump shall be put into
operation. By means of the distributing valve, oil under pressure shall be supplied to the lower side of the piston
of the servomotor to bring about the opening stroke. At the end of opening stroke, an electric contact shall cut off
the supply to the oil pump-motor. In case the piston of the servomotor descends due to any leakage, an electric
contact shall automatically start the oil pump motor after a movement of 5% (approx.) of valve door in the closing
direction. It shall also be possible to open the Valve by manually operated pump in case of failure of electric
supply to the oil pump motor.

The closing shall be affected as under:

 Normal closing

 Emergency closing

 For normal closing, the oil pressure shall be admitted by means of a distributing valve to the upper side of
the piston of the servomotor to bring about the closing stroke. At the end of closing stroke an electric
contact shall cut off supply to the oil pump motor.

 For emergency closing, the oil pressure in the cylinder shall be released through a solenoid operated
valve and due to the action of hydraulic torque and torque acting due to the counter weight, the valve disc
shall close. The movement of the disc shall be retarded by the servomotor which functions as dash pot
thus giving total security to the installation. The valve shall be designed to close against the maximum
velocity attained by pump .The operation of the valve may be carried out using the pressure oil system
contemplated for opening and closing of guide vanes. However, preferably the bidder should provide a
separate hydraulic power pack for operation of the valves.

The hydraulic power pack system shall consist of 1 main and 1 standby electrically driven high pressure oil pump
of vane type. The pump shall have sufficient capacity to supply the entire pressure oil requirement of the BF Valve
servomotor etc. The pump shall be of continuous duty, self primed under the maximum oil pressure. Necessary
sump tank, control valves, non-return valves, pressure switches etc., shall be supplied. The sump tank shall be
welded steel construction, and of sufficient capacity to hold all the oil in valve servomotor system. The interior of
 Page A-35

the sump tank shall be sand blasted and painted with two coats of suitable best quality oil resistant paint. The
sump tank shall be totally enclosed complete with inspection lid and provided with duplex strainers, which could
be cleaned with ease when the valve is in service. It shall also be provided with oil level gauge, breather and
suitable tapping required for connecting the filter set for circulation of oil. A hand operated stand-by pump of
adequate capacity for manual operation of the valve shall be provided. Oil pipes shall be of seamless, heavy
gauge and of suitable wall thickness. The electric motors shall be of continuous duty directly coupled to the pump
and it shall be TEFC with Class ‘B’ insulation suitable for operation on 415 10% volts, 3 phases, and 50 +3% /-5%
Hz AC supply. The motors shall be provided with starters with protection equipment. The starting equipment shall
incorporate a device so as to start the motor and permit it to reach full speed before the pump is connected to the
pressure system and to unload the pump before the motor is disconnected from the power supply.

The Contractor shall supply all the control equipment such as solenoid operated distributing valve, control and
check valves (arranged for local and remote operation) and they shall be suitably mounted. The electrical control
panel shall consist of contactors, operating switches, indicating lamps etc. The panel proposed for this and to be
mounted for remote operation in the control room of the Pump house shall match in colour and size with the other
control panels in the control room. Sufficient number of limit and auxiliary switches shall be provided on the valve
operating mechanism in order to energise the following signaling alarm and trip circuits. (i) Indication of Valve
‘Open’ and ‘Close’ and “In transit”.

The indication of bypass valves ‘Open’ and ‘Close’ shall be as follows:

 Indication and alarm for valve ‘Out of Control’ when oil leakage is excessive and the valve disc moves by
more than 5 deg. from the open position in the closing direction.

 Indication and alarm for valve ‘Over velocity trip’ when it acts to close the valve.

 Any abnormal condition.

The limit switches shall be hermetically sealed and shall be of reputed make.

All indications and alarm shall be provided on the control cubicles to be installed near the valve and at control
room. The control devices, indicating and alarm devices, starters for motors etc. shall be mounted on the control
cubicles.

The water passage shall be shot or sand blasted and painted with two coats of zinc rich epoxy primer and three
coats of epoxy paints before dispatch. Each coat of primer shall be of thickness not less than 40 microns and that
of epoxy not less than 100 microns. The outside shall be provided with suitable paints.

1.4.11 Pump Motors

Motors shall be capable of giving rated output without reduction in the expected life span when operated
continuously under the following supply conditions:

 Variation in supply voltage + 10%

 Variation in supply frequency + 5%

 Combined voltage and frequency variation 10%

LV motors shall be suitable for star- delta starting.

Any joints in the motor insulation such as at coil connections or between slot and winding sections, shall have
strength equivalent to that of slot sections of the coil. The insulation shall be given tropical and fungicidal
treatment for successful operation of the motor in hot, humid and tropical climate. The motors shall be provided
with class F insulation with temperature rise limited to that of class B insulation.
 Page A-36

Motors shall be given power house treatment. This comprises an additional treatment to the winding over and
above the normal specified treatment. After the coils are placed in slots and all connections have been made, the
entire motor assembly shall be impregnated by completely submerging in suitable insulating compound or varnish
followed by proper baking. At least three such submersions and baking shall be applied to the assembly.

The motor construction shall be suitable for easy disassembly and reassembly. The enclosure shall be sturdy
and shall permit easy removal of any part of the motor for inspection and repair.

Motors weighing more than 25 kg shall be provided with eyebolts, lugs or other means to facilitate safe lifting.

The rotor bars shall not be insulated in the slot portion between the iron core laminations for squirrel cage motors.

Terminal boxes shall be of weather proof construction designed for outdoor service. To eliminate entry to dust and
water, gaskets of neoprene or approved equivalent shall be provided at cover joints and between box and motor
frame. It shall be suitable for bottom entry of cables. It shall be capable of being turned through 360 degrees in
steps of 90 degrees.

The terminals shall be of the stud type with necessary plain washers, spring washers and check-nuts. They shall
be designed for the current carrying capacity and shall ensure ample phase to phase and phase to ground
clearances. Suitable cable glands and cable lugs shall be supplied to match specified cables.

Two independent earthling points shall be provided on opposite sides of the motor, for bolted connections. These
earthling points shall be in addition to earthling stud provided in the terminal box.

Technical Data Sheet for Induction Motor

Description Particulars
Application All type of pumps
Type of motor Squirrel cage induction
Make As per approved make
No. of units.
Supply system fault level. 250 MVA
Supply neutral Resistance earthed
No. of Phases & frequency 3 Phase and 50 Hz
Supply condition ± 10% voltage variation
± 5% frequency variation
± 10% combined voltage and frequency variation
Method of starting By VFD
Efficiency
a) Duty point 95 % (minimum)
1. Full Load 95 %
2. 0.75 Load 94.5%
3. 0.50 Load 93.4%
Power Factor
0.86 %
4. Full Load
0.82 %
5. 0.75 Load
0.72 %
6. 0.50 Load
Starting torque Sufficient starting torque to start the pump with delivery
% of full load torque valve closed and when other pumps are running.
Pull out torque Sufficient to bring the motor to normal speed in minimum
% of full load torque time
Class of insulation & temp. rise by Class “F” but Temperature rise restricted to that of class
thermometer “B” i.e. 65degrees c. / 75degrees c.
Ambient temperature 46degrees c.
Location Indoor
Hazardous area division N.A.
Atmosphere Humid, Dusty at a time
 Page A-37

Description Particulars
a) Type of Cooling CACA
c) Degree of protection IP – 55
Terminal box Phase segregated terminal box for line and neutral side.
And shall be suitable for termination of heat shrinkable
termination kit or push on type termination kit.
External cable details.
a) No. of cores. 3
b) Size As per single line diagram

Shaft orientation.
Horizontal / Vertical / Hollow shaft As per finalized pump design.
Type of Couplings Flexible
Type of bearings Antifriction Ball /Roller Bearing
Colour shade of paint if special Grey shade 632 as per IS 5

Space heater for motors required 240 V, 1 Ph., 50Hz., A.C. for winding heating
Thermisters / RTD’s / required for For trip, alarming and indicating
winding and bearings
Bearing temp. Detectors Required for alarm / trip.
Winding connections 6 Terminals
Standard to be followed IS 325, 8225, 4889, 4772, 4029, 4691 and other relevant
Indian Standard or equivalent BSS or JEC 37

For starting of pumps the bidder shall provide Variable Frequency Drive. Starting equipment offered shall be
suitable to start the pump-motor smoothly and without in rush current. The motor shall be soft started through
VFD and reach 90% of rated speed within five minutes. The bidder shall include the necessary transformer, H.T.
Switchgear, and all the control equipment in their scope of supply.

The starting equipment offered shall be of proven design and shall be robust and can withstand number of starts
in a day. All the control equipment for selection of the pumps to be started, and all interlock, indication, and alarm
and annunciation circuits shall be included in the scope supply. Drawings for the arrangement of starting isolators
to be furnished by the bidder.

All the protection and control circuits of starting equipment shall be incorporated in the system. The system shall
be suitable to start one pump at a time either from local panel or from remote control panel/ control desk/ panel in
the Control Room.

The Power Circuit Panels (11 kV System) shall be designed so that it can with stand fault system fault currents
during starting of pump. The starting equipment shall be housed in a sheet steel cubicles of thickness not less
than 14 gauge and painted with anti-corrosion resistive paint the colour of the final paint will finalized with the
successful bidder. The high voltage equipment of the starting equipment shall be type tested. The manufacturer
shall conduct all the routine tests as per IEC standards on the equipment offered.

1.4.12 Electro-mechanical Equipment and Works

The scope of work in this section includes, but not limited to the following:

 Detailing, supply and manufacture, inspection, shop assembly, testing, painting etc.

 Delivery, transit insurance, collection of equipment and custom clearance (if any), inland transportation to
site.

 Site storage, including insurance, transportation and handling. Site erection, painting, testing and
commissioning including provision of labour, plant material etc. for the above.
 Page A-38

 Handing over to Employer. Supply and installation of all incidentals not specified but are necessary for
proper completion and satisfactory functioning of the system.

 The Contractor shall supply the following equipment, which will meet in all respects, the requirements of
Employer in regard to performance, durability and satisfactory operation. All the equipment supplied shall
conform to the relevant IS. Wherever, IS are non-existent or silent, relevant International Standards (as
agreed between the Engineer and the Contractor) shall be followed. The sizes and numbers of units are
based upon Employer’s Base Design and may vary to suit site conditions and design requirements.

­ Pumps, gates with electro-mechanical components

­ Installation of embedded metal parts

 Installation of 33/132 kV electric line including step-up, step-down transformers from nearest available
source as directed by the Engineer-in-Charge. Actual cost of such installation will be reimbursed to
Contractor.

1.4.13 Rising Mains and Pipeline Distribution System

1.4.13.1 General Requirements

The maximum width of trench excavation for laying of rising main should not be more than 600 mm on
either side on pipeline.

The pipeline shall be divided into sections by valves to avoid the necessity of emptying the whole pipeline
in case of repair (in compliance with Clause No.6.16.14 of the CPHEEO manual). Each section being
provided with an air valve and scouring facilities. The need for scour should be particularly borne in mind
when layout of the pipeline and location of the valves is finalized, as they cannot always be arranged in the
best position due to likely difficulty in disposing of the discharge. They are necessary for scouring the mains
and hence should be in proportion to the size of the main. The value of CR adopted for head loss calculations
shall be 1 (one) for Modified Hazen-William Formula.

The complete surge analysis for rising mains, gravity main and should be vetted by Indian Institute of
Science Bangalore or any of the IIT. In case of junction and tapings WRD can direct the Bidder to get is
vetted from any expert of the field as decided by Chief Engineer, BODHI.

Note-
1. The thickness of Intermediate diameter pipe not provided in above shall be interpolated between the
immediately lower & higher category subject to such other restrictions as the Chief Engineer, BODHI
may decide.

2. The thickness provided shall also be subject to upward revision in surge analysis. No downward
revision is permissible.

3. For DI pipe the minimum acceptable category shall be K-7 confirming to IS-8329 for all diameters. In
addition to this K-9 category pipes may be used if required

4. For HDPE pipes, they shall confirm to relevant BIS standard and as per testing requirements of CIPET,
Bhopal.
 Page A-39

In case of MS pipes shotcreting/ 3 LPE / polyurethane outside lining is to be done. MS pipes

must be food grade epoxy coated inside. Factory made and stamped IS mark pipes shall only
be used. In case of MS pipes above 2000 mm dia, manufacturing at site can be permitted by
factory with IS marking approval from IS organization

Following standards shall be referred for manufacture of MS pipes using Structural Steel Sheets. In all cases,
latest revision of the standards / codes shall be referred to. If requirements of this specifications conflict with the
requirements of the standards / codes, this specification shall govern.

IS 1916 Steel cylinder pipe with concrete lining and coating

IS 5822 Laying of electrically welded steel pipes for water supply

IS 4853 Recommended practice for Radiographic inspection of fusion welded butt joints in steel
pipes.

IS 4260 Recommended practice for ultrasonic butt weld in ferric steel

IS 3600 Methods of testing fusion welded joints and weld mains in steel: (Part-1) part 1 cruciform fillet
weld tensile test

IS 4711 Sampling of pipe for various tests and criteria for conformity.

IS 1894 Methods of tensile testing of steel tubes.

IS 10748 Hot - Rolled Steel Strip for Welded Tubes and Pipes - Specifications

IS 1730 Dimensions for Steel Plates, Sheets, Strips and Flats for General Engineering Purpose-
Dimensions

The steel used for manufacture of the pipes (HR coils) shall confirm to IS: 2062, grade-B or IS: 10748, grade - 3
or equivalent ISO. The dimension of HR coils shall conform IS: 2062.The quality of steel, chemical composition
and tensile strength of the steel plates shall be as specified in IS: 3589 for steel of grade Fe 410. Positive
tolerance shall be allowed for plate thickness, but no negative tolerance shall be allowed.

Steel plates should confirm to IS: 1730, Dimensions for Steel Plates, Sheets, Strips and Flats for General
Engineer-in-Charge Purpose. The test certificate for the plates shall be issued by Plate Manufacturer.

The MS pipes shall be manufactured in lengths of 10 to 13m with beveled ends. Length of each pipe shall be
measured at diametrically opposite four places and average of the four measured lengths shall be considered for
measurements of pipe length. The pipes shall be manufactured by shop welding from steel plates, butt welded
spirally or longitudinally by automatic submerged arc welding process using at least two runs, one of which shall
be on the inner side of the pipes. Welding shall be so done that there will be through fusion and complete
penetration and shall be free from cracks, oxides, and slag inclusion and gas pockets. Longitudinally welded
pipes shall have circumferential weld at not less than 1.8 m centre to centre. Longitudinal weld shall be
staggered. Minimum distance between spiral welds should be 1.5 m. Finished pipe length shall not deviate from
straightness by more than 0.2 percent of the total length.

Three percent of all seams of pipes, welded in the fabrication shop, shall be radio graphed at the end of pipe (as
per IS: 4853) to render visible inspection of any internal defects such as blow holes, slag, inclusion of cracks. If
any defects are detected, the metal at the location shall be chipped out and re-welded. In addition to the
radiography of the joints, 100 percent testing by ultrasonic equipment (as per IS: 4260) shall also be done for
welding tests. Any defects found out shall be rectified free of cost. Welds found deficient in quality shall be
removed by chipping or melting and remade as per specifications. Chipping or cutting the weld shall not extend to
the base metal.

Each pipe shall be hydraulically tested at manufacturer’s works before applying any coating / lining.
 Page A-40

The allowable tolerances should be as follows:

 Allowable tolerance for outside diameter shall be ± 0.75% of the specified diameter.

 Negative tolerance for plate thickness shall not be allowed.

Sampling and conformity criteria for various tests shall be as given in IS: 4711. The test samples shall be cut
from pipes in the final condition of supply. Tests for tensile strength, percentage elongation, guided bend test,
shall be carried out and the test values shall be in conformity with those specified in IS: 4711.

The pipes ready in the manufacturer’s work yard shall be inspected and tested before dispatch, by the employer
and or inspecting agency appointed by the employer. All the tests including hydraulic test shall be carried out on
specified number of samples from each lot as specified in IS: 4711, in presence of the inspecting agency. The
internal lining shall be applied to the pipes only after the inspecting agency is satisfied regarding the test results,
which shall be in conformity with the limits specified in IS: 4711. The contractor shall produce the test certificate
issued by the inspecting agency charges for such inspection shall be born by the turn key agency.

Technical Specification for internal lining and external coating of M.S. pipeline
Scope :
The specification governs requirements for material, equipment, application, inspection, repair and handling aspects
associated with the internal lining and external coating.

Internal Lining:
Internal surface of the pipe should be coated with one coat of two part epoxy primer with not less than 30 micron DFT(dry
film thickness)followed by two part food grade polyamide cured solventless epoxy. The minimum dry film thickness
(DFT) of internal lining shall be 400 micron. The epoxy coating should offer highest resistance to cathodic disbondment
and provide excellent adhesion to steel. The manufacturer should have the certificate issued in support of portable water
service for tests of pH, turbidity, total hardness, chloride nitrate, iron, arsenic & fluride as per IS 10500 :2003.

External Coating:
External surface of the pipe and specials to be painted with one coat of two part chemically cured polyurethane primer of
min 30 micron dry film thickness followed by three or maximum four coats of two part solventfree polyurethane provide
a high build coating of dry film thickness of 1000 micron including primer coat. Polyurethane coating should have good
resistance to ultraviolet degradation along with corrosion resistance. PU coating should provide hard yet flexible, with
very low water absorption with outstanding adhesion as well as impact and abrasion resistance. Solventless PU systems
are to be used eliminating solvent health hazards.
Internal lining and external coating damaged during transportation should be repaired at site by Paint Manufacturer.

General Requirement:
I) The work shall conform to the following documents / specifications (latest revision or as specified).
a) SSPC SP 10 / NACE 2 / Sa2½ Near White Blast Cleaning

b) SSPC PA 2 Measurement of dry film Coating Thickness with magnetic gauges.

c) ASTM D 4541 Method for pull off strength using portable Adhesion Tester.
d) NACE RP 0274 – 2004 High-Voltage Electrical Inspection of Pipeline Coatings

e) NACE SP 0188 – 2006 Discontinuity (Holiday) Testing of New Protective Coatings on Conductive Substrates

f) NACE RP 0169 – 2002 Control of External Corrosion on Underground or Submerged Metallic Piping Systems
g) AWWA C 210 – 2007 Liquid-Epoxy Coating Systems for the Interior and Exterior of Steel Water Pipelines

h) IS 3589 : 2001 Annexure B Steel Pipes for Water and Sewage Specification.
 Page A-41

i) AWWA C222-2000 Polyurethane Coating for the Interior and Exterior of Steel Water Pipe and Fittings.

j) IS 13213 : 2000 Polyurethane Full Gloss Enamel (Two pack)

k) IS 10221 : 2008 Coating and wrapping of underground mild steel pipelines.

l) BIS DOC : CHD 20 (1938) P Solvent less Liquid Epoxy System for interior & exterior of Steel Water Pipeline.

II) The steel surface preparation prior to actual commencement of coating shall conform to SSPC SP 10 / NACE 2 /Sa2½
(near white metal) with sand blasting.
III) The contractor shall submit a detailed written description in the form of a manual covering coating equipment,
procedures, materials inspection test, and repair etc. to Owner’s Engineer In Charge’s approval.
IV) The contractor shall also provide copies of test reports from NABL approved laboratory (like National Test House,
Kolkata) evidencing that materials (paint / primer) shall conform to the technical specification.
V) The contractor shall also provide certificates from coating manufacturer quoting batch numbers, date of manufacture
and shelf life etc. the contractor shall also provide Manufacturing Quality Plan (MQP) and field
Quality Plan (FQP) before supply of material and starting of work.

VI) The coating shall be applied either by coating / paint manufacturer.

VII) Applied coating shall be tested for dry film thickness, holiday (electrical inspection for continuity) and adhesion as
per relevant standard such as SSPC PA 2, NACE RP 0274 and ASTM D 4541.
VIII) The material may be heated if necessary and applied by airless spray / plural component spray system

COATING PROCEDURE AND APPLICATION

Surface Preparation:
Pipe shall be blast cleaned by sand. The cleanliness achieved prior to application shall be in accordance with the
requirement of SSPC SP 10 / NACE 2 / Sa2½ of ISO 8501 (near white metal)
a) The blast pattern or profile depth shall be 40 to 100 micron and shall be measured by dial micrometer.

b) Before sand blasting is started or during blasting or coating, temperature of the pipe surface should be more than 3°C
above dew point temperature. Blast cleaned surface should be primed within 4 hours and shall be protected from rainfall or
surface moisture and shall not be allowed to flash rust. If the rust occurs, the surface again to be prepared by sand blasting
or wire brushing.

Application of Epoxy Coating

a) Coating shall be applied when

i) When the pipe surface temperature shall be at least 3°C above dew point temperature.

ii) The temperature of mixed coating material and the pipe at the time of application shall not be lower than 10°C or
greater that 50°C.
b) Material preparation shall be in accordance with manufacturer’s recommendations.

c) Application of epoxy coating system: The epoxy coating system shall be applied as per recommendation of the
manufacturer and shall be applied by airless spray / plural component spray machine. For more than one coat, the second
shall be applied with the time limits as recommended by the manufacturer.

Application of PU Coating
a) PU coating shall be applied when the pipe surface temperature at least 3°C above dew point temperature (when R.H is
more than 85%).
b) Material preparation and application shall be done as per manufacturer recommendation and shall be applied by plural
component machine.
 Page A-42

TEST REQUIREMENTS:
a) Measurement of dry film thickness

Measurement of dry film thickness of coating : Coating thickness shall be in the range of ±20% and as per SSPC PA2.
i) Apparatus / Instrument: The instrument used for dry film thickness may be Type 1 pull of gauges or Type 2 electronic
gauges.
ii) Procedures

ii.a) No. of measurements: For 100 square feet (9.29 square meters), five (5) spots per test area (each spot is 3.8 cm) in
diameter. Three gauge readings per spot (average becomes the spot measurement).
ii.b) If the structure is less than 300 square feet, each 100 square feet should be measured.
ii.c) If the structure is between 300 and 1000 sq ft, select 3 random 100 square feet test areas and measure.

ii.d) For structure exceeding 1000 square feet, select 3 random 100 square feet testing areas for the first 1000 sq ft and
select 1 random 100 square feet testing area for each additional 1000 square feet
ii.e) Coating thickness Tolerance: Individual reading taken to get a representative measurement for the spot are
unrestricted (usually low or high readings are discarded). Spot measurements (the average of 3 gauge readings) must be
within 80% of the minimum thickness and 120% of the maximum thickness. Area measurement must be within specified
range.

b) Electrical Inspection (Holiday) Test:

i) All the coated / lined pipes shall be tested with an approved high voltage holiday detector preferably equipped with an
audio visual signalling device to indicate any faults, holes, breaks or conductive particles in the protective coating.
ii) The applied output voltage of holiday detector shall have a spark discharge of thickness equal to at least twice the
thickness of the coating to assure adequate inspection voltage and compensate for any variation in coating thickness. The
electrode shall be passed over the coated surface at approximately half the spark discharge distance from the coated
surface only one time at the rate of approximately 10 to 20m/min. The edge effect shall be ignored. Excessive voltage shall
be avoided as it tends to induce holiday in the coated surface thereby giving erroneous readings.
iii) While selecting test voltages, consideration should be given to the tolerance on coating thickness and voltage should be
selected on the basis of maximum coating thickness likely to be encountered during testing of a particular pipe.
The testing voltage shall be calculated by using following formula. (as per NACE 0274 : 2004)
Testing Voltage V = 7900 _T ± 10 percent where T is the average coating thickness in mm.

iv) Any audio visual sound or spark leads to indicate pinhole, break or conductive particle.

c) Adhesion Pull off Test:

After holiday the coated surface is subjected to adhesion pull off test as per ASTM D 4541.

i) Apparatus / Instrument: Adhesion tester consists of three basic components: A hand wheel, a black column containing a
dragging indicator pin and scale in the middle and a base containing three legs and a pulling “Jaw”
at the bottom and also dollies.
ii) Prepare the test surface: Once test area is selected, test area shall be free of grease, oil, dirt, water. The area should be
flat surfaces and large enough to accommodate the specified number of replicate test.
iii) Prepare Dolly (Test Pull Stub) : The dolly is a round, two sided aluminum fixture. Both sides of the dolly looks same,
however, one side sloped on top surface while flat on bottom surface. As the surface of the dolly is polished aluminum,
roughen the same using a coarse sand paper.
iv) Select an adhesive: Use araldite, a 100% solid epoxy adhesive. This adhesive requires at least 24 hours at room
temperature to cure.
v) Attach the dolly to the surface.
 Page A-43

v.a) Using a wooden stick, apply an even layer of adhesive to the entire contact surface area of the dolly.

v.b) Carefully remove the excessive adhesive by using a cotton swab. Allow the adhesive to fully cure before performing
the adhesion test.
v.c) Attach the dolly to the coated surface and gently push downward to displace any excessive adhesive.
v.d) Push the dolly inward against the surface, then apply tape across the head of the dolly.

vi) Determine whether scoring is required

vi.a) No standard including ASTM does not recommend any tape of scoring around the base of dolly prior to testing.
Scoring may produce tiny factures in the coating or may generate friction heat, which can change the
properties of coating and result in lower adhesion values.
vii) Perform the Adhesion Test

vii.a) Attach the adhesion tester to the dolly by rotating the hand wheel counter clockwise to lower the jaw of

the device.
vii.b) Slide the jaw completely under the head of the dolly. Position the three legs of the instruments so that

they are sitting flat on the coated surface.

vii.c) Slide the dragging indicator pin on the black column to zero by pushing it downward.

vii.d) Firmly hold the base of the instrument in one hand and rotate the hand wheel clockwise to raise the jaw of the device
that is attached to the head of the dolly. The dragging indicator pin will move upward on the black column as the force is
increased and will hold the reading. Apply the tension using a moderate speed. Continue to increase the tension on the
head of the dolly until (a) the minimum PSI/MPa/Kg/cm² required by project specification is exceeded and the test is
discontinued, (b) the maximum PSI/MPa/Kg/cm² of adhesion tester has been achieved and dolly is still attached, (c) The
force applied by the adhesion tester causes the dolly to dislodge.
vii.e) Read the scale and record the adhesion value. The black column near the middle of the adhesion tester contains two
scales and a dragging indicator pin in between. Right scale is PSI and left scale is MPa. The dragging indicator pin will
hold the reading until push back to zero. When achieve the end point of test, read the scale across the bottom of the
dragging pin.

d) Coating Repair
i) Defective Coating: Coating shall be repaired in accordance with the following subsections.

ii)Surface Preparation : Accessible areas of pipe requiring coating repairs shall be cleaned to remove debris and damaged
coating using surface grinders or other means. The adjacent coating shall be feathered by sanding, grinding or other
method. Accumulated debris shall be removed by blowing with contaminant free air or wiping with clean rags.
Areas not accessible for coating repair such as interior surfaces of small diameter pipe shall be reprocessed and recoated.

iii) Coating Application: The coating system shall be applied to the prepared areas in accordance with procedure.

iv) Repair Inspection: Repaired portion shall be electrically inspected using a holiday detector.

e) Welded Field Joints

i) Preparation: The weld joints shall be cleaned so as to be free from mud, oil, grease, welding flux, weld spatter
and other foreign contaminants. The cleaned metal surfaces of the weld joint shall then be abraded using rotary
abrading pads or emery paper. The adjacent liquid Epoxy / PU coating shall be feathered by abrading the coating
surface for a distance of 25 mm.

ii) Electrical Inspection: After curing the coating system applied to the welding joints shall be holiday tested.
Any holidays indicated by the detector shall be marked with chalk to identify the area of repair.
 Page A-44

Material and pipe that are noticed to be defective or that do not confirm to the requirements will be subject to
rejection at any time prior to final acceptance of the pipe. Rejected material and pipe shall be removed from the
work site within a week after rejection without any liability to the WRD.

SPECIFICATION FOR 3 LAYER POLYETHYLENE COATING

1.00.0 GENERAL

This specification covers the minimum requirements for supply / arrangement of all
materials, plant, equipment, plant sites, consumables, utilities and application including
all labour, supervision, inspection and tests etc. for application of external anti-corrosion
coating of pipes by using 3 Layer Side Extruded Polyethylene coating conforming to
DIN-30670, 'Polyethylene Coatings for Steel Pipes and fittings - requirements and
testing' and the requirements of this specification.

2.00.0 REFERENCE DOCUMENTS

Reference has also been made to the latest edition of the following standards, codes
and specifications. The edition enforce at the time of floating the enquiry shall be
termed as latest edition.
a. ASTM D-149 : Standard Test Methods of Dielectric Breakdown Voltage and
Dielectric Strength of Solid Electrical Insulating
Materials at Commercial Frequencies.
b. ASTM D-257 : Standard Test Methods for D-C Resistance or

Conductance of Insulating Materials.

c. ASTM D-543 : Standard Method of Test for Resistance of

Plastics to Chemical Reagents.

d. ASTM D-570 : Standard Method of Test for Water Absorption of

Plastics.

e. ASTM D-638 : Standard Method of Test for Tensile Properties of Plastics.

f. ASTM D-792 : Standard Test Method for Density and Specific Gravity
(Relative Density) of Plastics by Displacement.

g. ASTM D-1238 : Test Method for Flow Rates of Thermoplastics by Extrusion.

h. ASTM D-1525 : Test Method for Vicat Softening Temperature of Plastics.

i. ASTM D-1603 : Test Method for Carbon Black in Olefin Plastics.

j. ASTM D-1693 : Test Method for Environmental Stress Cracking of Ethylene Plastics.

k. ASTM D-2240 : Test Method for Rubber Property – Durometer Hardness.

 Page A-45

l. ASTM D-3895 : Test Method for Oxidative-Induction Time of

Polyolefins by Differential Scanning Calorimetry.

m. ASTM G-42 : Tentative Methods for Cathodic Disbonding of

Pipeline coatings Subjected to Elevated or Cyclic

Temperatures.

n. API RP 5L1 : Recommended Practice for Railroad

Transportation of Linepipe.

o. API RP 5LW : Transportation of Line Pipe on Barges and

Marine Vessels.

p. DIN EN 10204 : Metallic Products – Types of Inspection Documents.

q. DIN 53735 : Testing of Plastics: Determination of Melt Index of Thermoplastics.

r. ISO 8502 - 3 : Preparation of Steel Stubstrates before
Application of Paints and Related Products –

Part 3 - Assessment of Dust on Steel Surfaces

Prepared for Painting (Pressure Sensitive Tape

Method).

s. ISO 9002 : Quality Systems: Specification of Production and Installation.

t. ISO 11124 : Preparation of Steel Substrates before

Application of Paints and Related Products.

u. SIS 055900 : Preparation of Steel Substrates before

Application of Paints and Related Products -

Visual Assessment of Surface Cleanliness.

v. API 5L : Specification for Line Pipe.

w. ASME B31.8 : Gas Transmission and Distribution Piping Systems.

x. ASME B31.4 : Liquid Transportation Systems for Hydrocarbons, Liquid

Petroleum Gas, Anhydrous Ammonia, and Alcohols.

y. CSA Z245.20 : External Fusion Bond Epoxy Coating for Steel Pipe.
 Page A-46

The CONTRACTOR shall be familiar with the requirements of these documents and shall
make them readily available at the coating plant to all persons concerned with carrying out the
works specified in this specification

3.00.0 PLANT SCALE AND INSTALLATION

3.01.0 Contractor / Manufacturer shall size coating plant(s) after evaluating the scale of work
and the time schedule required for the works.

