09 0 Mechanical and Electrical Equipment Combined

QCS 2014 Section 09: Mechanical and Electrical Equipment Page 1
Part 01: General
1 GENERAL ...................................................................................................... 2
1.1.1 Scope 2
1.1.2 Related Works 2
1.1.3 References 2
1.1.4 Submittals 3
1.1.5 Quality Standards 10
1.1.6 Manufacturer‟s Experience 11
1.1.7 Factory Inspection 11
1.1.8 Factory Tests and Test Certificates 11
1.1.9 Shipment, Storage and Handling 11
1.1.10 Adaptation of Equipment 12
1.1.11 Guarantee 12
1.1.12 Job Conditions 12
1.1.13 Approved Manufacturers and Subcontractors 12
1.1.14 Hydraulic Sump Model Testing 13
1.1.15 Sewage Characteristics 13
1.2.1 Materials 14
1.2.2 Workmanship 15
1.2.3 Tropicalisation 15
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1.2.4 De-rating Due to Climate Conditions 15
1.2.5 Steel 15
1.2.6 Equipment Bases and Bedplates 16
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1.2.7 Anchors and Sleeves 16

1.2.8 Safety Guards 16
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1.2.9 Drive Units 16

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1.2.10 Bearings 17
1.2.11 Lubrication 17
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1.2.12 Electric Motors 18

1.2.13 Pressure Gauges 18
1.2.14 Nameplates and Data Plates 18
1.2.15 Painting and Protective Coatings 19
1.2.16 Noise Levels and Vibration 19
1.2.17 Metal Plating 19
1.2.18 MV Factory Built Assemblies (FBA‟s) 20
1.1 INSTALLATION AND COMMISSIONING .................................................... 20
1.2.19 Co-ordination 20
1.2.20 Inspection During Installation 20
1.2.21 Preparation of Installation Areas 20
1.2.22 Manufacturers‟ Installation Supervision 20
1.2.23 Installation 21
1.2.24 Testing and Commissioning 21
1.2.25 Instruction and Training of the Employer‟s Personnel 23
1.2.26 In-Service Checks 23
1.2.27 Specialised Training Programme for Employer‟s Personnel 24
Part 01: General
1 GENERAL
1.1 GENERAL MECHANICAL AND ELECTRICAL REQUIREMENTS
1.1.1 Scope
1 This Part specifies the General Mechanical and Electrical Equipment Requirements, which
apply to all mechanical, and electrical systems and equipment and are a part of each and all
of the separate Sections of the Specification. The Contractor shall direct the attention of all
manufacturers and suppliers of mechanical and electrical equipment and related
appurtenances for the works to the provisions in the Contract Documents and this Section
and also to the extreme climatic conditions.
1.1.2 Related Works

Section 1, General
Section 8, Sewerage
Section 10, Instrumentation, Control and Automation
Section 16 Structural Metal work
Section 17 Metal work
Section 21, Electrical Works
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1.1.3 References
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1 The following standards or revised/updated versions are referred to in this Part:

BS 88,.........................Cartridge fuses for voltages up to and including 1000 Va.c. and 1500
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Vd.c
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BS 89,.........................(IEC 51) Direct acting indicating analogue electrical measuring

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instruments and their accessories

BS 142,.......................Electrical protection relays
BS 159,.......................High voltage busbars and connections
BS 162,.......................Electrical power switchgear and associated apparatus
BS 381C, ....................Colours for identification, coding and special purposes
BS 449,.......................The use of structural steel in building
BS 729, ......................(ISO 1459,1460,1461) Hot dip galvanised coatings
BS 970, ......................(ISO 683) Wrought steels for mechanical and allied engineering
purposes
BS EN 1561, .............(ISO 185) Flake graphite cast iron
BS 1780,.....................Bourdon tube pressure and vacuum gauges
BS 2048,.....................Dimensions of fractional horse power motors
BS EN 1563, .............(ISO 1083) Spheroidal graphite or nodular graphite cast iron
BS 3100,.....................Steel castings for general engineering purposes
BS 3643,..................... ISO metric screw threads. Principles and basic data
BS 3790, ....................(ISO 155, 254, 1813, 4183, 4184, 5292) Endless wedge belt drives
and endless
V-belt drives
Part 01: General
BS 4142, ....................(ISO 1996/2/3) Method of rating industrial noise affecting mixed

residential and
industrial areas
BS 4196, ....................(ISO 3740-3745) Sound power levels of noise sources
BS 4794, ....................Pt. 2 (IEC 337-2), Control switches
BS 4800, ....................Paint colours for building purposes
BS 4884,.....................Technical manuals
BS 4921,.....................Sheradised coatings on iron and steel
BS 4999,..................... General requirements for rotating machines
BS 5000,.....................Rotating electrical machines of particular types or for particular
applications
BS 5304,.....................Code of practice for the safety of machinery
BS 5472,.....................Low voltage switchgear and control-gear
BS 5685,.....................(IEC 521), Electricity meters
BS 5950,.....................Structural use of steel work in building
BS 6231,.....................PVC insulated cables for switchgear
BS 7626,.....................(IEC 185), Current transformers
BS 7671,.....................Requirements for electrical installations
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BS 8233,.....................Sound insulation and noise reduction for buildings
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BS EN ISO 9000, ......Quality management and quality assurance standards

BS EN 60439, ............Low voltage switchgear and control gear assemblies
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BS EN 60947, ............Low voltage switchgear and control gear

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BS EN 10084, ............Case hardening steels. Technical delivery conditions

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BS ISO 10816, Part 1,

Part 3 and Part 7, ......Mechanical vibration in rotating and reciprocating machinery.
AWS D1.1, ................Steel structure welding code
List of „Approved Suppliers‟ prepared by the Public Works Authority
1.1.4 Submittals
1 General
(a) in addition to the requirements of Sections 1, 8, 10 and 21 the Contractor shall submit
the following information as described in the below paragraphs
(b) the Contractor shall note that submittals will not be approved unless submitted in
order. All submittals shall be clearly marked with the name of the manufacturers, sub-
contractors and Contractor‟s contract number such that they can be clearly identified
and are unique to the Contract
(c) all drawings shall be on ISO standard sized paper A1 unless specified otherwise.
Each drawing shall be marked with the Contractor‟s and manufacturers names and
references, project title drawing number, drawing title, scale, the date of completion
and a full description and date of all amendments. A clear space 100m x 160 mm shall
be left at the bottom right hand corner of each drawing for the Engineer‟s approval and
disclaim stamps
Part 01: General
(d) any work commenced or materials ordered before receipt of the Engineer‟s approval
shall be entirely at the Contractor‟s risk. Modifications required to comply with
approved submittals shall be at the Contractor‟s expense.
2 Submittal Schedule
(a) general. The Contractor shall submit a programme for all the submittals, with dates, for
the Engineer‟s approval. Adequate time shall be left in this programme for approval
(b) submittal times. Table 1.1 shows a Table of times for submittals and approvals. These
times may be varied in the Project Specification depending on the scope and
complexity of the Works. The Contractor should also note that the times for approval
are dependent on the above, and drawings being submitted in an orderly fashion.
Submittals of many drawings and information at any one time will delay the approval
process. If the Engineer has to extend the approval time he will notify the Contractor
within 7 calendar days of receipt of the submittal of the date on which he will grant
approval or otherwise.
(c) copies: numbers of submittals are as required in Table 1.1 below. In addition to the
requirements of Table 1.1 the Contractor shall submit all record drawings,
photographic records, test records and operation and maintenance manuals in
electronic format on the latest form of digital record such as a CD.
Table 1.1
Submittals and Approvals
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Time for
Submittal type
Time to be submitted comments/approva
Submittal stage Number of copies in
20
(calendar days) l
brackets
(calendar days)
14 days after Contract
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Programme (4) 7 days

start
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Design data (4) 21 days
start
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Manufacturing programme 30 days before start of

21 days
(4) manufacture
Shipping and delivery
schedules 30 days before shipping 21 days
Material and (4)
products data Materials and product data 60 days after Contract
21 days
(4) start
Fabrication and assembly
drawings 21 days
start
(4)
30 days after approval
Working drawings
of materials and product 21 days
(4)
Shop drawings submittals
Co-ordination drawings 30 days after approval
21 days
(4) of working drawings
Record drawings 14 days after notification
21 days
(4) of change
Records
Photographic records 7 days after date of
14 days
(3) photograph
30 days before
Plan and procedures
commencement of 14 days
Testing and (4)
testing
commissioning
Test records
7 days after tests 21 days
(4)
Part 01: General
Time for
Submittal type
Time to be submitted comments/approva
Submittal stage Number of copies in
(calendar days) l
brackets
(calendar days)
Operation and
60 days before *
maintenance manuals and
commencement of 30 days
instructions
testing
Operation and (5)
maintenance As erection progresses,
As-built drawings but all drawings within
40 days
(5) 90 days of Practical
Completion Certificate
* Draft only. Final version to be submitted before issue of Practical Completion Certificate (PCC) or
similar.
3 Design Data
(a) this shall include data and supporting calculations which is required for the following:
(i) justification for the overall design, sizing of process units, levels and layout
(ii) to show compliance with standards used. This may include quality manuals and
procedures
(iii) as required in the particular and general project specification
(b) design data shall be derived from standard methods of calculations. Computer
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generated data will only be accepted if it is produced by software with a proven record
of use in the field in which it is supplied
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(c) any calculations which do not follow recognised standards or norms shall have full
supporting justifications, with technical references.
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4 Material and Product Data

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(a) programme. When required by the Engineer a critical path type programme shall be
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submitted showing all the manufacturing activities with the critical path clearly
identified.
(b) shipping and delivery schedules. These shall include the following:
(i) date of shipping, arrival at port and on site
(ii) details of packing methods. Any unique packing, shipping, handling and
unloading requirements shall be stated.
(c) materials and product data
(i) approval of materials and equipment shall be based on latest manufacturer‟s
published data
(ii) complete and detailed information of all materials and equipment to be
incorporated in the Works shall be submitted. Detailed descriptions and
specifications, catalogue cut outs, installation data, diagrams, dimensions,
controls, and any other data required to demonstrate compliance with the
Project Specification shall be submitted. Each item submitted shall be
referenced to the applicable paragraph in the specification.
(iii) materials of construction of materials, equipment or components shall be stated.
At the request of the Engineer, a sample of these shall be submitted for further
study before approval. Where samples are required by the Engineer, the period
required to obtain the sample will be taken into account when scheduling
approvals.
Part 01: General
(d) materials and product specification data forms shall be submitted for each item of
equipment. These shall summarise the specification features as called for in these
specifications, and including such other necessary data, as would provide a complete
and adequate specification, for reordering an exact duplicate of the original item from
the manufacturer at some future date. The assigned tag numbers and manufacturer‟s
part numbers shall be included, but will not be considered as a substitute for any of the
required statement of specifications. More than one tag numbered item may be
included on a sheet.
(e) fabrication and assembly drawings. These shall be supplied for any fabrication or
assembly of equipment which is to be carried out in the factory or on site. Sectional
drawings shall be provided for equipment such as pumps, clearly showing the
materials and individual components.
(f) test certificates. Manufacturer‟s test certificates, type test certificates, third party test
certificates and quality control test certificates shall be submitted as required in the
general and particular Project Specification. Certificates shall be originals or
certificated copies.
5 Shop Drawings
These shall include the following:
(a) working drawings. These shall include layout drawings. They are drawings, diagrams,
illustrations and schedules specifically prepared by the Contractor for each part or area
of the works. They shall include general arrangements of the equipment and
appurtenances in relation to the buildings and structures. Standard or specialised
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procedures for installation work recommended by the manufacturer‟s of materials or
equipment and method statements for installation work shall be submitted. They shall
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include drawings of any templates required for the installation work.

(b) co-ordination drawings. These shall be prepared by the Contractor to show how
multiple system and interdisciplinary work will be co-ordinated. The location, size and
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details of fixings, box-outs, apertures, ducts, holes, cable routes, access doors/covers
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and plinths shall be shown on detailed layout drawings which are coordinated with the
building and civil structural drawings. Drawings shall illustrate clearances for lifting
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equipment, maintenance, access requirements and loadings due to equipment

heights.
(c) electrical drawings. These shall include single line diagrams, load schedules, cable
schedules, cable schedules, loop diagrams, piping and instrumentation diagrams,
panel layouts and circuit diagrams
6 Record Submittals
(a) record drawings. These shall be prepared as work proceeds. They shall provide a
record of any modifications to materials and equipment, and to the layout,
arrangement and installation of the works.
(b) photographic records shall also be made, as specified in Section 8, and as required in
the Project Specification.
7 Testing and Commissioning Submittals
(a) test procedures plan. At least 30 days before testing and commissioning is to be
performed, a detailed and comprehensive procedure plan shall be submitted for the
performance of each separate test. Each procedure plan shall describe and itemise
the involved system including associated electrical equipment, and shall include
evidence of an organised step-by-step procedure, properly co-ordinating the efforts of
the various trades and manufacturers‟ representatives involved, and of the operations
of the facilities. Procedures shall include an estimated duration and date for each
procedure and the personnel and equipment required.
(b) procedure plan information. Each procedure plan shall include the following
information, as applicable:
Part 01: General
(i) description of temporary procedure facilities, including drawings and sketches

as required to fully illustrate the facilities
(ii) list of test materials and estimated quantities
(iii) list of instruments, measuring and recording devices, and other test equipment,
whether a part of the equipment or furnished separately for temporary use.
Copies of calibration certificates shall be submitted for any test equipment.
(iv) names of supervising and inspecting manufacturers, where applicable
(v) complete listing of all functional parameters to be served and recorded
(vi) recording intervals.
(c) record materials. Samples shall be submitted of the forms, charts, and other materials
to be used in recording demonstration and validation test results. Wherever possible,
standard forms shall be used.
(d) test recording. Neat and comprehensive records of each test shall be maintained by
the Contractor. Each portion of the test procedure shall be described with all
components itemised. Records shall be prepared on forms in a step-by-step fashion
paralleling the approved procedure plans. Forms shall list for each test or check the
following:
(i) check/list taken
(ii) result anticipated
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(iii) result obtained
(iv) if incorrect, corrective action taken
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(v) re-test/check result

(vi) step (iv) and (v) shall be repeated until all systems operate as required.
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Instruments, gauges, and other sensors and display devices forming a part of
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the various systems shall be employed for data acquisition where applicable.
The Contractor shall furnish all other instruments, gauges, recorders, and test
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devices as required, types conforming to the approved procedure plans. All

applicable data such as, but not limited to, water and other liquid levels, flows,
pressures, head differentials, duration of runs, instrument readings, voltage
settings, drive speeds, motor running currents, torque, voltages and related
information, as applicable, and in accordance with approved test procedures
shall be recorded at the start and finish of each operational demonstration and
at 30 minute intervals during system validation tests, unless other intervals are
specified or agreed with the Engineer.
(e) when a repeat of the same demonstration or validation test is required to verify the
results, the repeat procedure shall be indicated on the recorded data by numerical
indication, data and time.
8 Operation and Maintenance Manuals and Instructions - General
(a) the Contractor shall provide fully detailed manuals covering all mechanical, electrical
and electronic equipment. The manuals shall be in English
(b) two copies of the draft manuals shall be submitted to the Engineer for review and
approval, before the programmed commencement of commissioning works
(c) the remaining three copies of the manuals shall be provided to the Engineer, before
the commencement of the maintenance period. They shall include all revisions and
comments made by the Engineer and any revisions or corrections necessitated by
changes made during installation and testing
(d) manuals shall be contract specific, and be fully indexed and sectioned, for allocation
and distribution to the specialist staff involved on the particular plant and equipment
Part 01: General
(e) where several sub-contractors and manufacturers have supplied equipment the
Contractor shall, if required by the Engineer provide a complete integrated manual
which clearly demonstrates the inter-relation of the equipment
(f) manuals shall be provided in durable hard cover backed A4 sized loose-leaf four ring
binders. Lever arch binders are not acceptable. The full project title shall appear on the
cover and spine
(g) the manuals shall enable the client to safely operate, maintain, dismantle, reassemble
and adjust all parts of the works
(h) Original copies of leaflets and instructions provided by the specialist manufacturers
shall be provided. Superfluous information shall be clearly deleted and relevant
information referred to separately in the text
(i) all instructions and manuals shall be written in accordance with BS 4884, IEC 278, and
in accordance with other recognised guidelines on technical manual writing.
9 Operation and Maintenance Instructions and Manuals shall confirm to Section 1, Clause
7.12.2.
10 Operation and Maintenance Instructions and Manuals‟ Contents shall also confirm to the
following listed items or otherwise agreed with the Engineer.
(a) these shall comprise a number of volumes, dependent on the amount and technical
content of the equipment installed. The operating instructions shall always form a
separate volume. Manuals shall include sections containing information as described
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in the following paragraphs
(b) introduction. The names, addresses, telephone and fax numbers of the Site, Employer,
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Consultant, Contractor, sub-contractors, manufacturers and agents. The date the