3.02.0 Plant equipment, machinery and other facilities shall be in first class operating condition
to at least meet the job requirements of quality and production. Worn out and improvised
plants are not acceptable.

3.03.0 The Contractor / Manufacturer shall be fully responsible for adherence to all statutory
regulations applicable for handling and disposal of the hazardous chemicals during the
coating works.

3.04.0 The Contractor / Manufacturer shall be responsible for obtaining all statutory approvals /
clearances from relevant Authorities including Pollution Control Board, as applicable for
the coating plant(s).

4.00.0 MATERIALS
4.01.0 The three layer coating system shall comprise of a powder epoxy primer, polymeric
adhesive and a polyethylene top coat. Coating materials shall be suitable for the service
conditions and the pipe sizes involved. The coating materials i.e. epoxy powder,
adhesive and polyethylene compound shall have proven compatibility. The coating
system and materials shall be pre-qualified and approved by Engineer in charge in
accordance with provisions of this specification. Contractor / Manufacturer shall obtain
prior approval from Engineer in charge for the coating system and coating materials.
4.02.00 The coating materials Manufacturer shall carry out tests for all properties specified in para
5.03.01 and 5.03.02 for each batch of epoxy, adhesive and polyethylene compound. In
addition, the Manufacturer shall also furnish Infrared Scan for each batch of epoxy powder.
The coating materials Manufacturer shall issue test certificates as per DIN EN 10204, 3.1B for
each batch of materials supplied to Contractor / Manufacturer and the same shall be
submitted to Engineer in charge for approval prior to their use.

4.03.0 In addition to Manufacturer's certificate, the Contractor / Manufacturer shall draw

samples from each batch of epoxy, adhesive and polyethylene in the presence of
Engineer in charge's Representative and test for the following properties at the coating
yard at least one week prior to its use, to establish compliance with the Manufacturer's
test certificates.
a. Epoxy Powder:
i. Gel Time
ii. Cure time
iii. Moisture content

iv. Thermal Characteristics (Tg1, Tg2, ΔH)

b. Adhesive:
i. Specific Gravity

ii. Melt Flow Rate

iii. Vicat Softening Point

c. Polyethylene:
 Page A-47

i. Melt Flow Rate

ii. Specific Gravity

iii. Vicat Softening Point

iv. Moisture Content
v. Oxidative Induction Time

In case of failure of any of the above tests in a batch, that batch of material shall be
tested for all other tests required as per para 5.03.01 and 5.03.02 including the tests
which failed. If all tests pass, the batch shall be accepted for coating. If any of the tests
fail, entire batch of material shall be rejected and shall not be used for the coating.

4.04.0 All materials to be used shall be supplied in sealed, damage free containers and shall
be suitably marked with the following minimum information:

a. Name of the Manufacturer

b. Type of Material

c. Batch Number

d. Place and Date of Manufacture

e. Shelf Life / Expiry Date (if applicable)

f. Quantity

All materials noted to be without above identification shall be deemed suspect and shall
be rejected by engineer in charge. Such material shall not be used for coating and shall
be removed from plant site and replaced by Contractor / Manufacturer at his expense.

4.05.0 Contractor / Manufacturer shall ensure that all coating materials are properly stored in
accordance with the Manufacturer's recommendation at all times, to prevent damage
and deterioration in quality prior to use.

5.00.0 FUNCTIONAL REQUIREMENTS AND PROPERTIES OF COATING

5.01.0 The coating shall be able to withstand a maximum in service operating temperature of
(+) 65°C and shall conform to 'S' Type of coating as per DIN 30670. In addition, in open
storage the coating must be able to withstand a temperature of at least (+) 80°C,
without impairing its serviceability and properties specified.

5.02.0 The top coat polyethylene used shall be a black readymade compound, fully stabilized
against influence of ultraviolet radiation (i.e. sunlight), oxygen in air and heat (due to
environmental temperature as specified above). No appreciable changes shall occur
during exposure to such environments up to at least a period of 6000 hours. The
Contractor / Manufacturer shall submit certificate from Manufacturer in this regard.

5.03.0 Properties

Properties of coating system and coating material shall comply with the requirements
 Page A-48

indicated in subsequent paragraphs. In case the coating / material properties are tested
as per test methods / standards other than specified herein below, the same may be
accepted provided the test procedures and test conditions are same or more stringent
than the specified.

5.03.1 Properties of Epoxy Powder and Adhesive

Contractor / Manufacturer shall choose such a brand of epoxy powder and adhesive
that will achieve the functional requirements and properties of coating system as
specified in Para 4.01.00 and 4.03.03 of this specification respectively.
Epoxy powder properties shall be as per CSA Z245.20. The colour of epoxy powder
shall be either green or dark red or any other colour approved by engineer in charge
except grey colour.
Co-polymer grafted adhesive shall have the following properties:

Sl.No. Properties Unit Requirement

a. Melt Flow Rate g/10 minutes 1.0 (min.)

(190°C/ 2.16 kg)

o
b. Vicat Softening Point C 100 (min.)

c. Specific Gravity - 0.926 (min.)

5.03.2 Properties of Polyethylene Compound

Sl.No
. Properties Unit Requirement

a. Tensile Strength@ + 25 0C N/mm2 17 (min.)

b. Melt Flow Rate g/10minutes 0.25 (min.)

(190°C / 2.16 kg)

c. Specific Gravity @ + 25 °C - 0.926 (min.) (MDPE)

0.941 (min.)
 Page A-49

d. Hardness @ + 25 °C Shore D 50 (min.)

e. Water Absorption, % 0.05 (max.)

24 hours, @ + 25 °C

f. Volume Ohm-cm 1015 (min.)

Resistivity @ + 25°C

g. Dielectric withstand, 1000 Volts/mm 30,000 (min.)

Volt/sec rise @ + 25 °C

h. Vicat Softening Point oC 110 (min.)

i. Elongation % 600 (min.)

j. Oxidative Induction Time Minutes 10

in Oxygen at 220°C,

Aluminium pan, no screen

k. Environmental Stress Crack

Resistance (ESCR) (for F50) :

Medium Density-(Condition"C") Hours 300

High Density- (Condition"B") 300

l. Carbon Black Content % 2 (min.)

5.03.3 Properties of Coating System

Sl.No
. Properties Unit Requirement

a) Bond Strength (using Type 2 Test

Assembly i.e. Dynamometer)

@ 20 +/- 5°C Kg/cm 8.0 (min)

@ 65 +/- 5°C 5.0 (min)

Impact Strength(Min. of 30 impacts on Joules per mm

b) body along the length. No breakdown of coating 7 (min)

allowed when tested at 25 KV) thickness

 Page A-50

c) Indentation Hardness mm

@ 23 +/- 2°C 0.2 (max)

@ 70 +/- 2°C 0.3 (max)

d) Elongation at Failure % 300 (min.)

e) Coating Resistivity Ohm - m2 108 (min.)

f) Heat Ageing(*) - Melt Flow Rate shall

not deviate by more

than 35% of original

value

g) Light Ageing(*) - Melt Flow Rate shall

not deviate by more

than 35% of original

value

h) Cathodic Disbondment mm radius

of

@ + 65°C after 30 days 15 max.

Disbondment (**)

@ + 65°C after 48 hrs 1 max.

i) Degree of Cure of Epoxy(***)

Percentage Cure, H % 95

Tg °C +3 / -2

(*) Test carried out in an independent laboratory of national / international recognition

on PE top coat is also acceptable.

(**) Disbondment shall be equivalent circle radius of total unsealed area as per ASTMG
42.

(***) Temperature to which the test specimens are to be heated during cyclic heating
shall however be as per the recommendations of epoxy powder manufacturer.
5.04.1 The suggestive combination of coating material shall be as per these specifications.
6.00.0 MEASUREMENT AND LOGGING

Contractor / Manufacturer shall maintain records in computer using suitable database

Software containing all the relevant data of individual pipe and pipe coating including pipe
number, heat number, diameter, length, wall thickness, defects, coating number, batches
of materials, sampling, testing, damages, repairs, rejects and any other information that
engineer in charge considers to be relevant and required for all incoming bare pipes and
engineer in charge approved outgoing coated pipes as applicable. Contractor's /
 Page A-51

Manufacturer's documentation shall be designed to ensure full traceability of pipe and

coating materials through all stages of coating and testing. Contractor / Manufacturer shall
submit this information in the form of a report at the agreed intervals. Contractor /
Manufacturer shall provide one Computer Terminal to engineer in charge Representative
for monitoring/tracking of the above. The Contractor / Manufacturer shall also submit the
material balance details to engineer in charge for information at the end of each shift.

7.00.00 COATING PROCEDURE AND QUALIFICATION

7.01.00 Upon award of the Contract, the Contractor / Manufacturer shall submit within two (2)
weeks, for engineer in charge's approval, a detailed report in the form of bound manual
outlining, but not limited to, the following:

a. Details of plant(s), location(s), layout, capacity and production rate(s).

b. Details of the equipment available to carry out the coating works

including surface preparation, epoxy powder application and its

recycling system, adhesive & polyethylene extrusion, moisture control

facilities available for coating materials.

c. Details of process control and inspection equipment required for the

coating process such as temperature control, thickness control,

holiday testers, etc.

d. Details of chemical pre-treatment facilities including process control

and inspection equipment for phosphoric acid wash, de-ionised water

wash and chromate wash.

e. Facilities in the yard for unloading, handling, transport, production, storage,

stockpiling, loading of bare and coated pipes and warehouses for storage of other
coating materials.

f. Plant Organisation Chart and availability of manpower including

coating specialist

g. Details of utilities/facilities such as water, power, fuel, access roads

and communication etc.

After approval has been given by engineer in charge, no change in plant set-up shall be
made. However, unavoidable changes shall be executed only after obtaining written approval
from engineer in charge.
7.02.0 At least four (4) weeks prior to the commencement of coating, a detailed procedure of the
Contractor's / Manufacturer's methods, material proposed, etc., shall be formulated by the
Contractor / Manufacturer and submitted to engineer in charge for approval. The procedure
shall include, but not limited to, the following information and proposals:
 Page A-52

a. Steel surface preparation including preheating, removal of steel

defects, method of pipe cleaning, dust removal, abrasive blast

cleaning and surface profile; methods of measurements and

consumables.

b. Complete details of chemical pre-treatment viz. phosphoric acid

wash, de-ionized water wash and chromate wash including product

data sheets, health and safety sheets and manufacturer's

recommended application procedure.

c. Pipe heating, temperatures and control prior to epoxy application.

d. Complete details of raw materials including current data sheets

showing values for all the properties specified together with quality

control and application procedure recommendations from

manufacturer(s).

e. Application of FBE powder, adhesive and polyethylene, including

characteristics, temperature, line speed, application window, curing time, etc.-

Quenching and cooling, including time and temperature.
f. Detailed method of repair of coating defects duly classified depending upon nature and
magnitude of defects and repair thereof including coating stripping technique.
g. Details of instrument and equipment calibration methods including relevant standards
and examples of calibration certificates.
h. Complete details and inventory of laboratory and equipment for procedure qualification
and regular production.
i. Pipe handling and stock piling procedures.
j. Sample of recording and reporting formats, including laboratory reports, certificates
and requirement as per clause 5.00.00 of this specification.
k. Complete details of test certificates for raw materials including test methods and
standards used.
n. Test certificates from PE compound manufacturer for tests for thermal aging, coating
resistivity and aging under exposure to light. These tests certificates shall not be older
than three years.
o. Health, Safety and Environment Plans.
p. Storage details of coating materials and chemicals.
q. Continuous temperature monitoring at various stages of coating.

7.03.00

Procedure Qualification Tests (PQT) shall be carried out only after obtaining written
approval of the above procedure from Engineer in charge. No change in the procedure
shall be made after approval has been given by the Engineer in charge. However,
unavoidable changes shall be executed only after obtaining written approval from Engineer
in charge.
Prior to start of production, the Contractor / Manufacturer shall, at his expense, carry out a
coating PQT for each pipe diameter on max. wall thickness, for each type of pipe, for each
 Page A-53

coating material combination, and for each plant, to prove that his plant, materials, and
coating procedures result in a quality of end product conforming to the properties stated in
clause 4.03.00, relevant standards, specifications and material manufacturer's
recommendations.
A batch representing a normal production run, typically 15 pipes, shall be coated in
accordance with the approved coating procedure and the coating operations witnessed
by Engineer in charge‟s Representative. Out of these pipes, at least one pipe shall be
coated partly with epoxy and partly with both epoxy and adhesive layers.

At least 5 (five) test pipes shall be selected by Engineer in charge‟s Representative for
coating procedure approval tests and shall be subjected to procedure qualification testing
as described hereinafter. All tests shall be witnessed by the Engineer in charge‟s
Representative. Out of 5 (five) test pipes, 1 (one) pipe partly coated with epoxy and partly
coated with both epoxy and adhesive layers shall be included. Remaining 4 (four) test
pipes shall be have all three layers.
During PQT, the Contractor / Manufacturer shall qualify various procedures forming a part
of coating operations as detailed subsequently.
7.04.00 Qualification of Procedures

7.04.01 Epoxy Powder Application & Recycling

During pre-qualification, air pressure in the epoxy spray guns, satisfactory functioning of
monitoring system, line speed vs. coating thickness, etc. shall be established. Dew point of
air used to supply the fluidized bed, epoxy spray system and epoxy recycling system shall
be recorded during the PQT.

Also, the Contractor / Manufacturer shall remove samples of reclaimed powder from the
reclamation system. These samples of reclaimed powder shall be subject to a detailed
visual examination, thermal analysis and moisture content tests. The properties of the
reclaimed powder shall be within the range specified by the Manufacturer of epoxy powder.
In case the properties of the reclaimed powder are out of the range specified by the e p o x
y p o w d e r Manufacturer, Contractor /Manufacturer shall not use the reclaimed powder
during the regular production.
7.04.02 Pipe Pre-heating
The Contractor / Manufacturer shall establish the temperature variation due to in-coming
pipe temperature, line speed variation, wall thickness variation, emissivity, interruptions,
etc. and document the same during the PQT stage. During PQT, proper functioning of pipe
temperature monitoring and recording system including alarm/hooter shall be
demonstrated to the Engineer in charge Representative.
7.04.03
Surface Preparation

The procedure to clean and prepare the pipe surface shall be in

accordance with the requirements of this specification. The ratio of shots to

grits shall be established during procedure qualification testing, such that

the resultant surface profile is not dished and rounded. The qualification
shall be performed through a visual inspection, measurement of roughness and check of
 Page A-54

the presence of dust in the abrasive blast cleaned pipe surface.

7.04.4 NOT USED
7.04.5 Coating Application

The Engineer in charge Representative will check the correctness of each coating
application operation, values of the main parameters of each operation, preheating pipe
surface temperature prior to epoxy powder application temperature, line speed, fusion
bonded epoxy curing time, temperature and flow rate of co-polymer adhesive and
polyethylene, etc. and the same shall be recorded. These values shall be complied with
during regular production.

7.05.0 Qualification of Applied Coating

7.05.1 Tests on pipe coated partly with epoxy and partly with epoxy & adhesive
layers

a. Degree of Cure

Epoxy film samples (minimum 4 no.) shall be scrapped from the coated pipe and
the samples shall be taken for cure test using Differential Scanning Calorimetry
(DSC) procedure. Care shall be taken to remove the samples of full film thickness
avoiding inclusion of steel debris. Glass transition temperature differential (ΔTg)
and % cure (Δ H) shall comply with the specified requirements.
b. Epoxy Layer Thickness

Epoxy layer thickness shall be checked at every one metre spacing at 3, 6, 9 and
12 o'clock positions. The thickness shall comply with the specified thickness
requirements.
c. Adhesive layer Thickness

Adhesive layer thickness shall be checked at every one metre spacing at 3,

6, 9 and 12 o‟clock positions. The thickness shall comply with the specified
thickness requirements.
d. Holiday Inspection

Entire pipe shall be subject to holiday inspection and the test voltage shall be set
to exceed 5 v/micron of epoxy thickness specified for the portion coated only with
epoxy layer.

e. Adhesion Test

i) Adhesion Test (24 hrs or 48 hrs) shall be carried out on the epoxy coated pipe.
Test method, no. of test specimen and acceptance criteria shall comply CSA
Z.245, 20, Table 4.
ii) Adhesion of FBE shall also be separately determined at ambient temperature
at two locations by the "St Andrews Cross" method and the test shall comply with
the specified requirements.

f. 2.5° Flexibility Test

2.5° Flexibility test shall be carried out on the epoxy coated pipe at test
temperature of 0°C. Test method, no. of test specimen and acceptance criteria
shall comply CSA Z.245, 20, Table 4.
g. Cross-section & Interface Porosity Test
 Page A-55

Cross section porosity and interface porosity tests shall be carried out on the
epoxy coated pipe. Test method, no. of test specimen and acceptance criteria shall
comply CSA Z.245, 20, Table 4.

7.05.2 Tests on pipes coated with all three layers

a. Bond Strength
Three test pipes shall be selected for bond strength tests. On each of the selected pipes,
three bond strength test shall be performed for each specified temperature i.e. one at each
end and one in the middle of the pipe and specified requirements shall be complied with,
i.e. bond strength as well as mode of separation. Length of peel shall be minimum 65 mm.
None of these samples shall fail.
b. Impact Strength
Three test pipes shall be selected for impact strength test and the test shall meet the
specified requirements.

c. Indentation Hardness
Two samples for both temperatures from all pipes shall be taken. If any one of these
samples fails to satisfy the specified requirements, then the test shall be repeated on four
more samples. In this case, none of the samples shall fail.

d. Elongation at failure
Six samples each from three coated pipes i.e. 18 samples in all shall be tested and the test
shall comply the specified requirement. Only one sample per pipe may fail.

e. Cathodic Disbondment Test

Two CD tests shall be carried out for the total lot of test pipes having all three layers. One
test shall be carried out for 30 days duration and another test for 48 hours duration. The
tests shall comply the specified requirement. Whenever Procedure Qualification is
necessitated for different pipe size with same coating material combination, 48 hours test
only be conducted. 30 days CD test is not mandatory in this case.
f. Holiday Inspection
All the pipes shall be subject to holiday inspection. The test voltage shall be as specified in
QA sub-sections.
g. Coating Thickness Measurement
All pipes shall be subject to coating thickness measurements. Acceptance criteria shall be
as per QA sub-sections.
h. Air Entrapment
One sample each from pipe body and on weld (if applicable) shall be taken from all four
coated pipes and the specified requirements shall be complied with.
i. Degree of Cure

Epoxy film samples (minimum 4 no. equally spaced) shall be scrapped from one coated
pipe and the samples shall be taken for cure test using Differential Scanning Calorimetry
(DSC) procedure. Care shall be taken to remove the samples of full film thickness avoiding
inclusion of steel debris. Glass transition temperature differential (ΔTg) and % cure (ΔH)
shall comply with the specified requirements.
7.05.3 Inspection of all test pipes

All pipes shall be subject to the following inspections:

a. surface cleanliness, surface roughness measurements and dust
 Page A-56

control immediately after second abrasive blast cleaning and salt test

immediately after De-ionised water wash.

b. pH of pipe surface before and after phosphoric acid wash.

c. visual inspection of chromate coating.

d. visual inspection of finished coating, cut back dimension,

internal/external cleanliness, end sealing and bevel inspection.

Acceptance criteria for all inspection and testing shall be as specified in this specification.
7.06.0 After completion of the qualification tests and inspection as per para 7.04.00 and 7.05.00
above, the Contractor / Manufacturer shall prepare and issue to Engineer in charge for
approval a detailed report of the above tests and inspection including test reports/certificates
of all materials and coatings tested. Only upon written approval from Engineer in charge,
Contractor / Manufacturer shall commence production coating.

7.07.00 On successful completion of PQT, coating of all five (5) test pipes shall be removed and
completely recycled as per the approved coating procedure specification, at Contractor's /
Manufacturer's expense. Remaining pipes will be accepted by Engineer in charge provided
they meet the requirements of this specification and need not be stripped and re-cycled.

7.08.00 The Contractor / Manufacturer shall re-establish the requirements of qualification and in a
manner as stated before or to the extent considered necessary by Engineer in charge, in the
event of, but not limited to, the following:
- Every time there is a change in the previously qualified procedure.
- Every time there is a change in the manufacturer and change in formulation of any of
the raw materials and change in location of raw material manufacture.
- Every time the coating yard is shifted from one location to the other or every time the
critical coating equipment‟s (induction heater, epoxy spray system, extruder, etc) are
shifted.
- Any change in line speed during coating application.
- Any time when in COMPANY'S opinion the properties are deemed to be suspect
during regular production tests.
7.09.00
Engineer in charge reserves the right to conduct any or all the test required for qualification
through an independent laboratory or agency at the cost of Contractor / Manufacturer when in
Engineer in charge's opinion, the results are deemed suspect. Engineer in charge's decision
shall be final.

8.00.0 PIPE SURFACE PREPARATION

8.01.0 Prior to cleaning operation, Contractor / Manufacturer shall visually examine the pipes and
shall ensure that all defects, flats and other damages have been repaired or removed. The
Contractor / Manufacturer shall also remove marking stickers, if any, present within the
pipe. Record shall be kept of such marking on the stickers to ensure traceability of pipe
after coating.

8.02.0 Any oil, grease, salt or other contaminants detrimental to the formation of a good coating
bond or coating quality shall be removed prior to coating application. Contaminants may be
removed by the use of non-oily solvents. Gasoline or kerosene shall not be used for this
purpose. Visible oil and grease spots shall be removed by solvent wiping. Solvent cleaning
shall be in accordance with SSPC-SP1. Steel surface shall be allowed to dry before
 Page A-57

abrasive cleaning.

8.03.0 All pipes shall be preheated to a temperature of 65°C to 85°C prior to abrasive blast
cleaning. The external surface of the pipe shall be cleaned using 2 no. dry abrasive blast
cleaning units to achieve the specified surface cleanliness and profile.
The abrasive blast cleaning units shall have an effective dust collection system to ensure
total removal of dust generated during blast cleaning from the pipe surface. During
abrasive blast cleaning, the metallic abrasive shall be continuously sieved to remove
"fines" and "contaminants" and the quality checked at every four hours. Abrasives used for
blast cleaning shall comply with ISO-11124.
8.04.0 Suitable plugs shall be provided at both pipe ends to prevent entry of any shot/grit into the
pipe during blast cleaning operations. These plugs shall be removed after blast cleaning.
Alternatively, the Contractor / Manufacturer may link the pipes suitably together to prevent
the entry of any short/grit into the pipe.

8.05.0 NOT USED

8.06.00 Abrasive cleaning carried out shall be such that the resultant surface profile is not dished
and rounded when viewed with 30 X magnification. The standard of finish for
cleaned pipe shall conform to near white metal finish to SA 2 ½ of Swedish
Standard SIS 055900. Surface of pipe after abrasive blast cleaning shall have
an anchor pattern of 50 to 70 microns (RZ). This shall be measured for each
pipe by a suitable instrument such as surface profile depth gauge. In addition
the pipe surface after blast cleaning shall be checked for the degree of cleanliness (Sa
2½), degree of dust and shape of profile. Degree of dust shall comply with the
requirements of ISO 8502 - 3.
Acceptance limit shall be either quality rating 2 or Class 2. Tape used for assessment
of degree of dust shall comply with IEC 454-2. Pressure shall be exerted on the applied
tape usinga 4 kg roller, prior to peeling-off to assess the degree of dust.

8.07.0 All pipes shall be visually examined for presence of any shot/grit/loose material left inside the
pipe during blast cleaning. Suitable mechanical means (stiff brush) shall be employed to
remove the same before the pipes are processed further. In addition, inside surface of the
pipe shall also be visually inspected for presence of any foreign material or shots and grit
(free or embedded/sticking to pipe inside surface). The pipe inside surface shall be examined
using sharp floodlight focused at the middle of the pipe at one end while inspection is carried
out visually from other end. Any foreign material or shots/grit present in the pipe shall be
completely removed by mechanical brush, high pressure air jets, by tilting of pipe, etc.

8.08.0 At no time shall the blast cleaning be performed when the relative humidity exceeds 85%. The
Contractor / Manufacturer shall measure the ambient conditions at regular intervals during
blast cleaning and coating operations and keep records of prevailing temperature, humidity
and dew point.

8.09.0 The blast cleaned surface shall not be contaminated with dirt, dust, metal particles, oil, water
or any other foreign material, nor shall the surface or its anchor pattern be scarred or
burnished. All blast cleaned pipe surface shall be kept in dust free enclosure prior to coating.
After blast cleaning, all surfaces shall be thoroughly inspected under adequate lighting to
determine anchor pattern, quality of blasting and identify any surface defects prior to coating
application. All surface defects such as slivers, scab, burns, laminations, welds spatters,
gouges, scores, indentations, slugs or any other defects considered injurious to the coating
integrity made visible during blast cleaning shall be removed by filing or grinding. After any
grinding or mechanical repairs, the remaining wall thickness shall be checked and compared
with specified thickness. Any pipes having thickness less than 95% of specified thickness
shall be kept aside and disposed of. The method employed to remove surface defects shall
not burnish or destroy the anchor pattern or contaminate the surface. Pneumatic tools shall
 Page A-58

not be used unless they are fitted with effective air/oil and water traps. Where burnishing
results in destruction of anchor pattern, the anchor pattern shall be restored by suitable
means. Pipes which have damages repaired by grinding and have ground areas more than
50mm in diameter shall be re-blasted.
Any dust or loose residues that have been accumulated during blasting and/or during
filing/grinding operations shall be removed by vacuum cleaning.
If contamination of surface occurs, the quality of blast cleaning method and process shall be
examined. If the surface roughness is outside the specified limit, the blast cleaning material
shall be checked and replaced.

8.10.0 Upon Completion of the blasting operations, the quality control supervisor shall accept the
pipe for further processing or return for re-blasting after removal of
defects/imperfections.

8.11.0 In order to ensure that pipe with defects are not processed further, provisions shall be
available to lift the pipes from inspection stand.

8.12.0 NOT USED

8.13.00 The total allowable elapsed time between completion of the blasting operations

and commencement of the pre-coating and heating operations shall be such that

no detectable oxidation of the surface occurs. Relative humidity readings shall be

recorded every half an hour during the blasting operations in the immediate vicinity

of the operations. The maximum elapsed time shall not exceed the duration given

below:

Relative Humidity % Maximum elapsed time

> 80 2 hours

70 to 80 3 hours

< 70 4 hours

Any pipe not processed within the above time-humidity requirement shall be completely re-
blasted. Any pipe showing flash rusting shall be re-blasted even if the above conditions
have not been exceeded.

8.14.0 Pipe handling between abrasive blasting and pipe coating shall not damage the surface
profile achieved during blasting. Any pipe affected by the damage to the surface exceeding
200mm² in area and/or having contamination of steel surface shall be rejected and sent for
 Page A-59

re-blasting.

9.00.0 COATING APPLICATION

The external surface of the cleaned pipe conforming to this specification shall be
immediately coated with 3-layer extruded polyethylene coating in accordance with the
procedures approved by Engineer in charge, relevant standards and this specification. In
general the procedure shall be as follows:

9.01.0 Pipe Heating

9.01.1 Immediately prior to heating of pipe, all dust and grit shall be removed from inside of the
pipe by a combination of air blast, brushing and vacuum cleaning. Suitable arrangement
shall be made to protect the bevel ends from getting damaged during the coating
operation.
. Induction heater or gas fired heating shall be used for heating the pipe.
The method shall be capable of maintaining uniform temperature along the total length of
the pipe, and shall be such that it shall not contaminate the surface to be coated. In case
of induction heating, appropriate frequency shall be used to ensure 'deep heating' and
intense skin heating is avoided. Gas fired heating system shall be well adjusted so that no
combustion products are deposited on the steel surface. This shall be demonstrated on
bare pipes prior to start of PQT. Oxidation of the cleaned pipe surfaces prior to coating (in
the form of blueing or other apparent oxide formation) is not acceptable
9.01.3 External surface of the pipe shall be heated to about 190 °C or within a temperature range
(min. to max.) as recommended by the powder manufacturer. Required pipe temperature
shall be maintained as it enters the coating chamber.

9.01.4 Temperature of the pipe surface shall be continuously monitored & recorded by using
suitable instruments such as infrared sensors, contact thermometers, thermocouples etc.
The recording method shall allow to correlate each line pipe. The monitoring instrument
shall be able to raise an alarm / activate audio system (hooter) in the event of tripping of
induction heater / gas fired heater or in the event of pipe temperature being outside the
range recommended by the manufacturer. Any deviation from the application temperature
range recommended by manufacturer shall be rectified. If immediate rectification is not
feasible, the production shall be stopped until cause of deviation has been removed. Any
pipe coated during the duration of temperature deviation shall be identified by marking and
rejected. Such rejected pipes shall be stripped, re-cleaned and recoated.

9.01.5 Temperature measuring & monitoring equipment shall be calibrated twice every
shift and/or as per Engineer in charge Representative's instruction.
9.01.6 Contractor / Manufacturer shall ensure that pipe surface emissivity variations are
minimized during pipe heating. To avoid significant variance, more than once blasted joints
should be coated at the same time and not mixed with joints blasted only once.
9.02.0 Pipe Coating
9.02.1 Subsequent to pipe heating, coating consisting of following layers shall be applied onto
the pipe.

i. Electrostatic application of epoxy powder of minimum dry film thickness 0.150

mm, unless otherwise specified. The maximum thickness shall not exceed the
epoxy thickness specified by epoxy powder manufacturer.

ii. Grafted co-polymer adhesive application by extrusion, minimum thickness 0.200 mm.

iii. Polyethylene application by extrusion.

 Page A-60

Minimum total thickness of finished coating shall be 3.0 mm.

The coated pipe shall be subsequently quenched and cooled in water for a period that
shall sufficiently lower the temperature of pipe coating to permit handling and inspection.

9.02.2 Coating materials shall be inspected in accordance with the manufacturer‟s

recommendation prior to coating application and it shall be ensured that the materials are
moisture free. In case the relative humidity exceeds 80%, the adhesive and polyethylene
material shall be dried using hot dry air.

9.02.3 Prior to starting the application of fusion bonded epoxy powder, the recovery system shall
be thoroughly cleaned to remove any unused powder remaining from a previous line pipe
coating application. The use of recycled powder shall be permitted subject to:

a) Satisfactory qualification of the reclaimed system during PQT stage

b) The proportion of the reclaimed powder in the working mix does not
exceed 20% at any one time.

c) The quality of the recycled powder being routinely checked during

production, at a minimum frequency of once per shift and consistently meets the
requirements stated at Para 4.03.01
9.02.04
Dry air; free of oil and moisture shall be used in the coating chamber and spraying system.
Filters, dehumidifier/dryer as required along with control & monitoring system shall be
provided for this purpose. Dew point of air used to supply the fluidized bed, epoxy spray
system and epoxy recycling system shall be at least (-) 40°C and this shall be monitored
during the regular production.
9.02.05
Air pressure in the epoxy spray guns shall be controlled, continuously monitored and
recorded by using suitable instruments. The air pressure shall be controlled within the
limits established during coating procedure qualification. The monitoring system shall be
capable of raising an alarm / activate audio system (hooter) in the event of change in air
pressure beyond the set limits. Any deviation from the pre-set limits shall be rectified. If
immediate rectification is not feasible, the production shall be stopped until cause of
deviation has been removed. Any pipe coated during the duration of air pressure deviation
shall be identified by suitable marking and rejected. Such rejected pipes shall be stripped
and recoated.
9.02.06 Extruded adhesive layer shall be applied before gel time of the epoxy coating has elapsed
and within the window recommended by the manufacturer. The Contractor / Manufacturer shall
establish, to the satisfaction of the Engineer in charge
Representative, that the adhesive is applied within the gel time window of epoxy and at the
temperature recommended by the adhesive manufacturer. The Contractor / Manufacturer
shall state the minimum and maximum time interval between epoxy and adhesive application
at the proposed pre-heat temperature and line speed.

9.02.7 Extruded polyethylene layer shall be applied over the adhesive layer within the time limit
established during PQT stage and within the time/temperature range recommended by the
manufacturer. The extrusion temperatures of the adhesive and polyethylene shall be
continuously recorded. The monitoring instruments shall be independent of the temperature
 Page A-61

control equipment. The instruments shall be calibrated prior to start of each shift.

9.02.8 Contractor / Manufacturer shall ensure that there is no entrapment of air or void formation
along the seam weld (where applicable) during application of coating. Air entrapment below
the coating and also along the coating overlap shall be prevented by forcing the coating on to
the pipe using high pressure roller of suitable design during coating application. In case it is
not adequately achieved, Contractor / Manufacturer shall supplement by other methods to
avoid air entrapment. The methods used shall be witnessed and approved by Engineer in
charge.
9.02.09 Resultant coating shall have a uniform gloss and appearance and shall be free from air
bubbles, wrinkles, holidays, irregularities, discontinuities, separation between layers of
polyethylene & adhesive, etc.
9.02.10 Coating and/or adhesive shall terminate 150 mm (+) 20 / (-) 0 mm from pipe ends. The
adhesive shall seal the end of applied coating. Contractor / Manufacturer shall adopt
mechanical brushing for termination of the coating at pipe ends. Edge of the coating shall
be shaped to form a bevel angle of 30° to 45°.
9.02.11 Failure to comply with any of the above applicable requirement and of the approved
procedure shall cause for the rejection of the coating and such coating shall be
removed in a manner approved by Engineer in charge at Contractor's expense.

10.01.0 HANDLING, TRANSPORTATION AND STORAGE

The Contractor / Manufacturer shall load, unload, transport and stockpile the coated pipes
within the coating plant using approved suitable means and in a manner to avoid damage to
the pipe and coating. The Engineer in charge shall approve such procedure prior to
commencement of work.
Coated pipes may be handled by means of slings and belts of proper width (minimum 60
mm) made of non- abrasive/non-metallic materials. In this case, pipes to be stacked shall be
separated row by row to avoid damages by rubbing the coated surface in the process of
taking off the slings. Use of round sectional slings is prohibited. Fork lifts may be used
provided that the arms of the forklift are covered with suitable pads, preferably rubber.

10.03.0 Bare / coated pipes at all times shall be stacked completely clear from the ground, at least
300 mm, so that the bottom rows of pipes remain free from any surface water. The pipes shall
be stacked at a slope so that driving rain does not collect inside the pipe. Bare / coated pipes
may be stacked by placing them on ridges of sand, free from stones and covered with a
plastic film or on wooden supports provided with suitable cover. This cover can be of dry,
germ free straw covered with plastic film, otherwise foam rubber may be used. The supports
shall be spaced in such a manner as to avoid permanent bending of the pipes.
Stacks shall consist of limited number of layers such that the pressure exercised by the pipe's
own weight does not cause damages to the coating. Each pipe section shall be separated by
means of spacers suitably spaced for this purpose. Stacks shall be suitably secured against
falling down and shall consist of pipe sections having the same diameter and wall thickness.
The weld seam of pipes shall be positioned always in a manner so as not to touch the
adjacent pipes.
The ends of the pipes during handling and stacking shall always be protected with bevel
protectors.
At storage site, pipes shall be stacked in such a way that suitable gaps shall be left in the
pipes at intervals to permit access from one side to the other.

10.04.0 The lorries used for transportation shall be equipped with adequate pipe supports having as
many round hollow beds as there are pipes to be placed on the bottom of the lorry bed. Total
width of the supports shall be at least 5% of the pipe length and min. 3 no. support shall be
 Page A-62

provided. These supports shall be lined with a rubber protection and shall be spaced in a
manner as to support equal load from the pipes. The rubber protection must be free from all
nails and staples where pipes are in contact. The second layer and all following layers shall
be separated from the other with adequate number of separating layers of protective material
such as straw in plastic covers or mineral wool strips or equivalent, to avoid direct touch
between the coated pipes.

All stanchions of lorries used for transportation shall be covered by non- abrasive material like
rubber belts or equivalent. Care shall be exercised to properly cover the top of the stanchions
and other positions such as reinforcement of the truck body, rivets, etc. to prevent damage to
the coated surface. Slings or non-metallic straps shall be used for securing loads during
transportation. They shall be suitably padded at the contact points with the pipe.
10.05.00 Materials other than pipes and which are susceptible of deteriorating or suffering from
damages especially due to humidity, exposure to high thermal excursions or other adverse
weather conditions, shall be suitably stored and protected. Deteriorated materials shall not
be used and shall be replaced at Contractor's expenses. These materials shall always be
handled during loading, unloading and storage in a manner so as to prevent any damage,
alteration and dispersion. When supplied in containers and envelopes, they shall not be
dropped or thrown, or removed by means of hooks, both during the handling operations till
their complete use. During unloading, transport and utilization, any contact with water,
earth, crushed stone and any other foreign material shall be carefully avoided.
Contractor shall strictly follow Manufacturer's instructions regarding storage temperature
and methods for volatile materials that are susceptible to change in properties and
characteristics due to unsuitable storage. If necessary, the Contractor shall provide for a
proper conditioning.
10.06.0 In case of any marine transportation of bare/coated line pipes involved, the same shall be
carried out in compliance with API RP 5LW. Contractor shall furnish all details pertaining to
marine transportation including drawings of cargo barges, storing/stacking, sea fastening of
pipes on the barges/marine vessels to the Engineer in charge for approval prior to
undertaking such transportation works. In addition, contractor shall also carry out requisite
analyses considering the proposed transportation scheme and establish the same is safe
and stable. On-deck overseas shipment shall not be allowed.

11.00.0 REPAIR OF COATING

Contractor / Manufacturer shall submit to the Engineer in charge, its methods and
materials proposed to be used for executing a coating repair of the defects noticed after
receipt at site and shall receive approval from Engineer in charge prior to use. In open
storage the repair coating materials must be able to withstand a temperature of at least (+)
80°C without impairing its serviceability and properties.

Contractor shall furnish manufacturer's test certificates for the repair materials clearly
establishing the compliance of the repair materials with the applicable coating
requirements indicated in this specification.
All pipe leaving coating plant, shall have sound external coating with no holiday or porosity
on 100% of the surface.
Defects, repairs and acceptability criteria shall be as follows:
- Pipes showing porosities or very small damage not picked up during holiday test and
having a surface less than 0.5 cm2 or linear damage (cut) of less than 3 cm shall be
repaired by stick using material of same quality.
Damages caused to coating by handling such as scratches, cuts, dents, gouges, not picked
up during holiday test, having a total reduced thickness on damaged portion not less than 2 mm
and an area not exceeding 20 cm2 shall be rebuild by heat shrink patch only and without exposing
 Page A-63

to bare metal.

- Defects of size exceeding above mentioned area or holidays of width less than
300 mm shall be repaired with heat shrink repair patch by exposing the bare metal
surface.
- Defects exceeding the above and in number not exceeding 2 per pipe and linear
length not exceeding 500 mm shall be repaired using heat shrinkable sleeves of
HTLP 80 or equivalent.
- Pipes with bigger damage shall be stripped and recoated.

- In case of coating defect close to coating cut back, Contractor shall remove the
coating throughout the entire circumference of the pipe down to the steel surface
and increase the coating cut back length. Now if the coating cut back exceeds 140
mm of linear length of pipe then the coating shall be repaired by the use of heat
shrink sleeves thereby making up the coating cut back length of 120 mm.

Notwithstanding the above, under no circumstances, if the defect exceeds 70 mm from the
original coating cut back length, the entire coating shall be removed and the pipe shall be
recycled through the entire coating procedure.

Irrespective of type of repair, the maximum numbers of repair of coating shall be as

follows:

- Holiday repair of size  100 cm2 attributable to process of coating application shall
be maximum one number per pipe.

- In addition to the above, defects to be repaired by heat shrink patch/sleeve shall

be maximum 2 (two) per pipe.

Defects exceeding the above limits shall cause pipe coating rejection, stripping and
recoating. The above is exclusive of the repairs warranted due to testing as per this
specification.

All repairs carried out to coating for whatever reason shall be to the account of Contractor.

Cosmetic damages occurring in the polyethylene layer only, need not

be repaired by exposing up to steel surface, as deemed fit by the Engineer in

charge Representative. In any case the Contractor shall establish his

material, methods and procedure of repair that result in an acceptable

quality of product by testing and shall receive approval from Engineer in

charge prior to use

 Page A-64

All repairs shall result in a coating thickness no less than the parent coating thickness.

12.00.0 MARKING

Contractor / Manufacturer shall place marking on the outside surface of the coating at one
end of the coated pipe, and marking shall indicate, but not limited to the following
information:

a. Pipe number, Heat number

b. Diameter & Wall thickness

c. Coated pipe number

d. Colour band

e. Any other information considered relevant by Engineer in charge.

f. Pipe Manufacturer Name
g Inspection Mark / Punch
Contractor shall obtain prior approval on marking procedure to be adopted from the ENGINEER IN
CHARGE.

Epoxy coating is proposed for internal surface in all conditions and for external surface of the MS pipes laid
above ground on pedestals and outer surface of tees, manholes, covers and eccentric reducers.

The coating shall have one coat of two-part, chemically cured inhibitive Epoxy primer and two coats of a different
two-part, chemically cured, solvent free, and spray applied epoxy paint. The coating system shall meet the
performance requirements of relevant IS code or AWWA C-210 standard.

Prior to abrasive blast cleaning, the external surface shall be cleaned to remove oil, grease or other foreign
matter. Only approved solvents that do not leave a residue shall be used for cleaning.

The surface shall be abrasive blast cleaned to achieve a white metal surface. Prior to blast cleaning, any sharp
protuberances, surface laminations, weld spatter, etc shall be removed by thorough cleaning and grinding. The
abrasive used should be capable of producing a minimum profile of 50-75 microns corresponding to “medium” in
accordance with BS: 7079 part C4.

Prepared surfaces must be completely cleaned of dust and dirt by brush or vacuum cleaner and shall be
thoroughly dry. Coating shall not be applied in the following atmospheric conditions.

 Relative humidity exceeding 85%

 When the surface to be coated is less than 30 degrees C above the dew point

 The surface temperature is less than 7degrees C or greater than 50degrees C.

After application of the first coat, the next coat shall be applied within the time limits, surface conditions,
 Page A-65

Final thickness of the coating shall not be less than 400 micron DFT. The coating shall be applied leaving 15 cm
at the edge of pipes / specials for welding of the joint. Coating on this portion shall be applied after welding the
joint.

The temperature of mixed coating and that of the pipe at the time of application shall not be lower than
10degrees C. Preheating of the coating material, the use of inline heaters to heat the coating material; or heating
of the pipe, fittings or specials may be used to facilitate the application. Heating shall confirm to the
recommendations of the coating material manufacturer.

The finished coating shall be inspected for damage or reduced thickness. Any such areas shall be repaired by
thoroughly degreasing the surface and abrading using 180 grade abrasive papers, the abraded areas shall extend
from the edge of the damage for 50-75 mm on to surrounding sound coating. The prepared surface can then be
re-coated.

Sufficient curing period shall be allowed after application of the coating as per standards for the coating to gain
required strength. The epoxy applied pipes; specials shall be stored for curing in accordance with the durations
given in the following table.

Ambient Temperature, (deg C) 45 40 35 30 25 20 15 10 7*

Minimum number of days storage 1 1 2 4 5 7 11 17 22
*Minimum possible cure temperature

After curing, the coating shall be tested for holidays according to the procedures and using the voltage settings.
Any holidays indicated by the detector shall be got repaired.

The joint portion shall be cleaned thoroughly as stated above and coated in required coats for same thickness i.e.
400 micron DFT.

1.4.13.1 Installation and Testing of MS Pipelines

The excavation in hard rock will have to be carried out either by controlled blasting or chiselling, wedging or by
mechanical means and the tendered rate is supposed to cover all other means.

The pipeline alignment shall be cleared of all bushes, shrubs, roots, grass, weeds and if required trees, coming
in the alignment of pipeline in the trench width portion. The rates for excavation shall cover all such site clearance
work and no extra payment will be allowed on this account.

After the work site is cleared as above, pipeline alignment with required trench width shall be marked on the
ground with apex points, curves etc., as shown on the drawings or as directed by the Engineer-in-Charge in
charge for the stretch where the work is to be started. The contractor shall provide all labour, survey instruments,
and materials such as strings, pegs, nails, bamboos, stones, mortar, concrete etc. required for setting out and
establishment of bench marks. The contractor shall be responsible for the maintenance of bench marks and other
marks and stakes as long as they are required for the work in the opinion of the Engineer-in-Charge.

Working survey of the pipeline alignment shall be carried out by the contractor before start of the excavation work.
The contractor shall provide all the instruments such as levelling instruments, steel tape, ranging rods, strings,
pegs etc. for carrying out the survey. Based on the working survey, the alignments, L-section (depth of laying),
grade, and location of specials, valves and chambers shall be finalized and got approved from the competent
authority. The gradient and alignment shall be such that minimum horizontal and vertical bends shall be required.

All excavations shall be carried out by mechanical equipment / machinery unless, in the opinion of the Engineer-
in-Charge, the work involved and time schedule permit manual excavation.

All buried pipelines shall be minimum 1.2 meter below ground level.
 Page A-66

The trench width for respective pipe diameters permissible as required under respective IS code for Pipeline
laying and installation.

The trench width shall be constant throughout the trench depth, which will provide a clearance of about 0.30 m on
either side of the pipeline.

The Contractor may, for the facility of work or similar other reasons, excavate and also backfill later, if so
approved by the Engineer-in-Charge, at his own cost, outside the allowable trench width specified above. Should
any excavation be taken below the specified trench bottom, contractor shall fill it up to required level, at his own
cost, with the same material available at the trench bottom including watering and compaction.

The excavation shall be taken down to such depths as shown in drawings. Excavation for extra depth equal to the
thickness of proposed pipe bedding shall be done below pipe soffit level for providing bedding below pipeline. The
trench bottom shall be excavated to proper grade as shown on drawings. The contractor shall provide site rails
and levelling instruments required for checking the grade during excavation, bottom bedding and pipe laying
Projections in rock excavation shall be removed by chipping.

The contractor shall carryout extra excavation at the pipeline joints to be welded, as required (minimum 0.6 m
deep and 0.9 m lengthwise, all around the pipe), for facilitating proper welding of the bottom joint from outside.
The work of trench excavation should be commensurate with laying and jointing of the pipeline. It should not be
dug in advance for a length greater than 500 m ahead of work of laying and jointing of pipeline unless otherwise
permitted by the Engineer-in-Charge.

The minimum cover on pipe is to be maintained 1 meter. However the cover on pipe may be modified to suite
gradients and site conditions as per direction of Engineer-in-Charge.

To protect persons from injury and to avoid damage to property, adequate barricades, construction signs, red
lanterns and guards as required shall be placed and maintained during the progress of work, till filling of the
trenches after pipes are laid and jointed. The lighting, barricading, guarding of the trenches and the maintenance
of watchman shall be done by the contractor at his cost.

All precautions shall be taken during excavation and laying operation to guard against possible damage to any
existing structures, underground cables, pipelines of water, gas, sewage etc. Any damage done to such
properties will have to be repaired / rectified by the contractor at his cost. The Contractor has to ensure the
following:

 Safety protections as mentioned above have to be incorporated in the work process

 Hindrances to the public have to be minimized

 The trench must not be eroded before the pipes are laid

 The trench must not be filled with water when the pipes are laid

 The trench must not be refilled before laying of the pipes

The bed for the laying of the pipes has to be prepared according to the L-Section immediately before laying of the
pipes.

All surface materials, which in the opinion of the Engineer-in-Charge, are suitable for reuse in restoring the
surface shall be kept separate from the general excavation material, as directed by the Engineer-in-Charge.

All excavated materials shall be stacked in such a manner that it does not endanger the work and avoids
obstructing foot paths and roads. Hydrants under pressure, surface boxes, fire and other utility controls shall be
left unobstructed and accessible until the work is completed. Gutters shall be kept clean or other necessary
provisions made for street drainage and natural water courses shall not be obstructed. All the excavated material
shall be the property of the Employer and shall be stacked or disposed of as directed by the Engineer-in-Charge.
 Page A-67

The work of excavation and pipe laying shall be carried in such a manner that it causes the least interruption to
traffic and the road / street may be closed in such a manner that it causes the least interruption to the traffic.
Where it is necessary for traffic to cross open trenches, suitable bridging arrangement shall be provided. When
the street is closed for traffic, suitable signs indicating that street is closed shall be placed and necessary detour
signs for proper maintenance of traffic shall be provided.

Temporary support, adequate protection and maintenance of all underground and surface structures, drains,
sewers and other obstructions encountered in the progress of work shall be furnished under the direction of the
Engineer-in-Charge. The structures which have been disturbed shall be restored upon completion of work.

Trees, shrubbery fences, poles and all other property shall be protected unless their removal is allowed by the
Engineer-in-Charge. When it is necessary to cut roots and tree branches, such cutting shall be done under the
supervision and direction of the Engineer-in-Charge.

As far as possible, the pipeline shall be laid below existing services, such as water and gas pipes, cables, cable
ducts and drains but not below sewers. Excavation of the trenches shall be carried out to the required depth
accordingly. If it is unavoidable, the pipeline shall be suitably protected and lesser trench depth in such cases can
be allowed. A minimum clearance of 150 mm shall be provided between the pipeline and such other services.
When thrust or auger boring is proposed for laying pipeline across roads, railway or other utilities, larger
clearance as required shall be provided. Adequate arrangements shall be made to protect and support the other
services during excavation and pipe laying operations. The work shall be so carried out as not to obstruct access
to the other services for inspection, repair and replacement. When such utilities are met with during excavation,
the authority concerned shall be intimated and arrangements made to support the utilities in consultation with
them.

During the excavation if subsoil water is met with, contractor shall provide necessary equipment and labour for
dewatering the trenches. If pumping out subsoil water is found necessary, contractor shall provide sufficient
number of pumps for the same. The tendered rate shall cover all costs for bailing out of water including hire
charges of pumps, cost of diesel and labour etc and hence, no extra payment shall be allowed.

All loose boulders, semi-detached rocks, (along with earthy stuff which might move therewith), not directly in the
excavation but close to the area to be excavated, as to be liable, in the opinion of the Engineer-in-Charge, to fall
or otherwise endanger the workman equipment, or the work etc., shall be stripped off and removed away from the
area of the excavation. The method used shall be such as not to shatter or render unstable or unsafe the portion
which was originally sound and safe. The tendered rate is supposed to cover this job and no extra payment will be
allowed on this account.

All the excavated surplus material shall be disposed off on muck area with due consultation of Engineer-in-
Charge.

In case of hard rock and black cotton soil, before lowering of the MS pipes in trenches, a layer of selected
murum, shall be provided below the MS pipeline to act as bedding. The bedding shall be compacted properly
including required watering and the thickness of well compacted layer shall not be less than 150 mm. The
bedding shall be provided for full trench width with proper grade as shown on drawings.

Filling of excavated material in trenches shall be commenced as soon as the joints of pipes and specials have
been tested and passed. The backfilling material shall be properly consolidated by watering and ramming, taking
due care that no damage is caused to the pipes and the outer coating.

Selected surplus spoils from excavated material shall be used as backfill. Fill material shall be free from clods,
salts, sulphate, organic or other foreign material. All clods of earth shall be broken or removed. Where excavated
material is mostly rock, the boulders shall be broken into pieces not larger than 150 mm size, mixed with properly
graded fine material consisting of murum or earth to fill up the voids and the mixture used for filling.

For the purpose of back-filling, the depth of the trench shall be considered as divided in to the following three
zones from the bottom of the trench to its top:
 Page A-68

Zone A:
From the bottom of the pipe
(top of bedding) to the level of
the centre line of the pipe
Zone B:
From the level of the centre
line of the pipe to a level 300
mm above the top of the pipe
Zone C:
From a level 300 mm above
the top of pipe
Back-filling by hand with selected approved material available
from excavation, placed in layers of 150 mm and compacted by
tamping. The back-filling material shall be deposited in the
trench for its full width on each side of the pipe, specials and
appurtenances simultaneously. Special care shall be taken to
avoid damage of the pipe and the coating or moving of the pipe.
Back-filling and compaction shall be done by hand or approved
mechanical methods in layers of 150 mm; special care shall be
taken to avoid damage of the pipe and the coating or moving of
the pipe.
Back-filling shall be done by mechanical methods in 15 cm
compacted layers and carried to the level necessary or the
temporary restoration of road and path surfaces. If any hard core
surface for construction of road along the pipe trench, is ordered
by Engineer-in-charge, the same shall be done. Such level as
will leave the requisite space for the top soil, road surface etc. to
be reinstated as directed by the Engineer-in-Charge. In case of
agricultural or waste land and after approval by the Engineer-in-
Charge in Charge, back-filling may be made in thicker layers up
to 200 - 300 mm above the initial ground level.

All excavations shall be backfilled to the level of the original ground surfaces unless otherwise shown on the
drawings or ordered by the Engineer-in-Charge in Charge, and in accordance with the requirements of the
specification. The material used for backfill, the amount thereof, and the manner of depositing and compacting
shall be subject to the approval of the Engineer-in-Charge in Charge, but the Contractor will be held responsible
for any displacement of pipe or other structures, any damage to their surfaces, or any instability of pipes and
structures caused by improper depositing of backfill materials.

The back filled layers shall be wetted and compacted to a density of not less than 90 percent of the maximum dry
density at optimum moisture content of the surrounding material. Any deficiency in the quantity of material for
backfilling the trenches shall be supplied by the Contractor at his expense.

The Contractor shall at his own expense make good any settlement of the trench backfill occurring after
backfilling and until the expiry of the defects liability period.

On completion of pressure and leakage tests exposed joints shall be covered with approved selected backfill
placed above the top of the pipe and joints in accordance with the requirements of the above specifications. The
Contractor shall not use backfilling for disposal as refuse or unsuitable soil.

In case of excavation of trenches in rock, the filling up to a level of 30 cm above the top of the pipe shall be done
with fine materials, such as soft soil, murum etc. The filling up of the level of the centre line of the pipe shall be
done by hand compaction in layers not exceeding 15 cm, whereas the filing above the centre line of the pipe shall
be done by hand compaction or mechanical means in layers not exceeding 15 cm. The filling from a level of 30
cm above the top of the pipe to the top of the trench shall be done by mechanical methods with broken rock filing
of size not exceeding 15 cm mixed with fine material as available to fill up the voids.

The consolidation of the filled material shall be done to attain not less than 90 percent of the maximum dry
density. The density of the filled and compacted material shall be tested regularly and record maintained
accordingly.

Except as otherwise specified in this technical specification, the Indian Standards and Codes of Practice in their
latest version, National Building Code, PWD specification of the state of Madhya Pradesh and Manual of water
supply of GOI shall be adhered to for the, handling, laying, installation, and site testing of all material and works.
 Page A-69

The contractor has to provide all the tools and equipment required for the timely, efficient and professional
implementation of the work as specified in the various sections of the contract and as specified by the instructions
of manufacturers of the pipes and other material to be handled under this contract. On demand he shall provide to
the Engineer-in-Charge a detailed list of tools and equipment available. If in the opinion of the Engineer-in-Charge
the progress or the quality of the work cannot be guaranteed by the available quantity and type of tools and
equipment the contractor has to provide additional ones to the satisfaction of the Engineer-in-Charge. The
Contractor will always have a levelling instrument on site.

The Contractor has to transport the pipes and other materials from manufacturer or site store yard to the site of
laying as indicated by the Engineer-in-Charge. Pipes should be handled with care to avoid damage to the surface
and the socket and spigot ends, deformation or bending. Pipes shall not be dragged along the ground or the
loading bed of a vehicle. Pipes shall be transported on flat bed vehicles/trailers. The bed shall be smooth and
free from any sharp objects. The pipes shall rest uniformly on the vehicle bed in their entire length during
transportation. Pipes shall be loaded and unloaded by suitable mechanical means without causing any damage to
the stacked pipes.

The transportation and handling of pipes shall be made as per IS 12288 and IS 5822. Handling instructions of the
manufacturers of the pipes shall be followed. All precautions set out shall be taken to prevent damage to the
protective coating, damage of the jointing surfaces or the ends of the pipes.

Whatever method and means of transportation is used, it is essential that the pipes are carefully placed and firmly
secured against uncontrolled movement during transportation to the satisfaction of Engineer-in-Charge.

Cranes or chain shall be used for loading and un-loading of heavy pipes. However, for pipes up to 400 mm
nominal bore, skid timbers and ropes may be used. Where using crane hooks at sockets and spigot ends, hooks
shall be broad and protected by rubber or similar material, in order to avoid damage to pipe ends and lining /
coating. Damage to lining / coating must be repaired before pipe laying according to the specifications mentioned
elsewhere and as per instructions of the Engineer-in-Charge. Pipes shall not be thrown directly on the ground.

When using mechanical handling equipment, it is necessary to employ sufficient personnel to carry out the
operation efficiently with safety. The pipes should be lifted smoothly without any jerking motion and pipe
movement shall be controlled by the use of guide ropes in order to prevent damage caused by pipes bumping
together or against surrounding objects.

Rolling or dragging pipes along the ground or over other pipes already stacked shall be avoided.

The pipes shall be laid out properly along the proposed alignment in a manner that they do not create any
significant hindrance to the public and that they are not damaged. Stringing of the pipes end to end along the
working width should be done in such a manner that the least interference is caused in the land crossed. Gaps
should be left at intervals to permit the passing of equipment across the working area. Pipes shall be laid out that
they remain safe where placed and that no damage can occur to the pipes and the coating until incorporated in
the pipeline. If necessary, pipes shall be wedged to prevent accidental movement. Precautions shall be taken to
prevent excessive soil, mud etc. entering the pipe.

Generally, the pipes shall be laid within four weeks from the date of their dispatch from the manufacturer / store or
from out coating yard.

After the trench is made ready with bedding, and after the jointing pits are excavated at the joint position, the lined
pipes shall be lowered in the trenches.

The MS pipe ends shall be cleaned with special care to ensure that they are free from dirt and unwarranted
projections. The whole of the pipes shall be placed in position singly and shall be laid true to profile and direction
of slope indicated on longitudinal sections. The pipes shall be laid without deflection in a straight alignment
between bends and between high and low points. The alignment and levels shall be checked by the contractor
with theodolite.

Before pipes are jointed they shall be thoroughly cleaned of all earth lumps, stones, or any other objects that may
have entered the interior of the pipes.
 Page A-70

Pipes and the related specials shall be laid according to the instructions of the manufacturers and using the tools
recommended by them.

Cutting of pipes shall be reduced to a minimum required to conform to the drawings. Cutting has to be made with
suitable tools and according to the recommendations of the manufacturer without damage to the external coating
and internal lining. The spigot end has to be beveled again at the same angle as the original beveled end. While
assembling the pipes the ends shall be brought close enough to leave a uniform gap not exceeding 3 mm.
Marginal cutting shall be done if found necessary, for which no extra payment shall be admissible. There shall be
no lateral displacement between pipe faces to be jointed. After the pipes are properly assembled and checked for
the correct line and level, tack welding for the pipe joint shall be done. Final welding of the joint from inside and
outside shall be done thereafter.

Whenever the pipe laying work proceeds from two ends and if gap remained between two faces is less than 30
cm, such gap shall be bridged by providing a strap. Strap shall also be provided during fixing of expansion joint for
above ground pipeline. Such strap shall be fabricated on site by cutting a piece from the pipe. This piece shall be
split longitudinally and stepped over the gap. A minimum overlap of 8 cm shall be provided on both the pipe ends
to be connected. The strap shall be welded with pipe ends with required number of fillet wells from inside and
outside. The gap between ends of the strap shall be butt welded longitudinally.

Distance piece shall be provided when the gap between pipe faces to be jointed is more than 30 cm. Distance
pieces shall be cut from pipe pieces for required length either on site or in factory.

All specials like bends, tees etc. and appurtenances like sluice or butterfly valves etc. shall be laid in
synchronization with the pipes. The Contractor has to ensure that the specials and accessories are ready in time
to be installed together with the pipes.

At the end of each working day and whenever work is interrupted for any period of time, the free ends of laid pipes
shall be protected against the entry of dirt or other foreign matter by means of approved plugs or end caps.

When pipe laying is not in progress, the open ends of installed pipe shall be closed by approved means to prevent
entrance of trench water and dirt into the line. No pipe shall be laid in wet trench conditions that preclude proper
bedding, or when, in the opinion of the Engineer-in-Charge, the trench conditions or the weather are unsuitable
for proper installation. The pipeline laid should be absolutely straight unless planned otherwise. The accuracy of
alignment should be tested before starting refilling with the help of stretching a string between two ends of the
straight stretch of pipes to rectify possible small kinks in laying.

Above ground pipeline shall have epoxy coating on inner and outer surfaces with either 3LPE or Polyurethane..

Laying of pipeline shall be started only after sufficient number of chairs / pedestals have been casted as per
design which shelled not be less than 0.6 m in width to required level and have achieved their final strength
including fixing of the bearing plates and roller bearings.

The contractor shall lay the pipeline to the exact line and level as shown on the drawings, or as directed by the
Engineer-in-Charge.

The pipe laying shall start from the successive fixity points towards expansion joint, if proposed in that stretch.
Depending upon the distance between the successive chairs, and the length of the pipes fabricated, two pieces
may be welded on site before laying so that after laying the pipe rests on next chair and overhangs for at least half
the length of pipe.

Normally not more than one pipe shall be aligned, tacked and kept in position on the chairs at a time. During
assembly, the pipes shall be additionally supported on adequate wooden sleepers or scaffolding as necessary,
kept between the chairs / pedestals. While assembling the pipes, the ends shall be brought to leave a uniform gap
not exceeding 3 mm. The ends shall be tack welded to align the pipe properly.