Contract commenced, and the date of the Practical Completion Certificate. This item is
to be completed when the date is established. A brief description of the equipment
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provided and the contractual scope of the work, with descriptions of any work
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subcontracted
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(c) general equipment description

(i) general process description. This shall provide a general description of the
treatment processes based on process P&I drawings included with the manual
(ii) process design parameters. This shall provide information on the performance
of the process systems
(iii) general description of the mechanical equipment. This shall provide a brief
description of all mechanical equipment provided
(iv) general description of the electrical equipment. This shall provide a brief
description of the equipment provided, listing individual control panel
compartments and the remote controls
(d) detailed equipment description
(i) mechanical equipment. This shall provide details of all the mechanical
equipment including type, rating, duties, characteristic curves and
manufacturers, and full component schedules, with serial numbers
(ii) electrical equipment. This shall provide details of all electrical equipment and
cables including detailed information on the control panel(s), listing the display
and controls available for each compartment and stating the rating,
manufacturer and supplier of main components, and full component schedules
with serial numbers. This section shall include a schedule of input and output
signals, detailing number, signal type, polarity, digital open or closed state and
analogue range, and detailed calibration routine
Part 01: General
(e) operating instructions. These shall provide details of how each component of
equipment is controlled and operated in both automatic and hand modes, including the
control philosophy and its interrelationship with other interdependent equipment.
Details of equipment operation under non-routine conditions and details of start-up and
shut-down procedures with any associated safety checks shall be provided. (see note
below)
(f) inspection and maintenance instructions. This shall provide schedules and time
intervals for routine inspection, maintenance and lubrication tasks, referring to
individual manufacturer‟s instruction manuals for full details. They shall describe briefly
to more complex tasks that will be needed from time to time (see note below)
(g) fault finding and correction. This shall provide a guide to first line checks that can be
undertaken in the event of equipment failure, without the need for reference to the
detailed instructions. A detailed guide of more complex checks shall be provided as
below
Note: section (f), (g) and (h) should, in addition to the routine operating and
maintenance tasks, identify the following:
(i) more complex tasks, involved with plant shut-downs, fault rectification to
component level, fault diagnostics, overhauls, etc.
specific hazards associated with operating and maintaining the equipment, e.g. auto
starting, high voltage, noise levels
(ii) highlight any particular complex or critical tasks over the above normal
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requirements
(iii) measurements and guidance on limits of acceptable wear for all items subject to
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wear.
(h) spare parts
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(i) The Contractor shall assess and recommend the consumable and strategic
spares requirements of all equipment supplied under the Contract. They shall be
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listed in the manuals. These and any other recommended spares shall also be
identified in sufficient detail for the Employer to select and purchase spares, and
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shall be provided with drawings or annotated diagrams showing the spare parts
(ii) consumable spares are for those components which are scheduled for routine
replacement during annual or more frequent service
(iii) strategic spares are for those components or items of equipment (e.g. gear box)
not duplicated by standby equipment, which are expected to operate for not less
than 5 years under normal operating conditions, but whose premature failure
would cause the process to fail
(iv) the Contractor shall indicate which spares are available ex-stock.
(v) the Contractor shall provide all the above necessary spares during the
maintenance period and in addition shall provide sufficient spares for 2 years of
operation on issue of the PCC.
(i) special tools. A list of the special tools supplied for the maintenance of all equipment
included in the Contract shall be provided
(j) test certificates. Certificates and documents of equipment tests shall be provided (e.g.
pressure vessels, lifting equipment, etc.). Performance test certificates and
characteristic details shall be provided. Set points for timers, overloads, pressure
switches, relief valves, etc. shall be provided
(k) inventory of as-fitted equipment. A schedule of this shall be provided
(l) drawings list. A list of the as-built drawings shall be provided
Part 01: General
11 As built drawings
(a) after erection has been completed, the Contractor shall submit to the Engineer copies
of the following “As-built” drawings for approval, including:-
(i) piping and instrumentation diagrams
(ii) site layouts showing main works operational features
(iii) equipment layout
(iv) general arrangement drawings
(v) mechanical details
(vi) electrical power circuit diagrams
(vii) control schematic diagrams
(viii) HV and LV distribution single line diagrams
(ix) HV and LV cable routes
(x) PLC or computer programs
one master copy of the proprietary software package shall be provided to the
Engineer within one week of the issue of the PCC. All software licences and/or
registration requirements must be forwarded promptly to the Engineer for
subsequent registration with the manufacturer. Sole rights to all software
developed and written on all schemes financed by Employer will be retained by
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the Employer
(xi) assembly drawings shall clearly show the construction details and be in
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sufficient detail to facilitate dismantling and re-assembly

(xii) parts lists shall be included for identification of replacement items
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(xiii) cable schedules shall include cable reference numbers and core reference
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numbers relating to power circuit diagrams

(xiv) diagrams where necessary shall be in colour to identify different components,
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networks, systems etc.

(b) the above are to be supplied to the approval of the Engineer. The Contractor shall
provide the Employer prints of each on thick paper and one ISO size A1 (594 x 420)
negative of each. All drawings shall be prepared on a CAD system and printed on ISO
standard sized paper A3 unless specifically requested otherwise. One set of drawings
shall also be submitted in Windows based AutoCAD System, software version and
storage media shall be as approved by the Engineer. Each drawing shall be marked
with the Employer‟s, Consultant‟s, Contractor‟s and manufacturer‟s names and
references, drawing number, title, scales, date of completion and a full description and
date of all amendments, and shall be certified „as-built‟. The project title shall be
included in a box at the bottom right hand corner of each drawing.
1.1.5 Quality Standards
1 All equipment furnished shall be new, and where feasible, shall be a standard product of an
approved or experienced manufacturer, and assembled from standard components readily
available.
2 Equipment shall conform to the requirements of the Project Specifications and reference
standards.
3 Manufacturers shall operate an ISO 9000 approved quality system, or equivalent in-house
quality system. If requested, details of the quality system shall be submitted to the Engineer.
Part 01: General
1.1.6 Manufacturer’s Experience
1 Manufacturer‟s shall be from the approved list in the Project Specification and shall have
furnished equipment of the type and equal or larger size than specified, which has been
installed, and demonstrated successful operation for at least 5 years and at least 5
installations in the Gulf countries, or in countries with similar weather conditions. User
certificates will be required to be submitted.
1.1.7 Factory Inspection
1 The Engineer or his representative may inspect the equipment at the factory. The Contractor
shall notify the Engineer of the manufacturing schedule 30 days before commencement in
order that the factory inspection can be arranged. Factory inspections will be made at any
reasonable time during manufacturing, testing or after the completion of testing and prior to
shipment. Approval of equipment at the factory only allows the manufacturer to ship the
equipment to the Site and does not constitute final acceptance. Where specified, the
Contractor shall include in the Contract Price for all the costs of the Engineer or his
representative.
1.1.8 Factory Tests and Test Certificates
1 Factory tests shall be carried out as specified in the Project Specification, and as required by
international standards and industry norms.
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2 The Contractor shall ensure that the manufacturer provides all labour, materials, electricity,
fuel, stores, apparatus and all instruments as are requisite and as may reasonably be
required to carry out the test efficiently. The Engineer or his representative may witness the
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tests. Where specified the Contractor shall include in the Contract Price for all the costs of
the Engineer or his representative.
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3 The Contractor shall submit from the equipment manufacturer, or his authorised
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representative, a certified written test certificate in accordance with the requirements of the
relevant test procedure.
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4 If after examining or testing any equipment the Engineer, or his representative, shall decide
that such equipment or any part thereof is defective or, not in accordance with the
specification, he may reject the said equipment or part thereof. He shall notify the Contractor
in writing within 7 calendar days of the rejection, stating the grounds on which the rejection is
based.
5 Wherever possible Site conditions shall be simulated, or the tests shall be extended to allow
for Site conditions.
1.1.9 Shipment, Storage and Handling
1 All equipment shall be boxed, crated or otherwise enclosed and protected for shipment,
handling, and storage. Electrical materials shall be delivered in manufacturer‟s original
cartons or containers with seals intact as applicable. Large multicomponent assemblies shall
be delivered in sections that facilitate site handling and installation.
2 All equipment shall be kept dry, off the ground and covered from exposure to weather prior to
installation. Pumps, motors, electrical equipment and equipment having anti-friction or sleeve
bearings shall be stored in weather proof storage facilities. Where possible, heaters provided
in equipment shall be connected and operated until the equipment is placed in operation. The
Contractor shall prevent corrosion, contamination or deterioration of stored equipment.
Storage shall be covered and the temperature and humidity maintained according to the
manufacturer‟s requirements.
Part 01: General
3 Equipment and materials shall be handled in accordance with manufacturer‟s

recommendations. Large or heavy items shall only be lifted by the designated points.
Padded slings and hooks shall be used for lifting to prevent damage.
4 All equipment shall be fully protected until final acceptance and all factory surfaces shall be
protected from impact, abrasion, discoloration and other damage. All damaged equipment
shall be repaired or replaced before final acceptance.
1.1.10 Adaptation of Equipment
1 Any alteration of the structure or building shown on the Contract Drawings to accommodate
substitute equipment shall be the responsibility of the Contractor. Equipment which requires
alteration of the structures or buildings will be considered only if the Contractor assumes all
responsibility for making and co-ordinating all necessary alterations, at no additional cost to
the Employer. All modifications to structures, mechanical, electrical, or other work made
necessary by such substitution shall require the approval of the Engineer. The cost of this
work shall be made at the Contractor‟s expense.
2 Following approval of the mechanical and electrical drawings the Contractor shall prepare
and submit to the Engineer the revised drawings showing any necessary modifications to the
proposed buildings and civil structures. The location, size and details of box-outs and fixings
for mechanical and electrical and other equipment shall be shown on the revised Drawings
and the Contractor shall be responsible for providing in the civil structures the correct location
and size of the box-outs and fixings shown on the approved mechanical and electrical
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drawings. The Contractor shall prepare at his own cost the necessary revised civil drawings
and detailed structural and other design calculations and submit them to the Engineer for
approval. The Contractor shall not be entitled to an extension of time for completion for any
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delays from the preparation of such revised drawings.
1.1.11 Guarantee
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1 The Contractor shall provide a guarantee during the maintenance period for all the equipment
in accordance with the General Conditions of Contract. In addition to the general guarantee
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requirements, equipment warranty shall cover:
(a) faulty or inadequate design

(b) improper assembly or erection
(c) defective workmanship or materials
1.1.12 Job Conditions
1 The Contract Drawings indicate the general arrangement, layout and locations of equipment,
valves, inserts, anchors, motors, panels, pull boxes, cables, conduits, stub-ups, lighting
fixtures, power and convenience outlets, and exterior lighting units, and may not be exact.
The Contractor shall conform to the Drawings as closely as possible, exercising care to
secure approved headroom and clearances, to overcome structural interference and to verify
scaled dimensions, field dimensions and conditions at the place of work.
1.1.13 Approved Manufacturers and Subcontractors
1 The Contractor shall ensure that all equipment shall be supplied, installed, tested and
commissioned by subcontractors recommended by the equipment manufacturer and
approved by Engineer. Large complex units, shall be installed, tested and commissioned by
the manufacturers representatives as specified. Installation procedures shall be supplied
and authorised by the equipment manufacturer.
Part 01: General
1.1.14 Hydraulic Sump Model Testing
1 Unless otherwise specified in the Project Specification hydraulic sump model tests shall be
performed by the pump manufacturer or an approved specialist hydraulic testing laboratory.
2 Physical hydraulic model tests shall be carried out to study the hydraulic performance of the
sump and behaviour of flows in the wet well for all possible combinations of pump operation.
3 Models shall be designed and constructed to a scale approved by the Engineer as necessary
to properly assess the wet well performance.
4 The model tests shall investigate the effects of the pump performance on sump operation
and provide information on the following as a minimum:
(a) hydraulic conditions in the pumping station inlet and wet wells under varying flows and
pump combinations
(b) formation of air entraining vortices in the sumps
(c) formation of swirl at the suction pipework of the pumps
(d) velocity distribution in the suction pipework of each pump
(e) hydraulic surge effects in the pumping station inlet and wet wells caused by starting or
stopping of one or more pumps
(f) start/stop levels for the pumps
(g) grit and solids deposition in the wet well.
(h) videos and coloured photographs with time and date stamping shall be produced to
show the model test and important features. Commentaries shall be added to videos
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to describe the events recorded.
5 The model tests and study shall make recommendations on any modifications to the
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pumping station inlet and wet wells considered necessary to overcome adverse hydraulic
conditions, and the provision of any flow splitters, diverters and benching required to improve
the hydraulic conditions.
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6 Model Requirements:
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(a) the model shall be constructed to an approved scale based on an appropriate Froude
number and the pumping station general arrangement drawings
(b) the walls of the wet well and inlet arrangement shall be constructed from transparent
material to allow the flows to be viewed. The top of the model shall be open to allow
viewing of the flows. A viewing platform above the model shall be provided for
inspection and measurement
(c) the method of construction shall be such that the dimensions of the wet well may be
adjusted to vary the hydraulic distribution and identify the optimum shape
(d) the Contractor shall submit four copies of drawings showing the general arrangement
and details of the models for approval by the Engineer. The drawings shall also show
details of all ancillary equipment forming part of the testing
(e) after completion of the testing the Contractor shall submit to the Engineer 4 copies of
the Model Test report, including all documentation, photographs and videos.
1.1.15 Sewage Characteristics
1 Sewage characteristics are typical of an arid climate municipal area with a sewerage system
comprising gravity sewers and rising mains. Hydrogen Sulphide is present in varying levels
throughout the sewerage system and the levels given in the Project Specification must be
used for materials selection.
Part 01: General
2 Unless otherwise specified in the Contract documents, typical Qatar sewage characteristic
shall be taken as:
(a) Temp °C 25 - 45
(b) PH 7.0 - 7.5
(c) BOD mg/l 200 - 220
(d) SS mg/l 150 - 200
(e) Alkalinity (caco3) 225 - 245
(f) Chloride mg/l 400 - 500
(g) Sulphide mg/l 10 – 16
(h) TDS 1500 - 2000
1.2 PRODUCTS
1.2.1 Materials
1 All materials used in the manufacture of equipment shall be new, and guaranteed free from
defects, and shall be capable of resisting corrosion from sewage. The Contractor shall
ensure that the manufacturer ascertains the conditions and service under which materials
and equipment are to operate and warrants that operation under those conditions shall be
successful. Equipment and materials provided shall be suitable for the service conditions and
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for meeting the specifications. All structural members shall be considered as subject to shock
or vibratory loads.
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2 All equipment and materials shall be designed to sustain all stresses that are likely to occur
during fabrication, handling, transportation, erection, and intermittent or continuous operation.
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3 Iron castings shall be tough, close-grained grey iron free from blow-holes, flaws, or excessive
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shrinkage and shall conform to BS EN 1561 Grade 250 and to BS EN 1563 Grade 250 for
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ductile iron unless otherwise specified.
4 Structural steel shall be as specified in Section 8, 16 and 17.
5 Stainless steel shall be BS 970 Grade 316 S31 unless otherwise specified. All references to
BS 970 Grade 316 shall include the statement „(partially replaced by BS EN 10084) after
„Grade 316‟.
6 Bolts, nuts, washers and anchor plates, shall be of stainless steel Grade 316 S31, to BS 970-
1, and shall remain unpainted. At lest two washers shall be provided with each nut and bolt
set. PTFE or nylon washers and spacers shall be fitted beneath stainless steel washers for
both bolt head and nut when used to fix dissimilar metals.
7 All nuts and bolts shall be threaded in accordance with BS 3643 "ISO metric screw threads"
Part 2 "Specification for selected limits of size" and fitted with 3mm thick washers beneath
bolt and nut.
8 All exposed bolt heads and nuts shall be hexagonal and the length of all bolts shall be such
that when fitted with a nut and washers and tightened down, the threaded portion shall fill the
nut and not protrude from the face thereof by more than half the diameter of the bolt.
However, two complete threads must be visible as a minimum.
9 Safety guards shall be of stainless steel of Grade 316S31 to BS 970-1.

Part 01: General
1.2.2 Workmanship
1 All equipment shall be designed, fabricated, and assembled in accordance with the best
modern engineering practice. Individual parts shall be manufactured to standard sizes and
gauges so that repair parts, are readily available and where practicable can be replaced on
site. Corresponding parts of duplicate units shall be interchangeable.
1.2.3 Tropicalisation
1 The equipment shall be suitable for installation in tropical areas. Tropical grade materials
shall be used wherever practicable. Some relaxation of these provisions may be permitted
where equipment is hermetically sealed.
2 Iron and steel are to be painted or galvanised unless specified otherwise. Indoor parts may
alternatively be chromium or copper-nickel plated or other approved protective finish. Small
iron and steel parts (other than stainless steel) of all instruments and electrical equipment,
the cores of electro-magnets, and the metal parts of relays and mechanisms shall be treated
in an approved manner to prevent rusting. Cores which are built up of laminations or cannot
be anti-rust treated shall have all exposed parts thoroughly cleaned and heavily enamelled,
lacquered or compounded.
3 Iron and steel shall not be used in instruments and relays. Where used, steel screws shall
be zinc, cadmium or chrome plated or, where plating is not possible due to tolerance
limitations, shall be dull nickel plated brass or be of other approved finish. Instrument screws
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except those forming part of a magnetic circuit shall be brass or bronze. Springs shall be of
non-rusting material. Pivots and other parts for which non-ferrous material is unsuitable shall
be of an approved stainless steel.
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4 Fabrics, corks, paper and similar materials, which are not subsequently to be treated by
impregnation, shall be adequately treated with an approved fungicide. Sleeving and fabrics
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treated with linseed oil varnishes shall not be used.

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5 Wood shall not be used in equipment unless absolutely necessary. Where used, woodwork
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shall be of thoroughly seasoned teak or other approved wood which is resistant to fungal
decay and free from shakes and warp, sap and wane, knots, faults and other blemishes. All
woodwork shall be suitably treated to protect it from the ingress of moisture and the growth of
fungus and termite attack. All joints in woodwork shall be dove-tailed or tongued and pinned.
Where used, metal fittings shall be of non-ferrous material.
6 Adhesives shall be impervious to moisture, resistant to mould growth and not subject to the
ravages of insects. For jointing woodwork only synthetic resin cement shall be used.
1.2.4 De-rating Due to Climate Conditions
1 The De-rating requirements for the climate conditions for all materials and equipments shall
be in accordance with Section 21 unless otherwise agreed with the Engineer.
1.2.5 Steel
1 Fabrication of structural steel shall conform to BS 449 and BS 5950 AWS D1.1 unless
otherwise indicated or specified. All fabrications shall be designed for dynamic and vibratory
loadings. Welding shall conform to Sections 16 and 17. All steelworks shall be galvanised
after fabrication unless otherwise specified. Galvanised bolts and fasteners shall be used
with galvanised assemblies.
2 If practicable, steel plate and members shall have a minimum nominal thickness of 6 mm
Part 01: General
3 Wrought steels shall be selected from the appropriate steel grade of BS 970 and shall be
free from blemishes, shot or hammer marks. The steel grade used shall be subject to the
Engineer‟s approval.
4 Cast molybdenum steel shall be to BS 3100 Grade B unless otherwise specified.
1.2.6 Equipment Bases and Bedplates
1 Equipment assemblies shall be mounted on a single heavy cast iron or welded steel bedplate
unless otherwise shown or specified. Bases and bedplates shall be provided with machined
support pads, tapered dowels for alignment or mating of adjacent items, adequate openings
to facilitate grouting, and openings for electrical conduits. Seams and contact edges between
steel plates and shapes shall be continuously welded, and welds ground smooth. Machinery
or piping shall not be supported on bedplates other than that which is factory installed.
Jacking screws shall be provided in equipment bases and bedplates to aid in levelling prior to
grouting. Plates of minimum thickness of 6 mm shall be provided. Pump bedplates shall
include a drip lip and provisions for directing gland leakage to a single disposal point.
1.2.7 Anchors and Sleeves
1 Each equipment manufacturer shall supply the required anchor bolts, nuts, washers, and
sleeves of adequate design for securing the bases and bedplates to concrete plinths. They
shall be stainless steel or, hot-dip galvanised as specified. Sleeves shall be at least
1.5 times anchor bolt diameter. Anchor bolts shall be provided of sufficient length to allow for
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maximum of 40 mm of grout under baseplates and adequate anchorage into structural
concrete.
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2 All anchors used in wet areas or areas containing sewage or sewage gases shall be resin
anchors of BS 970 grade 316 S31 approved stainless steel. Fixing anchors shall be sealed
with material appropriate to and recommended by the manufacturers of the concrete
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protection material.
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3 Steel work shall normally be bolted to the concrete, with grout added as necessary. G.R.P.
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lamination or other lining material shall be terminated on the equipment secured.

Consideration shall be given to subsequent removal of equipment, using additional brackets
or bolts which can be demounted without affecting the lining material.
1.2.8 Safety Guards
1 Belt or chain drives, fan blades, couplings, exposed shafts and other moving or rotating parts
shall be covered on all sides with safety guards to BS 5304. Safety guards shall be free of all
sharp edges and corners. Safety guards shall be fabricated from a minimum of either 2 mm
thick, galvanised or aluminium-clad steel, or 12 mm mesh galvanised expanded metal.
Guards shall also be of sufficient strength to contain rotating parts in the event of a
catastrophic failure. Guards shall be designed for easy installation and removal. Necessary
supports, accessories, and fasteners shall be provided, of hot-dip galvanised steel or
stainless steel. Guards in outdoor locations shall be designed to prevent entrance of sand.
Hinged access doors shall be provided for routine maintenance. Microswitches shall be
provided on guards to prevent the main drive from starting, if specified.
1.2.9 Drive Units
1 The requirements for the design, manufacture, construction installation, testing and
commissioning of drive units shall be in accordance with Section 21 unless otherwise agreed
with the Engineer.
Part 01: General
1.2.10 Bearings
1 The Contractor shall select the most appropriate type of bearing for the equipment being
supplied.
2 Equipment with vertical shafts shall have thrust and guide bearings.
3 Sealed for life units are to subject the Engineer‟s approval and shall have a minimum design
life of 50,000 hours operation at maximum loading.
4 Bearings fitted to gearboxes shall have a minimum design life of 100,000 hours at maximum
loading.
5 Plant which may be subject to vibration whilst stationary shall be provided with bearings
designed to withstand damage from such a cause.
6 Single journal plain bearings shall have phosphor bronze or synthetic lubrication impregnated
bushes with carbon or stainless steel journals respectively. Synthetic bearings shall only be
used where bearing conditions can readily be inspected.
7 Plain type bearings shall be self-lubricating by either grease, forced oil or impregnation.
8 Ball and Roller type bearings shall be adequately lubricated by oil or grease and sealed to
prevent leakage of lubricant along the shaft or the ingress of dust and water.
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9 Bearings not integral with a casting shall be mounted in substantial Plummer blocks.
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10 Bearings shall be sized and rated for the temperatures encountered in service conditions.
Additional cooling shall be provided if necessary.
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1.2.11 Lubrication
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1 Suitable lubrication shall be provided to ensure smooth operation, heat removal and freedom
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from undue wear. Plant selected shall require minimum lubrication attendance and down
time for lubricant change.
2 The Contractor shall supply the first fill of oil and grease from approved lubricant suppliers
prior to completion, testing, and final acceptance. In addition sufficient approved lubricants
for two years normal operation shall be provided.
3 All grease nipples, oil cups and dip sticks shall be readily accessible, being piped to a point
as near as practicable to the lubrication point.
4 Gearboxes and oil baths shall be provided with adequately sized filling and draining plugs
and suitable means of oil level indication.
5 Roller chain drives shall have a constant feed of lubricant, when in operation (viz oil bath or
autolube system).
6 Drain points shall be located or piped to a position such that an adequately sized container
can be placed beneath them. Where a large quantity of oil is involved or drainage to a
container difficult, a drain valve and plug shall be provided at the point of discharge.
7 Bearings equipped with forced fed oil lubrication shall be automatically charged prior to
machinery starting up, and pressure monitored during operation, with automatic shutdown of
machinery and alarm on low oil pressure.
8 Access, without the use of portable ladders, to lubrication systems shall be such as to permit
maintenance, draining and re-filling, without contamination of the charged lubricant.
Part 01: General
9 The design of breathers shall take into account the humidity and atmospheric contamination
at the vent point and measures shall be incorporated to prevent contamination of the
lubricant.
10 Grease application shall be by steel lubrication nipples manufactured in accordance with B.S.
1486, Part 1 and 4.
11 Anti friction bearings requiring infrequent charging shall be fitted with hydraulic type nipples.
12 Plain bearings requiring frequent charging shall be fitted with button head pattern nipples.
13 A separate nipple shall be provided to serve each lubrication point. Where a number of
nipples supply remote lubricating points they shall be grouped together on a conveniently
placed battery plate, with spacing in accordance with the recommendations of B.S. 1486,
Part I, Table 9 and 10.
14 The type, grade and amount of lubricant shall be clearly marked on a label adjacent to the
equipment.
15 Lubricants shall be suitable for the temperatures encountered in service conditions.

Additional cooling of lubricant shall be provided if necessary.
16 Lubrication of equipment shall ensure constant presence of lubricant on all wearing surfaces.
Lubricant fill and drain openings shall be readily accessible. Easy means for checking the
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lubricant level shall be provided. Prior to testing and/or operation, the equipment shall
receive the prescribed amount and type of lubricant as required by the equipment
manufacturer. Equipment lubrication systems shall require no more than weekly attention
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during continuous operation, shall not require attention during start-up or shut down, and
shall not waste lubricants.
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1.2.12 Electric Motors

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1 The requirements for the design, manufacture, construction installation, testing and
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commissioning of motors shall be in accordance with Section 21 unless otherwise agreed

with the Engineer.
1.2.13 Pressure Gauges
1 Gauges shall be connected to the suction (where applicable) and discharge pipework of each
pump, compressor and blower. The gauges shall be 150 mm diameter and in accordance
with BS 1780 and Section 10 and shall include a petcock between the pump/blower and the
gauge. A non-corrosive diaphragm gauge isolator shall be provided for solids-bearing or
corrosive fluids. Suction gauges shall be of the compound type and shall have a range of + 1
bar. Discharge gauge ranges shall be a standard commercially available range with the
maximum reading 1.2 times greater than the pump‟s rated shut-off pressure. Discharge
gauges shall also read to –1.0 bar. All gauge mountings shall be free of vibration.
2 The pressure readings shall be recorded on the MCC/SCADA system using pressure
transmitters.
3 Pressure gauges shall be always kept calibrated as QCS Section 10 requirements.
1.2.14 Nameplates and Data Plates
1 Nameplates and data plates shall be stainless steel of ample size with embossed, stamped
or etched lettering in English, fastened to the equipment in a prominent place with corrosion-
resisting pins. The manufacturer, serial number, date of manufacture, model number and
essential operating characteristics shall be displayed on nameplates, which shall be to the
approval of the Engineer. Data plates shall be inscribed with specific or directed information.
Part 01: General
1.2.15 Painting and Protective Coatings
1 Protection of Finish. The Contractor shall provide adequate means for fully protecting all
finished parts of the materials and equipment against damage, from whatever cause, during
the progress of the work, and until final completion. All materials and equipment in storage
and during erection shall be protected in such a manner that no finished surfaces shall be
damaged or marred, and all moving parts shall be kept perfectly clean and dry. Painting and
protective coatings shall conform to applicable requirements of colours. They shall be to the
approval of the Engineer, and the following requirements, unless modified or otherwise
specified elsewhere. Painting systems shall be as specified in Section 8 Part 8.
2 Factory Painting. On mechanical equipment, drives, starters, control panels and other similar
self-contained or enclosed components, a factory primer and high-quality oil-resistant baked
industrial enamel finish shall be applied. Surfaces that are inaccessible after assembly shall
be painted or otherwise protected by a method which provides protection for the life of the
equipment.
3 Shop Priming. Two shop coats of metal primer shall be applied on surfaces to be finish
painted at the site, the coating thickness to protect surfaces until finished. Primers specified
for the required field applied paint systems as in Section 8 shall be used. The Contractor
shall submit for approval the coating systems intended for use. Shop primers for affected
items of equipment shall consist of only those approved for the intended protective coating
system. Working drawings indicating compliance with this requirement shall be submitted.
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4 Rust Prevention. Machined, polished, other ferrous surfaces, and non-ferrous surfaces which
are not to be painted shall be coated with an approved rust preventive compound, and, in the
case of aluminium be anodised. Structural galvanised steel and stainless steel need not be
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coated.
1.2.16 Noise Levels and Vibration