Full welding of the circumferential joint shall be done only after the Engineer-in-Charge has checked the
correctness of the alignment and level. Further laying of pipes shall not be undertaken unless full welding of the
 Page A-71

circumferential joints of the piped laid earlier is completed. Expansion joint shall be fixed at the location shown on
drawing or as directed by the Engineer-in-Charge.

Before aligning, assembling and welding, the pipe faces shall be cleaned by scrapping with wire brushes or by
any other approved method.

Welding of pipes in field shall confirm to IS: 816 (code of practice for use of metal arc welding for general
construction in mild steel). Electrodes used for welding shall comply with IS: 814. In case of variation,
specifications hereunder shall have precedence.

Welders shall be qualified and well experienced and shall be approved by the Engineer-in-Charge. Contractor
shall remove such of the welders from the job whose work is not satisfactory.

The contractor shall keep record of the welding for each circumferential joint. It shall contain the name of the
welder, date of completion of the welding runs internal as well as external.

MS pipes to be jointed are large in diameter and hence the joints shall be welded with two numbers of runs from
inside and a sealing run from outside. External sealing run shall be done only after internal welding is completed.
Before starting the external welding, the weld material in the joint shall be cleaned by chipping out loose scales.
Gauging shall be done before rectification of any defective welding wherever necessary and as directed by
Engineer-in-Charge.

Gauging and chipping shall not be paid separately and the rate for welding shall be deemed to include the cost of
gauging and chipping.

Welding electrodes shall confirm to IS: 814. The contractor shall use electrodes of Advani and Premier or
equivalent depending on thickness of the plates to be welded and the type of joint. The contractor shall use
standard current and AC voltage required for the machine as per manufacturer’s directions.

The circumferential joints of the pipes shall have butt welded with required number of runs externally and
internally.

All the fillet welds / lap welds shall have throat thickness not less than 0.7 times the thickness of the pipe to be
welded.

Welded joints shall be tested in accordance with the procedure laid down in IS: 3600, Method of testing fusion
welded joints and weld metals in steel.

At least one test specimen shall be taken out for testing for every 50 field joints. Test pieces shall be taken out
from the places pointed out by the Engineer-in-Charge. These shall be machined and tested as early as possible.

The shape of the test pieces removed for testing shall be such that it shall give the specimen of the required
dimensions with the weld in the middle of the specimen. It must ensure good butt weld.

The test specimen taken perpendicularly across the weld shall be shaped in accordance with IS: 3600 (part 3).
The tension test specimen shall be machined. The protruding welded portion from inside as well as outside shall
be removed by machining before the specimen is tested. The specimen shall be tested in tension in accordance
with IS: 1608.

If the specimen shows defective machining or develops flaws not associated with welding, it shall be discarded
and another specimen substituted. The welded joint shall show strength not less than the minimum tensile
strength for the plate in accordance with IS: 226.

Bend test specimen shall also be prepared in the same fashion as the tensile test specimen. The specimen shall
be bent cold 180degrees around a pin that has a diameter equal to 4½ time the plate thickness, without
developing cracks. For this test, face representing inside of the pipe shall be placed next to the pin.
 Page A-72

Tree-panned plugs shall be taken out from any welded portion as pointed out by the Engineer-in-Charge. These
plugs shall not show any defects in welding such as inclusion of slag, blow holes, cavities, etc. The plug shall be
12 mm in diameter and shall be taken out by means of suitable electrically operated machine. Such holes in the
pipe shall either be filled back by inserting a steel stud and welding around or threading the hole and providing
suitable GI plug. This test shall be done if considered necessary by the Engineer-in-Charge.

Non-destructive testing of the completed weld shall be carried out on pipelines by radiographic method as
specified under IS: 4853 or ultrasonic method as per IS: 4260. Non-destructive test for every 50 joints shall be
carried out.

If the test specimen fails in either tensile or bent test or in both, two additional test specimens shall be taken out
from the section and shall be tested again for both the tests. If any one of them fails, extensive gouging and
repairing shall be carried out for the welded joints in that section to the full satisfaction of the Engineer-in-Charge
in charge. However, if both the samples give satisfactory results, the joint from which the original sample was
taken and had failed, shall be repaired at contractor’s cost. The joints shall be coated with same lining as specified
for pipe material both outside and inside with 10 cm overlap of lining.

Welder who has done the welding of the joint that has failed shall be solely held responsible for bad workmanship
and failure. Since all other factors like electrodes, current, arc voltage, etc. are already controlled; negligence on
the part of the welder only is responsible for such failure. For first such failure, the welder shall be warned and if
the failure is repeated, he shall be removed from the job.

Reinforced concrete thrust blocks shall be provided at each bend, tee, taper, end piece to prevent undue
movements of the pipeline under pressure. They shall be constructed as per design done by Engineer-in-Charge
considering the highest pressure during operation or testing of the pipes, the safe bearing pressure of the
surrounding soil and the friction coefficient of the soil.

The quantity of water added in order to re-establish the test pressure should not exceed 0.1 liter per mm of pipe
diameter per km of pipeline per day for each 30 m head of pressure applied.

All pressure testing at site should be carried out hydrostatically. The pipes shall be accepted to have passed the
pressure test satisfactorily, if the quantity of water required to restore the test pressure does not exceed the
amount calculated as above.

All pipes or joints which are proved to be in any way defective shall be replaced or remade and re-tested as often
as may be necessary until a satisfactory test shall have been obtained. Any work which fails or is proved by test
to be unsatisfactory in any way shall be redone by the Contractor.

Water used for testing should not be carelessly disposed off on land which would ultimately find its way to
trenches

On completion of a satisfactory test any temporary anchor blocks shall be broken out and stop ends removed.
Backfilling of the pipeline shall be completed.

After testing and commissioning the contractor shall flush the pipes with a velocity not less than 1 m/s or as
approved by the Engineer-in-Charge in Charge. Disinfection of drinking water pipelines should be done by
Contractor.

1.4.13.2 Ductile Iron Pipelines

The pipes will be Ductile Iron Pipes for Water and Sewage confirming to the IS: 8329. The pipes used will be
either with push on joints (Rubber Gasket Joints) or Flanged joints. The class of pipe to be used shall be of the
class K-7.

The pipes shall be coated with bitumen as per Appendix C and have factory provided cement mortar lining in the
inside as per the provisions of Appendix B of the IS 8329.
 Page A-73

The pipes will be supplied in standard length of 5.50 and 6.00 meters length with suitably rounded or chamfered
ends. Each pipe of the push on joint variety will also be supplied with a rubber EPDM gasket. The Engineer will
approve any change in the stipulated lengths. The gaskets will confirm to the IS: 5382.

The manufacturer of the pipes shall also supply the gaskets. The manufacturer of the pipes should preferably
manufacture them. In case they are not, it will be the responsibility of the manufacturer of the pipes to have them
manufactured from a suitable manufacturer under its own supervision and have it tested at his/sub-Contractors
premises as per the contract. The pipe manufacturer will however be responsible for the compatibility and quality
of the products.

The flanged joints will confirm to the Clause 6.2 of IS 8329. The pipe supply will also include one rubber gasket for
each flange.

The pipes will be subjected to following tests for acceptance:

 Visual and dimensional check as per Clause 13 and 15 of IS 8329

 Mechanical Test as per Clause 10 of IS 8329

 Hydrostatic Test as per Clause 11 of IS 8329

The test reports for the rubber gaskets shall be as per acceptance tests of the IS 5832 and will be in accordance
to Clause 3.8

The sampling shall be as per the provisions of the IS 8329.

All pipes will be marked as per Clause 18 of IS 8329 and show as below:

 Manufacturer’s name/stamp

 Nominal diameter

 Class reference

 A white ring line showing length of insertion at spigot end

The pipes should be preferably transported by road from the factory and stored as per the manufacturer
Specifications to protect damage.

This section covers the general requirements for Ductile Iron (DI) fittings suitable for Tyton joints to be used with
Ductile Iron pipes with flanged and Tyton jointing system.

The following types of DI fittings shall be manufactured and tested in accordance with IS: 9523 or BS 4772.

 Flanged socket

 Flanged spigot

 Double socket bends (90degrees, 45degrees 22 /12degrees, 11 ¼degrees)

 Double socket branch flanged tee

 All socket tee

 Double socket taper

 Page A-74

 All flanged tee

 All flanged taper

All the DI fittings shall be supplied with one rubber ring for each socket. The rubber ring shall conform to IS: 12820
and IS: 5382 as described in the preceding chapter. Flanged fittings shall be supplied with one rubber gasket per
flange and the required number of nuts and bolts.

This section covers the requirements for lubricant for the assembly of Ductile Iron pipes and specials suitable for
Tyton push-in rubber ring joints.

The lubricant has to have the following characteristics:

 Must have a paste like consistency and be ready for use

 Has to adhere to wet and dry surfaces of DI pipes and rubber rings

 To be applied in hot and cold weather; ambient temperature 0 – 50 degrees C, temperature of exposed
pipes up to 70 degrees C

 Must be non-toxic

 Must be water soluble

 Must not affect the properties of the drinking water carried in the pipes

 Must not have an objectionable odour

 Has to inhibit bacterial growth

 Must not be harmful to the skin

 Must have a shelf live not less than 2 years

They shall be conducted in line with the provisions of the IS 9523

All the DI fittings shall be properly packed with jute cloth. Rubber rings shall be packed in polyethylene bags.
Rubber rings in PE bags and nuts, bolts, etc. shall be supplied in separate jute bags.

The manufacturer of the pipes shall also supply the fittings. The manufacturer of the pipes should preferably
manufacture them. In case they are not, it will be the responsibility of the manufacturer of the pipes to have
them manufactured from a suitable manufacturer under its own supervision and have it tested at his/ sub-
contractors premises as per the contract. The pipe manufacturer will however be responsible for the
compatibility and quality of the products.

The pipes will be cleaned in the whole length with special care of the spigot and sockets on the inside/ outside to
ensure that they are free from dirt unwarranted projections. The whole of the pipes shall be placed in position
singly and shall be laid true to profile and direction of slope indicated on longitudinal sections. The pipes shall be
laid without deflection in a straight alignment between bends and between high and low points. Vertical and
horizontal deflections between individual pipes need the approval of the Engineer. In no case the deflection shall
be more than 75% of those recommended by the manufacturer.

Before pipes are jointed they shall be thoroughly cleaned of all earth lumps, stones or any other objects that may
have entered the interior of the pipes, particularly the spigot end and the socket including the groove for the
rubber ring.
 Page A-75

Pipes and the related specials shall be laid according to the instructions of the manufacturers and using the tools
recommended by them.

Cutting of pipes shall be reduced to a minimum required to conform to the drawings. Cutting has to be made with
suitable tools and according to the recommendations of the manufacturer. The spigot end has to be chamfered
again at the same angle as the original chamfered end. Cutting shall be perpendicular to the centre line of the
pipe. In case of ductile iron pipes the cut and chamfered end shall be painted with two coats of epoxy paint. If
there is no mark for the insertion depth on the spigot ends of the (cut) pipe it shall be marked again according to
the instructions of the manufacturer.

Before pipes are jointed they shall be thoroughly cleaned of all earth lumps, stones, or any other objects that may
have entered the interior of the pipes, particularly the spigot end and the socket including the groove for the
rubber ring. End caps are removed only just before laying and jointing.

All specials like bends, tees etc. and appurtenances like sluice or butterfly valves etc. shall be laid in
synchronization with the pipes. The Contractor has to ensure that the specials and accessories are ready in time
to be installed together with the pipes.

At the end of each working day and whenever work is interrupted for any period of time, the free ends of laid pipes
shall be protected against the entry of dirt or other foreign matter by means of approved plugs or end caps.

When pipe laying is not in progress, the open ends of installed pipe shall be closed by approved means to prevent
entrance of trench water and dirt into the line.

No pipe shall be laid in wet trench conditions that preclude proper bedding or when, in the opinion of the Engineer,
the trench conditions or the weather are unsuitable for proper installation.

The pipeline laid shall be absolutely straight unless planned otherwise. The accuracy of alignment should be
tested before starting refilling with the help of stretching a string between two ends of the straight stretch of pipes
to rectify possible small kinks in laying.

Pipes shall be lowered into be trench with tackle suitable for the weight of pipes. For smaller sizes, up to 200 mm
nominal bore; the pipe may be lowered by the use of ropes but for heavier pipes suitable mechanical equipment
have to be used.

All construction debris shall be cleared from the inside of the pipe either before or just after a joint is made. This is
done by passing a pull-through in the pipe, or by hand, depending on the size of the pipe. All persons should
vacate any section of trench into which the pipe is being lowered.

On gradients of 1:15 or steeper, precautions should be taken to ensure that the spigot of the pipe being laid does
not move into or out of the socket during the jointing operations. As soon as the joint assembly has been
completed, the pipe shall be held firmly in position while the trench is back filled over the barrel of the pipe.

The designed anchorage shall be provided to resist the thrusts developed by internal pressure at bends, tees, etc.

Where a pipeline crosses a watercourse, the design and method of construction should take into account the
characteristics of the watercourse to ascertain the nature of bed, scour levels, maximum velocities, high flood
levels, seasonal variation, etc. which affect the design and laying of pipeline. The pipe shall be laid accordingly
with adequate protection.

The assembly of the pipes shall be made as recommended by the pipe manufacturer and using the suitable tools.

The socket and spigot ends of the pipes shall be brushed and cleaned. The chamfered surface and the end of the
spigot end have to be coated with a suitable lubricant recommended by the manufacturer of the pipes. Oil,
petroleum bound oils, grease or other material, which may damage the rubber gasket, shall not be used as
lubricant. The rubber gasket shall be inserted into the cleaned groove of the socket. It has to be checked for
correct positioning.
 Page A-76

The two pipes shall be aligned properly in the trench and the spigot end shall be pushed axially into the socket
either manually or with a suitable tool specially designed for the assembly of pipes and as recommended by the
manufacturer. The spigot has to be inserted up to the insertion mark on the pipe spigot. After insertion, the correct
position of the socket has to be tested with a feeler blade.

Deflection of the pipes – if any – shall be made only after they have fully been assembled. The deflection shall not
exceed 75% of the values indicated by the pipe manufacturer.

Double-flanged Dismantling joints shall be fabricated from MS sheets in such a manner that valves can be
dismantled without stress to the joints. Dismantling joints shall be suitable for installation with all valves of
diameters of more than 250 mm. These shall be for working pressures of 7 kg/cm2 to 25 kg/cm2 and shall be
completely leak proof with proper gasket arrangement. Flange dimensions shall conform to IS 1538 (part I to
XXII). Flanged specials shall be supplied with required nuts, bolts and rubber gaskets. The nuts and bolts shall
be of best quality carbon steel, machined on the shank and electro-galvanized. Rubber gasket shall be as per IS
5382. Dimensions and drilling of flat gasket will be as per IS 1538, suitable for making flanged joint. The
dismantling pieces shall provide minimum clearance of + 25MM (total distance 50 mm). The dismantling joint shall
be internally and externally coated with hot applied (dip) bituminous paint.

After laying and jointing the pipeline shall be tested for tightness of barrels and joints, and stability of thrust blocks
in sections approved by the Engineer-in-Charge in Charge. The length of the sections depends on the
topographical conditions. Preferably the pipeline stretches to be tested shall be between two chambers (air valve,
scour valve, bifurcation, other chamber).At the beginning, the Contractor shall test stretches not exceeding 1 km.
After successful organization and execution of tests the length may be extended to more than 1 km after
approval of the Engineer-in-Charge in Charge. The hydraulic testing shall have to be commenced immediately
after laying and jointing of 1 km reach is completed.

The water required for testing shall be arranged by the contractor himself. The Contractor shall fill the pipe and
compensate the leakage during testing. The Contractor shall provide and maintain all requisite facilities,
instruments, etc. for the field testing of the pipelines. The testing of the pipelines generally consists in three
phases: preparation, pre-test/saturation and test, immediately following the pre-test. Generally, the following steps
are required which shall be monitored and recorded in a test protocol.

 Complete setting of the thrust blocks.

 Partial backfilling and compaction to hold the pipes in position while leaving the joints exposed for
leakage control

 Opening of all intermediate valves (if any)

 Fixing the end pieces for tests and after temporarily anchoring them against the soil (not against the
preceding pipe stretch)

 At the lower end with a precision pressure gauge and the connection to the reciprocating pump for
establishing the test pressure

 At the higher end with a valve for air outlet

 If the pressure gauge cannot be installed at the lowest point of the pipeline, an allowance in the test
pressure to be read at the position of the gauge has to be made accordingly

 Slowly filling the pipe from the lowest point(s).

 The water for this purpose shall be reasonably clear and free of solids and suspended matter

 Complete removal of air through air valves along the line.

 Closing all air valves and scour valves.

 Page A-77

 Slowly raising the pressure to the test pressure while inspecting the thrust blocks and the temporary
anchoring.

 Keeping the pipeline under pressure for the duration of the pre-test / saturation of the lining by adding
make-up water to maintain the pressure at the desired test level. Make up water to be arranged by
Contractor himself at his own cost.

 Start the test by maintaining the test pressure at the desired level by adding more make-up water; record
the water added carefully and the pressure in intervals of 15 minutes at the beginning and 30 minutes at
the end of the test period.

The pipeline stretch will pass the test if the water added during the test period is not exceeding the admissible
limits. No section of the pipe work shall be accepted by the Engineer-in-Charge in Charge until all requirements
of the test have been obtained.

1.4.13.3 Supply of MS Pipes and DI Pipes, Specials, Valves, Laying and Jointing of Pipelines

Except as otherwise specified elsewhere in this tender document, the Indian/International Standards and Codes
of Practice in their latest version shall be adhered to for the design manufacturing, inspection, factory testing,
packing, handling and transportation of product wherever applicable. Should any product be offered conforming to
other standards, the equipment or products shall be equal to or superior to those specified and the documentary
confirmation shall be submitted for the prior approval of the Engineer.

This specification requires a reference to the following standard specifications:

IS: 8329 Centrifugally cast (spun) ductile iron pressure pipes for water, gas and sewage.

IS: 9523 Specification for DI fittings for pressure pipes for water, gas, and sewage

IS: 12288 Code of Practice for use and laying of ductile iron pipes

IS: 12820 Dimensional requirements for rubber gaskets for mechanical joints and push on joint for
use with cast iron pies and fittings for carrying water, gas and sewage.

IS: 1387 General requirements for the supply of metallurgical material

IS: 210 Grey Iron casting

IS: 1363 Hexagon head bolts, screws and nuts of product grade A and B (Part 1-5)

IS: 14846 Sluice valve for water works purposes

IS: 318 Leaded tin bronze ingots and casting

IS: 7181 Horizontally cast iron double-flanged pipes for water, gas and sewage

IS: 5382 Rubber sealing rings for gas mains, water mains and sewers

IS: 3624 Pressure and vacuum gauges

IS: 341 Black Japan, types A, B, and C

IS: 9862 Ready mixed paint, brushing, bituminous, and black, lead free, acid, alkali, water and
chlorine resisting.

IS: 1239 Mild Steel tubes, tubular and other wrought steel fittings
 Page A-78

IS: 554 Dimensions for pipe threads where pressure tight joints are required on the threads

IS: 778 Specifications for copper alloy gate, globe and check valves for water works purposes.

IS: 2062 Specification for steel for general structural purposes

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: 3613 Acceptance tests for wire flux combination for submerged arc welding.

IS: 7280 Specification for bare wire electrodes for submerged arc welding of structural steel

IS: 1367 Technical supply conditions for threaded steel fasteners

IS: 2016 Specification for plain washers.

IS: 2074 Specification for ready mixed paint air drying, red oxide zinc chrome and priming

IS: 102 Ready mixed paint, brushing, red lead, non-setting, Priming.

IS: 1786 Specification for high strength deformed steel bars and wires for concrete reinforcement.

IS: 432(Part-I) Specification for mild steel & medium tensile steel bars and hard drawn steel wire for
concrete reinforcement: Mild steel and medium tensile steel bars

IS: 432(Part-II) Specification for mild steel and medium tensile steel bars and hard drawn steel wire for
concrete reinforcement: Hard drawn steel wire

IS: 269 Specification for 33 grade ordinary Portland cement

IS: 8041 Specification for rapid hardening Portland cement.

IS: 383 Specification for coarse and fine aggregates from natural sources for concrete

IS: 12330 Specification for sulphate resisting Portland cement

IS: 456 Code of practice for plain and reinforced concrete

IS: 800 Code of practice for general construction in steel

IS: 816 Code of practice for use of metal arc welding for general construction in mild steel

IS: 4353 Recommendation for submerged arc welding of mild steel & low allow steels

IS: 817 Code of practice for training and testing of metal arc welders.

IS: 1182 Recommended practice for radiographic examination of fusion- welded butt joints in steel
plates.

IS: 2595 Code of practice for radiographic testing.

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

IS: 5334 Code of practice for magnetic particle flaw detection of welds.
 Page A-79

IS: 3600 Code of procedure for testing of fusion welded joints and weld metal in steel

IS: 4853 Recommended practice for radiographic examination of fusion welded circumferential
joints in steel pipes.

IS: 3589 Specification for seamless or electrically welded steel pipes for water gas and sewage
(168.3 to 2032mm outside diameter).

IS: 5822 Laying of electrically welded steel pipes for water supply.

IS: 6631 Steel pipes for hydraulic purposes

IS: 7343 Code of practice for ultrasonic testing of ferrous welded pipes and tubular products.

IS: 2598 Safety code for industrial radiographic practice

IS: 5822 Code of practice for laying of welded steel pipes for water supply

BS EN 499 Welding Consumables. Covered Electrodes for Manual Metal Arc Welding of Non Allow
and Fine Grain Steel Classification

AWS:A-5.1 Specification for Mild steel Covered Arc Welding Electrodes

AWS:A-5.17 Specification for Bare Mild Steel Electrodes and Fluxes for Submerged Arc Welding

ASTM E 94 Guide for Radiographic Testing

ASTM E 709 Guide for Magnetic Particle Examination

ASTM E 165 Test Method for Liquid Penetrant Examination

IS: 5504 &3589 Code for SW pipes

IS: 10748 Requirement for Weldable Hot Rolled Carbon Steel Strip in Coils

BS: 4772 Specification for DI fittings

CPHEEO Manual on Water Supply and Treatment, II edition, Ministry of Urban Development, New
Delhi – May 1999

1.4.13.4 Pre-stressed Concrete Steel Cylinder Pipes (PCCP)

Scope

This Specification covers the requirements for designing, manufacturing, testing, supplying, laying,
jointing, welding and testing at works and site of Pre-stressed Concrete Cylinder (PCCP) pipes used
for water supply mains.

The manufacturer of PCCP Pipe shall have the valid BIS 784 license for past five years and
experience of manufacturing the same type of pipes for at least two years and should have the plants
and equipments capability of meeting the requirements of tender specifications.

Applicable Codes

The manufacturing, testing, supplying, jointing, welding and testing of PCCP pipes shall comply with all
currently applicable statutes, regulations, standards and Codes. In particular, the following standards,
unless otherwise specified herein, shall be referred. In all cases, the latest revision of the Codes shall
be referred to. If requirements of this Specification conflict with the requirements of the standards/
Codes, this Specification shall govern,
 Page A-80

IS 383 Specifications for coarse and fine aggregates from natural sources for concrete.

IS 1785 Specifications for Plain Hard –drawn steel wire for Pre-stressed Concrete.
Part 1&Part 2

IS:2062 Specification for steel for General Structural purposes

IS: 784 Specifications for Prestressed Concrete pipes ( Including specials)

IS: 7322 Specifications for Specials for Steel Cylinder Reinforced Concrete pipes

IS 3658 Code of Practice for liquid penetrate flaw detection

IS:3597 Methods of Test for Concrete pipes

IS:783 Code of practice for Laying of Concrete Pipes

IS 1566 Specifications for Hard Drawn Steel Wire for Concrete Reinforcement

IS 5822 Code of practice for Laying of Electrically Welded Steel pipes for Water Supply

AWWA Manual M- 9 ‘Concrete pressure Pipe-2007

Others I. S. Codes not specifically, mentioned here but pertaining to the use of PCCP pipes forms
part of these Specifications.

DESIGN

The PCCP pipes shall be designed as per the Specifications for PCCP pipes, to withstand the likely
extreme conditions of stresses that may arise during all stages of manufacturing handling and
service. The all pipes shall be designed to withstand the combined effects of internal water pressure,
overburden, water hammer pressure, external loads etc giving due regards to the worst accompanying
conditions.

In case of corrosive soils in which pipes are to be laid, necessary precautions against chemical attack
and corrosion shall be taken in manufacturing these pipes with prior approval from engineer in charge.
The design of PCCP pipes shall be in accordance with the basic assumptions and general
requirements stipulated in IS: 784. The contractor shall carry out surge analysis using latest software’s
for checking the designs of gravity mains (Raw and muddy water) and provide surge arrestors
accordingly. The design shall be approved by the Engineer in Charge additional surge valves at
available locations. Also the contractor shall provide 10 years warranty against any manufacturing
defects.

Working Pressure

The maximum sustained internal pressure excluding surge to which each portion of the pipe line may
be subjected when installed.

a) SITE TEST PRESSURE

1.5 times working pressure pertaining to the section or 1.1 times static pressure, whichever is
more.
b) FACTORY TEST PRESSURE

Site test pressure plus 0.1 N/ mm2 for working pressure up to 1 N/mm2, and Site test pressure
plus 0.2 N/mm2 for working pressure above 1 N/mm2
 Page A-81

c) SURGE (WATER HAMMER) PRESSURE

Pressure which is produced by a change of velocity of the moving stream and becomes
maximum when there is sudden stoppage which may be caused by the closing of a valve for by
shutting down a pump station, Surge pressure is to be controlled within 25 percent of the pump head.
DESIGN CRITERIA

Design Criteria for Pre-stressed Concrete Cylinder Pipe.

Internal dia. : As applicable

Minimum Thickness of core : As per IS 784-2001

Minimum coating thickness : Not less than 18 mm over steel

Reinforcement (IS-784:2001)

Consideration of coating thickness in : Nil (for internal pressure design)

Length : As per IS-784:2001.

Concrete Strength : Not less than 40 N/mm2 at 28 days.

H.R Sheet & M.S Plates for joint rings : As per IS 2062 / IS 5986 or equivalent.Minimum
thickness of Cylinder : 1.6 mm.

Minimum thickness of joint ring : 5 mm.

Hydraulic testing of cylinder : As per IS 784:2001

Minimum compressive strength of core concrete at the time of wire winding should be 25 N/mm2.

H.T WIRE

Dia. of Wire mm. UTS kg/cm2

4 175

5 160

Maximum initial tension at winding : As per process by max. up to 75% of UTS.

Modulus of Elasticity for concrete and

steel. : As per IS – 1343

Cl. 4.5.3.1 for Concrete &

Cl.5.2.3.1 for Steel.

Pitch for circumferential wire : IS – 784.

Loss of Stress in H. T. Wire at different : IS - 784 Stages For Circumferential Winding

a) Hydrostatic Proof Test : As applicable as per IS 784.

b) Site Test pressure : 1.5 times (c)

c) Working pressure : As shown in L-Section.

Bedding Angle : 90 degree

Fill load

a) Density of soil : 1800 kg/m3

b) Fill height minimum : As per site, min 1.2m.

 Page A-82

c) Width of trench of design purpose (As per specifications)

d) Coefficient for fill load : As per IS-783

LIVE LOAD : As per IS –783

As per manual on Sewerage and Sewerage Treatment (GOI) page 33 formula 6.11.

OLEANDER COEFFICIENT FOR 90 DEGREE BEDDING

Ext. Load Bottom

Moment(MB) Thrust(HB

a) Earth load +0.125 Wer +0.326 we

b) Self Wt. +0.121 Wsr +0.207 Ws

c) Water St +0.12 Wwr - 0.27 Ws

d) Live load +0.125 Wlr +0.326 Wl

Notes:

a) + Moment indicates tension on inside of pipe at bottom.

b) ‘r’ is the mean radius.
Design criteria for different loading conditions (as per IS-784:2001.)
Tolerance in length, dia and thickness as per IS-784:2001.

‘c’ value ( Hazen William Coefficient ) for : For design purpose c= 140 Internal surface.
Material

Cement

The cement used in the manufacture of PCCP pipes shall conform to one of the following:

1. 43/53 grade Ordinary Portland Cement conforming to IS:8112 /IS:12269

2. Rapid Hardening Portland cement conforming to IS: 8041

3. Slag cement (with not more than 50% slag) conforming to IS: 455

4. Sulphate Resistant Cement conforming to IS: 12330

5. Supersulphated Cement conforming to IS: 6906

6. Portland Pozzolona Cement Conforming to IS 1489 Part I or IS 1489 Part II

AGGREGATE

The coarse and fine aggregates shall conform to I.S.383. The maximum size of aggregate shall not
exceed one third the thickness of the pipe or 20mm whichever is smaller. The requirements of Grading
4 (Zone IV for F.A.) of IS: 383 shall not apply. Manufacturer shall furnish the grading curve for fine
 Page A-83

aggregate. The variation in finesses modulus during manufacture shall not be more than 5 percent. Silt
Content in Natural Sand aggregates shall be less than 3 percent and in case of Crushed Sand, it shall
be less than 10 %.Silt Content in fine aggregates shall be less than 3 percent. The fineness modulus
of aggregates for coating shall be between 2.6 to 3.2.

WATER

The water used in the preparation of concrete mix shall be clean and free from harmful or injurious
compounds such as acids, alkali, oil, organic material or other substances and shall conform to the
requirements of mixing water as per clause 5.4 of IS : 456.
ADMIXTURES

No admixtures shall be used in the preparation of concrete mix.

CONCRETE

Suitable mix of concrete shall be proportioned such that the pipes and fittings made from it shall
conform to all the requirements of the Specifications for PCCP pipes. The quality control of the
concrete shall be exercised in accordance with IS: 456.

STEEL REINFORCEMENT

The H.T Wire for circumferential prestressing used for manufacturing PCCP pipes shall conform to the
Specifications of IS: 1785 part 1 or part 2.

STEEL FOR CYLINDER, JOINT RINGS AND SPECIALS

Steel plates for Cylinder, Joint Rings and Specials shall confirm to IS: 2062 or IS 5986or IS 2041 or IS
6240 provided minimum yield strength shall be 250 N/mm2. The steel sheet or plates other than above
Indian Standards may be permitted if their mechanical properties match as per the above specification.

. DIMENSIONS AND TOLERANCES

 Nominal internal diameter of the pipes, minimum wall thickness and minimum thickness of
concrete lining shall be as per Table-A below in 2.6.10.
 The cement mortar coating shall provide a minimum cover of 18 mm over the circumferential
prestressing wires.
 Pipe sections shall be manufactured in lengths of 5m to 7m unless otherwise specified or
approved by Engineer.
 The tolerances applicable to the internal diameter shall be as per table 2 of IS: 784.
 The tolerance for the wall thickness shall not be less than the design thickness by the more
than 5 percent or 5mm whichever is greater. The manufacture shall declare the wall thickness
for any given design and the above tolerance shall be applicable to that for wall thickness.
 The tolerance on length of pipe shall be +1% of the stipulated length.