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1 Noise levels: With the envisaged maximum number of items of equipment operating „on load‟
(including existing equipment), the sound level outside an envelope of 1 metre radius from
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any items of equipment, shall not exceed 85 dB (A). The Contractor shall include for suitable
sound attenuation to achieve this level, generally in accordance with BS 8233. This will apply
in the audible frequency range 20 Hz - 20k Hz. Above 20k Hz, the Contractor must state
whether any fundamental frequencies are generated in the ultrasonic region. Noise levels
shall be assessed in accordance with BS 4196, taking into account the actual or proposed
site conditions. Noise levels shall be limited to the values specified for designated
equipment.
2 Vibration Levels : The Contractor shall ensure that the stiffness of the floors/buildings and
supporting structures must be meet the requirements of vibration and resonance respect to
frequencies. Vibration levels shall be within the limits and comply with BS ISO 10816, Part 1,
3 and 7.
1.2.17 Metal Plating
1 Chromium plating shall be to BS 1224.
2 Sheradising shall only be used in internal air conditioned environments, and shall be to
BS 4921.
3 Galvanising shall be hot-dip, to BS 729. Whenever possible steel in a wet or external

environment shall be galvanised.
Part 01: General
1.2.18 MV Factory Built Assemblies (FBA’s)
1 The requirements for the design, manufacture, construction, installation testing and
commissioning of all labour, materials and accessories for the MV Cubicle Switchboards,
Main Switchboards, Submain Switchboards, Motor Control Centres, MCCB panel boards,
distribution boards etc shall be in accordance with Section 21 unless otherwise agreed with
the Engineer.
1.1 INSTALLATION AND COMMISSIONING
1.2.19 Co-ordination
1 The Contract Drawings show in a general arrangement form the arrangements desired for
the principal equipment, piping, and similar appurtenances, and shall be followed as closely
as possible. Proper judgement shall be exercised in carrying out the work to secure the best
possible headroom and space conditions throughout, to secure neat arrangement of all
equipment, and accessories, and to overcome local difficulties and interference of structural
conditions wherever encountered.
2 The Contractor shall take all measurements for his work at the installation sites, verify all
dimensions and conditions at the place of installation, verify the Sub-contractor‟s drawings
and be responsible for the proper installation, within the available space of the equipment
specified and shown on the Drawings. Written details and reasons for proposed deviations
from Drawing and Specifications shall be submitted. The Engineer‟s approval for any
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variations shall be obtained before making any changes.
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1.2.20 Inspection During Installation
1 For the tests on the Site the Contractor shall provide at his own expense unless specified
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otherwise, such labour, materials, electricity, fuel, stores and apparatus and instruments as
may be requisite and as may be reasonably demanded to carry out such tests efficiently.
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2 If after inspecting, examining, or testing any equipment the Engineer shall decide that such
equipment or any part thereof is defective, or not in accordance with the Contract, he may
reject the said equipment or part thereof, by giving the Contractor written notice within 7
calendar days of such rejection, stating therein the grounds upon which the decision is
based.
1.2.21 Preparation of Installation Areas
1 Prior to installing the equipment, the Contractor shall ensure that installation areas are clean,
free of dust intrusion and that concrete or masonry operations are completed. The
installation areas shall be maintained in broom-clean condition during installation operations.
All buildings where permanent doors and windows have not been installed shall be provided
with temporary protection to prevent dust ingress and any other damage to equipment, all to
the approval of the Engineer.
1.2.22 Manufacturers’ Installation Supervision
1 Where specified in the Project Specification, the Contractor shall ensure that each equipment
manufacturer furnishes the services of an authorised representative especially trained and
experienced in the installation of his equipment to:
(a) supervise the equipment installation in accordance with the approved instruction
manual
(b) be present when the equipment is first put into operation
(c) inspect, check and adjust until all trouble or defects are corrected and the equipment
installation and operation are acceptable
Part 01: General
(d) witness and supervise operational demonstrations and system validation tests to the
extent specified.
(e) prepare and submit certified test report.
2 All costs for manufacturers‟ representatives services shall be included in the Contract Price.
1.2.23 Installation
1 General. Prior to installation the equipment shall be cleaned, conditioned, and serviced in
accordance with the approved instruction manuals.
2 Equipment. Equipment shall be installed in accordance with approved instruction manuals by

an approved specialist sub-contractor. The Contractor shall employ skilled craftsmen
experienced in installation of the types of equipment specified, and shall use specialised tools
and equipment, such as precision machinist levels, dial indicators, gauges, and micrometers,
as applicable.
3 Anchor Bolts. The Contractor shall provide bolts with templates or setting drawings and
verify that bolts are correctly located before structural concrete is placed.
4 Base and Bedplate Grouting. Grouting shall not be carried out until initial fitting and
alignment of connected piping is completed and approved by the Engineer. The Contractor
shall level and align equipment on concrete foundations using suitable steel and brass
shimming, then entirely fill the space under base or bedplates with non shrink grout.
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Exposed grout shall be bevelled at a 45  angle, except that exposed grout at horizontal
surfaces shall be rounded for drainage. Exposed grout shall be trowelled or pointed to a
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smooth dense finish and damp cured with burlap for three days. After the grout has fully
hardened, the Contractor shall remove jacking screws and tighten nuts on anchor bolts. The
Contractor shall check the installation for alignment and level, and perform approved
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corrective work as required to conform to the tolerances given in the instruction manual.
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1.2.24 Testing and Commissioning

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1 General
(a) operational demonstrations and system validation tests are required for all mechanical
and electrical equipment, and systems specified including all associated and related
electrical systems and control devices specified in this Section, Sections 10 and 21,
and the Project Specification
(b) all costs for these shall be included in the Contract Price
(c) materials, potable water, chemicals and electrical power for testing and commissioning
and validation shall be supplied by the Contractor. Temporary facilities, storage, and
similar facilities necessary for these shall be supplied by the Contractor. Testing and
commissioning shall be performed under continuous inspection by the Engineer. The
Contractor shall provide sufficient experienced skilled staff to carry out the testing and
commissioning. Various equipment manufacturers shall be present, if specified.
(d) all defects and malfunctions found by testing and commissioning shall be corrected
immediately, using approved methods and new materials for repairs as required.
Interruption time necessary for corrective work may, at the Engineer‟s discretion, be
added to the specified testing and commissioning periods
(e) satisfactory completion and approval of required commissioning and testing is one of
the conditions precedent to the Engineer‟s acceptance of the work, but does not
constitute final acceptance
(f) testing and commissioning shall be in accordance with the Project Specification, the
QCS, the relevant International Standards, QGEWC requirements, industry norms and
to the Engineer‟s approval.
Part 01: General
2 Test Procedures
(a) testing shall be carried out in stages as follows:-

(i) primary tests and checks
(ii) unit testing
(iii) system validation tests
(iv) commissioning and setting to work
(b) the Contractor shall not proceed from one stage to the next without the Engineer‟s
written approval
(c) consolidation of demonstration, testing, and instruction requirements. Unit and system
validation testing, commissioning and instruction of the Employer‟s personnel may be
performed simultaneously.
3 Primary Checks and Tests
(a) all component units and complete systems shall conform to the Specifications,
Drawings and the approved working drawings, samples, construction manuals,
material lists, and other approved submittals
(b) all specified components and complete systems shall have been installed satisfactorily
and are operable
(c) all installations shall be safe to use. Temporary access, covers etc. will only be
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permitted if approved by the Engineer
(d) all cleaning work shall be completed
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(e) equipment shall be free from physical damage due to mechanical force, exposure to
the elements, incorrect connection, etc.
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4 Unit Testing
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(a) unit testing is defined as tests on individual equipment such as pumps, compressors,
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blowers, fans conveyors and all similar equipment item. Tests may be performed
simultaneously on groups of identical equipment, items, and groups of items supplied
by one manufacturer, if practicable
(b) potable water shall be used to fill tanks, wells piping and systems that contain water,
sewage, or sludge in normal operation. Where necessary specified chemicals shall be
used for chemical systems but shall not exceed in-service concentrations
(c) tests shall show that all component units operate with the quantities, efficiency,
repeatability, and accuracy specified
(d) tests shall be carried out continuously for a minimum period of 8 hours, unless other
periods are specified.
5 System validation tests
(a) system validation tests shall not commence until unit tests have been satisfactorily
completed
(b) this is defined as testing of complete systems that perform a discrete process function
such as pumping systems, emergency power systems and similar systems. Each
system shall include associated structures, tanks, piping, utilities, instrumentation and
controls, and like related items. Two or more separate systems shall be validation
tested simultaneously when necessary to validate an entire specific function
(c) potable water shall be used for system validation tests if it is possible to carry them out
satisfactorily with this medium. If the tests require use of the medium used in service,
then this shall be used
Part 01: General
(d) each system validation tests shall be carried out for minimum of 24 hours, unless
longer is needed to prove the performance of the system.
6 Commissioning and Setting to Work
(a) commissioning is defined as testing all the equipment and systems together under
actual operating conditions using all the mediums used in actual operating conditions.
Setting to work follows consecutively from this. Once the equipment and systems are
operating satisfactory they are left to work
(b) each system shall be tested, including standby equipment, by continuous operation
under the “in-service” condition for not less than 7 consecutive days unless required
otherwise by the Engineer, with no interruptions except for normal maintenance or
corrective work. Where the in-service condition is an automatically controlled repeat
cycle with on/off intervals, it shall be so operated
(c) systems shall be operated continuously under constant inspection of trained operators.
System operation shall be cycled from full load to light load and back to full load each
24 h. Variable speed equipment shall cycle through the applicable speed range at a
steady rate of change. Simulated alarm and failure operating conditions shall be
induced. Test controls and protective devices shall be tested for correct operation in
adjusting system functions or causing system shutdown
(d) failure of an item of equipment or a system during the stated periods will result in
termination of the test. The test will only recommence when the Engineer is satisfied
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with the remedial work. The test shall then recommence for a further 24 hours
(e) subject to Contractor‟s request and Engineer‟s approval in each specific case, the
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Contractor may be permitted to simulate certain operating conditions relating to flow

rates, water levels, and malfunctions. Permission for simulations will be granted only
where it is unwise or impossible to obtain the conditions covered by the capability of
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ranges or equipment. The simulation methods shall reflect reasonable anticipated

operating conditions.
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1.2.25 Instruction and Training of the Employer’s Personnel

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1 After the equipment has been installed, tested, adjusted and placed in satisfactory operation
the Contractor shall provide the services of qualified staff approved by the Engineer, or if
specified in the Project Specification, of the manufacturer‟s representatives, to instruct and
train the Employer‟s operating personnel in the use and maintenance of the key items of
equipment as specified. An instruction and training programme shall be conducted for up to
six operators designated by the Employer. The Contractor shall give the Employer at least
one month‟s written notice of the proposed instruction and training programme. Instruction
and training covering basic system operation theory, routine maintenance and repair, and
“hands on” operation of equipment shall be included. The duration of the programme shall
be based on the complexity of equipment involved, and the Engineer‟s approval of instruction
adequacy obtained before terminating the programme. Instruction and training periods shall
be acceptable to the Engineer and Employer.
1.2.26 In-Service Checks
1 General. In-service checks of all systems and equipment shall be carried out by the
Contractor twice during the Contract maintenance period by the Contractor with qualified
technical representatives of the various system manufacturers, including manufacturers of
equipment components within systems, if specified. Checks shall be detailed and complete
and shall be performed under the observation and to the satisfaction of the Employer. All
costs for in-service checks shall be included in the Contract Price.
2 Notification. The Employer shall be notified in writing at least 10 days before carrying out of
in-service checks and the Employer‟s approval shall be obtained prior to commencing work.
Part 01: General
3 Consultation. During the in-service checks, the manufacturer‟s technical representatives shall
consult with the Employer to review the instruction manuals and the pertinent operational and
maintenance problems encountered, and shall furnish technical advice and
recommendations to the Employer.
4 Programme. Initial in-service checks shall be performed approximately 6 months after final
acceptance. The last in-service checks shall be performed 30 days prior to the end of the
Contract maintenance period.
5 Reports. A written report on each in-service check, signed by the appropriate manufacturer
or his representative, shall be delivered to the Employer within 10 days following the checks.
The report shall describe the checking procedures in detail, and shall state all advice and
recommendations given to the Employer.
6 Operation and Maintenance Manuals. These shall be altered to take into account any
modifications to equipment, drawings or operating procedures. Replacement drawings and
pages, marked as revisions, shall be supplied with sufficient copies to allow all the operation
and maintenance manuals to be updated.
1.2.27 Specialised Training Programme for Employer’s Personnel
1 Where designated in the Project Specification the Contractor shall provide a specialised
training programme and manual for the Employer‟s key personnel in the equipment, electrical
systems and instrumentation systems, to be conducted by the supplier/manufacturer and
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held at locations outside Qatar. The training programme and manual shall be submitted to
the Employer for approval and shall be designed to:
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(a) provide in depth information and familiarisation of the equipment installed in the
Project
(b) receive specialised training in the design, proper operation, maintenance and
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replacement of the equipment and components

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2 The Contractor shall provide whatever assistance is requested by the Employer to develop
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meaningful itineraries for the training programme. The Contractor shall provide hotel
accommodation, travelling expenses by air, land transport and per diem allowance as per the
Ministry of Education guidelines.
END OF PART
Part 02: Submersible Pumps
2 SUBMERSIBLE PUMPS................................................................................ 2
2.1 GENERAL ...................................................................................................... 2

2.1.1 Scope 2
2.1.2 References 2
2.1.3 Submittals 2
2.2 PRODUCTS ................................................................................................... 3
2.2.1 General 3
2.2.2 Design Conditions 4
2.2.3 Materials 5
2.2.4 Fabrication 5
2.2.5 Accessories 8
2.2.6 Factory Inspection and Testing 8
2.2.7 Spare Parts and Tools 9
2.3 INSTALLATION AND COMMISSIONING ...................................................... 9
2.3.1 General 9
2.3.2 Site Inspection and Testing 9
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2 SUBMERSIBLE PUMPS
2.1 GENERAL
2.1.1 Scope
1 This Part specifies this requirements for the design manufacture, construction, installation,
testing and commissioning of submersible pumps, designed to handle raw unscreened
sewage with a non-clog type impeller, complete and ready for operation as shown on the
Drawings and as specified herein.
Pumps may be used for applications other than sewage, in which case they shall be modified
accordingly.
2 Related Parts and Sections are as follows:
This Section
Part 1, General
Section 1, General
Section 8, Sewerage
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2.1.2 References
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BS 970, (ISO 683) ......Wrought steels for mechanical and allied engineering purposes
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BS 1400,.....................Copper alloy ingots and copper alloy and high conductivity copper
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coatings
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BS 3468, (ISO 2892) ..Austenitic cast iron

BS 4999,.....................General requirements for rotating electrical machines
BS 5345,.....................Codes of practice for the selection, installation and maintenance of
electrical apparatus for use in potentially explosive atmospheres
BS 5512, (ISO 281) ....Methods of calculating dynamic load ratings and rating life of rolling
bearings
BS 6007, (IEC 245) ....Rubber insulated cables for electric power and lighting
BS 6105, (ISO 3506) ..Corrosion-resistant stainless steel fasteners
BS 6861, (ISO 1940) Balance quality of requirements of rigid rotors
BS 7671,.....................Requirements for electrical installations
BS EN 1092,...............Circular flanges for pipes, valves and fittings
BS EN 1561, (ISO 185) Flake graphite cast iron
BS EN ISO 9906 Grades 1, 2 and 3 Acceptance tests for centrifugal mixed flow and axial
flow centrifugal pumps Part 1 Class C tests
ISO 10816 Part 1 & Part 7, Mechanical vibration in rotating and reciprocating machinery
2.1.3 Submittals
1 In addition to the requirements of Part 1 of this Section the Contractor shall provide data and
information described in the following paragraphs
2 Design Data
(a) the Contractor shall provide manufacturer‟s published pump curves, system curves
and the necessary hydraulic calculations to justify the sizes of any pumps selected.
3 Shop Drawings
(a) the Contractor shall provide the following:

(i) impeller diameter
(ii) maximum impeller diameter
(iii) minimum impeller diameter
(iv) velocity of liquid in pump suction at duty point
(v) velocity of liquid in pump delivery at duty point
(vi) velocity of liquid in the pump casing or impeller eye at duty point
(vii) net positive suction head (dry well submersibles only)
(viii) the materials of construction shall be specified in detail and itemised against a
sectional drawing of the pump proposed.
(ix) characteristic curves for the full range of impeller diameters.
(b) after approval of the pump types the Contractor shall submit the test data as required
under factory inspection and testing
4 Operation and Maintenance Manuals and Instructions. The Contractor shall include all the
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documentation provided as above and as required in Part 1.
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2.2 PRODUCTS
2.2.1 General
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1 Pumps and drives shall be rated for continuous duty and shall be capable of pumping the
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flow range specified in the Project Specification without surging, cavitation, or excessive
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vibration to the limits specified. All pumps and drives shall be from approved manufacturers.
2 The pumps shall meet maximum allowable shut-off head, and if dry-mounted submersibles,
the maximum allowable required net positive suction head (NPSH) designated in the Project
Specification.
3 The pumps shall not overload the motors for any point on the maximum pump speed
performance characteristic curve and the pump operating range, within the limits of stable
pump operation, as recommended by the manufacturer, to prevent surging, cavitation, and
vibration.
4 To ensure vibration-free operation, all rotative components of each pumping unit shall be
statically and dynamically balanced to BS 6861 and the following requirements shall be met:
(a) the mass of the unit and its distribution shall be such that resonance at normal
operating speeds is within acceptable limits
(b) in any case, the amplitude of vibration as measured at any point on the pumping unit
shall not exceed the below limits
(c) at any operating speed, the ratio of rotative speed to the critical speed of a unit, or
components thereof, shall be less than 0.8 or more than 1.3.
5 Vibration outside the limits specified in 2.2.2.8 shall be sufficient cause for rejection of the
equipment.
6 The completed units, when assembled and operating, shall be free of cavitation, vibration,
noise, and oil or water leaks over the range of operation.
7 All units shall be so constructed that dismantling and repairing can be accomplished without
difficulty.
8 The Contractor shall be responsible for proper operation of the complete pumping system,
which includes the pump, motor, variable speed drive unit (if designated), and associated
controls furnished with the pump.
9 The Contractor shall ensure that the controls and starting equipment are suitable for use with
the pump motor, taking into account all requirements including starting currents and number
of starts per hour.
10 For the performance curve of the selected pump impeller, the head shall continuously rise as
flow decreases throughout the entire curve from run out to shutoff head.
11 The Contractor shall ensure that drive motors, variable speed drive systems (if designated)
and pumps shall be supplied and tested together by the pump manufacturer, who shall
supply full certification for the proper function of the entire pumping system.
12 If variable speed drive systems are specified, motor and drive system shall be fully
compatible, and shall be of sufficient power and torque, and be capable of sufficient heat
transfer for starting, accelerating and continuously operating over the entire range of
head/capacity conditions, from minimum to maximum pump operating speed, as designated.
The motor shall be derated to take into consideration the reduced cooling effect when
running at the lowest speed with the variable speed drive.
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2.2.2 Design Conditions
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1 Pumps shall be designed and constructed to satisfactorily operate and perform within the
designated design conditions and the requirements specified herein. They shall be designed
for a life of 100,000 hours with service intervals at 20,000 hours.
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2 Castings, fabrications, machined parts and drives shall conform to the industry standards for
strength and durability and shall be rated for continuous duty over the entire operating range.
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3 Bearings shall be of the anti-friction type designed for an L10 life of at least 50, 000 hours in
accordance with BS 5512.
4 Pump maximum operating speed shall not exceed 1500 rpm.
5 Pumps shall be designed to pass all suspended solids up to 100mm diameter, including
stringy matter, rags, paper, plastics, etc. without choking except in the case of pumps
delivering into a 100mm diameter rising main where the capability shall be 80mm diameter.
6 Pumps shall be suitable for use in the conditions specified in Section 1.
7 Renewable impeller wear rings shall be fitted, to the impeller and case, except where not
available on a standard production unit.
8 Vibration levels shall not exceed the levels given in ISO 10816 Part 1 and Part 7, quality
bands A and B.
9 Submersible pumps shall have the duckfoot bends flanged to BS EN 1092 PN16. In the
case of dry mounted submersible pump the outlet and inlet shall be flanged to BS EN 1092
PN16.
10 The pump, motor and associated electrical equipment shall be rated for a minimum 10 starts
per hour, unless otherwise designated.
11 The Contractor shall ensure that the pump manufacturer provides certification which
guarantees the following:
(a) flow rate

(b) total head
(c) power input
(d) efficiency
2.2.3 Materials
1 Pumps shall be manufactured of the following materials as a minimum:
(a) volute casings shall be cast iron, BS EN 1561 Grade 250

(b) impellers shall be duplex stainless steel
(c) casing wear rings (where fitted) shall be brass BS 1400 or for abrasive
(d) applications nitrile-rubber clad steel or to the approved manufacturer‟s standard
(e) impeller wear rings shall be stainless steel BS 970 316 S31
(f) bends shall be cast iron, BS 1452 Grade 250
(g) motor casings shall be cast iron, grade 250 or SS316 S31
(h) shafts shall be stainless steel, Grade 316 S31 to BS 970 Part 1
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(i) fasteners shall be stainless steel Grade 316S31 to BS970-1.
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2 The lifting system shall be manufactured of the following materials:

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(a) the guide rail system shall be stainless steel, BS 970 Type 316 S31
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(b) lifting chains, rings, hooks and shackles shall be stainless steel BS970 Grade 316
S31.
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2.2.4 Fabrication
1 General. Pumps shall be fabricated in accordance with the following requirements:
(a) pump shall be capable of handling raw, unscreened sewage

(b) in the case of submersible installations no portion of the pump shall bear directly on
the floor of the wet well. In the case of dry mounted pumps a substantial purpose
built mounting frame shall be provided by the pump manufacturer
(c) pressure gauge taps and air bleed taps shall be provided as stated under accessories
(d) all castings shall be produced in accordance with the pump manufacturer‟s
specifications under the manufacturer‟s direct supervision
(e) pumps shall be designed with dual mechanical seals, as below
2 Wet well pumps shall incorporate the following features:
(a) pumps shall utilise a guide system to permit easy removal and reinstallation
without dewatering the pump sump
(b) discharge connections shall be made automatically with a simple downward
motion without rotation when the pump is lowered into operating position. The pump
shall be capable of being removed without disconnecting any fasteners
(c) an appropriate length of chain shall be connected to the motor eyebolts to permit
raising and lowering of the pump. The lifting chains shall be fitted with suitable
additional rings in order that the pumps can be lifted in stages from the sump invert
level using the lifting gear. An additional hook and chain permanently fixed to the
bottom of the lifting equipment to support the weight of the pump set during lifting
operations shall be provided.
3 Impeller. Impellers shall be fabricated according to the rated motor size as follows:
(a) non-clog type statically and dynamically balanced, keyed to the shaft
(b) provided with pump-out vanes to prevent material from getting behind the impeller
and into mechanical seal area
(c) provided with wear ring as necessary to assure efficient sealing between volute
and impeller
(d) impellers shall not be trimmed unless approved by the Engineer
(e) single/multi vane or vortex type, with a cutter impeller in the case of small flows.
4 Discharge Connection and Guide Rails. Sliding guide bracket and discharge connections
shall be provided which, when bolted to the floor of the sump and to the discharge line, will
receive the pump discharge connecting flange without need of adjustment, fasteners, clamp,
or similar devices. The guide rails shall not support any portion of the weight of the pump.
The pump discharge connections shall incorporate a sealing face and connection yoke to
allow for automatic coupling to fixed discharge connection pipework. The guide rails shall be
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fabricated in stainless steel BS 970 Grade 316 S31.
5 Pump Shafts:
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(a) pump shafts shall be of such diameter that they will not deflect more than 0.05 mm
measured at the mechanical seal, whilst operating at full driver output
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(b) the shaft shall be turned, round and polished

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(c) shaft shall be key-seated for securing the impeller.

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6 Shaft Seals:
(a) the drive motor and pump/motor bearings shall be sealed along the shaft with
tandem mechanical seals operating in an oil filled chamber. The seals shall require
neither routine maintenance or adjustment, but shall be capable of being easily
inspected and replaced.
(b) two back to back mechanical seals shall seal the motor off from the pump.
(c) the upper seal shall be oil lubricated with a carbon rotating component and fixed
tungsten carbide component
(d) the lower seal shall have both parts in tungsten carbide.
(e) a detector shall indicate when moisture is leaking past the first seal.
7 Bearings:
(a) bearings shall be capable of taking the static weight of the rotating parts and any
thrust generated by the operation of the pump
(b) the upper bearing(s) shall be of the grease lubricated sealed for life type, the lower
bearing(s) shall be lubricated by the internal oil supply
(c) the bottom bearing(s) shall be of the angular contact ball bearing type in
combinations with roller bearing(s)
(d) if required in the project specification, remote indication shall be provided for bearing
high temperature, using a thermistor at the lower bearing, to provide a signal at
95 °C.
8 Motors:
(a) motors shall be 415 V / 690V or as indicated in project requirements, phase, 50 Hz,
rated at 10 % above the maximum power requirement
(b) motors shall be squirrel cage, induction, air filled, totally sealed to IP 68, suitable
for the maximum immersion depth likely to be encountered, rated for zone 2 use with
group 1 gases, to BS 5345
(c) motor insulation shall be Class F, limited to a Class B temperature rise
(d) motor temperature shall be monitored using a thermistor, in each phase of
the winding, set to stop the motor when the monitored absolute temperature reaches
130 °C
(e) a watertight cable junction box sealed from the motor shall be provided for the motor
power and signalling
(f) cables shall be EPR insulated, Niplas sheathed, flexible 450/750 volts grade, oil and
grease resistant, with tinned annealed copper conductors in accordance with
BS 6007. The cable shall be brought directly out of the submersible motor without
joints, and shall be of sufficient length, minimum 20 m to be terminated in an IP67
junction box outside adjacent to the wet well. They shall be sized in accordance with
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QGEWC regulations and BS 7671
(g) cables shall be supported using a proprietary „sock‟ arrangement at the top of the wet
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well
(h) Pumps shall be provided with proprietary monitoring and control units for inclusion
in the motor controls. Analogue inputs shall include the following:
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(i) winding temperature

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(ii) bearing temperature

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(iii) cooling oil temperature
Digital inputs shall include the following:
(iv) high winding temperature

(v) high bearing temperature
(vi) loss of coolant oil/seal failure
(vii) over temperature
(viii) moisture ingress
(i) Motors shall be capable of start up and operation in the event of a completely
flooded wet well. Motors shall be selected to meet the maximum power required for
the selected impeller at all operating conditions
(j) Motor cooling shall be an efficient system to the manufacturer's design.
(k) motors shall be derated for dry well and/or variable speed operation
9 Coatings and Protection
(a) Cathodic protection with replaceable sacrificial zinc anodes shall be provided if
required in the Project Specification.
(b) The cooling jacket shall be stainless steel
(c) all other parts shall be to the approved manufacturer's standard protection
2.2.5 Accessories
1 The following accessories shall be provided for each pump:
(a) pressure gauges. The discharge pipework of each pump shall be provided with a
19 mm diameter tapped opening and stainless or brass isolating valves and
diaphragm pressure gauges In the case of dry-mounted submersibles a similar
tapping valve and gauge shall also be provided on the suction pipework of each pump
(b) air bleed offs. In the case of submersible pumps automatic brass air bleed ball
valves shall be provided on the reflux valves, venting via a 40 mm diameter
stainless steel pipe to the wet well. In the case of dry mounted submersible pumps
these valves shall be provided on the highest point of the volute casing
(c) labels. Each pump shall have a stainless steel label permanently fixed to the pump
and an identical label fixed to the pump starter compartment.
2.2.6 Factory Inspection and Testing
1 The Contractor shall secure from the pump manufacturer certification that the following
internal inspections and tests have been conducted on each pump at the factory, and submit
to the Engineer prior to FAT witness proposed:
(a) the pump casing has been tested hydrostatically to 1.5 times the maximum closed
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valve pressure
(b) impeller, motor rating and electrical connections checked for compliance with the
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Project Specifications
(c) motor and cable insulation tested for moisture content or insulation defects
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(d) prior to submergence, the pump has been run dry to establish correct rotation and
mechanical integrity
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(e) the pump has been run for 30 minutes submerged under a minimum of 2 m water
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(f) after the operational test (e) above, the insulation tests (b) above has been
performed again, and after the performance test (2) below
(g) NPSH (dry well mounted pumps only)
2 Each pump shall tested at the factory for performance according to BS EN ISO 9906 Grades
1, 2 and 3, including:
(a) flow
(b) inlet pressure
(c) outlet pressure
(d) motor power
(e) torque
(f) efficiency
(g) Net Positive Suction Head (NPSH) (valid for all type of pumps).
3 The Contractor shall secure from the pump manufacturer the following certification and
submit to the Engineer prior to shipment:
(a) certified copies of the pump characteristic curves and reports generated by the tests
described above and as required by BS EN ISO 9906 Grades 1,2 and 3
(b) foundry composition certificates for all major castings (pump case, impeller, motor
housing) showing exact material composition and tests conducted to ensure
compliance with the pump manufacturer‟s material specifications.
(c) the lifting chains, rings and shackles shall be load tested and Proof tested compare
with one of the below mentioned applicable codes requirements, and clearly and
permanently tagged with the SWL. Test certificates shall be supplied with Authorised
TPA approval.
Chain (sling and hooks): BS 4942 part 1 and 6 / ISO 2903 / ISO 7595
Shackles: BS 3551 / BS 3032 / BS 6994
Ring and Links: BS 2902
2.2.7 Spare Parts and Tools
1 The Contractor shall ensure that the pump manufacturer provides all spares and special tools
required during the commissioning and maintenance periods, and as required below.
2 In addition to the spare parts required in Part 1 the following spare parts for each pump shall
be furnished to the Employer:
(a) three sets of complete upper and lower bearings

(b) three sets of wear rings
(c) three sets of gaskets and three sets of „O‟ rings complete
(d) three sets of upper and lower mechanical seals
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(e) additional spare parts as recommended by pump manufacturer to cover two years of
operation following the maintenance period.
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2.3.1 General
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1 The equipment delivered to the Site shall be examined by the Contractor to determine that it
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is in good condition and in conformance with the approved working drawings and
certifications. All equipment shall be installed in strict conformance with Part 1 of this Section
and the manufacturer‟s instructions.
2.3.2 Site Inspection and Testing
1 If required in the Project Specification, or in the case of submersible pumps rated at 50 kW or

greater, the Contractor shall provide the services of the pump manufacturer‟s representative
to supervise the installation, commissioning and start-up of the pumping equipment.
2 The commissioning tests shall be performance and reliability trials, mainly for the purpose of
satisfying the Engineer that the pumpsets have been correctly assembled and installed and
that their performance matches that obtained during the manufacturer‟s works tests. In the
event of an unwarranted change in the pump performance characteristics or power
consumption, all necessary steps shall be taken as soon as possible to establish the cause
and remove the fault. Similar action shall be taken for an undue increase in bearing or gland
temperature, increased gland leakage rates, unsatisfactory vibration levels or any other fault
or defect in the operation of the pumpset.
3 The site reliability trials shall include the following:
(a) a record of bearing and coupling clearance and alignments shall be tabulated to
show the “as-built” condition of each pump
(b) a record of all overload, timing relay and oil pressure relays shall be tabulated to
show the “as-built” condition of each motor starter
(c) all cables shall be “megger” tested to confirm the integrity of the insulation. A
tabulated record of results shall be made
(d) the control panel shall be statically tested with motors disconnected to confirm the
correct sequence of operation
(e) each pump shall be operated individually over the range from closed valve to
maximum emergency top water level, on a recirculation basis, using fresh water, and
for a minimum of four hours continuously. During this test the following parameters
will be recorded:-
(i) motor phase currents
(ii) pump output
(iii) ambient and test water temperatures
(iv) motor/pump casing temperature
(v) power consumed
(vi) power factor
(vii) vibration
(viii) signs of cavitation noise
(f) the commissioning trials shall extend until each pump unit has run „continuously‟ for
at least 3 days under all operating conditions. The term „continuously‟ shall include
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running at various speeds or on a start/stop basis as determined by the control
system
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(g) the Contractor‟s supervisory staff, and the pump manufacturer‟s representative, if
required by the Project Specification or the above, shall be present during the period
of the tests and trials. The Contractor shall be responsible for any failure of the whole
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equipment or any part thereof, whether such failure shall be determined by the
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methods detailed herein or otherwise. If the pump test or trial is interrupted by the
Contractor, or through negligence on the part of the Contractor‟s staff, it shall be
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completely repeated for the pumpset concerned.
END OF PART
Part 03: Centrifugal Pumps (Dry Well)
3 CENTRIFUGAL PUMPS (DRY WELL) .......................................................... 2
3.1 GENERAL ...................................................................................................... 2