MANUFACTURE AND FABRICATION-(ONLY FACTORY M&F PERMITTED)

WELDING PROCEDURE
The manufacturer shall prepare written welding procedure specifications for all welding to be used for
fabrication of steel cylinders & joint rings according to applicable standards & if requested by the
purchaser, the welding specification shall be submitted.
FABRICATION OF JOINT RINGS
The Structure of pipe Joint shall only be Welded Joint.

Each ring shall be formed by one piece of steel or a number of pieces of steel butt welded together.
The rings shall be expanded beyond their elastic limit so as to achieve accurate dimensions and
shape.
 Page A-84

Welds on pipe jointing surface shall be smooth and flush with the adjacent surface.
Width of Steel Spigot and Socket Joint ring shall not be less than 125 mm up to dia 1200 mm and 150
mm for pipe diameter above 1200 mm.

FABRICATION OF STEEL CYLINDERS

The steel cylinders shall be formed by shaping and welding together cut lengths or coils of required
material & thickness. In case of welding cut lengths together, the sheet shall be fitted closely prior to
welding & they shall be held firmly during welding. Welding shall be either by spiral welding or
circumferential & longitudinal welding.
The cylinders shall be shaped accurately to the size required, and the joint rings shall be attached to
the steel cylinder by watertight fillet or butt joint welding.
When the wire is to be wrapped directly on the cylinder, butt welding of the helical or transverse &
longitudinal seams shall have smooth & continuous external surface.

Representative weld samples shall be made at the beginning of each production run, when either the
pipe diameter or cylinder thickness is changed. These samples shall be tested transverse to the weld,
and the tensile strength shall meet or exceed the required tensile strength of the steel used for the
cylinder.
HYDROSTATIC TEST OF CYLINDER
Each steel cylinder, with joint rings welded to its ends, shall be subjected to hydrostatic test by the
manufacturer to a hydrostatic pressure not less than that determined by the following formula
P = 2Sty / Dy
P = Minimum hydrostatic test pressure in N / mm2
S = Stress on cylinder during hydrostatic test in N / mm2 which
shall at least 138 Mpa but not greater than 170 Mpa
ty = Cylinder thickness in mm
Dy = Inside diameter of steel cylinder in mm

All flux (if welding By MMAW) shall be removed from the weld prior to Hydrostatic testing of cylinder.
The test pressure shall be held for 1 min. to observe leakages through welds. While under pressure
test, all welds shall be inspected thoroughly and all parts showing leakage shall be marked. Cylinder
that shown leakage under test, pressure shall be released be re-welded at the points of leakage & to
be subjected to another hydrostatic test. The above procedure shall be repeated until the finished
cylinder, with joint rings attached, proves to be completely watertight under the required hydrostatic
test pressure.
CORE
STEEL SURFACE PREPARATION
Before the concrete core or mortar coating is placed, each steel cylinder shall be free from foreign matter
that would interfere with the bonding of the concrete or mortar.
All indentations and bulges in the steel cylinder deviating from the cylindrical surface shall be removed
prior to placing of concrete. No indentation or bulges in the cylinder of lined cylinder pipe should be
permitted causing more than 1.6 mm clear space between prestressing wire & cylinder after wrapping.
CONCRETE FOR PIPE CORE
The concrete in the core may be placed by the centrifugal method or by vertical casting method.
CONCRETE MIX
The proportions of cement, fine aggregate, coarse aggregates and water used in concrete for pipe
cores shall be determined and controlled as the work proceeds to obtain homogenous, dense,
 Page A-85

workable, durable concrete of specified strength in the pipe, and minimum defects on the surface of
the pipe.

The proportions shall be those that will give the best overall results with the particular materials and
the methods of placing used for the work. A minimum of 350 kg/m3 of cement shall be used for
concrete. The water cement ratio shall be such, as to ensure that the concrete will meet the strength
requirements, but in no case shall it exceed 0.5 for concrete placed by centrifugal spinning process, or
0.45 for concrete placed by vertical cast.
MIXING
Mixing time shall be consistent with the types of materials, admixtures & the mixer. Transit mixer shall
not be used except by written authorization. The temperature of mix shall not be less than 4° C at the
time of placement. The temperature of mix for vertically cast cores shall not exceed 32 ° C at the time
of placement & that of centrifugally cast cores by 38 ° C.

STRENGTH OF CONCRETE
The minimum compressive strength of the core concrete at time of circumferential prestressing shall
be 25 N /mm2.

Unless the design calls for higher concrete strength, the minimum compressive strength of core
concrete at 28 days shall not be less than 40 N/mm2 for cores placed by centrifugal casting.

The core concrete compressive strength shall be taken on 150 x 150 mm cube.

In case of centrifugally cast concrete, the compressive strength of the concrete core differs from that
given by test by vibrated cube. Therefore strength of concrete core should be related by the
conversion factor established by the manufacturer at different age of concrete. The core concrete
strength shall be obtained by multiplying the vibrated cube strength with the conversion factor & shall
be used for designed purpose.
If the purchaser requires evidence of these factors, he shall ask for it before placing the order.

PLACING CONCRETE BY CENTRIFUGAL METHOD

The steel pipe cylinder with joint rings attached shall be placed in the mould horizontally. The mould for
the cylinder shall be designed so that cylinder is held firmly and accurately at proper position without
distortion during placing the concrete & also during centrifugal spinning on spinning machine.

End gauge rings shall be attached securely to the pipe ends to control the core thickness & to stiffen &
hold pipe ends round.

The method of placing concrete in the cylinder & speed of rotation during placing shall be such, that
concrete will be evenly distributed, sufficiently compacted at the specified thickness throughout the
length of the pipe. After the concrete has been deposited, the rotation shall be continued at an
increased speed, for a length of time sufficient to provide the specified strength and sufficient
compaction and bond to permit handling of the mould from the spinning machine, without damage to
the pipe core.

Excess water and laitance shall be removed from the interior surface of the pipe in an approved
manner so that the surface is solid, straight and true.
The end gauge rings shall remain in place until the end of primary cure unless the other measure
equally effective are taken to stiffen and hold the pipe ends round.
PCCP CONCRETE CORE MANUFACTURING

The PCCP core is cast either by centrifugal spinning process or Vertical casting method.
BY CENTRIFUGAL SPINNING PROC ESS

The steel cylinder with joint rings attached shall be placed horizontally on the spinning machine and
may be held by spinning frame. Effective measures shall be taken to maintain the circularity of the
 Page A-86

steel cylinder during spinning process. Feeding and Spinning speed of the mould shall be such that
concrete will get evenly distributed and sufficiently compacted for the designed uniform thickness and
duration of the spinning shall be to achieve required concrete strength to permit removal from the
spinning machine without damage.
Belt lining machine shall not be used for casting PCCP Concrete core.

BY VERTICAL CASTING METHOD

The concrete lining of core shall be cast on – end on a cast iron or steel base ring with rigid steel
collapsible mould or forms for concrete surfaces. The mould shall have smooth contact surfaces, tight
joints and will firmly and accurately held in proper position without distortion during casting the
concrete. Adequate vibrations shall be provided to compact the concrete in the mould by mechanical
means.
CONCRETE CORE WALL THICKNESS

Minimum core thickness for nominal internal diameter shall be as per Table given below:
TABLE - A

Diameter of pipe (mm) Minimum core

thickness (mm )

400 - 800 50

900 55

1000 65

CURING OF CORE

Pipe cores shall be cured set forth by water to obtain concrete of strengths required for cubes specified
in IS 784. The core shall be cured by water curing, accelerated curing or by the combination of both
as per procedure described below. Water curing may be used only if the ambient temperature exceeds
4 ° C.

WATER CURING
Water curing shall begin as soon as the concrete has set sufficiently to prevent damage to the
exposed portion of concrete surfaces. All exposed concrete surfaces shall be kept moist by intermittent
or continuous water spraying throughout the water curing period.
Forms shall not be removed until the concrete has attained strength sufficient to resist damage during
form removal operation & during handling the core to transfer in sprinkler yard but in no case the forms
be removed until 12 h after completion of concrete placement.
The total cure consisting of water cure & the ambient air cure shall be sufficient to produce the
concrete strength required as specified in IS 784.

CIRCUMFERENTIAL PRESTRESSING
Circumferential prestressing shall not take place until the concrete in the core has reached a
minimum compressive strength of specified in IS 784.
The pre-stressing wire shall be wrapped around the core in helical form of the designed predetermined
spacing and tension for the full length of the core except wire anchoring at the ends. The number of
turns per meter shall not be less than required by the pipe design. The initial stress in the wire during
circumferential pre-stressing shall not be more than 75% of the minimum ultimate tensile strength of
the wire when counter weight or break system is used for developing tension.
 Page A-87

The nominal wire size for circumferential pre-stressing shall not be less than 4 mm in diameter.

There shall be no rust scale or pitting of the wire surface visible to the unaided eye after wiping or light
cleaning shall not be cause for rejection of wire.

The initial compressive stress induced in the core concrete shall not exceed 55% of the compressive
strength of the concrete in the pipe at the time of wrapping.

Methods and equipment for wrapping the wire shall be such that wire shall be wound around the core in a
helical form at the predetermined design spacing and capable of controlling the tension for full length of core
except at the ends of the core where one circumferential turn of wire may be applied at one-half of the
designed tension. Fluctuation in tension shall not deviate from designed tension by more than ± 10 % the
number of turns in any 500 mm length of core shall not be less than required by the design.

Wire splicing shall be capable of with-standing a force equal to the full strength of wire. At the ends of
core pipe, the wire shall continue for at least one extra circumferential turn before being anchored.
Anchorage of the wire at the end of core shall be capable of resisting a force equal to 75 % of the
specified minimum tensile strength of wire.
As the circumferential prestressing wire is wound, a Portland cement slurry composed of 1.6 kg
cement to per liter of water shall be applied so that portion of wire bearing against the core will be coated
with cement slurry. .Immediately prior to placement of the cement slurry, all loose mill scale, excessive
rust oil, grease and other foreign substances shall be removed from all surfaces to receive cement
slurry.
Circumferential cracks in the core, due to discontinuity of prestressed at the spigot end are allowed
provided they do not affect water tightness.

COVER COATING
The circumferential prestressing wires on the core pipes shall be protected with a layer of rich cement
mortar.
Cement mortar coating shall be applied by the rotary brushes or by other approved methods within 16
hours of the prestressing wire is wound. The minimum cement content in the mortar shall be 540
kg/m3 and the water cement ratio shall be not less than 0.27. The cement, sand and water shall be
thoroughly mixed, before being fed into the cover coating machine. Rebound or dropping not
exceeding one fourth of the total weight of mix may be used but the resulting mix proportion shall not
be leaner than original design mix. Rebound not used within one hour, shall be discarded.
The mortar coating shall have a minimum cover of 18 mm over all steel except at the end joint rings.
Patchwork to the coating mortar will not be permitted in case of coating peel off take place.

Pneumatic process in which mixing of ingredients is carried out at the nozzle or gun shall not be
permitted.
The compressive strength of the cover coating mortar shall be obtained from cubes having area of
face 50 cm2 or the compressive strength of the cover coating concrete shall be obtained from cube
having area of face 100 cm2 and shall not be less than 35 N/mm2 at the time of factory testing of pipe.
To achieve adequate bond between core and coat, approved bonding agent shall be applied, at ends
of pipe for a width of 50 mm, along the circumference to prevent separation between core and coat, at
ends.
Concurrently with the mortar coating cement slurry shall be applied on to the core at rate of not less
than 0.5 lit/m2 just ahead of the mortar coating. The slurry shall consist of 1.2 kg. of cement to 1 lit. of
water.
The thickness shall be checked for every pipe as soon as, coating is done.
As soon as the coating has set sufficiently, it shall be kept moist by intermittent spraying for a period of
at least 7 days.
WORKMANSHIP AND FINISH
DEVIATION FROM THE STRAIGHTNESS
When measured by means of a one meter straight edge the deviation from straight per meter length
shall not exceed 5 mm.
 Page A-88

FINISH
Pipe shall be free from local depressions or bulges greater than 5 mm extending over a length, in any
direction, greater than twice the thickness of barrel. The external surface of the pipe may be sand
faced, when coating of cement mortar is applied.

TEST
HYDROSTATIC FACTORY TEST
Each and Every completed pipe shall be subjected to Hydrostatic test to the factory test pressure after
7 days curing is completed. The factory test pressure shall be maintained for a period of 3 minutes by
continuous pumping the water using throttling device. During the test pipe shall be absolutely water
tight and show no leaks.

For pipes with welded joint, end leakages through bulk heads shall not be treated as leakage.
Should a pipe fail the test, then a further two pipes from the same batch of 50 shall be tested. If both
pipe pass then the batch shall be accepted. If one or both pipe fail then the batch shall be rejected or
each pipe in the batch shall be tested for individual approval.
When submitted to hydrostatic, No cracks in the external surface shall be wider than 0.5 mm and the
length exceeding 300 mm using feeler gauge.

HANDLING AND TRANSPORTATION OF PIPES

 During manufacturing and during the entire period of the application of concrete or mortar
lining protection and the curing thereof, the section shall be carefully supported and handled
so as to avoid injury to the fresh lining. If a pipe section must be rolled or otherwise moved,
such operation shall be done slowly and with every reasonable precaution against damage.
Any portion of the lining, Coating that may become damaged shall be repaired with polymer
Mortar.
 Pipes shall be handled and transported to the site carefully as per the general Specification
for Laying of pipes and Fittings given in this chapter as per IS:783
 Pipes manufactured at factory are to be carried to the site of work directly or stacked suitably
and neatly along the alignment/ road side/elsewhere near by the work site, as directed by the
Engineer.
 All pipes shall be loaded in trucks by mechanical crane/ tripod and unloaded carefully using
crane/ tripod. No unloading using crow bars or on tyres will be allowed in any case. Rubber
belt may be used instead of crow bars or chains.
 Extreme care shall be taken while handing the pipes. Damages during transit will be to the
Contractor’s account and replacement for such pipes has to be made by the Contractor
without any extra cost.
 The rates should be inclusive of payment of entry tax, work contract tax and all other statutory
taxes prevailing at the time of tendering. All such taxes are to be paid by the Contractor at no
extra cost to the Engineer. This does not include any increase of slabs of levy due to turn
over.
LOWERING, LAYING AND JOINTING OF PIPES

 Pipes shall be lowered, laid and jointed carefully as per the general specifications for Laying
of pipes and Fittings given in this chapter, as per IS: 783
 Each pipe shall be thoroughly checked for any damages before laying and only the pipes
which are approved by the Engineer shall be laid.
 As directed by the Engineer, murum / sand bedding has to be done at the place shown. At
other places, consolidation of bottom depth to the required grade will be done, as far as
possible.
 The trench shall be kept free of water till the jointing/ welding has been properly done.
 Walking on completed line shall not be permitted until trenches are back filled
 In additional, the provisions of IS: 5822 shall also be applicable.
 Page A-89

 Pipe Joints are covered with rich cement mortar from inside (applicable for pipe diameter 600
mm and above) & Outside of the joint is protected with rich cement mortar using polyethylene
diaper. Polyethylene diaper ensures proper placing of mortar throughout the periphery even
at the bottom of the joint. The diaper remains in position and helps to retain the moisture
inside requiring no further curing of the joint.

SPECIALS AND FITTINGS

The steel for fabricated steel plate specials, is cut, shaped and welded so that finished special has the
required shape and internal dimensions. Adjacent segments are joined by butt welding. Before lining
and coating the welding of special shall be tested by use of hot oil or dye penetrate according to IS
3658 and defects, If any shall be rectified. The steel plate thickness for specials shall be as given in IS
7322.

In die penetration test, a white wash is applied over the weld on one side of the cylinder, on other side
when coloured paraffin or similar

Product is applied over the weld, no coloured spot shall appear on the whitewash before 4 h. if any
coloured spots appear before 4 h. weld shall be repaired and retested.

Specials and fittings for PCCP pipes shall be made out of steel plate fabricated to the required
dimensions and given a coating of cement mortar inside and outside and shall be as per the
specifications below:

These specials shall be suitable for fixing PCCP pipeline and shall conform to the requirements of IS:
784 and IS: 7322.

The steel for fabricated steel plate fittings is cut, shaped and welded so that the finished has the
required shape and interior dimensions. Adjacent segments shall be joined by means of lap or butt
welding.
The steel used for manufacturing of specials shall conform to IS: 2062

The specials shall be protected by Concrete / Cement mortar or anticorrosive Epoxy Coating.

In case of lining & coating with concrete / cement mortar, the following procedure shall be applicable.

The specials shall be lined inside and outside with 25mm thick concrete / cement mortar, reinforced
with 50X50 mm weld mesh of specified gauge. The cement mortar inside shall be 1:1.5 (1 part cement:
1.5 part sand) and cement mortar outside shall be 1:2(1 part cement: 2 part sand).

All specials shall be hydrostatically tested before using as per Clause 8 of IS : 7322. All the specials
shall be tested for hydrostatic pressure as specified for PCCP pipe and to the pressure specified for
pipes in the reaches where the specials are fitted.

All fittings shall be inspected by the Engineer at the place of manufacture and also at site. The
contractor is fully responsible for any defects in manufacturing not conforming to IS Specifications. All
defective specials shall be replaced by the Contractor free of cost.

Extreme care shall be taken while carting the specials to site, so that inside or outside coating is not
damaged. If damages are observed the Contractor shall have to make it good at his cost.

TESTING

Pipes shall be given different tests for ensuring quality of manufacture as per IS: 784 & IS: 3597 and
quality of laying as per IS: 783 & 5822.

When the site test pressure is applied, the additional quantity of water necessary to maintain the site
test pressure shall be as per IS 783.

DIMENSIONAL TESTS
INTERNAL DIAMETER
 Page A-90

The internal diameter shall be measured at each end at approximately 50 mm from the ends. Two
measurements of the internal diameter at 90 to each other shall be made at each end and centre. The
internal diameter shall be maintained within the tolerance specified.

WALL THICKNESS

Measurement of outside circumference of the pipe shall be made at three positions and average
outside diameter of the pipe shall be calculated. The inside diameter shall be measured at three
positions and average shall be calculated. The wall thickness shall be calculated as follows:
Average outside diameter – Average inside diameter

The wall thickness shall be maintained within the tolerance specified.

Concrete Lining Thickness shall be maintained within the tolerance specified

INTERNAL BARREL LENGTH

The length shall be measured on four longitudinal at 90 intervals. The average reading shall be internal
barrel length.

STRAIGHTNESS

The straightness shall be measured by 1 m long gauge. The deviation from straight line taken between
two points 1 m apart, along the pipe barrel shall not exceed 5 mm
PERMEABILITY TEST ON COATING

The drop of water level, in the specimens of pipes selected when tested according to method
described in IS 3597 shall not exceed 2 cm3 at the end of two hours and the final permeability between
fourth and fifth hours shall not exceed 0.3 cm3 when a higher result is obtained, the test shall be
repeated on twice the number of pipes originally tested and the lot shall be accepted, if all pipes pass
the test. Where retest is not satisfactory, all pipes from that lot may be tested individually and only
those with satisfactory results shall be accepted. No additional treatment of any type shall be allowed
on the pipe before permeability test is taken. The criteria for acceptance are the final permeability. The
measurement should to be taken immediately after factory test. In case this is taken later, then the
pipe has to be kept wet for 48 hrs prior to test.

. Pressure Permeability Test on Coating as per European Specification EN 642.

The Test is to determine the water permeability of the Mortar Cover coat of cured pipe under a
constant pressure on water column by non destructive means.
Test is to be conducted as per European Specification EN 642

The ratio of cumulative absorption per hour to area of cup orifice in contact with the pipe surface is to
be calculated. The ratio shall not exceed0.15 per hour for the period between 121 and 180 minutes
in to the test.

If this requirement has not been attained in the above stipulated period, the test is to be continued for
further periods 240, 300, 360, 420 or 480 minutes until the requirement is met. If the requirement has
not been met at 480 minutes, the pipe has failed to the test, and in such case further 2 Pipes from
the batch shall be tested. If both pipes passed for the test the batch shall be accepted. The test shall
be applied to one pipe in batch up to 500 Pipes.

BOILING ABSORPTION TEST ON COATING MORTAR.

Coating mortar samples shall be drawn and tested for boiling absorption test According to American
Society for Testing and Materials, (now known as ASTM International, is an International standards
organization that develops standards for a wide range of products) ASTM Standard C 497 method “A”.

Test value shall consist of the average of a minimum of three samples taken on same day from the
same working shift. The average absorption shall not exceed 9 percent and no individual sample shall
have an absorption exceeding 11 percent .Testing shall be performed on a weekly basis.
 Page A-91

HYDRAULIC TESTING OF PIPELINE

Pipe line shall be tested for site test pressure as per IS 783 & IS 784 for ensuring quality of
manufacture as per procedure specified in IS 783.
PRESSURE DETAILS OF PCCP PIPES

Sr. Dia of pipe Working Site test Factory test Earth fill
Pressure pressure pressure
No. (Kg/Sqcm) (inMtr.)
(Kg/Sqcm) (Kg/Sqcm)

1. 700 mm 12 18.00 20.00 1.20

2. 800 to 500 6 9.00 10.00 1.20

mm

MEASUREMENT

The net length of pipes as laid or fixed shall be measured in running meters correct to a cm. Specials
shall be excluded and measured along centerline in running meters. The portion of the pipe
overlapped at the joints shall not be included in the length of pipe work. Excavation, refilling, shoring
and timbering in trenches masonry of concrete pillars and thrust blocks wherever required shall be
measured separately under relevant items of work.

CARTING OF PIPES

Pipes manufactured at factory shall to be carried to site of work either directly or stacked suitably along
pipeline alignment. All pipes shall be loaded/unloaded on/from truck by mechanical crane only. No
hook shall be used and nylon tape of sufficient size and width shall be used. Unloading on tires shall
not be allowed in any case. Extreme care shall be taken while handling the pipes damaged during the
transit & handling shall not be accepted & contractor will be fully responsible for the damage.

AGREEMENT WITH THE MANUFACTURER

Whenever manufacturer is separate and contractor for lowering, laying, jointing and testing is separate
the principal contractor shall enter into agreement with PCCP Pipe manufacturer for satisfactory
manufacturing, transporting, lowering, laying, jointing and testing of pipes

1.4.13.5 Supply, Laying and Jointing of High Density Polyethylene (HDPE) Pipes and Fittings

This specification covers the requirements for successfully designing, manufacturing, supplying, laying, jointing
and testing at works and site of High Density Polyethylene Pipes used for water supply. Use of HDPE Pipes shall
be Pressure class of minimum PN 6 or above.

The manufacturing, testing, supplying, laying, jointing and testing at work sites of HDPE pipes shall comply with all
currently applicable statutes, regulations, standards and Codes. In particular, the following standards, unless
otherwise specified herein, shall be referred. In all cases the latest revision of the Codes shall be referred to. If
requirements of this Specification conflict with the requirements of the standards / Codes, this Specification shall
govern.

Others Codes not specifically mentioned here but pertaining to the use of HDPE pipes form part of these
Specifications.

IS 4984 High Density Polyethylene Pipes for Water Supply

 Page A-92

IS 5382 Rubber sealing rings for gas mains, water mains and sewers.

IS 4905 Methods for random sampling

IS 7328 High density polyethylene materials for moulding and extrusion

IS 7634 Laying & Jointing of Polyethylene (PE) Pipes

IS 9845 Method of analysis for the determination of specific and/or overall migration of constituents
of plastics material and articles intended to come into contact with foodstuffs

IS 10141 Positive list of constituents of polyethylene in contact with food stuffs, pharmaceuticals and
drinking water.

IS 10146 Polyethylene for its safe use in contact with foodstuff, Pharmaceuticals and drinking water.

Pipes shall be designated as per IS 4984, according to the grade of material, followed by pressure rating and
nominal diameter, for example, PE 100 PN 10 DN 200 indicates a pipe pertaining to material grade 100 having a
pressure rating 1.0 MPa and outside nominal diameter 200 mm. All IS specifications shall apply to HDPE pipes
and they shall be tested by CIPET for the standards required for HDPE pipes.

The colour of the pipe shall be black.

The material used for the manufacturer of pipes should not constitute toxicity hazard, should not support microbial
growth, should not give rise to unpleasant taste or odour, cloudiness or discoloration of water. Pipe manufacturers
shall obtain a certificate to this effect from the manufacturers of raw material by any internationally reputed
organization as per the satisfaction of the Engineer-in-Charge.

Raw material used to manufacture the HDPE pipes shall be 100% virgin PE 100, compounded or natural black
PE resin confirming to IS: 4984, IS: 7328 and ISO: 4427. For this a certification has to be given by the resin
manufacturer as per clause 3.2.3 of IS: 4984. The resin proposed to be used for manufacturing of the pipes
should also comply with the following norms as per ISO 9080.

The resin should have been certified by an independent laboratory of international repute for having passed
10,000 hour long term hydrostatic strength (LTHS) test extrapolated to 50 years to show that the resin has a
minimum MRS of over 10MPa. Internal certificate of any resin manufacturer will not be acceptable.

Certificate from reputed organization OR Raw material supplier for having passed the full scale rapid crack
propagation test as per ISO 13478. High density Polyethylene (HDPE) used for the manufacture of pipes shall
conform to designation PEEWA-50-T-003 of IS 7328. HDPE conforming to designation PEEWA-50- T-003 of IS
7328 may also be used with the exception that melt flow rate (MFR) shall not exceed 1.10 g/10 min. In addition
the material shall also conform to clause 5.6.2 of IS 7328.

The specified base density shall be between 940 kg/ m³ and 958 kg/ m³ (both inclusive) when determined at 27
degrees C according to procedure prescribed in IS 7328 The value of the density shall also not differ from the
nominal value by more than 3 kg/ m³ as per 5.2.1.1 of IS 7328. The MFR of the material shall be between 0.20
and 1.10 (both inclusive) when tested at 190 degrees C with nominal load of 5 kgf as determined by method
prescribed in IS 2530. The MFR of the material shall also be within ±20 percent of the value declared by the
manufacturer.

The resin shall be compounded with carbon black. The carbon black content in the material shall be within 2.5
±0.5% and the dispersion of carbon black shall be satisfactory when tested as per IS 2530.

The percentage of anti-oxidant used shall not be more than 0.3 percent by mass of finished resin. The anti-
oxidant used shall be physiologically harm less and shall be selected from the list given in IS 10141.

No addition of Reworked/ Recycled Material from the manufacturer’s own rework material resulting from the
manufacture of pipes is permissible and the vendor is required to use only 100% virgin resin compound.
 Page A-93

The outside diameter of pipes, tolerance on the same and ovality of pipe shall be as given in Table 2 of IS 4984.
Ovality shall be measured as the difference between maximum outside diameter and minimum outside diameter
measured at the same cross section of the pipe, at 300 mm away from the cut end. For pipes to be coiled the
ovality shall be measured prior to coiling. For coiled pipes, however, re-rounding of pipes shall be carried out prior
to the measurement of ovality.

HDPE Pipes should be detectable when buried underground, by providing a copper wire of 1.20mm +/- 0.2 mm Ø,
co-extruded along the entire length of pipe.

The length of straight pipe used shall be more than 6 m or as agreed by Engineer-in-Charge in charge. Short
lengths of 3 meter (minimum) up to a maximum of 10% of the total supply may be permitted.

The pipes supplied in coils shall be coiled on drums of minimum diameter of 25 times the nominal diameter of the
pipe ensuring that kinking of pipe is prevented. Pipe beyond 110mm dia shall be supplied in straight length not
less than 6m.

Pipes shall be free from all defect including indentations, delaminating, bubbles, pinholes, cracks, pits, blisters,
foreign inclusions that due to their nature degree or extent detrimentally affect the strength and serviceability of
the pipe. The pipe shall be as uniform as commercially practicable in colour opacity, density and other physical
properties as per relevant IS Code or equivalent International Code. The inside surface of each pipe shall be free
of scouring, cavities, bulges, dents, ridges and other defects that result in a variation of inside diameter from that
obtained on adjacent unaffected portions of the surface. The pipe ends shall be cut clearly and square to the axis
of the pipe. IS 4984:1995 will be followed for visual appearance.

During handling, transportation, storage and lowering, all sections shall be handled by such means and in such a
manner that no distortion or damage is done to the section or to the pipes as a whole.

The following procedures should be followed so as to eliminate potential damage to pipes and fittings and to
maintain maximum safety during unloading, lifting and lowering.

 Pipes must not be stored or transported where they are exposed to heat sources likely to exceed
60degrees C.

 Pipes shall be stored such that they are not in contact with direct sunlight, lubricating or hydraulic oils,
petrol, solvents and other aggressive materials.

 Scores or scratches to a depth of greater than 10% or more of wall thickness are not permissible; any
pipes having such defects should be strictly rejected.

 PE pipes should not be subjected to rough handling during loading and unloading operations. Rollers
shall be used to move, drag the pipes across any surface.

 Only polyester webbing slings should be used to lift heavy PE (>315mm) pipes by crane. Under no
circumstances, chains, wire ropes and hooks are used on PE pipes.

 Pipes shall not be dropped to avoid impact or bump. If any time during handling or during installation, any
damage, such as gouge, crack or fracture occurs, the pipe shall be repaired if so permitted by the
competent authority before installation.

 During coiling care should be taken to maintain the coil diameter at or above the specified minimum to
prevent kinks. Coiling shall be done when the pipe attains the ambient temperature from the extruder. In
uncoiling or recoiling care should be taken that sharp objects do not scour the pipe.

 When releasing coils, it must be remembered that the coil is under tension and must be released in a
controlled manner. The end of the coil should be retained at all times, then the straps released steadily,
one at a time. If the coil has bands at different layers of the coil, then they should be released
 Page A-94

sequentially starting from the outer layers. The amount of the energy locked up in the coil will depend on
the size of the pipe, the SDR of the pipe, and the size of the coil.

 Straight lengths should be stored on horizontal racks giving continuous support to prevent the pipe taking
on a permanent set

 Bare coils shall be wrapped with hessian cloth for long distance (> 300Kms) transportation. The truck
used for transportation of the PE pipes shall be exclusively used of PE pipes only with no other material
loaded – especially no metallic, glass and wooden items. The truck shall not have sharp edges that can
damage the Pipe.

 Pipes manufactured at factory are to be carried to the site of work directly or stacked suitably and neatly
along the alignment/road side/elsewhere near by the work site or as directed by the Engineer-in-Charge.

 Damages during transit, handling, storage will be to the Contractor’s account and replacement for such
pipes has to be made by the Contractor without any extra cost as directed by the Engineer-in-Charge.

Each pipe shall be thoroughly checked for any damages before laying and only the pipes which are approved by
the Engineer-in-Charge shall be laid.