3.1.1 Scope 2
3.1.2 References 2
3.1.3 Submittals 2
3.2 PRODUCTS ................................................................................................... 3
3.2.1 General 3
3.2.3 Materials 5
3.2.4 Fabrication 5
3.2.5 Accessories 9
3.3.1 Installation and Commissioning 10
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3 CENTRIFUGAL PUMPS (DRY WELL)

3.1 GENERAL
3.1.1 Scope
1 This Part specifies the requirements for the design, manufacture construction, installation
testing and commissioning of vertical spindle, single-suction, dry-well, non-clog, centrifugal
type pumps, to handle sewage, surface and groundwater as specified.
2 Related Sections and Parts are as follows:

This Section
Part 1, General
Section 1, General
Section 8, Sewerage
3.1.2 References
1 The following standards or revised/updated versions and documents of other organisations

are referred to in this Part:
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BS 4,...........................Structural steel sections
BS 449,.......................The use of structural steel in building
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BS 970 (ISO 683) .......Wrought steels for mechanical and allied engineering purposes
BS 1400,.....................Copper alloy ingots and copper alloy and high conductivity copper
coatings
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BS 3100,.....................Steel castings for general engineering purposes

BS 3170,.....................Flexible couplings for power transmission
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BS EN 1092,............... Circular flanges for pipes valves and fittings
(ISO 10816 ) Part 1 and Part 7, Mechanical vibration in rotating and reciprocating machinery
BS 4999,.....................(IEC 34,72) General requirements for rotating electrical machines
BS 5304......................Code of Practice for the safety of machinery
...................................BS EN ISO 9906 Grades 1, 2 and 3 Acceptance tests for centrifugal
mixed flow and axial flow centrifugal pumps
bearings
BS 6861, (ISO 1940) ..Balance quality of requirements of rigid rotors
BS 7613,.....................Hot rolled quenched and weldable steel plates
BS EN 10113..............Hot rolled products in weldable fine grain structural steels
ASME V ......................Boiler and Pressure Vessel Code, Nondestructive Examination

ASME VIII Div. 1 .........Boiler and Pressure Vessel Code, Design and Fabrication of Pressure
Vessels
3.1.3 Submittals
1 In addition to the requirements of Part 1 of this section the Contractor shall provide data and
information as described in the following paragraphs.
2 Design Data
3 Shop Drawings

(i) duty impeller diameter
(vii) net positive suction head
sectional drawing of the pump motor, drive shafting and flywheel proposed.
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documentation provided as above and the results of all the factory and site inspection and
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testing in the manuals
3.2 PRODUCTS
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3.2.1 General
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flow range specified in the Project Specification without surging, cavitation, or vibration.
2 The pumps shall meet maximum allowable shut-off head and maximum allowable required
net positive suction head (NPSH) specified in the Project Specification.
3 The pumps shall not overload the motors for any point on the maximum speed pump
performance characteristic curve within the limits of stable pump operation as recommended
by the manufacturer to prevent surging, cavitation, and vibration, as well as throughout the
entire pump operating range.
4 To ensure vibration-free operation, all rotative components of each pumping unit shall be
statically and dynamically balanced to BS 6861, and the following requirements shall be met:
operating speeds is avoided
(b) in any case, the amplitude of vibration as measured at any point on the pumping unit,
motor or drive shafts shall not exceed the below limits 3.2.2.
(c) at any operating speed, the ratio of rotative speed to the critical speed of a unit, or
5 Vibration outside the below limits shall be sufficient cause for rejection of the equipment.
6 All parts of each pump shall be designed to withstand the stresses that will be imposed upon
them during their handling, shipping, erection, and operation.
difficulty.
9 The pump supplier shall be responsible for proper operation of the complete pumping
system, which includes the pump, motor, variable speed drive unit (if designated), and
associated controls furnished with the pump.
10 For the performance curve of the selected pump impeller, head shall continuously rise as
flow decreases throughout the entire curve from runout to shutoff head.
11 The Contractor shall ensure that drive motors, variable speed drive or softer starter systems
(if designated) and pumps are furnished and tested together by the pump manufacturer, who
shall supply full certification for the proper function of the entire pumping system, within the
limits of the designated design conditions.
12 If variable speed drive systems are specified, motor and drive system shall be fully
compatible, and shall be of sufficient power and torque, and be capable of sufficient heat

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for a life of 100,000 hours with service intervals at 20,000 hours.
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3 Bearings shall be of the anti-friction type designed for an L10 life of at least 50 000 h in
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4 Pump and motor maximum operating speed shall not exceed 1500 rpm, unless a lower
speed is specified in the Project Specification.
5 Pumps shall be of non-clog design, capable of passing spheres of a minimum 100 mm

diameter unless other diameters are designated.
6 Pumps shall be suitable for use in the conditions specified in Section 1. The pumped media
temperature shall be taken as 40 °C.
7 Renewable impeller wear rings shall be fitted, to the impeller and volute case, except where
not available on a standard production unit.
8 Vibration levels shall not exceed the levels given in ISO 10816 Part 1 and Part 7 quality
bands A and B
9 The pump, motor and associated electrical equipment shall be rated for a minimum of
10 starts per hour, unless otherwise designated.
guarantees the following:-
(a) flow rate

(b) total head
(c) power input

(d) efficiency
(e) NPSH required
3.2.3 Materials
(a) volute casings shall be Ni-resist cast iron, BS EN 1561, Grade 250
(b) impellers shall be duplex stainless steel DIN 1.4517;
(c) impeller wear rings shall be of duplex stainless steel DIN 1.4462;
(d) casing wear rings shall be of non ferrous or stainless steel BS970-1 Grade 316 S31
with good anti- seizure propertied against the rotating element. There shall be a
difference of at least 50 points Brinell hardness of the opposed wear surfaces;
(e) suction elbows shall be cast or ductile iron, BS EN 1561, Grade 250
(f) stuffing box covers shall be cast iron, BS 1452, Grade 250
(g) bearing frames shall be cast iron, BS EN 1561, Grade 250
(h) pump shafts shall be of Duplex stainless steel conform to DIN 1.4462 or a suitable
duplex ferritic – austenitic stainless steel;
(i) pump shaft sleeves shall be stainless steel Grade 316 S31;
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(j) fasteners shall be stainless steel to BS 970-1 Grade 316 S31.
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(k) fly wheels if fitted shall be steel, BS 3100.
2 Supporting steelwork for bearings, drive shafts, platforms, ladders and stairways shall comply
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Specification
3.2.4 Fabrication
1 General: The pump shall be fabricated in accordance with the following requirements, and
as described in the following paragraphs.
(a) pumps shall be capable of handling raw, unscreened sewage, effluent, storm or
groundwater as required
(b) all castings shall be produced in accordance with the pump manufacturer‟s
(c) components shall conform with the requirements listed in the following paragraphs.
2 Volute casings:
(a) volute casings shall be large enough at all points to pass any size solid which can
pass through the impeller
(b) wall thickness shall be sufficient to withstand all stresses in service at full operating
pressure
(c) volute casings and integral discharge nozzle shall be cast in one piece, with smooth
water passage lined with a proprietary corrosion and erosion liner to the
manufacturer‟s recommended specification,
(d) a hand hole (minimum size 75 mm by 125 mm) shall be provided near discharge
flanges for inspection and cleaning. The inner contour of hand hole covers shall
conform to that of volute casings
(e) a minimum 12 mm brass or stainless steel tap shall be provided on the top and
bottom of discharge nozzles, next to discharge flanges, for venting and draining
(f) volute casings shall be so arranged that impellers may be removed without disturbing
either suction or discharge piping.
3 Impellers:
(a) impellers shall be cast or machined in one piece

(b) impellers shall be designed with smooth water passages to prevent clogging by string
or fibrous materials
(c) impellers shall be fitted with a renewable wear ring and the casing shall be fitted with
a matching wear ring
(d) entire rotating assemblies shall be designed so that they may be withdrawn from
pump assemblies without disturbing the suction or discharge piping connections
4 Suction elbows:
(a) suction elbow shall be supplied by the pump manufacturer as DI flanged long radius
reduced elbow with integral lining to resist cavitation.
(b) (b) a minimum 25 mm brass or stainless steel pipe tap shall be provided near the
suction flanges for a pressure gauge connection.
5 Stuffing boxes:
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(a) stuffing box covers shall be accurately machined to fit onto the volute casing and
shall be of sufficient thickness to withstand the pressure imposed upon it under
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operating conditions. Stuffing box cover and back vanes of the impeller shall allow
water cooling to the gland packing.
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(b) stuffing boxes shall be cast integrally with the stuffing box cover and shall be of
sufficient depth to hold at least 5 rings of packing
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(c) soft-packed glands shall be designed for grease or water lubrication and shall be
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provided with large size grease lubricators with indicators

(d) glands and lantern rings shall be split to facilitate easy repacking and shall have
tapped easy withdrawal holes on the upper face.
6 Bearing frames, bearing housings, and bearings:
(a) bearing frames shall be cast in one piece

(b) frames shall carry both radial and thrust bearings
(c) outboard bearings shall be the thrust bearing and the housing shall be designed to
provide an axial clearance adjustment downward between the impeller and suction
cover by use of shims or other suitable means
(d) bearing housings shall be fitted with suitable grease seals to prevent loss of grease
and to prevent entrance of contaminants
(e) frames shall be provided with a tapped hole with a minimum diameter of 25 mm,
located as low as practicable to drain the leakage from packing glands
(f) bearing frames shall be accurately machined, centered, and securely bolted to
volutes and stuffing box cover assemblies
(g) construction shall be such that entire rotating assemblies may be removed without
disturbing the suction or discharge piping
(h) large openings shall be provided adjacent to stuffing boxes to facilitate adjustment
and repacking
(i) upper bearings shall be the thrust type and shall carry the entire pump thrust load
(j) bearings shall be grease lubricated with a provision for forcing out the old grease and
limiting back pressure.
7 Supporting bases:
(a) pumps shall be furnished with a suitable supporting base either cast integrally with the
volute or otherwise attached to the pump casing
(b) bases shall provide openings large enough to permit access to suction elbows and
cleanout hand holes
(c) bases shall be designed to support the assembled weight of the pump and shall safely
withstand all stresses imposed thereon by vibration, shock, and all possible direct and
eccentric loads
(d) pump bases shall be of an adequate horizontal dimension to provide sufficient footing
contact area and anchorage facilities
(e) the height of pump bases shall be such that the suction flange will clear the floor,
footing surfaces or ducts, with sufficient space allowed for dismantling bolts.
8 Pump shafts:
(a) pump shafts shall be of such diameter that they will not deflect more than 0.05 mm at
the face of the stuffing box while operating at the maximum design speed, as
determined by calculations from the manufacturer
(b) the entire length of shafts shall be turned, ground, and polished
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(c) a renewable shaft sleeve shall be provided over shafts through the stuffing box
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(d) shafts shall be key-seated for securing the impeller and coupling
(e) sleeves shall be secured either by key or suitable locking screw to the Engineer‟s
approval.
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9 Drive shafts:
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(a) vertical shafting shall be connected to drive motors with a direct, close coupled
connection or of the flexible type, consisting of sections with flanged universal joints
and intermediate bearings and Plummer blocks as designated or required
(b) splined connections shall be provided adjacent to the pump
(c) mating steel flanges for connection to driver and driven units shall be furnished
(d) shafts shall be designed for continuous duty to transmit the maximum output torque
and power of the units
(e) components shall be adequately sized and designed for the service intended,
including transient due to power failure
(f) all shaft sections shall be statically and dynamically balanced individually. Shaft
sections shall not exceed 3 m and shall run below their first critical speed
(g) intermediate shaft support bearings shall be of the anti-friction type, grease
lubricated, mounted in Plummer blocks dowelled to the supporting steel work
(h) slip splines in drive shafts shall permit removal of the pump rotating assemblies
without removal of any section of intermediate shafting, bearings, or discharge piping
(i) intermediate bearings shall be supported by steel channel sections either fixed
in position on the dry well walls, or mounted on a substantial frame with support
from the dry well walls. There shall be no transmission of vibration from each
bearing.
10 Ring bases and base plates:
(a) pump drive units shall be mounted on a suitable cast iron or fabricated steel ring base
with adequate clearance and openings to provide ready access to the upper shaft
coupling
(b) ring bases shall be a minimum of 250 mm high and shall be rugged enough to
support the full weight of the motor
(c) base plates shall be square and shall be of sufficient thickness to support the drive
assemblies
(d) base plates shall be drilled to accommodate the size and number of anchor bolts
required
(e) where designated, bases shall be mounted on a suitable bolted, removable framing to
cover access openings.
11 Fly wheels:
(a) fly wheels shall be fitted where required for surge protection and to achieve smooth
start and smooth stop to avoid NRV slamming
(b) fly wheels shall be mounted in a housing directly beneath the drive motor and above
the motor room floor, if the motors are mounted in a motor room
(c) the top bearing housing and drive shaft shall carry the flywheel. Unless agreed by the
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Engineer, the fly wheel shall not be mounted on the motor shaft
(d) fly wheels shall be statically and dynamically balanced to BS 6861 and shall be
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positively keyed to the drive shaft

(e) flywheels shall be designed such that there is an even tangential stress distribution
throughout the flywheel
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(f) flywheel speeds shall not exceed 30ms for cast iron and 50ms for cast steel.
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12 Motors:
(a) motors shall be in accordance Section 21

(b) motors shall be 3 phase 50 Hz, voltage as specified in the Project Specification
(c) motors shall be squirrel cage, induction air cooled to IP 54, as a minimum, unless
specified otherwise in the Project Specification
(d) motors shall be derated for variable speed operation
(e) Motors above 75 KW shall be provided with bearing vibration monitoring on 2 axes
(f) Motors above 75 KW shall be provided with winding temperature monitoring PT100 or
similar subject of Engineers/Client approval.
13 Pump Control Systems: Pump control systems shall be furnished and installed in
accordance with Section 10 and the Project Specification.
14 Coatings:
(a) all parts of the pump shall be fusion bonded epoxy coated to a minimum thickness of
300 microns. External parts and the motor shall be coated as the paint specification in
Section 8
(b) Coupling, pump shaft and impeller shall be balanced together to ISO 1940 quality level
G 6.3 prior to final assembly.
(i) drive motor / flywheel coupling.
(ii) flywheel / drive shaft coupling.