While installing the pipes in trenches, the bed of the trench should be level and free from sharp edged stones. In
most cases, the bedding is not required, as long as the sharp and protruding stones are removed, by sieving the
dug earth, before using the same a backfill material. While laying in rocky areas suitable bed of sand or gravel
should be provided. The fill to about 10 to 15 cm above the pipe should be fine sand or screened excavated
material. Where hard rock is met with, bed concrete M15, 15 cm or 20cm thick sand bed as approved by the
Engineer-in-Charge may be provided.

As PE pipes are flexible, long lengths of fusion-jointed pipes having joints made above ground can be rolled or
snaked into narrow trenches. Such trenches can be excavated by narrow buckets.

During the pipe laying of continuous fusion jointed systems, due care and allowance should be made for the
movements likely to occur due to the thermal expansion/contraction of the material. This effect is most
pronounced at end connections to fixed positions (such as valves etc) and at branch connections. Care should be
taken in fixing by finishing the connections at a time the length of the pipe is minimal (lower temperature times of
the day.)

For summer time installations with two fixed connection points, a slightly longer length of PE pipe may be required
to compensate for contraction of the pipe in the cooler trench bottom.

The final tie-in connections should be deferred until the thermal stability of the pipeline is achieved.

The flexibility of polyethylene pipes allows the pipe to be cold bend. The fusion jointed PE pipe is also flexible as
the plain Pipe. Thus the total system enables directional changes within the trench without recourse to the
provision of special bends or anchor blocks. However, the pipe should not be cold bend to a radius less than 25
times the OD of the pipe.

The installation of flanged fittings such as connections to sluice/air/gate valves and hydrant tees etc., requires the
use of stub ends (collars/flange adaptors complete with backing rings and gaskets. Care should be taken when
tightening these flanges to provide even and balance torque.

Provision should be made at all heavy fittings installation points for supports (such as anchoring of the flange in
the soil) for the flange joint to avoid the transfer of valve wheel turning torque on to the PE flange joint.

PE pipe is lighter than water. Hence care should be taken for normal installations where there could be a
possibility of flooding of the trench thus the trench shall be kept free of water till the jointing has been properly
done
 Page A-95

When flooded, some soils may lose cohesiveness, which may allow the PE pipe to float out of the ground. Several
design checks are necessary to see if groundwater flotation may be a concern. Obviously, if the pipeline typically
runs full or nearly full of liquid, or if groundwater is always below the pipe, flotation may not be a significant
concern.

However, weights by way of concrete blocks (anchors) are to be provided so that the PE pipe does not float when
suddenly the trench is flooded and the soil surrounding the pipe is washed away. Thus site conditions study is
necessary to ensure the avoidance of flotation.

Pipe embedment backfill shall be stone-free excavated material placed and compacted to the 95% maximum dry
density.

The pipe shall have Electro-fusion jointing system that shall provide for fluid tightness for the intended service
conditions.

In case of sandy strata no separate bedding is required. However the bottom face / trench bed where pipe shall
be placed shall be compacted to provide a minimum compaction corresponding to 95% of maximum dry density.
The pipe bedding should be placed so as to give complete contact between the bottom of the trench and the pipe.
The minimum cover over buried pipe should be 1 m.

Backfilling should be placed in layers not exceeding 15cm thickness per layer, and should be compacted to a
minimum of 95% maximum dry density. The refilling should be done on both sides of pipe together & height
difference in earth fill on each side should not be more to cause lateral movement of pipe.

Most coarse grained soil is acceptable. This may comprise of gravel or sand. However silty sand, clayey sand,
silty and clayey gravel shall not be used unless proposed to be used in conjunction with gravel or clean sand.

It is very important that the pipe zone backfill material does not wash away or migrate in to the native soil.
Likewise, potential migration of the native soil in to the pipe zone backfill must also be prevented.

Heavy earth moving equipment used for backfilling should not be brought until the minimum cover over the pipe is
90 cm in the case of wide tracked bulldozers or 120 cm in the case of wheeled roaders or roller compactors.

Vibratory methods should be used for compaction. Compaction within distances of 15 cm to 45 cm from the pipe
should be usually done with hand tempers. The backfill material should be compacted not less than 95% of
maximum dry density.

RCC thrust block should be suitably designed & provided at bends and at places of reduction in cross section to
take care of trust

All HDPE fittings/ specials shall be of minimum PN 6 or above Pressure class, fabricated in accordance with IS:
8360 (Part I & III). PE Injection moulded fittings shall be as per IS: 8008 (Part I to IX). All fittings/specials shall be
fabricated or moulded at factory only. No fabrication or moulding will be allowed at site, unless specifically
permitted by the Engineer-in-Charge. Fittings will be welded on to the pipes or other fittings by use of Electro-
fusion process. Recommended makes for PE / PP fittings / specials are Georg-Fischer, Glynwed, Astore,
Magnum and GPS.

HDPE bends shall be plain square ended conforming to IS: 8360 Part I & III Specifications. Bends shall be
moulded.

HDPE Tees shall be plain square ended conforming to IS: 8360 Part I & II Specifications. Tees may be equal
tees or reduced take off tees. Tees shall be moulded.

HDPE Reducers shall be plain square ended conforming to IS: 8008 Part I & VII Specifications. Reducer must be
moulded.

HDPE Stub ends shall be square ended conforming to IS: 8008 Part I & VI Specifications. Stub ends will be
welded on the pipe. Flange will be of slip on flange type.
 Page A-96

Slip-on flanges shall be metallic flanges covered by epoxy coating or plastic powder coating. Slip-on-flanges shall
be conforming to standard mating relevant flange of valves, pipes etc. Nominal pressure rating of flanges will be
PN10.

Jointing between HDPE pipes and specials shall be done as per the latest IS: 7634 part II. Method of jointing
between the pipes to pipes and pipes to specials shall be with Electro-fusion welding using automatic or semi
automatic, hydraulically operated, superior quality Electro-fusion machines which will ensure good quality fusion
welding of HDPE pipes.

Pipes shall be given different hydraulic tests for ensuring quality of manufacture as per clause 16.9.5.6.2 of
Standard Specification.

Two or more PE specials coming at one place (like PE tee, Reducer, Flanged end etc.) shall be jointed at
contractor’s workshop and transported to the site of works for final installation with proposed PE pipelines. In no
case, jointing of three or more welds in one place, at site will be allowed.

The Contractor shall provide on-site training on PE pipe laying, jointing, testing and maintenance etc., to the
personnel authorized by Employer.

Technical Manual on PE pipes including precautions to be taken during operation of the pipeline.

All flanges employed in the project must be compatible whatever material used.

All pipes shall be marked at maximum interval of 1 m.

The marking shall indicate at least the following information:

 Manufacturer’s name and / or trade mark.

 The dimensions (nominal outside diameter X nominal wall thickness)

 The outside diameter tolerance (A or B)

 The designation of pipes material (PE 100, PE 80 etc)

 The nominal pressure (PN)

 The production period (date or code)

 The number of the International standard.

 The word “Water” and name of project shall also be included.

The pipes should be preferably transported by road from the factory and stored as per the manufacturer
specifications to protect damage.

Summary of quality tests is as follows:

 Quality Mark Pipe: IS 4984

 Material : As per IS 4984. However only virgin resin is allowed, reworked material is not
allowed.

 Grade of Material : PE 100 as per IS 4984 (Certificate from raw material manufacturer is
required).

 Pressure Rating : Minimum PN 4 or above as per requirement.

 Page A-97

 Colour : as per IS 4984

 Dimensions of Pipe :

Diameter : The nominal diameter (outside)

Wall thickness : As per IS 4984.

Length :

 For diameter 90 mm and 110 mm : 100 meter

 For diameter more than 110 mm : minimum 6 meter.

(Tolerance as per IS 4984)

 Visual Appearance : as per IS 4984

 Test and sampling : as per IS 4984

 Special Test : Notch hydraulic Test for the HDPE pipe made from PE-100 grade raw
material as per ASTM 1474 OR ISO 13479 at manufacturers laboratory or independent laboratory and
should pass the Hydraulic test as per IS:4984:1995 for a minimum 165 Hours. The test reports shall
not be more than three months old. Pipe shall convey water under variable temperature conditions
ranging from 4 degree centigrade to 45 degree centigrade.

 Jointing of pipes (pipe end):

 More than 110 mm diameter: Electro-fusion (Heat Fusion Process)

 Quality Assurance : Quality Assurance Plan shall be got approved from the employer before
production start.

1.4.13.6 Sluice Valves

The sluice valves shall confirm to IS: 14846. Double flanged short body, Gland less (stem sealing rings)type
Sluice valves with appropriate pressure rating.

The material to be supplied under this sub-section shall include, but not be limited to, the following: All necessary
fittings including bolts, nuts, gaskets, backing rings, counter flanges, jointing material, strainers etc. shall be
supplied as required. The entire Gland less (stem sealing rings) sluice valve shall be provided with ball thrust
bearing and spur gear arrangement.

The Gland less (stem sealing rings) sluice valves shall be with non rising stem type. The valves will be used for
water supply on line installations in upright positions, with double flange, and cap or hand wheel for manual
operation. The valves shall be suitable for continuous use at their PN rating within the temperature range of -
10degrees C to 65degrees C.

The working pressure on the valves shall be appropriate to the working conditions and approved by the Employer.
The flanges and their dimensions of drilling shall be in accordance with IS: 1538 (part-I to XXII).

The makes given are acceptable makes however the material for different component parts of sluice valve shall
conform to the requirements given below:

Component Material Ref. to IS Grade / Designation

Body, bonnet, dome, stool S. G. iron 1865 Gr.400/ 12
cover, wedge, stuffing box,
 Page A-98

gland, thrust plate, hand wheel

and cap.
Stem Stainless steel 6603 12Cr 13 04Cr 18Ni 10 04Cr
17Ni 12 MO 2
Wedge, nut, shoe Leaded tin bronze 318 LTB-2
Body seat ring, wedge facing Leaded tin bronze 318 LTB – 2
ring and bushes
Bolt Carbon steel 1363 (Part 1) Class 4.6
Nut Carbon steel 1363 (Part 3) Class 4
Gasket EPDM Rubber 11855 -
Gland packing Stem Sealing Ring 5414 Nil
Gear Spheroidal graphite 1865 Gr 500 / 7
iron
Gear housing S.G. iron 1865 Gr.400/12
Pinion and pinion shaft Wrought carbon 1570 (Part 3) C55Mn75
steel

The standard marking and packing of the valves shall be done as per Clause 11 and 13of IS: 14846. The
direction of rotation for OPEN, CLOSE position shall be marked on the hand wheel and on the bonnet of the
valve.

Hydraulic testing of each sluice valve shall be done for close end test in accordance with IS: 14846 Annex B, to
the test pressure and test duration as specified in table 5 and 6 of the IS.

All the valves shall be inspected for flaw detection test in accordance with IS: 14846, clause 10.2.The design,
construction material, manufacture, inspection, performance and testing shall comply with all applicable Indian
Standards and Codes. Nothing in the specification will be construed to relieve the supplier of this responsibility.

The manufacturer shall provide a test certificate confirming that all the valves have been tested in accordance with
IS: 14846 and stating the pressures and medium used in the test.

The inspection and testing of the sample valves from a lot will be carried out by the employer and or inspecting
agency appointed by the employer, in the manufacture’s workshop, before application of any paint. All the tests as
required as per the IS: 14846 shall be carried out on samples from each lot (Number of samples from a lot shall
be as per the relevant IS for sampling and testing), in presence of the inspecting agency. The valves shall be
dispatched only after issue of the test certificate by the inspecting agency for satisfactory performance of the
tested valves. The inspection charges for such tests shall be paid by the contractor to the inspecting agency.

Acceptable makes for the sluice valves shall be either, VAG, IVC or Kirloskar or other reputed make as may be
approved by Chief engineer.

The installation of the sluice valves shall be done at the locations shown on L-sections of the pumping main as
washout valves and isolating valves for air valves. The job covers supply of the valves at work site with cost of all
the required material and all types of taxes and duties, cost of packing, loading, transportation, unloading,
stacking and installation at the specified location with cost of all jointing materials such as nuts and bolts,
EPDM rubber gaskets etc. The job also covers field hydraulic testing of the valves after installation for the
specified test pressure for the respective pipeline section.

1.4.13.7 Butterfly Valves

The Butterfly valves shall confirm to IS: 13095. Double flanged short body butterfly valves of required nominal
diameter and pressure rating shall be supplied. The material to be supplied shall include, but not be limited to,
that as shown in the table given below. All necessary fittings including bolts, nuts, gaskets, jointing material etc.
shall be supplied as required.

The butterfly valves shall be with disc and shaft and shall be designed to withstand the maximum pressure
differential across the valve in either direction of flow. The valves shall have no visible leakage past the disc in
closed position under test conditions. The shaft may be of one piece design or in two pieces separately attached
 Page A-99

to the disc. The valves will be used for water supply on line installations in upright positions with manual operation.
The valves shall be suitable for continuous use at their pressure rating within the temperature range of -100C to
650C.

The working pressure on the valves shall be appropriate to the working conditions and approved by the Employer.
The flanges and their dimensions of drilling shall be in accordance with IS: 1538 (part-I to XXII).

The makes given are acceptable makes however the material for different component parts of butterfly valves
shall conform to the requirements given below:

Component Material Ref. to IS Grade

Body Sphéroïdal graphite 1865 Gr. 400/12
Iron. / Ductile Iron.
Disc Sphéroïdal graphite 1865 Gr. 400/12
Iron. / Ductile Iron.
Shaft Stainless steel 6603 -

Seating ring / Seal Integral Nicol - -

retaining ring Crominium
Welding
Seat EPDM Rubber - -
Shaft bearing seals Bronze / brass bearing with ‘O’ - -
rings
Internal fastners Stainless steel Manufacturer’s Suitable for duty
standard
External bolting Carbon steel; tensile strength - -
390 Mpa

All valves shall be capable of being operated at a differential pressure across the disc as marked on the valves.
Leaver, worm gear / traveling nut type or any other suitable type of operator can be used.

Manually operated valves shall be closed by turning hand wheel or leaver in a clockwise direction when facing the
hand wheel or leaver. The design of leaver when fitted shall be such that the leaver may only be assembled to the
valve so that it is parallel to the direction of flow when the valve is open.

All travelling nut operators shall be provided with suitable stops to prevent movement of the shaft beyond the limit
corresponding to the fully closed position of the disc.

All gear / travelling nut operators shall be self-locking type. All leaver operated valves shall be capable of being
locked at at-least three intermediate positions. The operating hand wheels shall be marked ‘CLOSE’ or ‘SHUT’ to
indicate the direction of closure. The operator shall be provided with arrangement to indicate disc position.

All valves shall be hydraulically tested by the manufacturer before dispatch. The pressure shall be applied without
any significant hydraulic shock. Testing shall be carried out before application of paint or other similar treatment.

The body ends shall be blanked. The valve disc shall be in slightly open position and the pressure equivalent to
1.5 times the maximum permissible working pressure shall be applied with water. The duration of test shall be 5
minutes for 1600 mm diameter valve.

Seat test shall be carried in accordance with clause 17.3 of IS: 13095 for 3 minute duration.

The test shall be conducted with the body flanges in horizontal position. The test pressure shall be 1.5 times the
maximum permissible pressure. With disc in closed position, hydro test pressure shall be applied to the lower
face of the disc for duration as per table 3 of the IS: 13095. There shall be no damage to the valve disc or any
part of the valve, or disc shall not be permanently deformed.
 Page A-100

The manufacture shall provide a test certificate confirming that all the valves have been tested in accordance with
IS: 13095. The manufacturer shall also provide documentary evidence of having manufactured and supplied BFV
of similar design and specifications, working satisfactorily for minimum 10 years in India, through Performance
Certificate.

The inspection and testing of the sample butterfly valves shall be carried out by the employer and or inspecting
agency appointed by the employer, in the manufacture’s workshop before application of any paint. All the tests as
required as per the IS: 13095 shall be conducted in presence of the inspecting agency on the sample valves from
the lot (Number of valves to be tested from a lot shall be as per the relevant IS for sampling and testing). The
valves shall be dispatched only after issue of the test certificate by the inspecting agency for satisfactory
performance of the tested valves. The inspection charges for such tests shall be paid by the contractor to the
inspecting agency.

Marking shall be cast integral on the body or on a plate securely attached to the body. Marking shall be as
specified under clause 21 of IS: 13095.

The design, construction material, manufacture, inspection, performance and testing shall comply with all
applicable Indian Standards and Codes. Nothing in the specification will be construed to relieve the supplier of this
responsibility.

Acceptable makes for the double flanged butterfly valves shall be either, Fouress, VAG or IVC or other reputed
make as may be approved by the Chief Engineer.

The installation of the butterfly valves shall be done at the locations shown on L-sections of the pumping main as
online valves. The job covers supply of the valves at work site including all type of taxes and duties, cost of
packing, loading, transportation, unloading, stacking and installation at the specified location with cost of all
jointing materials such as nuts and bolts, EPDM rubber gaskets etc. The job covers field hydraulic testing of the
valve after installation for the specified test pressure for the respective pipeline section.

1.4.13.8 Kinetic Air valves

Kinetic air valves are required with pressure rating appropriate for the working conditions and approved by the
Employer, confirming to IS: 14845.

The air valves shall be capable of exhausting air from pipeline automatically when being filled. Air shall be
released at sufficiently higher rate so that there shall be no restriction for the inflow rate. Similarly, the valves shall
be capable of ventilating pipeline automatically when being emptied. The air inflow rate should be sufficiently high
to avoid development of vacuum in the pipeline.

The design shall be such that, higher the rate of flow the greater the resultant down thrust, keeping the ball 'glued'
to its seat until the last drop of air is expelled from the pipe system.

Each air valve shall be provided with an isolating sluice valve with flanged end connection. The possible air
velocity (inflow and outflow) must be at least 10 m/s.

The flow of air should be as unobstructed as possible. The low pressure orifice shall be in the same axis as the
main discharge / incoming air flow and must have a diameter sufficiently large. The valve body shall be designed
in such a way that the turbulent air at the time of filling of pipeline shall not circulate and cause the ball to be
caught in the discharging air stream and blowing the valve shut permanently. The cone angle of the low pressure
(large orifice) chamber shall be such that even at a critical velocity of air escaping at 344 m / sec the total impact
force on the vulcanite covered ball is less than the suction force on the annular area between the ball and cone.
The annulus around the low pressure vulcanite covered ball is to be generously proportioned for discharge of air
under various differential pressures. Normal range of cone angle is 450 to 600.

The orifice shall be carefully profiled to allow the requisite flow of air under varying differential pressures. It shall
be in moulded synthetic rubber such that even after extended contact the, vulcanite covered ball does not stick to
it, when the line pressure becomes zero.
 Page A-101

The high pressure chamber having small orifice shall be so designed that the orifice is effectively sealed in
working condition. The orifice shall be profiled in such a manner that the rubber covered ball is not damaged even
after extended contact. There should be machined guide in the chamber which ensures that the ball travels
vertically and makes contact with the nipple and seals off the orifice without fail. The orifice size shall

Not be less than 2.5 mm and tapering to 10 mm suitable to release accumulated air within the pipeline. High
pressure orifice may be fitted from bottom side of the cover.

The makes given are acceptable makes however the material for different components parts of the air valve shall
conform to the requirements given below:

Component Material Reference to IS No. Grade of designation

Body,cover, valve disc, stuffing S. G. iron / Ductile 1865 Gr.400/ 12
box, valve guide, cowl, gland, iron
cap, joint support ring
Low Pressure seat ring and face Natural rubber 11855
ring
High pressure orifice Leaded tin bronze 318 LTB-2
Bolts Carbon steel 1363 Class 4, 6
Nuts Carbon steel 1363 Class 4
Gasket Rubber 638 Type B
Float Stainless steel - -
Float guide Leaded tin bronze 318 LTB-2

Minimum float diameters for kinetic air valves shall be as indicated in Table 3 of IS 14845. The inner core of the
floats shall be made from stainless steel having sufficient bearing strength and equivalent specific gravity.

Testing of all the air valves shall be carried out in the suppliers work shop as per IS:14845.

Following tests shall be carried for each valve.

 Function and performance test as per clause 12.4.1

 High pressure orifice test as per clause 12.4.2

 Low pressure orifice test as per clause 12.4.3

 Body test as per clause 12.4.4

The performance of the valve for the above mentioned tests shall be as specified under Clause 12.1, 12.2 and
12.3 of IS 14845.

The manufacturer shall provide a test certificate confirming that all the air valves have been tested in accordance
with the relevant standards and performance of the test results observed.

The inspection and testing of the sample air valves shall be carried out by the employer and or inspecting agency
appointed by the employer, in the manufacture’s workshop before application of any paint. All the tests as
required as per IS 14845 shall be conducted in presence of the inspecting agency on the sample valves from the
lot (Number of valves to be tested from a lot shall be as per the relevant IS for sampling and testing). The valves
shall be dispatched only after issue of the test certificate by the inspecting agency for satisfactory performance of
the tested valves. The inspection charges for such tests shall be paid by the contractor to the inspecting agency.

Each valve shall be permanently marked with a plate securely fixed to the body with the information as specified
under clause 15.1 of IS 14845.
 Page A-102

The design, construction material, manufacture, inspection, performance and testing shall comply with all
applicable Indian Standards and Codes. Nothing in the specification will be construed to relieve the supplier of this
responsibility.

Acceptable makes for the kinetic double orifice air valves shall be either, VAG, IVC or Kirloskar or other reputed
make as may be approved by the chief engineer.

The installation of the air valves shall be done with isolating sluice valve. The job covers supply of the valves at
the work site including all taxes and duties, cost of packing, loading, transportation, unloading, stacking and
installation at the specified location with cost of all jointing materials such as nuts and bolts, EPDM rubber gaskets
etc. The job covers field hydraulic testing of the valves after installation for the specified test pressure for the
respective pipeline section

1.4.13.9 Non-return Valves

Non-return valves generally conforming to IS 5312 Part I & II (Single or Multi Door Type) shall be provided on
delivery side of a l l pumps. The valves shall be suitable for continuous use at their pressure rating within the
temperature up to 60degrees C and shall be conforming to following specifications and requirements.

The non-return valve shall be swing check reflux valve type with S i n g l e o r multiple doors.

The valve shall be suitable for mounting on a horizontal pipeline and flow direction shall be clearly embossed on
the valve body.

Valves shall possess inbuilt high speed closing and non-slam characteristics achieved by suitable disposition of
weight on door and the hydraulic passage.

Valves of multi-door type shall be additionally provided with a supporting foot.

All faces and seat rings shall be riveted to the machined surface in the Casting. The door shall be integral with the
hinge and shall have a flat seating face. Minimum two (2) nos. suspension lugs shall be cast integrally on the
diaphragm plate and shall be of adequate strength.

Bypass of appropriate diameter with sluice valve of appropriate size and pressure class as per relevant applicable
code shall be provided.

No spring loaded/ spring return action or external dampening arrangement will be acceptable. All the Non-return
valves shall be from the same manufacturer.

The material for different component parts of Multi-door non-return valves shall conform to the requirements given
below:

Component Material of construction

Body / Door Ductile Iron GGG 40 / IS 1865 Gr. 500/7 to IS 1865 OR
(and Diaphragm) Caststeel gradeBconformingtoIS1030
Stub pin SS AISI 410
Seat and Face rings Soft seated up to 300 mm.
350 mm and above: Gun metal : IS 318 Gr. LTB 2
Rivets Soft annealed brass
Fasteners Carbon steel
Painting Liquid epoxy coating of DFT 300 microns with proper Blast
cleaning to near white - SA 2 ½ Grade and 2 coats of epoxy
based primer coating, prior to final coating.
Flange Drilling IS 1538 Table 4 & 6/ BS En 1092 – 2

The working pressure on the valves shall be appropriate to the working conditions and approved by the Employer.
 Page A-103

All valves shall be marked to show the following information permanently.

 Manufacturer’s name or trademark.

 PN rating

 Valve size

 Direction of flow

The following tests shall be conducted on the valves at manufacture’s works before painting. The tests shall be
generally as per IS 5312 Part 2.

Body of each valve shall be hydrostatically pressure tested at 1.5 times its rated working pressure. The test fluid
shall be water. Duration of test shall be 2 minutes. There shall be no leakage or permanent distortion of any
component under the test.

Each valve shall be tested for seat test by applying hydrostatic test pressure equal to its rated working pressure,
on outlet side. Duration of test shall be 2 minutes. During the test, there shall be no leakage of water through the
seats.

The manufacture shall provide a test certificate confirming that all the valves have been tested in accordance with
above specifications and relevant IS 5312 Part II. The manufacturer shall also provide documentary evidence of
having manufactured and supplied non-return valve of similar size and design, working satisfactorily for minimum
5 years in India, through Performance Certificate.

Acceptable makes for the double flanged butterfly valves shall be either, Kirloskar, VAG or IVC or other reputed
make as may be approved by the chief engineer.

The job covers supply of the Non-return valves at the work site including all taxes and duties, cost of packing,
loading, transportation, unloading, stacking and installation at the specified location with cost of all jointing
materials such as nuts and bolts, EPDM rubber gaskets etc. The job covers field hydraulic testing of the valves
after installation for the specified test pressure for the respective pipeline section.

1.4.13.10 Anti-vacuum Valves

The Anti vacuum valve will be installed to prevent the formation of vacuum in large diameter (having Ø of 1000
mm. and above) water mains to prevent line collapse under such conditions of flow as may result, for example,
from too rapid a closure of an upstream head gate or shut down valve, a downstream burst or ordinary emptying
or recharging of a pipeline.

Design of the anti – vacuum valve shall automatically allow induction of large volumes of air to prevent vacuum
formation; and also provide an automatic means of ventilating a line when it is being emptied of water, and of
exhausting air when it is being recharged.

It should be suitable to react automatically, sensitively, and positively even after long periods of inactivity, to
changes of pressure within a pipe, and whenever necessary, permit air to flow in at a sufficiently high velocity, and
at low enough induction pressure, to safeguard the line against collapse.

Cowled Inlet Type of the anti - vacuum valve should have an annular cowl shrouding the orifice, providing
protection to the orifice and the seating. It should be suitable for air to flow through the ports provided around the
periphery of the body assembly. Such application is confined to situations where no damage is likely to occur
surrounding structures from sudden intakes of air.

About Operation, the valve element should be in the form of the disk which is sensitively balanced by a
counterpoising mechanism. The disk guide pin should be attached to a crosshead, to which is fitted at either end
a cranked lever that should rock about an intermediate pivot pin and should be applicable to carry an adjustable
 Page A-104

counterweight on its outer arm. The parts should so arranged that by adjusting the position of the counterweights,
the valve must be balanced at any desired points on its working travel.

Thus, when swinging freely the valve may be balanced at a partially opened position in which case, if it is closed
by hand, it self-opens to the pre determined point of equilibrium, and vice- versa. Also attached to the crosshead
should be an oil dashpot which should give free opening, in a downward direction, but offer resistance to closing,
in an upward direction, and avoid all possibility of oscillation of the suspended.

In action, therefore, the valve should not remain at either extremity of its travel unless it is acted upon by some
external force. During normal operation, the disk should be held shut by the water pressure in the pipe. If the
pressure on the underside of the disk falls below that of the atmosphere, the valve should immediately open to
admit air and break vacuum. With very small vacuum, say 1 inch of mercury or about ½ psi below atmosphere,
should open fully and offer a wide passage for free flow of air. On the cessation of air inflow, the valve must return
to a position of slightly open, which is sufficient for the escape of air during refilling of the line. When the rising
water makes contact with the underside of the disk, closure is completed: only a very small water pressure should
be required to close the valve, consequently, the quantity of water over- flowing through the orifice during final
closure will be negligible.

The manufacturer shall provide a test certificate confirming that all the Anti vacuum valves have been tested in
accordance with the relevant standards and performance of the test results observed.

The inspection and testing of the sample Anti vacuum valves shall be carried out by the employer and or
inspecting agency appointed by the employer, in the manufacture’s workshop before application of any paint. The
valves shall be dispatched only after issue of the test certificate by the inspecting agency for satisfactory
performance of the tested valves. The inspection charges for such tests shall be paid by the contractor to the
inspecting agency.

Each valve shall be permanently marked with a plate securely fixed to the body with the information as specified
under relevant standards.

The design, construction material, manufacture, inspection, performance and testing shall comply with all
applicable Indian Standards and Codes. Nothing in the specification will be construed to relieve the supplier of this
responsibility.

Acceptable makes for the Anti vacuum valves shall be either, Fouress, VAG or IVC or other reputed make as
may be approved by the chief engineer.

The job covers supply of the Anti vacuum valves at the work site including all taxes and duties, cost of packing,
loading, transportation, unloading, stacking and installation at the specified location with cost of all jointing
materials such as nuts and bolts, EPDM rubber gaskets etc. The job covers field hydraulic testing of the valves
after installation for the specified test pressure for the respective pipeline section.

1.4.13.11 Painting Specification for Valves

Final coating on internal and external surface of the Valve shall be carried out after satisfactory testing, prior to
dispatch.

Before inspection: Each valve shall be cleaned and surface shall be prepared by Sand blasting to SA 2½ Grade –
Near white blast cleaning, and suitably protected by applying one coat of two component high build polyamide
cured re-coatable zinc phosphate epoxy primer.

After inspection: One coat of two component high build polyamide crude re-coatable epoxy coating shall be
applied to achieve DFT 150 micron, followed by one coat of two component aliphatic polyurethane finish to
achieve DFT 80 micron.
 Page A-105

1.4.13.12 MS Expansion Joints and Cover Box

Expansion joints are necessary on the MS pipeline laid above ground to accommodate expansion and contraction
of the MS line due to temperature variations, so that the expansion or contraction is not cumulative over several
lengths. These joints permit linear movement of the pipe relative to the packing provided in the joint. Fabricated
steel Bellow-type expansion joints, as per the EJMA standards, shall be provided and installed at the locations
shown on longitudinal section of the pipeline.

Normally, on plain ground, the centre to centre distance of the expansion joints shall not be more than 300m.
When the length of above ground pipeline is less than 300 m but more than 100 m, one expansion joint at the
centre shall be provided. The pipe line shall be anchored firmly with concrete anchor blocks between two
expansion joints, so that the expansion or contraction between two anchor blocks is accommodated by the
expansion joint provided between the blocks. Supports / saddles shall be placed on each side of the expansion
joint at about one meter distance from the centre of the joint to avoid unequal deflection of the pipe on either side
of the joint.

The item covers providing and packing, transportation to work site and fixing wherever required on the pipeline
with hydraulic testing along with the pipeline section.

Acceptable makes for the Bellow-type expansion joints shall be of firm of repute make as may be approved by
the chief engineer.

BELLOWS MATERIAL SA 240 GR. 304

CENTRE SPOOL / WELD ENDS IS 2062 GR. B
INTERNAL SLEEVE SA 240 GR. 304

LIMIT RODS / NUTS & CHECK NUTS IS 1367

FLANGES IS 2062 ( AS PER IS 1538/ IS 6392)

Circular MS covers as shown on drawing shall be fabricated and fixed on the expansion joint for protecting the
joint from possible damages. The item covers the cost of plates and material required, nut bolts, all taxes and
duties, providing and applying two coats of epoxy paint in addition to one primer coat, transportation and fixing
charges etc complete

Bellow type Dismantling joint shall be provided for each online sluice valves, butterfly valve and washout valve to
facilitate removal of the valve for repairs whenever required.