(iii) drive shaft / pump coupling.
3.2.5 Accessories
1 The following accessories shall be provided for pumps:
(a) guards. Substantial galvanised perforated guards shall be provided at all exposed
couplings, drives and shafts, in accordance with Part 1. The guards shall extend the
whole length of the shaft and include hinged access doors at lubrication/inspection
points for all points requiring maintenance
(b) pressure gauges. The suction and discharge nozzle of each pump shall be provided
with a 19 mm diameter tapped opening, stainless steel or brass isolating valves and
diaphragm gauges as Part 1
(c) volute bleed-off. Each pump shall be installed with a volute automatic air bleed-off
brass valve from high point of the volute, venting via pipe to the wet well as below.
25mm tee with isolation valve and piping to drain channel, shall be given below the air
bleed-off valve for manual venting of the air in the casing.
(d) access ladders, stair ways and platforms shall be provided to
all points requiring maintenance, including couplings, bearings and sliding joints,
as Sections 8, 16 and 17.
2 Arrangements shall be made for draining away to the drainage channel or sump any water
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which leaks from pump glands or any other source using 50 mm minimum diameter stainless
steel pipe.
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3 Vibration sensors (in both axial and traverse direction) and temperature sensors shall be
fixed on large pumps and motors (i.e. above 75 KW) for condition monitoring. Similarly
vibration sensors (in both axial and traverse direction) shall be provided for the plumber block
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bearings of the drive shaft and the data should be made available in the SCADA panel.
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inspections and tests have been conducted on each pump at the factory, and submit to the
Engineer prior to shipment:
valve pressure
Specifications
(c) motor insulation tested for moisture content or insulation defects
(d) the insulation test (b) above has been performed again after the performance
test (2) below.
2 Each pump has been factory tested for performance according to BS EN ISO 9906 Grades
1, 2 and 3, including:
(a) flow
(b) inlet pressure
(c) outlet pressure
(d) motor power
(e) torque
(f) efficiency
submit to the Engineer prior to shipment.
(b) foundry Composition Certificates for all major castings (pump case, impeller, motor
compliance with the pump manufacturer material specifications
(c) non destructive test certificates for major parts as "pump shaft" and "impeller" to be
issued under ASME V requirements
(i) Ultrasound test (UT) method for pump shaft shall satisfy the required criteria of
ASME VIII Div.1 Appendix 12.
(ii) Magnetic particle inspection (MPI) and/or dye penetration inspection (DPI)
methods for impeller shall satisfy the required criteria of ASME VIII Div. 1
Appendices 6, 8 and/or 7.
(d) driving shaft balancing certificate as ISO 1940 requirements with balancing quality
level G16.
1 The Contractor shall provide from the pump manufacturer all the spare parts and tools
required during the commissioning and maintenance periods as specified in Part 1, including
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those below:
(a) one set of complete bearings

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(b) three sets of stuffing box packing

(c) one complete coupling
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(d) one set of wear rings

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(e) two sets of rubber coupling buffers

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(f) one set of shaft sleeves

(g) three lantern rings for packing box.
2 The Contractor shall supply, furnished by the pump manufacturer, a complete set of all
special tools required for maintenance of the pumping equipment, in a lockable tool box,
complete with the list of spares.
3.3.1 Installation and Commissioning
1 The equipment delivered to the Site shall be examined by the Engineer to determine that it is
in good condition and in conformance with the approved working drawings and certification.
All equipment shall be installed in strict conformance with Part 1 of this Section and the
manufacturer‟s instructions.
1 The Contractor shall provide the services of the pump manufacturer‟s representative to
supervise the installation and commissioning of the pumping equipment.
satisfying the Engineer that the pumpsets have been correctly assembled and installed and
and remedy or rectify the fault. Similar action shall be taken for an undue increase in bearing
or gland temperature, increased gland leakage rates, unsatisfactory vibration levels or any
other fault or defect in the operation of the pumpset.
(a) a record of bearing and coupling clearance and alignments shall be tabulated to
show the “as-built” condition of each pump
(b) a record of all overload, timing relay and oil pressure relays shall be tabulated to
show the “as-built” condition of each motor starter
(c) all cables shall be “megger” tested to confirm the integrity of the insulation. A
tabulated record of results shall be made
maximum emergency top water level on a recirculation basis using fresh water and
for a minimum of four hours continuously. During this test the following parameters
will be recorded:-
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(i) motor phase currents and voltages
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(ii) pump output

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(v) power consumed

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(vi) power factor

(vii) vibration
(f)
(g) the commissioning trials shall extend until each pump unit has run „continuously‟ for
at least 3 days under all operating conditions. The term „continuously‟ shall include
running at various speeds or on a start/stop basis as determined by the control
system
(h) the Contractor‟s supervisory staff, and the pump manufacturer‟s staff if required by the
Project Specification, shall be present during the period of the tests and
trials. The Contractor shall be responsible for any failure of the whole equipment or
any part thereof, whether such failure shall be determined by the methods detailed
herein or otherwise. If the pump test or trial is interrupted by the Contractor, or through
negligence on the part of the Contractor‟s staff, it shall be completely repeated for the
pumpset concerned.
4 The operation, over the entire specified range, shall be free of cavitation, excessive vibration
or noise.
5 Vibration shall be checked and recorded. The full speed vibration of all pumps shall be within
acceptable limits as 3.2.2.8 Excessive vibration shall constitute sufficient cause for rejection
of the equipment.
6 Each pump performance shall be documented by obtaining concurrent reading showing

motor voltage and amperage, pump suction head and pump discharge head as follows:
(a) readings shall be documented for a least four pumping conditions to ascertain the
actual pumping curve
(b) one test shall be at shutoff head
(c) each power lead to the motor shall be checked for proper current balance.
7 Bearing temperatures shall be determined by a contact type thermometer. A running time of

at least two hours shall be maintained at the maximum specified operating head.
8 In the event any of the pumping equipment fails to meet the above test requirements, it shall
be modified and retested in accordance with the requirements of this Section until it meets
the specified requirements, and approval of the Engineer.
END OF PART
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QCS 2014 Section 09: Mechanical And Electrical Equipment Page 1
Part 04: Centrifugal Pumps (Split Casing)
4 CENTRIFUGAL PUMPS (SPLIT CASING) .................................................... 2
4.1 GENERAL ...................................................................................................... 2

4.1.1 Scope 2
4.1.2 References 2
4.1.3 Submittals 2
4.2 PRODUCTS ................................................................................................... 3
4.2.1 General 3
4.2.3 Materials 5
4.2.4 Fabrication 5
4.2.5 Accessories 9
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4 CENTRIFUGAL PUMPS (SPLIT CASING)

4.1 GENERAL
4.1.1 Scope
1 This Part specifies the requirements for the design, manufacture construction, installation
testing and commissioning of single stage centrifugal split casing pumps, to handle treated
sewage effluent, surface and groundwater as specified.
This Section
Part 1, General
Section 1, General
Section 8, Drainage Works
4.1.2 References

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BS 4............................Structural steel sections
BS 449........................The use of structural steel in building
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BS 1400......................Copper alloy ingots and copper alloy and high conductivity copper
coatings
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BS 970, (ISO 683) ......Wrought steels for mechanical and allied engineering purposes
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BS 3100......................Steel castings for general engineering purposes

BS 3170......................Flexible couplings for power transmission
BS EN 1092................Circular flanges for pipes valves and fittings
BS 4999, (IEC 34,72) .General requirements for rotating electrical machines
BS 5304......................Code of Practice for the safety of machinery
bearings
BS 7613......................Hot rolled quenched and weldable steel plates
BS EN ISO 9906 Grades 1, 2 and 3 Acceptance tests for centrifugal mixed flow and axial
flow centrifugal pumps
BS 6861, (ISO 1940) ..Balance quality of requirements of rigid rotors
BS 7854 (ISO 10816) Part 1 and Part 7, Mechanical vibration in rotating and reciprocating
machinery
BS EN 10113..............Hot rolled products in weldable fine grain structural steels
4.1.3 Submittals
1 In addition to the requirements of Part 1 of this section the Contractor shall provide data and
2 Design Data
3 Shop Drawings

(i) duty impeller diameter
(vii) net positive suction head
sectional drawing of the pump motor, drive shafting and flywheel proposed.
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documentation provided as above and the results of all the factory and site inspection and
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testing in the manuals
4.2 PRODUCTS
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4.2.1 General
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flow range specified in the Project Specification without surging, cavitation, or vibration.
2 The pumps shall meet maximum allowable shut-off head and maximum allowable required
net positive suction head (NPSH) specified in the Project Specification.
3 The pumps shall not overload the motors for any point on the maximum speed pump
performance characteristic curve within the limits of stable pump operation as recommended
by the manufacturer to prevent surging, cavitation, and vibration, as well as throughout the
entire pump operating range.
4 To ensure vibration-free operation, all rotating components of each pumping unit shall be
statically and dynamically balanced to BS 6861, and the following requirements shall be met:
operating speeds is avoided
(b) in any case, the amplitude of vibration as measured at any point on the pumping unit,
motor or drive shafts shall not exceed the below limits 4.2.2.
(c) at any operating speed, the ratio of rotating speed to the critical speed of a unit, or
5 Vibration outside the below limits shall be sufficient cause for rejection of the equipment.
6 All parts of each pump shall be designed to withstand the stresses that will be imposed upon
them during their handling, shipping, erection, and operation.
difficulty.
9 The pump supplier shall be responsible for proper operation of the complete pumping
system, which includes the pump, motor, variable speed drive unit (if designated), and
associated controls furnished with the pump.
10 For the performance curve of the selected pump impeller, head shall continuously rise as
flow decreases throughout the entire curve from runout to shutoff head.
11 The Contractor shall ensure that drive motors, variable speed drive systems (if designated)
and pumps are furnished and tested together by the pump manufacturer, who shall supply
full certification for the proper function of the entire pumping system, within the limits of the
designated design conditions.
12 If variable speed drive or soft starter systems are specified, motor and drive system shall be
fully compatible, and shall be of sufficient power and torque, and be capable of sufficient heat

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for an operating life of 100,000 hours with service intervals at 20,000 hours. Wearing
components shall have a design life of not less than 5 years or 10 years where major
dismantling is required.
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3 Bearings shall be of the anti-friction type designed for an L10 life of at least 100,000 hours in
4 Pump and motor maximum operating speed shall not exceed 1500 rpm, unless a lower
speed is specified in the Project Specification.
5 Horizontal shaft pumps installed on plinths at ground level are the preferred arrangement.
6 Pumps shall be suitable for use in the conditions specified in Section 1. The pumped media
temperature shall be taken as 40 °C.
7 Renewable impeller wear rings shall be fitted, to the impeller and volute case, except where
not available on a standard production unit.
8 Vibration levels shall not exceed the levels given in ISO 10816 Part 1 and Part 7 quality
bands A and B.
9 The pump, motor and associated electrical equipment shall be rated for a minimum of 10
starts per hour, unless otherwise designated.
guarantees the following:-
(a) flow rate

(b) Duty Head

(c) power input
(d) efficiency
(e) NPSH required
4.2.3 Materials
(a) volute casings shall be Ni-resist cast iron, BS EN 1561, Grade 250.
(b) impellers for sewage, treated effluent and ground water shall be duplex stainless steel
DIN 1.4517.
(c) impeller wear rings shall be of duplex stainless steel DIN 1.4462
(d) casing wear rings shall be of non ferrous or stainless steel BS 970-1 Grade 316 S31
with good anti seizure propertied against the rotating element.. There shall be a
difference of at least 50 points Brinell hardness of the opposed wear surfaces.
(e) suction elbows shall be cast or ductile iron, BS EN 1561 or BS EN 1563, Grade 250.
(f) stuffing box covers shall be cast iron, BS EN 1561, Grade 250.
(g) bearing frames shall be cast iron, BS EN 1561, Grade 250.
(h) pump shafts shall be duplex stainless steel to DIN 1.4462.
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(i) pump shaft sleeves shall be stainless steel Grade 316 S31.
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(j) fasteners shall be stainless steel to BS 970-1 Grade 316 S31.

(k) fly wheels if fitted shall be steel, BS 3100.
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2 Supporting steelwork for bearings, drive shafts, platforms, ladders and stairways shall comply
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3 Additional or other requirements for materials of construction may be specified in the Project
Specification
4.2.4 Fabrication
1 General: The pump shall be fabricated in accordance with the following requirements, and as
described in the following paragraphs.
(a) pumps shall be capable of handling treated sewage effluent, stormwater or

groundwater as required
(b) all castings shall be produced in accordance with the pump manufacturer‟s
(c) components shall conform with the requirements listed in the following paragraphs.
(d) components that would come in contact with chlorine shall, as far as practically
possible, be resistant to attack by chlorine.
2 Volute casings:
(a) volute casings shall be large enough at all points to pass any size solid which can pass
through the impeller
(b) volute casings shall be of the double volute type split axially with the suction and
delivery branches, bearing housing and feet cast integrally with the same half casing,
thus enabling the whole of the rotating assembly to be removed without opening pipe
joints or disturbing the alignment of the pumpset.
(c) wall thickness shall be sufficient to withstand all stresses in service at full operating
pressure
(d) volute casing halves shall be cast in one piece, with smooth water passage lined with a
proprietary corrosion and erosion lining to the Manufacturer‟s recommended
specification,
(e) two lifting screws eye bolts shall be fitted to the upper casing
(f) a minimum 12 mm brass or stainless steel tap shall be provided on the top and bottom
of discharge nozzles, next to discharge flanges, for venting and draining
(g) volute casings shall be so arranged that impellers may be removed without disturbing
either suction or discharge piping.
(h) the split casing pumps shall be constructed of two half casings fitted with tapered
guide pins to BS EN 22339 to ensure accurate alignment on re-assembly. The casing
joint shall be a metal face to face joint with a non hardening sealing compound, no
jointing gasket shall be used. Metal face to face joints shall be flat and parallel with a
maximum gap of 0.05mm, mating faces shall have a surface finish of 0.8 microns
C.L.A or better.
3 Impellers:
(a) impellers shall be cast or machined in one piece and fusion bonded epoxy coated with
a minimum 500 micron thickness.
(b) impellers shall be designed with smooth water passages and finished to smooth
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surfaces, they shall be balanced statically and dynamically as a whole assembly
together with the shaft and secured on the shaft by a suitable locking nut
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arrangement..
(c) impellers shall be fitted with a renewable wear ring and the casing shall be fitted with a
matching wear ring
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(d) entire rotating assemblies shall be designed so that they may be withdrawn from pump
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(e) impellers shall be double entry shrouded type, and shall be fully balanced and
supported between bearings.
(f) impellers shall be supplied from the manufacturers standard range and shall not be
trimmed or cropped to meet the specified duty.
(g) Impellers shall be selected from middle range for their pump casing and shall be sized
such that a larger impeller (with 10% increase in diameter) capable of supplying an
additional 25% flow can be fitted in the pump casing with no modifications.
4 Suction elbows:
(a) suction elbows shall be supplied by the pump manufacturer as DI flanged long radius
reduced elbows with integral lining to resist cavitation.
(b) a minimum 25 mm brass or stainless steel pipe tap shall be provided near the suction
flanges for a pressure gauge connection.
5 Stuffing boxes:
(a) stuffing box covers shall be accurately machined to fit onto the volute casing and shall
be of sufficient thickness to withstand the pressure imposed upon it under operating
conditions. The stuffing box cover and back vanes of the impeller shall allow water
cooling to the gland packing.
(b) stuffing boxes shall be cast integrally with the stuffing box cover and shall be of
sufficient depth to hold at least 5 rings of packing
(c) soft-packed glands shall be designed for grease or water lubrication and shall be
provided with large size grease lubricators or water connections with indicators.
(d) (d) glands and lantern rings shall be split to facilitate easy repacking and shall have
tapped easy withdrawal holes on the upper face.
6 Bearing frames, bearing housings, and bearings:
(a) bearing frames shall be cast in one piece