The joints shall be fabricated as per EJMA standard. The item covers cost of Bellow type Dismantling joint,
including all taxes and duties and cost of coating, packing, transportation, cost of jointing including required
material such as nut bolts, rubber packing, labour cost, etc. complete with hydraulic testing to required pressure.

Alloy material SA 240 GR. 304

Centre spool / welding IS 2062 GR. B
Internal sleeve SA 240 GR. 304
Limit rods / nuts / check nuts IS 1367
Flanges IS 2062 ( AS PER IS 1538/ IS 6392)

Steel roller bearings shall be provided and fixed on the bearing plates fixed on concrete pedestals for above
ground pipeline, as shown on drawing. The bearing boxes shall be firmly fixed to the bearing plate. Number of
bearings and rollers, size of rollers etc. shall depend on the pressure and thrust on the pipeline and shall be as
directed by the Chief Engineer.
 Page A-106

1.4.14 Earthworks and Excavation

The relevant specification for irrigation projects (November 1991) Volume I, Section II, Chapter 4 and 21 of
Engineer-in-Chief WRD, M.P. Bhopal shall be strictly followed for carrying out excavation for rising main/gravity
pipelines along with distribution network complete, including excavation for construction of pump houses, various
structures, buildings, roads and transmission line etc.

In addition to above the relevant IS code (updated) / IRC specifications (updated) / MPPKVVCL specifications and
“Manual on Water Supply in Treatment” published by Central Public Health and Environmental Engineering
Organization (CPHEEO) shall also be followed for the above work and as directed by Engineer-in-Charge.

1.4.15 Steel and Iron Works

The relevant specification for irrigation projects (November 1991) Volume II of Engineer-in-Chief WRD M.P.
Bhopal shall be strictly followed for carrying out steel works for rising main/gravity main pipelines along with
distribution network complete, including steel works for construction of pump houses, various structures, buildings,
roads and transmission line etc.

In addition to above the relevant IS code (updated) / IRC specifications (updated) / MPPKVVCL specifications and
"manual on water supply in treatment" publish by Central Public Health and Environmental Engineering
Organization (CPHEEO) shall also be followed for the above work and as directed by Engineer-in-Charge.

1.4.16 Concrete Works

The relevant specification for irrigation projects (November 1991) Volume I, II and III of the Engineer-in-Chief
WRD, M.P. Bhopal shall be strictly followed for carrying out concrete works for rising main/gravity main pipelines
along with distribution network complete, including concrete works for construction of pump houses, various
structures, buildings, roads and transmission line etc.

In addition to above the relevant IS code (updated) / IRC specifications (updated) / MPPKVVCL specifications and
“Manual on Water Supply in Treatment” publish by Central Public Health and Environmental Engineering
Organization (CPHEEO) shall also be followed for the above work and as directed by Engineer-in-Charge.

1.4.17 Building Works

The relevant specification for irrigation projects (November 1991) Volume I, II, III and V of Engineer-in-Chief WRD
M.P. Bhopal shall be strictly followed for carrying out Buildings construction works.

In addition to above the relevant Indian standard code (updated) shall also be followed for the above work and as
directed by Engineer-in-Charge.

1.4.18 Road Works

The Specifications of relevant IS code (updated) / IRC specifications (updated)/M.O.S.T. specifications (updated)/
MPPKVVCL specifications and “Manual on Water Supply in Treatment” published by Central Public Health and
Environmental Engineering Organization (CPHEEO) shall also be followed for the above work and as directed by
Engineer-in-Charge.

1.4.19 Other Facilities

The Contractor has to construct and maintain asphalted road from nearest PMGSY road to pump houses, the
dam site, distribution chambers and other necessary haul roads. Mechanical workshops and residential and non-
residential facilities as mentioned in volume II shall be constructed by the Contractor at locations decided by the
Engineer-in-Charge.
 Page A-107

The Contractor shall supply at his own cost materials, plant, tools appliances, implements, tackle, scaffolding and
temporary works requisite for the proper execution of the work, whether original, altered or substituted and
whether included in the specifications or other documents forming part of the contract or referred to in these
conditions or not, or which may be necessary for the purpose of satisfying or complying with the requirements of
the Engineer-in-Charge as to any matter as to which under these conditions he is entitled to be satisfied, or which
he is entitled to require together with carriage to and from the work. The Contractor shall also supply without
charge the requisite number of persons with the means and materials necessary for the purpose of setting out
works and counting, weighing and assisting in the checking measurement or examinations at any time and from
time to time of the work or materials.

Failing his so doing, the same may be provided by the Engineer-in-Charge or at the expense of the Contractor
and the expenses may be deducted from any money due to the Contractor under the Contract, or from his
security deposit or the proceeds of sale thereof, or of a sufficient portion thereof Contractor is liable for damages
arising from non provisions of lights, fencing etc., The Contractor shall also provide at his own cost, except when
the contract specifically provided otherwise, all necessary fencing and lights required to protect the public from
accidents, and shall be bound to bear the expenses or defence of every suit, action or other proceedings of law
that may be brought by any person for injury sustained owing to neglect of the above precautions and to pay any
damages and costs which may be awarded in any such suit, action or proceedings, to any such persons or which
may be paid to compromise any claim by any such person.

1.4.20 Quality Control

The Contractor shall execute the whole and every part of the work in the most substantial and workmen like
manner and both as regards materials and otherwise in every respect in strict accordance with the tender
documents. The Contractor shall also confirm exactly, fully and faithfully to the designs, drawings and instructions
in writing relating to the work signed by the Engineer-in-Charge and lodged in his office, and to which the
Contractor shall be entitled to have access at such office or on the site of the work for the purpose of inspection
during office hours, and the Contractor shall if he so requires, be entitled at his own expense to make or cause to
be made copies of specifications and of all such designs, drawings and instructions as aforesaid.

Ensuring quality control measures during construction shall the responsibility of the Contractor. The Contractor
shall establish a fully furnished quality control lab with good quality required equipment and operating staff. The
Contractor shall produce results of quality control tests carried out on the works by his staff and the quality audit
conducted by the department or by Engineer’s Representative on these works. If the test result do not fulfil the
stipulated criteria laid down in Contract the payment will be limited as per the provisions in the tender documents
and if number of results fail beyond the limit of acceptance, then the Contractor shall not be paid unless he
rectified all such imperfect work(s). The decision of the Engineer-in-Charge in respect of the matters pertaining to
the quality control shall be final and binding on the Contractor.

The relevant Quality Control Manual for irrigation projects (June 1995) Volume I and II of Engineer-in-Chief WRD
M.P. Bhopal shall be strictly followed for carrying out earth works, concrete works, buildings works, road works
and tunnels etc. In addition to above the relevant IS code (updated) / IRC specifications shall also be followed for
the above work and as directed by Engineer-in-Charge.

The Quality Assurance Plan for all the components of the pump, controller/governor and associated equipment
shall be furnished for the approval of Employer indicating the tests at factory with customer witness points. The
same shall be generally according to the Quality Assurance Plan.

1.4.21 Construction Program

Execution of work shall be according to the Time Schedule. The program shall be supplemented with Master
Control Network. The employer reserves the right to request for change in Master Control Network after
discussions with the successful bidder. A mutually agreed Master Control Network shall form part of the Contract.
If for any reason, any parts of the Works of the Project are delayed, then the total program may be re-scheduled
by mutual agreement between the Engineer-in-Charge and the Contractor, if necessary, keeping the overall
completion schedule of the project unaltered. No extra cost whatsoever, on account of such re-scheduling shall be
payable to the Contractor.
 Page A-108

Within thirty (30) days from the Date of Commencement, the Contractor shall submit to the Employer a work
programme showing the sequence in which he proposes to carry out various components for completing the
Works as per the Master Control Network within the time for completion. The Master Control Network shall
indicate the sequence of various activities and highlight the critical activities including delivery of equipment. Such
work program shall be subject to review and revision by the Employer/Engineer in consultation with the Contractor
from time to time in order to achieve completion of the Works within the time for completion. The Contractor shall
also make it in computer aided project management software to generate Bar Chart based on network technique.

The Contractor shall also submit to the Employer/Engineer the information on detailed methodology of carrying
out investigation surveys, design engineering, detailed construction methodology along with schedule for
deployment of plant and machineries, which shall successively be adjusted in order to meet the actual
requirement to complete the works within the time for completion along with the work program.

Work of pipeline distribution network shall be taken up at least ten separate locations / section simultaneously; so
that the work can be completed within time for completion.

Every effort should be made to complete the work from upstream to downstream of along the alignment of the
pipe network simultaneously.

If the progress of a crucial item of work, which is important for timely completion of work is unsatisfactory, the
Engineer-in-Charge, shall not withstanding, that the general progress of work is satisfactory, in accordance with
relevant clause be entitled to take action under this clause after giving the Contractor seven (7) days notice in
writing and the Contractor will have no claim for compensation for any loss sustained by owing to such action.

The Works shall be executed and performed in accordance with the Master Control Network (Work Programme)
which shall clearly indicate the interlinking / interdependencies of all the works of the Contract including relative
activities of civil works and hydro-mechanical works. The program shall be reviewed jointly by the Employer/
Engineer and the Contractor, at least once in a month wherein delays, if any, in the progress of Works, with
reference to the agreed schedule shall be given special attention. Necessary modifications (updating / revisions)
of the program, within the overall time for completion, shall be carried out by mutual agreement between the
Employer/ Engineer and the Contractor. If for any reason, any parts of the Works of the Project are delayed, then
the total program may be re-scheduled by mutual agreement between the Employer/ Engineer and the
Contractor, if necessary, keeping the overall completion schedule of the project unaltered. No extra cost
whatsoever, on account of such re-scheduling shall be payable to the Contractor.

1.4.22 Inspections and Tests

Except as otherwise provided, all materials and workmanship if not otherwise designated by the tender
documents, shall be subject to inspection, examination and test by the Engineer-in-Charge at any and all times
during manufacture and/or Construction and at any/all places where such manufacture or Construction are carried
on. The Engineer-in-Charge shall have the right to reject defective material and workmanship or require its
corrections. Rejected workmanship shall be satisfactorily replaced with proper material without charge thereof and
the Contractor shall properly segregate and remove the rejected material from the premises, if the Contractor fails
to proceed at once with the replacement of the rejected material and / or the Construction of defective
workmanship, the Engineer-in-Charge may replace such material and / or correct such workmanship and charge
the cost thereof to the Contractor.

The Contractor shall be liable for replacement of defective work up to the time in accordance with the conditions of
contract of all work to be done under the contract.

All works, under or in course of execution or executed in pursuance of the Contract shall at all times be open to
the inspection and supervision of the Engineer-in-Charge and his subordinates and the Contractor shall at all
times during the usual working hours and at all other times at which reasonable notice of the intention of
Engineer-in-Charge or his subordinate to visit the work shall have been given to the Contractor either he himself
be present to receive orders and instructions, or have a responsible agent duly accredited in writing, present for
that purpose. Orders given to the Contractor’s agent shall be considered to have the same force as if they had
been given to the Contractor himself.
 Page A-109

The Contractor shall furnish promptly without additional charge all facilities, labour and material necessary for the
safe and convenient inspection and tests that may be required by the Engineer-in-Charge.

All inspections and tests by the department shall be performed in such a manner as not to unnecessarily delay the
work. Special full size and performance test shall be charged with any additional cost of inspection when the
Contractor does not make materials and workmanship ready at the time of inspection.

Government shall have the right to cause any audit and technical examination of the works and the final bills of
the Contractor including all supporting vouchers, abstracts etc. to be made after payment of the final bill and if as
a result of such audit and technical examinations any sum is found to have been overpaid in respect of any work
done by the Contractor under the Contract or any work claimed by him to have been done by him under the
Contract and found not to have been executed, the Contractor shall be liable to refund the amount of
overpayment and it shall be lawful for Government to recover the same from him and if it is found that the
Contractor was paid less than what was due to him under the contract in respect of any work executed by him
under it, the amount of such under payment shall be duly paid by Government to the Contractor.

Provided that Government shall not be entitled to recover any sum overpaid, nor the Contractor shall be entitled to
payment of any sum paid short where such payment has been agreed upon between the Engineer-in-Charge on
one hand and the Contractor on the other hand under any terms of the Contract permitting payment for work after
assessment by the Engineer-in-Charge.

The Contractor shall furnish the material composition certificates for all the important components of pump and
motors. Random test certificates for raw stock materials and typical test certificates for special stock items like
bearing metal etc., used for the manufacture of the several components shall also be furnished.

Before commencement of manufacture of prototype pumps the Contractor shall perform model tests to
demonstrate that the efficiency and other guarantees as well as requirements of the specifications for the
performance of the pumps will be met.

The test shall comply with the international code for model acceptance of hydraulic pump IEC publication no. 193.

The place where model tests would be conducted shall be indicated by the Bidder in his Bid. A team of
Employer’s Representatives shall be deputed to the manufacturer’s works where the model test is proposed to be
conducted for witnessing the model tests. The Contractor shall extend all facilities to witness the tests.

Material testing of important casting/ forging fabricated steel works shall be according to the enclosed Quality
Assurance Plan.

The Contractor shall furnish inspection reports in respect of assembly of main pump and other associated
equipment duly mentioning the key points, such as limits of tolerance etc. or such information for use/ guidance
during erection/ maintenance at site.

Any other tests and inspection that the Employer considers necessary to satisfy itself that the pump conforms to
these specifications in performance, workmanship, design and quality of materials.

The Contractor shall furnish in detail the method proposed by him to do the field efficiency test on the pumping
unit.

Finalization of measurement section and location of installing various instruments shall be done after obtaining the
permission of the Employer.

The layout, scheme and details of the tappings etc.,stainless steel tubing along with the valves and fittings for
various tappings, which are to be embedded shall be included in the scope of supply.

The calibration of instruments, arrangement of all required instruments, arrangement of personnel for testing,
supervision of field tests at site etc. shall be the responsibility of the Contractor

After complete installation of the pumping units at site the units shall be tested in accordance with IEC standard.
 Page A-110

1.4.23 Commissioning
Commissioning and trial run of the constructed systems has to be carried out by the Contractor for 24 hours over
seven days continuous complying with provisions as given in the specifications. Rectifying the systems for defects
as directed by the Engineer-in-charge will be the responsibility of the Contractor. The measurement of
seepage/losses, discharge, treatment of the piped canal where seepage/losses shall not be more than
permissible limits. Costs for electricity during commissioning and the testing period will be borne by the
Contractor. Cost for electricity during the operations service period shall be borne by WRD.

During the construction period, the Contractor shall maintain, at its cost, all the constructed structure, installed
equipment and machinery and laid pipe network, and shall undertake the all necessary repair and maintenance
works. The works whether fully completed or incomplete, all the works materials, machinery, plants, tools,
temporary buildings and other things connected there with shall remain at the risk and in the sole charge of the
Contractor until whole of the completed work under the Contract has been delivered to the Engineer-in-Charge.
Until such delivery of the entire completed work the Contractor shall at his own cost take all precautions
reasonably to keep all the aforesaid works, materials, machinery, plants, temporary buildings and other things
connected there with free from any loss or damage and in the event of the same or any part thereof being lost or
damaged, he shall forth with reinstate and make good such loss or damage at his own cost.

On the completion of the work the Engineer-in-Charge shall make such examination and tests of the work as may
then seem to him possible, necessary or desirable, and the Contractor shall furnish free of cost any materials and
labour which may be necessary thereof, and shall facilitate in every way all operations required by the Engineer-
in-Charge, in making examination and tests.

1.5 Operations Service Period

1.5.1 General Requirements

The Contractor shall be responsible for the operation and maintenance (O&M) of the Works for Five (5) years
from the substantially completion date of the construction of the Project. All items will be the property of the
Employer at hand back at the end of the 5-year O&M-year term.

The Contractor shall provide full O&M services of all plant and works constructed to satisfy the performance
standards and also in accordance with the O&M scope of services as detailed in these tender documents. All
O&M services shall be performed in accordance with legal and statutory requirements in Madhya Pradesh, meet
Employer’s Requirements, and adhere to prudent industry standards. The Contractor shall adhere to the
requirements in the “Operation and Maintenance Requirements for Pressurized Micro Irrigation Systems”,
MPWRD, December 2016. The Contractor shall follow the appropriate Standard Operating Procedures (SOPs) in
the “Operation and Maintenance Manual for Rural Water Supplies,” Government of India, Ministry of Drinking
Water and Sanitation, May 2013.

The scope of services shall include the following for a period of 5 years:

 Maintain whole pipeline system including its structures and maintenance of all pumps and electro-
mechanical components

 Provide all services necessary to maintain the Project efficiently, maximize the availability of the project;
optimize the useful life of the Project etc.

 Provide requisite numbers of qualified (and if required licensed) personnel to perform the services

 Carryout maintenance of the total pipeline canal system and carry out repair and preventive maintenance
in accordance with the recommendations of the Engineer-in-Charge

 Carryout maintenance of the pump stations and approach channels and carry out repair and preventive
maintenance in accordance with the recommendations of the Engineer-in-Charge
 Page A-111

 Carryout maintenance of the electrical sub-stations and carry out repair and preventive maintenance in
accordance with the recommendations of the Engineer-in-Charge

 Carry out any maintenance or repairs or rectification work in case of any problem or emergency that may
arise while the system is in operation

 Provide technical and other assistance to the Engineer-in-Charge, in solving operational and
maintenance problems

 Conduct appropriate inspections and make the plant and Works available for inspection by Employer,
Auditor, lenders, Employer’s authorised representatives or agents and water customers

 Provide an operating plan and annual budget

 Maintain comprehensive records relating to Works performance

 Development, implementation, and enforcement of programs for safety, quality assurance and quality
control

 Development of and assurance of adherence to a preventative maintenance program in accordance with

the approved O&M Manuals to ensure that the plant and Works can meet the Guarantees and
Performance Standards and requirements

 Maintain all roads, yards, walkways, the colony, housekeeping and security of the Project

 Suggest improvements in the operation and maintenance schedule for better performance

 Prepare Monthly or Annual Operation Plan and submit to the Engineer-in-Charge for approval

 Compliance with all permits and Governmental approvals related to Works operation

At all times, the Contractor shall keep the Works in good condition and working order, performing services twenty-
four (24) hours per day, seven (7) days per week.

The scope of services under the O&M Agreement encompasses the operation and maintenance of all equipment,
instrumentation, processes, facilities, systems, structures and utilities.

Overall O&M shall be based on the following key objectives:

 Meeting of Works process and high-efficiency irrigation objectives and performance warrantees

 Protection of the health and safety of the operating staff and any sub-contractors or service providers
during the O&M period

 Protection of the environment according to Madhya Pradesh guidelines

 Protection and preservation of the equipment and structures of the Works in good working order

 Maximization of operational efficiency

The Bidder is responsible for all items that pertain to meet the Performance Standards of the Works including:

 Management and oversight of day-to-day Works operations

 Works performance analysis and direction of Bidder staff to optimize Works operations and meet
Performance Standards
 Page A-112

 Process control and testing

 Safety and process training

 Employee training and certification

 Purchase of materials, supplies and services associated with Works operation and maintenance

 Preventative maintenance, replacement and repair of all equipment, instrumentation, systems, pipelines,
and structures of the Works;

 Maintaining of all equipment, process, membrane and other warrantees and guarantees by provided by
equipment suppliers;

 Management and oversight of Works waste handling and disposal;

 The Bidder shall provide all required spare parts at the substantially completion date of the construction
of the Project and the quantity and type of theses provided spare parts shall be maintained throughout
the O&M contract (for 3 years).

 Emergency response

 Preparation of reports and data for regulatory reporting and monitoring

The Contractor shall formally meet with Employer on a pre-determined basis to review performance of services,
maintenance issues, equipment conditions, environmental and permit compliance, and any other relevant issues.
The Bidder shall also attend and participate at other related meetings as requested in advance.

The Bidder shall maintain Works in good working order and repair and in a neat and orderly condition. The Bidder
shall maintain the aesthetic quality of the Works as originally constructed and subsequently modified, with due
allowance for reasonable wear and tear. The Bidder shall manage, direct and oversee Works staff to ascertain
that they perform all predictive, preventive and corrective maintenance procedures in accordance with applicable
laws, regulations and permits; OEM guidelines, conditions of the applicable permits, and Standard Industry
Practices. In no event shall such predictive, preventative, and corrective maintenance procedures be performed
less frequently and comprehensively than recommended or specified to comply with manufacturer’s warranties.
The Bidder shall maintain all manufacturer warranties on purchased equipment and membranes.

The Bidder shall manage and oversee Works operations and maintenance such that all equipment is kept in a
good operating condition and adequate equipment inventory is maintained in order to facilitate the repair and
replacement of equipment. The Bidder shall direct and oversee the operation and maintenance of all equipment,
and perform or cause Works O&M staff to perform all tests as may be required or recommended pursuant to
applicable warranties.

Good housekeeping is an integral part of Works operations. The Bidder shall manage and oversee Works
operations in such manner that all Works buildings, equipment and structures are kept reasonably clean and
orderly. Equipment oil and grease should be wiped clean after any repair work is completed. Buildings will be kept
clean and neat in accordance with Standard Industry Practices.

1.5.2 Operation and Maintenance Operator Requirements

The Contractor shall deploy experienced personnel for operation and maintenance of the project. The deployment
schedule indicating the name of the persons, responsibility assigned to each of them and their bio-data shall be
provided in the Bid.

The Contractor will include in their bid the proposed staffing arrangements, which would be formalized in the
operations service contract. It is envisioned that 12 staff categories would be filled by the Contractor, involving
approximately 100 employees per main pump station and the distribution network it supplies. The MPWRD would
 Page A-113

have a small team of about 10 people covering the command area served by each main pump station during
implementation.

Location
For pipe
Category For control For pump
distribution Overall
room room
network
Pump station manager 2 2
Maintenance supervisor 2 2 4
Operator (mechanical) 4 8 4 16
Operator (electrical) 4 8 2 14
Attendant (mechanical) 2 4 4 10
Attendant (electrical) 2 4 6
SCADA technician 4 4 2 10
Irrigation planner 10 10
Database administrator 2 2
Driver 4 4
Watchman 2 1 3
Labourers 4 4 8
Based on 8-hour or 12-rotating shifts for non-management and non-administrative positions

The Bidder shall be responsible for staffing of the Works and for payment of all labor costs associated with Works
operations and maintenance for the duration of the term of this agreement. Staffing shall be in compliance with the
structure indicated in the Bidder’s submitted design and as necessary to meet all performance requirements. The
Bidder will organize Works operations work force in shifts and will maintain Bidder staffing levels in accordance
with the Bidder’s agreed Scope of Services. The Bidder shall ensure that its Works operations work force is
familiar with and complies with all applicable safety requirements and conduct requirements of the Employer.

1.5.3 Operation and Maintenance Plan

The Bidder will manage and oversee the operation and maintenance of the Works in accordance with an
operations and maintenance plan (O&M Plan) prepared by the Contractor and reviewed and approved by the
Employer. The O&M Plan will describe principal aspects of routine and emergency operating procedures, repair
and replacement, predictive and preventive maintenance, corrosion protection, staffing and training. The O&M
Plan will contain as a minimum an overview description of the following:

 Plan for day-to-day operations of the Works (Operations Plan)

 Works Management and Staffing Plan

 Maintenance, Repair and Replacement Plan

 Works Safety and Security Plan

 Emergency Response Plan

 Transition Plan

The Bidder will provide to Employer: (1) a preliminary O&M Plan forty-five (45) days prior to the Commencement
Date; (2) a draft final O&M Plan thirty (30) days prior to the anticipated Commencement Date, and (3) a final O&M
Plan fifteen (15) Days prior to the Commencement Date. The Employer may provide a copy of the final draft O&M
Plan to the pertinent regulatory agencies or Employer agents for their review, as required by applicable permits
and guidelines. The Contractor will discuss in a good faith with Employer any aspect of the preliminary, draft final
and final O&M Plan. The content of the O&M Plan will be consistent with the Contractor’s ability to perform its
obligations in accordance with terms and provisions of this O&M Agreement.
 Page A-114

The Bidder will update and submit to Employer any material changes to the O&M Plan at least ninety(90) days
prior to the commencement of each year for the duration of the term of this O&M Agreement. Specific
requirements related to the individual plans, which are integral parts of the O&M Plan are presented in the
following sections.

The Operations Plan shall describe principal procedures for normal, emergency and standby Works operations to
meet the Contractor’s obligations under the O&M Agreement, including overall Works startup and shutdown
during unusual events or other conditions which require such shutdown. The Operations Plan shall contain copies
of all permits, licenses, certifications, and other regulatory documents associated with the Contractor’s service.
This plan shall specify all tests to be conducted for the performance of this O&M Agreement, including all
sampling and analyses procedures and related QA/QC reports and performance guarantees.

The Works Management and Staffing Plan shall include a thorough description of the Works staffing organization
planned to be used by the Contractor with description of the roles and responsibilities of each staff position. This
plan will include the following:

 Organizational Chart

 Employee Resumes/Licensing Information

 Employee Training Schedules

The Maintenance Plan shall describe how the Contractor will manage and direct Works staff to:

 Preserve the principal process equipment warranties

 Perform predictive and preventive maintenance on all equipment and buildings in accordance with the
recommendations of the manufacturer, Standard Industry Practices and this O&M Agreement

 Perform corrective maintenance in such a manner that the equipment operation is not impacted and the
performance standards are not threatened

 Generally perform all maintenance, repair and replacement activities in accordance with Standard
Industry Practices and this O&M Agreement.

 Prepare reports on maintenance, repairs, and replacements of any major equipment components

The Maintenance Plan shall contain a section describing the plan approach to major maintenance, repair and
replacement program. This program shall contain a detailed description of major maintenance, and replacement
activities, which are recommended to be performed by the Works staff over the term of the agreement to maintain
operability, durability, and reliability.

The Bidder shall describe the computerized maintenance system they propose to use for the predictive,
preventive and corrective maintenance of the Works and indicate their experience with this system in other
projects with similar size and complexity, which they currently operate.

1.5.4 Reporting

Within thirty (30) days prior to the anticipated Commencement Date of operations, the Contractor shall develop
and submit for Employer’s approval reporting procedures and forms for recording of Works performance during
the Term of this contract. As a minimum, the Contractor shall provide the following reports:

 Monthly Operating Report

 Quarterly Performance Report

 Annual Operating Report

 Page A-115

The Contractor shall prepare a Monthly Operating Report regarding the Works performance, operations and
maintenance. This report shall be submitted to Employer no later than fifteen (15) Days after the end of the Month.

The Monthly Operating Report shall include data pertaining to performance compliance with applicable permit
requirements, performance standards, irrigation water deliveries, and any other information stipulated in this O&M
Agreement. The Monthly Operating Report shall also include a description of maintenance activities and
emergency services performed during the previous month. The Monthly Operating Report shall include as a
minimum the following:

 Compilations of the daily flow records with respect to quantities of water delivered to the distribution
system, as measured and monitored by the SCADA at every 30 ha chak outlet.

 A description of recommended Works or unit shutdowns for maintenance and repairs during the current
month and anticipated during the following month

 Description of unscheduled repairs

 A list of significant preventive maintenance activities performed on major pieces of equipment and Works
during this month and similar activities anticipated for the following month

 Any anticipated adverse conditions that may affect the ability of the Works to deliver irrigation water to
the distribution system

 The results of any inspections conducted by governmental regulatory authorities during the current
month, including recommended follow-up actions by the Contractor.

 The quantities (units) of electricity used during such month

 Information on any utility (power, water or other) outages that have occurred during the current month
that have an impact on the ability of the Contractor to perform his obligations under this agreement.

 A description of all incidents wherein any performance standards were not met, including the follow-up
actions recommended by the Contractor to taken to eliminate or reduce the likelihood of re-occurrence.

 A description of any incidents (hazardous materials emergencies, security breaches, etc.) that adversely
impacted Works operations and Contractor’s ability to fulfill its obligations under this agreement.

 Summary of Contractor’s worker claims filed, third party claims filed, and updates on the status of
existing claims.

 Semi-annually, an update of the spare parts inventory

 Any other data or information as mutually agreed by the Parties

Employer jointly with the Bidder may conduct a walk through the Works site to verify that Works operations and
maintenance is being properly performed. Once per year this review will coincide with a more thorough annual
review and preparation of an Annual Operation Report.

Approximately two weeks prior to the annual walk-through site review, and not later than thirty (30) days after the
completed year’s operation, the Bidder shall submit to Employer three copies of the Bidder’s Annual Operation
Report. This report shall include, at a minimum:

 Total irrigation water quantity (m3/year) and Annual Average flows of irrigation water pumped and
delivered to the each of the 30 ha chak outlets.

 A summary of the information provided in the Monthly Operation Reports

 Page A-116

 A summary of environmental and safety regulatory compliance

 Updated Annual Operation and Maintenance Plan

 An assessment of outstanding issues, including any recommendations for changes to Works operation or
Works equipment

The results from joint Employer / Contractor annual survey will be compiled for use as an annual addendum to
the Bidder’s Annual Operation Report. Approximately two weeks following the distribution of the addendum, the
Employer and the Contractor will hold a one-day Annual Review Meeting during which the results of the joint
Employer / Contractor survey and the Contractor’s comments and responses will be discussed and all other
matters of common interest and concern will be discussed and resolved. The Annual Operation Report will be
finalized by the Contractor and issued within two weeks of the Annual Review Meeting.

1.5.5 Site Security

All security measures for the Site must comply with all government requirements. The Contractor must operate
and maintain an integrated and Site-wide security system to prevent unauthorised entry to the Site.

Site security must, as a minimum, include and comply with the following:

 Access Control System – working at all times and if damaged must be repaired within one shift.

 Perimeter and inner fences – kept in good state of maintenance

 Intercoms – available at all times

 Security lighting – no more than 10% of the area lighting unavailable at any time

 Building perimeter access doors – kept in working order at all times

 Security personnel must attend the location of an attempted or actual security breach or suspicious
behaviour within 30 minutes of detection

1.5.6 Environmental Requirements

The Contractor must integrate and achieve the documented environmental assessment outcomes, commitments
and approval obligations for the Project.

The Contractor must, at all times, exercise necessary and reasonable precautions appropriate to the nature of the
work and the conditions under which the Project is to be performed to protect the Environment.

The Contractor must comply with the above requirements and must provide evidence of such compliance upon
request by the Employer or statutory bodies - as a precondition of continued access to the Site.

The Contractor’s environmental management and monitoring planning for the Project must be hierarchically
structured upon the Requirements for Management Plans and the Contractor’s Project specific systems.

Environmental management and monitoring planning is to be reflected in all aspect of operation and must be
consistent with the commitments made by the Employer and the Contractor as part of the Environmental Approval
process and the operating licenses and or other conditions of approval.

The Contractor must assess the environmental performance of the O&M Services and the environmental
performance of its sub-contractors. This assessment must conform with established environmental performance
evaluation standards and practices.
 Page A-117

1.5.7 Training

The Contractor shall be responsible for training of the Contractor’s and Government staff such that this staff shall
be capable of operating the Works in compliance with all requirements and provisions of this Agreement. The
purpose of this training is to educate personnel about the proper procedures associated with the operations and
maintenance of the Works. All training shall be documented and the records maintained at the Works. Staff
training shall be such that MPWRD staff can be capable of completing the responsibilities of plant staff at the end
of the 3-year O&M period.

The O&M Contractor shall provide with their proposal and in the Agreement a comprehensive training plan of their
employees encompassing three (3) categories: Site Specific Training, Health & Safety Training, and Additional
Technical/General Training.

All operation and maintenance personnel will undergo on-the-job training exercises with various equipment
manufacturers. This program requires the signature of the employee and their trainer to verify that the employee
has received and understands the operation, maintenance, and safety aspects of the equipment/material. This
section of the plan will outline specific training on the proper operation and maintenance of new and/or modified
equipment at the Works.

The Health and Safety of Works employees and the environment is essential for the proper operation and
maintenance of the Works. All Works personnel shall attend Health & Safety training sessions. This training
includes but is not limited to:

 Safe operations of all equipment and plant

 Electrical safety training

 Disaster preparedness and awareness

 Emergency response planning

In addition to Health and Safety training, each Works has site-specific topics where employees must be trained,
including but not limited to:

 Laboratory safety

 Spill containment/control plan

 Security training

 Evacuation plan

 Accident reporting procedures

 Slips, trips and falls

 Hearing conservation

 Using hand and power tools

 Hazard communication

 Fire prevention/ suppression

 Page A-118

1.5.8 Water User Associations

For establishing Water Users Associations for CCA under this contract, all works up to preparation of voter list of
cultivators based on revenue records with due marking for the area of Water Users Association and territorial
constituencies is to be prepared on village map.

1.5.8.1 Defect liability period and operation and Maintenance

1. Objectives of Operation and Maintenance

The objective of an efficient operation and maintenance of pressurized irrigation system is to provide
irrigation water as per designed quality and quantity, with adequate pressure at designated location and
time at competitive cost on a sustainable basis. Operation refers to timely and daily operation of the
components of pressurized irrigation system such as Pumping system (pumps/motors /VFD), Rising mains/
gravity mains, distribution system and balancing reservoirs/distribution chamber. Maintenance is defined as
the act of keeping the structures, plants, machinery, equipment, other facilities and ancillary requirements
like access roads, buildings etc. in an optimum working order. Maintenance includes replacements,
correction of defects, preventive /routine maintenance and also breakdown maintenance.

2. Preparation of O&M Plan

A plan has to be prepared for operation and maintenance by the contractor based on make and type of
equipment installed in the project and as per manufacturers recommendations and submitted to the
Engineer in charge for approval at least six months prior to intended date of completion of the contract. The
start of services for operation and maintenance will commence from the date of entire completion of the
contract. In case of DBO contracts, the partial completion /commissioning and O&M will be the part of
construction contract except for electricity charges. The O&M Manual shall be approved by the Department
at least three months prior to the commencement of services.

3. Scope of services

The scope of work for construction includes, trial run and rectification of defects of the scheme as a whole and
its individual component as well. Under this trial run period of 7 days continuously for 24 hours after the
completion of works in all respects, the contractor has to run the scheme as a whole and will have to prove
performance of each component individually as well as severally and that of whole scheme as per the
standards laid down in contract. After completion of 30 days trial run the completion certificate shall be issued by
the Engineer in charge. After which the scheme shall be deemed to be under O&M period. After operation and
maintenance for 5 years the same shall be handed over to the Department.

During this period (5 years) the contractor shall have to appoint necessary staff for running and maintenance of
scheme. The candidature of the staff being engaged by the contractor shall have to be as per O&M Manual. During
this period, the staff engaged for running and maintenance of scheme will be paid by the contractor as per the
wages rules. All the responsibilities of employees regarding safety/ insurance etc. shall be of the contractor.

The contractor can outsource/sublet the part or whole O&M work with the approval of Department but with his
liability to the Contract intact with the Department.
 Page A-119

During the last year i.e. 120 Days approx. of O&M, the Engineer-in-Charge will appoint staff or another O&M
Contractor to get hands on training to run and maintain the scheme. Contractor and his staff will arrange training for
the staff to the satisfaction of the Engineer In charge. The O&M contract can be extended to further 5 years with 6%
annual escalation on 2.5 year price of original Contract.

The contractor will bring into the notice of the Engineer in charge all repairs and maintenance works done and
will generate and submit monthly reports on each important parameter being monitored and an alarm
enunciated during the days.
The contractor shall arrange for the training of departmental staff as nominated by the Engineer in charge to
monitor during the O&M period up to the satisfaction of Engineer in charge.

The contractor shall have to arrange and provide for watch and ward, security against theft, sabotage and
upkeep of premises of the plant and pipe network during trial run period and O&M period. He will
maintain/replace the furniture/ equipment etc. if damaged during this period.

1. Approach Channel/Sluice: The contractor will provide the staff to run, maintain and keep records.
The Contractor will remove any slide of slope or rock fall obstructing the flow in the approach channel,
he shall keep the designed section always clear at the end of dry season i.e. May and June.

2. Pump House: The contractor will provide necessary staff to run and maintain the pumps and motors
and other ancillary devices installed in the pump house. The electricity charges will be borne by the
Department.

3. Distribution Reservoirs and Overhead Tanks: The contractor will provide necessary staff for watch
and ward and maintenance of break pressure tanks/Distribution Chamber(DC) and all over head tanks
under this project and will upkeep the premises of the tanks to the satisfaction of the Engineer in
Charge. The contractor's staff will maintain the digital record of water level in tanks and stock of
inventory if any at these tanks and communication to Control Room and department portal.

4. Rising/ Gravity Mains: The contractor will have to arrange and provide for regular surveillance of
rising/gravity feeder mains from Break Pressure Tanks/Distribution Chamber to the distribution network
and will have to arrange for any repairs and maintenance during O&M period. All necessary T&P,
consumables, pipes etc. will be provided by the contractor at his own cost and expenses.

5. Distribution Network: All the pipes, valves, nozzles and OMS (outlet management system) should be
run and maintained by the contractor. List of inventory is to be prepared by the contractor for record.
The Contractor shall provide complete data base of end user farmers along with AADHAR and mobile
numbers for informing the status of services and creating a data base matrix for the cycle of project.
Contractor shall be responsible for creating a project wise Mobile Application for the users and service
providers and linking it to the department portal.

6. Electrical Substations and Electric Supply Line: The contractor will provide necessary staff and
arrange for the maintenance/repairs/replacement of electrical substations and systems developed/
constructed under this contract. All expenses to operate and maintain shall be borne by the contractor,
except the electricity charges.

7. SCADA, Communication and Instrumentation: The contractor shall ensure that all the components
are functional and their availability is 100% for which he will provide necessary experts, Engineers and
staff and arrange for the maintenance/ repairs/replacement of systems developed as per the vendors'
recommendations. All expenses to operate and maintain shall be borne by the contractor.
 Page A-120

8. Ancillary Works: All ancillary works constructed or provided under the work Contract like availability
of access road and bridge round the year in good condition, all buildings, parking areas, fencing, land
shaping, gardens, vehicles shall be kept in good shape to provide support to Department as well as to
the staff of contractor engaged in O&M work.

9. Insurance: All the work as per condition (Above ground/underground) shall be insured against theft,
fire and other eventualities. All the service staff shall be insured including third party insurance.

10. The Grievance Redressal System: This will be in place and a call center will be established in the
Control Room for the purpose. The record of break down/complaints and their redressal/compliance
will be electronically logged and will be made available to MPWRD portal. Aggrieved party can make
an appeal to Engineer in Charge.

Handing-over after O&M period: Before handing over the components tothe department all the structures and
the Electrical & Mechanical equipment and distribution network must be in good running condition. It will be the
responsibility of the contractor to show that all stipulated Service Level Standards have been fulfilled and are
up to the mark on the date of handing over the works to the Department. The Department will not take any
responsibility of the employees engaged by the contractor to run the scheme during trial run and O&M period.
The scheme and all its components individually, shall be handed over to the Department in a very good
maintained condition. If the contract is expiring before March 31 st, then it can be extended up to 31st March by
the department on same terms and conditions to facilitate smooth Rabi irrigation. The final evaluation of the
project should be carried out by an independent engineer appointed by the department. The fee of independent
engineer will be borne by the contractor and the department equally.

4. SERVICE LEVEL BENCHMARKS DURING OPERATION & MAINTENANCE

1. General: The contractor shall be responsible to maintain service level standards during the 5 years of
operation and maintenance period and these standards shall be effective on the date of handing over the
project to the Department.

2. Service Level Standards: The following standards shall be maintained by the contractor:-

a. Duty and pressure at field: Water for irrigation should be ensured at the outlet of 1 ha chak with exit head
of 20m and with specified duty during demand. This is the key deliverable and prime service level benchmark
required in the contract and through the O & M period.

b. Pump and motor efficiency: The pump and motor efficiency should be maintained as provided in O&M
manual.

In case of not meeting the standard the penalty shall be imposed as per Contract.
Technical Specifications

Annexure I - General Guidelines

Management, Operation and Maintenance (MOM)

1. General Responsibilities

Management, Operation and Maintenance (MOM) of the Project will be done on a joint basis, with clear roles
for management, as well as defined financial and staffing responsibilities, for each respective entity. Joint
management of Project involves a newly constituted tripartite institution comprising the MPWRD, federated
WUAs and the DBO Contractor.
The MPWRD means officer designated by MPWRD or any person or agency nominated by the Chief Engineer
MPWRD to work on behalf of the department.

The proposed structure for the MOM of the Project is as under:-

(i) The overall project would be under Chief Engineer, who would have a small support staff comprising of
project management unit. The dam and reservoir, would remain under the authority of Madhya Pradesh
Government.
(ii) The scope for the contractor will consider not only design and construction costs, but also performance
requirements, so that it as a single entity, will be responsible and accountable for MOM. The service portion of
their contract will establish the contractor’s specific responsibilities to meet all present and future requirements
for delivering appropriate water quantities at flows and pressures determined by the MPWRD-approved
detailed design. Coordination between the contractor and the WUAs for developing the planned irrigation
schedule, based on the availability of surface water supplies, shall be monitored by the Engineer in Charge
every year .

(iii) The day-to-day management of the distribution and delivery of irrigation water, comprising mainly the
operation of the pump stations and pipeline distribution network, is assigned to the Contractor. He shall
provide for over all irrigation management services and maintenance of physical assets covering the whole
scheme.

(iv) Each WUA will be responsible for monitoring the pipelines and hydrants in their respective area, including
record-keeping and water planning.

(v) A stakeholder committee (ICC) will be established by the Chief Engineer to liaise and coordinate between
the different stakeholders, the committee would be chaired by the Superintending Engineer MPWRD. The
committee will meet at least once in a quarter. The members of committee headed by SE will include 5-7
members from WUA, two from contractor and two officers from water resources supervising distribution
system. The above approach will ensure that all facilities (built to the MPWRD’s specifications) will be
compatible, coordinated and cost-effectively maintained to assure long-term reliability, optimized energy use
and meet future agricultural goals.

2. Approach to the Seasonal Water Planning Process

In general, the key to sustainable MOM of the Project – meaning efficient, cost-effective, and meeting the
needs of agricultural and non-agricultural water users – is developing the proper combination of physical
infrastructure, communications, information management, and cost recovery. To achieve this principal
objective, the management institutions at all levels of the system must: (i) implement an Annual Operation Plan
– MPWRD and DBO Contractor for the main pump stations and the WUA for the irrigation systems; (ii) ensure
Technical Specifications

equitable and timely irrigation supplies insufficient quantities and in accordance with water user’s requirement
and schedule; and (iii) manage the distribution of irrigated water to farmers in accordance with hydrological
and climatic conditions like rainfall and water shortage. A critical feature of future operations in the Project will
be a comprehensive water planning process that occurs at the beginning of every irrigation season. This
planning process will result in a water management plan that governs all aspects of water deliveries,
scheduled maintenance, and cost recovery (payment amounts and fee collection).

At a suitable time prior to the start of the main pump station, the irrespective WUA's, will submit a cropping and
irrigation plan for the upcoming season. At the same time, the MPWRD will prepare a plan of forecasted water
availability and tentative delivery schedule, taking into account required maintenance periods and water use
during previous years. It will be the role of the contractor, to reconcile the cropping and irrigation plans with the
projected operation of the irrigation system. It is anticipated that there may be several iterations in the planning
process involving extensive dialogue between WUAs/farmers throughout the entire command area and the
MPWRD, facilitated and led by the contractor.

This joint water management plan will also be updated and adjusted as necessary during year to account for
current conditions. The plan will serve as the basis for charging farmers/WUAs for irrigation water service.
However, the crucial point in terms of the MOM of the Project is that there will be robust planning process put
in place that provides an administrative framework for day-to-day and hour-to-hour distribution and delivery of
water.

It is envisioned that the assigned staff in the control center at the main pump station(s) will control the
distribution of irrigation water in the pipeline distribution system on the basis of an arranged demand schedule.
On a daily basis, the contractor will arrange for delivery of water to each primary control at 300 ha where it will
be measured and recorded on a real-time basis. The pipelines themselves are operated automatically,
supplied by gravity flow from the DCs. Below the primary control water will be distributed through secondary
control at 30 ha (Hydrants). The distribution at 3 ha tertiary points will be the responsibility of the WUGs in
each WUA acting on behalf of its member-farmers. The essential point is that the irrigation system must
function in terms of each level whose primary responsibility is to provide an agreed-upon service to its next
lower level.

The service portion of the agreement will require the contractor to achieve water delivery performance
standards at field level.

3. Daily Operations Procedures

The fundamental requirements of an effective daily operations procedure of the Project are as follows:

(i) Planned water delivery orders are processed daily at a central location (i.e., at the control room of each
main pump station, where flow rates in the pipeline are monitored in near real-time)

(ii) Required flow rates are summed for each sub-command area system, to make certain that the capacities
will not be exceeded.

(iii) Generally, field operators should be mobile and be able to quickly travel throughout their zone of
responsibility
Technical Specifications

(iv) Daily, operators within the main pump stations are told what flow rates must be delivered at all delivery
points within their zone of responsibility. On a weekly or 10-day basis, they check the delivered volume against
the planned volume.

(v) The delivery schedule carried out by the staff at the pump stations properly reflects the downstream needs
and requests (i.e., it is based on feedback from WUAs).

(vi) The official seasonal planning schedule of deliveries for each main pump station is regularly adjusted,
based on observations of actual conditions and forecasts of irrigation demand.

(vii) Major changes in the flow rate in the main pipelines supplying the administrative levels of the system are
made several times per day.

(viii) Changes in flow rate at village block level may occur multiple times per day, based on downstream water
orders.

4. Water User Associations

WUAs must enjoy the trust of farmers in order to effectively carry out normal MOM of the water delivery
facilities under their responsibility, as well as helping MPWRD in recording of irrigated areas and collecting
irrigation revenue and energy charges. For this purpose each WUA will monitor water deliveries throughout the
season according to the planned irrigation schedule. WUA shall be governed by Participatory Irrigation
Management Act 1999, Madhya Pradesh.

The WUAs in the Project will be responsible for: (i) monitoring the status of the farm irrigation and drainage
infrastructure; (ii) planning maintenance activities in their area of responsibility; (iii)
determining the area to be cropped each season for determination of water requirements; (iv)monitoring water
use according to the agreed-upon delivery schedule; and, (v) ensuring equitable water delivery service among
farmers.

5. Role and responsibility of Contractor

A written manual will be prepared by the contractor during project implementation for each electrical and
mechanical component (or electrical and mechanical sub-system, as appropriate) and that of the constructed
distribution network that contains the following sections:
(i) functional description

(ii) maintenance inspections to be carried out

(iii) maintenance intervals
(iv) diagnostic and trouble-shooting procedures

(v) technical specifications

Generally this information will be provided by the manufacturer or supplier of the equipment; however, the
contractor will prepare these MOM manuals to the requirements of the MPWRD.
Technical Specifications

Appropriate steps will be taken to transfer knowledge and technical skills to MPWRD staff in the project and
avoid the potential pitfalls associated with steep learning curves of such a complex technology. This will
require substantial and sustained efforts in terms of training and capacity building. This will help ensure the
MOM of the pump stations , to the norms of international standards. In addition, improvement of scheme-level
MOM practices will contribute to reduced running costs and better service for water users.

In the interest of proper and efficient maintenance, it is imperative for the contractor to arrange training
program and refresher courses. Because of the constant changing maintenance techniques, group
discussions and lectures will also be required to improve the efficiency of maintenance staff and widen their
knowledge.

a. General Maintenance

The operation service contract will contain specifications addressing maintenance, repair and replacement of
project facilities. In addition to ordinary maintenance and upkeep of the pump stations and pipelines, the
contractor will also be responsible for major maintenance and repairs.

The MPWRD will conduct unscheduled inspections, periodic maintenance inspections and full scale annual
inspections as outlined in the following sections. The contract agreement will require that the facilities be
returned to the MPWRD in good condition at the end of the defined operating period (i.e., 3 years). The
method for determining the condition level of the structures and equipment, as well as the expected condition
of the facilities at the end of the contract term, will be described in the contract. The final evaluation of the
project should be carried out by an independent engineer appointed by the department.

It is of utmost importance to follow the manufacturer’s recommendations for operation and maintenance
procedures. On the basis of the recommendations of the manufacturer of the various equipment, a schedule of
preventive maintenance should be drawn in a simple language to be easily understood by the maintenance
staff. It should be ensured that the schedule of maintenance is strictly followed. Only the recommended
lubricants should be used. Sufficient space should be available for carrying out repairs and for keeping oil,
grease, spare parts and tools, etc. It is necessary to have a good workshop for this purpose, particularly in
case of large installations like the main pump stations. The repair of heavy equipment, depending upon the
scope of repair involved, may require a truck, electric generator, flood lights with extension cords, a small
crane for handling the materials safely during repairs. The workshop should have the facility of welding set,
grinder, drilling machine, small lathe and any other equipment depending upon the scope of repair involved.

b. Preventive Maintenance

The main reason for setting up a preventive maintenance program is to prevent unscheduled outages from
failure of pump station equipment. Depending on the circumstances, an unscheduled outage will be, at least,
very inconvenient and can be extremely expensive. A successful program of preventive and routine
maintenance will reduce equipment failures, extend the life of the equipment, and reduce the overall operating
costs.

The maintenance program should be set up initially by each of the major equipment manufacturers. The
manufacturers should be the foremost authority on what is required to keep the equipment operating properly.
The manufacturers' maintenance and operating manuals will provide recommendations on lubricants, spare
parts, maintenance procedures, and intervals between maintenance.

The contractor’s engineer-in-charge of maintenance should have readily available with him the following
information:
Technical Specifications

(i) Manufacture’s guideline and catalogues for repair and maintenance of all equipment

(ii) Name and addresses of firms dealing in related spare parts

For the pump station maintenance program, it is important to utilize personal experience and the equipment's
history in preparing a maintenance schedule. An effective maintenance program requires tailoring the
schedule to the equipment and the conditions under which it operates. Maintenance performed more
frequently than required can cause undue wear and tear to the equipment being serviced as well as being a
waste of time, while insufficient maintenance will cause premature equipment failure and a reduced service
life. It should be noted that some equipment, e.g., most lifting equipment, must be maintained on a regular
basis to meet safety regulations.

An equipment maintenance record system is essential in establishing a successful preventive maintenance

program. The record system should contain a description of the equipment and its location; manufacturer's
data such as size, model, type, and serial number; pertinent electrical and mechanical data; schedule for
preventive maintenance and periodic inspections, and data on repairs or maintenance performed including
actual work accomplished, material used, number of hours required to accomplish the work, and the cost of
labor and materials.

The most important point for the operator to understand is to know when to call for skilled assistance, for
instance where there is trouble because of worn out bearing requiring proper alignment, etc. The operator
should however be able to maintain logbooks properly and regularly indicating the fuel consumption, hours
worked and quantity of water pumped, etc. The logbook of the equipment should also indicate the record of
break downs and repairs, date wise and cost of repairs and consumption of fuel etc. This record would provide
a fairly good idea and timely indication about the particular equipment being worn out, requiring major over-
haul or replacement. It is extremely essential to provide communication and transport facilities at the plants. In
case of emergency situations requiring some unexpected spare part or materials, adequate communication
and transport facility can only help to arrange the required material promptly.

In addition to the records for routine maintenance, a comprehensive report should be written after major
overhauls or extraordinary maintenance describing the work done and how it was accomplished. Pertinent
photographs should be included in the report. These reports, along with manufacturer's drawings and
operation and maintenance manuals, should be kept in a history file where they are readily accessible to
maintenance personnel.

Well-kept maintenance records are invaluable in any maintenance program. They provide the necessary
information for establishing a preventive maintenance and inspection schedule and a spare parts inventory.
The records can also provide some consistency in the program even when personnel turnover is high.

c. Predictive Maintenance

For predictive maintenance the maintenance program is scheduled based on the analysis of data collected on
the condition of the machine or equipment, not necessarily on any set schedule. To be effective, the machine
being monitored has to be instrumented sufficiently to obtain meaningful data. An automated means of
collecting, storing, and analyzing the data is helpful as well. The most difficult part of a predictive maintenance
program is setting the limits or alarms that indicate when failure is near and maintenance is required. More
information and guidelines are becoming available, but there will always be some fine-tuning required for each
individual application. Not all equipment lends itself to predictive maintenance, i.e., it will be more cost effective
to continue with periodic maintenance rather than analyze data to determine the best time for action. A
combination of predictive and preventive maintenance would provide the best maintenance program.
Technical Specifications

d. Inspection of Pump Station Equipment

The information in the Table below provides typical maintenance and inspection information for some of the
most common mechanical and electrical equipment for a pump station. This information, combined with actual
operating experience and manufacturer's recommendations, should be used to develop specific inspection
schedules and check lists.

The checklist should be concise, but descriptive enough to leave no question to what information is required
and how it should be obtained. For example, if a bearing temperature is to be checked, indicate where the
thermometer is located and that the reading should be in degrees Centigrade. This should infer to the person
performing the inspection that a simple check mark indicating the temperature is okay is not acceptable. The
checklist should also include the range of acceptable values or conditions for each item on the list. This will
allow the person performing the checks to quickly recognize a problem, and notify maintenance personnel.

Typical Inspection Interval and Inspection Items for Pump Station Equipment

Interval Items

Routine - Suction pressure

- Discharge pressure

- Motor current
- Pump discharge

- Liquid temperature

- Bearing temperatures pump and motor

- Room temperatures

- Running noise and vibration

(diagnosis by noise sensor and vibration monitoring system)

The data to be stored through pump station control and monitoring

system.

Weekly Leakage from the pump shaft seal

- Gland packing type, to be adjusted

- Mechanical seal, leakage check

Monthly - Check for pump to driver alignment

- Measure and record vibration amplitude (to be stored)

Quarterly - Check of lubrication oil

(three month)

Half- yearly - Check pump to drive unit alignment (realign if necessary)

- Check of coupling (rubber, replace if required)
Technical Specifications

- Check of suction strainer, trash racks

Yearly - Overhaul, inspection and maintenance

- Clearance check

- Replacement of damaged parts

- Replenishment of spare parts

- Inspection and maintenance of valves and pipelines

- Removal of scales

The same should be developed in O&M Manual for all component of work.

Suggested Staffing Pattern for MOM of Irrigation System

(per single main pump station and distribution network)

Category Entity Location

For For For pipe Delivery of Overall

control pump distribution irrigation

room room network water to farm

hydrants

Project manager DBO 1

Pump station manager DBO 1

Maintenance supervisor DBO 2 2

Operator (mechanical) DBO 4 3 per 4 11

pump
house

Operator (electrical) DBO 4 3 per 7

pump
house

Attendant (mechanical) DBO 2 3 per 4 9

P.H.

Attendant (electrical) DBO 2 3 per 5

P.H.

Agricultural specialist DBO 1 per 5000

ha
Technical Specifications

Irrigation engineer DBO 3 3

Irrigation planner DBO 2 2

Field operator (valve operator) DBO One per As required

1000 ha.

SCADA technician DBO 2 2 2 6

Database administrator DBO 2 2

Driver DBO 4

Watchman/Security DBO 6 As As required

required

Labourers DBO 6 6 6 18

Penalty for Failure to Reach Production Outputs

The performance damages due by the Contractor to the Employer, shall be as follows.

Amount of Performance Evaluation Allowable

Item Damage Methodology Exclusions

Design Build Period

Discharge of specified If discharge and head is less Till rectified.

duty in l/s/ha for the net than 95% of requirement at
CCA at 20m exit gradient outlet: Rs200/ha/day Daily With written
at each 1 ha. instruction from
MPWRD

Operation Services Period

Interruption of operation Damage: Rs 200 day/ha A day is deemed With written

non-compliant if the instruction from
operation is MPWRD
interrupted
(discharge or
pressure not
compliant with the
requirement) 12
hours or more in the
day.
Technical Specifications

Amount of Performance Evaluation Allowable

Item Damage Methodology Exclusions

Power consumption kW- If power consumption is more Monthly. With written

hr/m3 than 2% in excess of the values instruction from
in schedule for the MPWRD
corresponding reservoir level: 3
times the prevailing rate of the
kW-hr in excess.

Conveyance efficiency of If the difference between water Volumetric With written

system pumped and water delivered at instruction from
field is more than 0.5% the MPWRD
penalty @ three times the
prevailing rate of kW-hr for
extra water pumped.
Technical Specifications

Appendix 1
List of Recommended makes of major items of Plant and Services.
The following manufacturers are recommended for manufacturing of the major
items given below. Where more than one manufacturer is listed, the Contractor is
free to choose between them. For additional items, the Contractor is free to submit
proposals for other manufacturers from time to time and the same shall be effective
after approval by the Employer.
The Contractor may substitute alternative brand names for the major items given
below provided that it demonstrates to the emmployer’s satisfaction that
substitution is inevitable in the interest of project and the alternative makes
proposed by the Contractor are substantially equivalent or superior to the one
recommended hereunder.

Item/Component Recommended Makes

High Head, high discharge Pumps
Pump Motors
Power Transformers
Sluice Valves/Scour Valves
Butterfly Valve
Non-return Valve
Kinetic Air Valve
Valve Actuators
Hydraulically operated flow Cum VAG/Darling-Muesco/Singer
Pressure control Valves
Zero Velocity Valve
Single faces Sluice Gates
Water Hammer Control Devices
Dismanling/Expansion Joints
Electro-magnetic Flow meters
Kirloskar/Jyoti/Mather+Platt/WPIL/Becon
Weir/flowmore ltd
Kirloskar/Jyoti/Crompton
Grieves/ABB/Alsthom/BHEL/Siemens/Bharat
Bijlee
ABB/Crompton Grieves/Emco/Siemens/BHEL
Kirloskar/IVC/VAG/IVI/Fouress
Kirloskar/IVC/VAG/IVI/Fouress
Kirloskar/IVC/VAG/IVI/Fouress
Kirloskar/IVC/VAG/IVI/Fouress
Auma/Rotork/Limitork
Vardhman Electomech/Flownix Valves
JASH/WAG/Kirloskar
Sureseal or equilvalent
AnupEngg./LoneStar/Vedanta/Precise
Emerson/Krohne
Marshall/Yokogawa/Siemens/Endress+Hauser
(India)/ITRON India/Nivo Controls
Technical Specifications

Items for Instrumentation/Automation

Item/Component Recommended Makes

Programmable Logic Controllers Rockwell (Allen Bradly)/Siemens/Honeywell

(PLC)
HT Switch Gear Alstom/Jyoti/Crompton/Siemens
Vacuum Circuit Breaker (VCB) Siemens/Schneider M.G./Jyoti/L&T
Air Circuit Breaker (ACB) Siemens/Schneider M.G./Jyoti/L&T
Moulded Case Circuit Breaker Siemens/Schneider M.G./Jyoti/L&T
(MCCB)
Soft starters/VFD Siemens/Alstom/Jyoti/ABB
Relay and Contractors Siemens/Alstom/Jyoti/ABB/L&T

Cables Tropodur/Finolex/Asian/Gloster/Incab/
Universal/Polycab
EOT crane Hitech/Indef/Hiking/Ambika
Panel Enclosures and Consoles Rittal/President/Cutler Hammer

Switch fuse Disconnector L&T, FN Type, Siemens 3 KL Type, GEPC

Multi-Function Energy Meters Enercon, L&T, SOCOMEC
Capacitor Bank Crompton Greaves, Khatau Junker, Malde, L&T
Cable Termination Kit Raychem, Denson, M-Seal
Battery HBL NIFE, Exide, Amco
Battery Charger Chaabi Electrical, Masstech

Tacho Meter on line Kana Electric, Proton, Jay Shree Electronics

Ultrasonic Type Level Endress+Hauser/Krohne Marshall/Hycontrol

Measurement Device UK, Electronet
Float & Board type Level Nivo (Toshniwal), Endress+Hauser, Pune
Measuring system Techtrol
Pressure Switch Indfoss, Switzer, Tag Process Instruments
Technical Specifications

Pressure gauge WAREE, WIKA, AN Instruments, Guru, HIteck,

Pressure Transmitter
Pressure Reducing Valves
Flow Switch
Electonet
Emerson, Foxbro, Druck, Endress+Hauser, ABB,
Honeywell Automation
IVC or equivalent
Switzer, General Instrument, Forbes Marshall

Engineering cum Operator work IBM, Compaq, Dell

Station
Local Supervisory Station IBM, Compaq, Dell
HMI Software Wincc, Rs View, Monitorpro, Intellution, Indusoft
Alarm Annunciator Minilec, Peacon, ICA, APLAB, Electronet

Uninterruptible Power Supply HI-Real, Pulse, Tata Libert, APC, APLAB

Lightening Protection Unit MH Inst, Crompton Greaves, MTL, Pepper &
fuchs, Rittmeyer, Cirprotec
Instruments & Control Cables Delton, Asian, Servel, TCL, Thermopad

Receiver Indicator/Digital panel Masibus, Yokogawa, Lectrotek, NISHKO, SaiTech,

meter MTL INSTS, Electronet
Intercom system Betel, Samsung, Tata, Panasonic, Matrix
Conductivity level switch Pune techrol, SBEM, Krohne Marshall,
Endress+Hauser India NIVO, Electronet
Printer Samsung, HP, CANNON

Multifunction Power Monitor MASIBUS, L&T, ENERCON, SOCOMECH, SECURE,

DAE
Temperature Scanner SaiTech, Masibus, Nishko, Lectrotek

Analog Signal Multiplier MASIBUS, SaiTech, MTL INSTS, NISHKO

Portable vibration measuring Shrenk Every, IRD, STM Instrument, TIME

equipment
Portable sound measuring CENTER, MECORD, CYNGET
equipment
Technical Specifications

Air Conditioning Voltas, Samsung, Carrier, Hitachi

Furniture Godrej, Ergo, Featherlite

Anti Vacuum Valves IVC or equivalent