(b) frames shall carry both radial and thrust bearings
(c) outboard bearings shall be the thrust bearing and the housing shall be designed to
provide an axial clearance adjustment downward between the impeller and suction
cover by use of shims or other suitable means
(d) bearing housings shall be fitted with suitable grease seals to prevent loss of grease
and to prevent entrance of contaminants
(e) frames shall be provided with a tapped hole with a minimum diameter of 25 mm,
located as low as practicable to drain the leakage from packing glands
(f) bearing frames shall be accurately machined, centred, and securely bolted to volutes
and stuffing box cover assemblies
(g) construction shall be such that entire rotating assemblies may be removed without
disturbing the suction or discharge piping
(h) large openings shall be provided adjacent to stuffing boxes to facilitate adjustment and
repacking
(i) upper bearings shall be the thrust type and shall carry the entire pump thrust load
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(j) bearings shall be grease lubricated with a provision for forcing out the old grease and
limiting back pressure.
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7 Supporting bases:
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(a) pumps shall be furnished with a suitable supporting base either cast integrally with the
volute or otherwise attached to the pump casing
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(b) bases shall provide openings large enough to permit access to suction elbows and
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cleanout hand holes

(c) bases shall be designed to support the assembled weight of the pump and shall safely
withstand all stresses imposed thereon by vibration, shock, and all possible direct and
eccentric loads
(d) pump bases shall be of an adequate horizontal dimension to provide sufficient footing
contact area and anchorage facilities
(e) the height of pump bases shall be such that the suction flange will clear the floor,
footing surfaces or ducts, with sufficient space allowed for dismantling bolts.
(f) Motors of horizontal pumps shall be mounted on an extension of the pump base plate
and shall drive the pump directly through a flexible coupling.
(g) Motors of close coupled vertical pumps shall be mounted on an extension of the pump
support frame and shall drive the pump directly through a flexible coupling.
(h) Remotely driven vertical pumps shall have a plummer block bearing mounted on an
extension of the pump support frame and shall drive the pump directly through a
flexible coupling between the plummer block and pump shaft, the drive shaft between
the plummer block and motor shall have flexible couplings at each end.
8 Pump shafts:
(a) pump shafts shall be of such diameter that they will not deflect more than 0.05 mm at
the face of the stuffing box while operating at the maximum design speed, as
determined by calculations from the manufacturer
(b) the entire length of shafts shall be turned, ground, and polished
(c) a renewable shaft sleeve shall be provided over shafts where exposed to the process
fluid and through the stuffing box
(d) shafts shall be key-seated for securing the impeller and coupling
(e) sleeves shall be secured either by key or suitable locking screw to the Engineer‟s
approval.
(f) shaft sleeves shall be sealed internally to prevent leakage along the shaft.
9 Drive shafts:
(a) vertical shafting shall be connected to drive motors with a direct, close coupled
connection or of the flexible type, consisting of sections with flanged universal joints
and intermediate bearings and plummer blocks as designated or required
(b) splined connections shall be provided adjacent to the pump
(c) mating steel flanges for connection to driver and driven units shall be furnished
(d) shafts shall be designed for continuous duty to transmit the maximum output torque
and power of the units
(e) components shall be adequately sized and designed for the service intended, including
transient due to power failure
(f) all shaft sections shall be statically and dynamically balanced individually. Shaft
sections shall not exceed 3 m and shall run below their first critical speed
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(g) intermediate shaft support bearings shall be of the anti-friction type, grease lubricated,
mounted in plummer blocks dowelled to the supporting steel work
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(h) slip splines in drive shafts shall permit removal of the pump rotating assemblies
without removal of any section of intermediate shafting, bearings, or discharge piping
(i) intermediate bearings shall be supported by concrete beam, or steel channel sections
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either fixed in position on the dry well walls, or mounted on a substantial frame with
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support from the dry well walls. There shall be no transmission of vibration from each
bearing.
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10 Ring bases and base plates:
(a) pump drive units shall be mounted on a suitable cast iron or fabricated steel ring base
with adequate clearance and openings to provide ready access to the upper shaft
coupling
(b) ring bases shall be a minimum of 250 mm high and shall be rugged enough to support
the full weight of the motor
(c) base plates shall be square and shall be of sufficient thickness to support the drive
assemblies
(d) base plates shall be drilled to accommodate the size and number of anchor bolts
required
(e) where designated, bases shall be mounted on a suitable bolted, removable framing to
cover access openings.
11 Fly wheels:
(a) fly wheels shall be fitted where required for surge protection and to achieve smooth
start and smooth stop to avoid NRV slamming.
(b) fly wheels shall be mounted in a housing directly beneath the drive motor and above
the motor room floor, if the motors are mounted in a motor room
(c) the top bearing housing and drive shaft shall carry the flywheel. Unless agreed by the
Engineer, the fly wheel shall not be mounted on the motor shaft
(d) fly wheels shall be statically and dynamically balanced to BS 6861 and shall be
positively keyed to the drive shaft
(e) flywheels shall be designed such that there is an even tangential stress distribution
throughout the flywheel
(f) flywheel speeds shall not exceed 30ms-1 for cast iron and 50ms-1 for cast steel.
12 Motors:
(a) shall be in accordance with Section 21.

(b) motors shall be 3 phase 50 Hz, voltage as specified in the Project Specification
(c) motors shall be squirrel cage, induction air cooled to IP 54, as a minimum, unless
specified otherwise in the Project Specification
(d) motors shall be de-rated for variable speed operation
(e) motor shall be sized to be able to drive the larger impeller (as per 4.2.4.- 3g) with no
modification.
13 Pump Control Systems: Pump control systems shall be furnished and installed in accordance
with Section 10 and the Project Specification.
14 Coatings:
(a) all parts of the pump shall be fusion bonded epoxy coated to a minimum thickness of
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300 microns unless otherwise stated. External parts and the motor shall be coated as
the paint specification in Section 8
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15 Couplings:
(a) Coupling, pump shaft and impeller shall be balanced together to ISO 1940 quality level
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(i) drive motor / flywheel coupling.

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(ii) flywheel / drive shaft coupling.

(iii) drive shaft / pump coupling.
4.2.5 Accessories
1 The following accessories shall be provided for pumps:
(a) guards. Substantial galvanised perforated guards shall be provided at all exposed
couplings, drives and shafts, in accordance with Part 1. The guards shall extend the
whole length of the shaft and include hinged access doors at lubrication/inspection
points for all points requiring maintenance
(b) pressure gauges. The suction and discharge nozzle of each pump shall be provided
with a 25 mm diameter tapped opening, stainless steel or brass isolating valves and
diaphragm gauges as Part 1
(c) volute bleed-off. Each pump shall be installed with a volute automatic air bleed-off
brass valve from high point of the volute, venting via pipe to the drain channel as
below, a 25mm tee with isolation valve and piping to the drain channel, shall be
provided below the air bleed-off valve for manual venting of the air in the casing..
(d) access ladders, stair ways and platforms shall be provided to all points requiring
maintenance, including couplings, bearings and sliding joints, as Sections 8, 16 and
17.
2 Arrangements shall be made for draining away to the drainage channel or sump any water
which leaks from pump glands or any other source using 50 mm minimum diameter stainless
steel pipe.
3 Vibration sensors (axial and radial) and temperature sensors shall be fixed on large pumps
and motors‟ upper and lower bearings (i.e. above 75 KW) for condition monitoring. Similarly
vibration sensors (axial and radial) shall be provided for the plumber block bearings of the
drive shaft, the data from all sensors should be made available in the SCADA panel.
inspections and tests have been conducted on each pump at the factory, and submit to the
Engineer prior to shipment:
valve pressure
Specifications
(c) motor insulation tested for moisture content or insulation defects
(d) the Insulation Test (c) above has been performed again after the performance test (2)
below.
2 Each pump has been factory tested for performance according to BS EN ISO 9906 Grades 1,
2 and 3, including:
(a) flow
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(b) inlet pressure
(c) outlet pressure
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(d) motor power

(e) torque
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(f) efficiency
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submit to the Engineer prior to shipment.
(b) foundry Composition Certificates for all major castings (pump case, impeller, motor
compliance with the pump manufacturer material specifications.
(c) non destructive test certificates for major parts as "pump shaft" and "impeller" to be
issued under ASME V requirements.
(i) ultrasound test (UT) method for pump shaft shall satisfy the required criteria of
ASME VIII Div.1 Appendix 12.
(ii) magnetic particle inspection (MPI) and/or dye penetration inspection (DPI)
methods for impeller shall satisfy the required criteria of ASME VIII Div. 1
Appendices 6, 7 and/or 8.
(d) driving shaft balancing certificate as ISO 1940 requirements with balancing quality
level G16
1 The Contractor shall provide from the pump manufacturer all the spare parts and tools
those below:
(a) one complete set bearings

(b) three sets of stuffing box packing

(c) one complete coupling
(d) one set of wear rings
(e) two sets of rubber coupling buffers
(f) one set of shaft sleeves
(g) three lantern rings for packing box.
2 The Contractor shall supply, furnished by the pump manufacturer, a complete set of all
special tools required for maintenance of the pumping equipment, in a lockable tool box,
complete with the list of spares.
1 The equipment delivered to the Site shall be examined by the Engineer to determine that it is
All equipment shall be installed in strict conformance with Part 1 of this Section and the
manufacturer‟s instructions.

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1 The Contractor shall provide the services of the pump manufacturer‟s representative to
supervise the installation and commissioning of the pumping equipment.
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satisfying the Engineer that the pump sets have been correctly assembled and installed and
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and remedy or rectify the fault. Similar action shall be taken for an undue increase in bearing
or gland temperature, increased gland leakage rates, unsatisfactory vibration levels or any
other fault or defect in the operation of the pumpset.
(a) a record of bearing and coupling clearance and alignments shall be tabulated to show
the “as-built” condition of each pump
(b) a record of all overload, timing relay and oil pressure relays shall be tabulated to show
the “as-built” condition of each motor starter
(c) all cables shall be “megger” tested to confirm the integrity of the insulation. A tabulated
record of results shall be made
maximum emergency top water level on a recirculation basis using fresh water and for
a minimum of four hours continuously. During this test the following parameters will be
recorded:-
(i) motor phase currents and voltages
(ii) pump output
(v) power consumed

(vi) power factor
(vii) vibration
(f) the commissioning trials shall extend until each pump unit has run „continuously‟ for at
least 3 days under all operating conditions. The term „continuously‟ shall include
running at various speeds or on a start/stop basis as determined by the control system
(g) the Contractor‟s supervisory staff, and the pump manufacturer‟s staff if required by the
Project Specification, shall be present during the period of the tests and trials. The
Contractor shall be responsible for any failure of the whole equipment or any part
thereof, whether such failure shall be determined by the methods detailed herein or
otherwise. If the pump test or trial is interrupted by the Contractor, or through
negligence on the part of the Contractor‟s staff, it shall be completely repeated for the
pumpset concerned.
4 The operation, over the entire specified range, shall be free of cavitation, excessive vibration
or noise.
5 Vibration shall be checked and recorded. The full speed vibration of all pumps shall be within
acceptable limits as 4.2.2.8 Excessive vibration shall constitute sufficient cause for rejection
of the equipment.
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6 Each pump performance shall be documented by obtaining concurrent reading showing
motor voltage and amperage, pump suction head and pump discharge head as follows:
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(a) readings shall be documented for a least four pumping conditions to ascertain the
actual pumping curve
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(b) one test shall be at shutoff head

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(c) each power lead to the motor shall be checked for proper current balance.
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7 Bearing temperatures shall be determined by a contact type thermometer. A running time of

at least two hours shall be maintained at the maximum specified operating head.
8 In the event any of the pumping equipment fails to meet the above test requirements, it shall
be modified and retested in accordance with the requirements of this Section until it meets
the specified requirements, and approval of the Engineer.
END OF PART
Part 05: Archimedian Screw Pumps
5 ARCHIMEDIAN SCREW PUMPS.................................................................. 2
5.1 GENERAL ...................................................................................................... 2

5.1.1 Scope 2
5.1.2 References 2
5.1.3 Submittals 2
5.2 PRODUCTS ................................................................................................... 3
5.2.1 General 3
5.2.3 Materials 4
5.2.4 Fabrication 4
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5 ARCHIMEDIAN SCREW PUMPS

5.1 GENERAL
5.1.1 Scope
1 This Part specifies the requirements for the design, manufacture, construction, installation
testing and commissioning of open type Archimedes screw pumps.

Section 1, General
Section 8 Drainage Works
Section 13, Building Electrical Works
Section 21 Electrical works
5.1.2 References

BS 970 (ISO 683) ......Wrought steels for mechanical and allied engineering purposes
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BS 1400......................Copper alloy ingots and copper alloy and high conductivity copper
coatings
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BS 3496 (ISO 1888) ...E glass fibre chopped strand mat for the reinforcement of polyester
and epoxy resin systems.
BS 3532......................Method of specifying unsaturated polyester resin systems
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BS 3749......................E glass fibre woven roving fabrics the reinforcement of polyester and
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epoxy resin systems

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BS 4395......................High strength friction grip bolts and associated nuts and washers for
structural engineering
BS 4604 (ISO 225, 272, 885, 887, 888, 4759) The use of high strength friction grip bolts in
structural steel.
BS 4870......................Approval testing of welding procedures
BS 4871......................Approval testing of welders working to approved test procedures
BS 5512......................(ISO 281) Methods of calculating dynamic load ratings and rating life
of rolling bearings
BS 5950......................Structural use of steel work in building
BS 6105 (ISO 3506) ..Corrosion resistant stainless steel fasteners
BS EN 287 .................Approval testing of welders for fusion welding

BS EN 288 .................Approval of welding procedures for metallic materials
AGMA ......................... American Gear Manufacturers’ Association Standards
5.1.3 Submittals
In addition to the requirements of Part 1 of this Section, the Contractor shall provide data and
1 Design data providing the following information:
(a) the calculations justifying the sizing of the screw, speed, flow rate, efficiency, rating of
motor, gearbox and bearings
(b) User certificates shall be supplied.
2 Shop Drawings
The Contractor shall provide calculations for the following:
(a) the maximum deflection of the screw

(b) the maximum static and dynamic stresses on the torque tube, torque tube -to -flight
welded joints and radial welded joints on the tube segment
(c) the calculations shall demonstrate that, including for cyclic stress, the screw has a life
in excess of 10 years
(d) Mill certificates for the steel used, welding consumables and procedures.
3 Operation and maintenance manuals and instructions. These shall include the
documentation required above and the results of any factory tests, site inspections and
testing.
5.2 PRODUCTS
5.2.1 General
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1 All equipment shall be provided including screw, bearings, gearbox, motor drive, lubrication
system, couplings, guards and appurtenances to provide a fully operational system to
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perform the duties specified herein and in the Project Specification.
2 The Contractor shall be fully responsible for the integrated operation and warranty of all
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components supplied.
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3 The screw pumps welding and NDT to meet the AWS D1.1 requirements.
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1 The pumps shall be designed to handle raw sewage with stringy wastes, rags, paper and
plastics.
2 The Contractor shall obtain a chemical analysis of the particular sewage to be pumped, and
select the pump materials and coatings accordingly.
3 The equipment shall be capable of continuous duty unattended, be fully automatic in

operation, and require the minimum of maintenance.
4 The design criteria for the system are given in the Project Specification. The peripheral
speed of the screw blades shall not exceed 3 m/s and the shaft speed shall not exceed
60 rpm.
5 The screw pumps shall be designed taking into account the emergency top water level in the
sump. The pumps may operate at this level. The tendency for the rotating assembly of the
pump to float shall be taken into consideration when selecting bearings and other
components, and also in the design of the screw assembly and fixings.
6 The screw pump and bearings shall be sized for the worst case i.e. the weight of the screw
and water, neglecting any buoyancy effect.
7 The design of the screw pump must take into account the following:
(a) start-up inertia forces

(b) cyclic forces during operation
(c) deflection induced stresses
(d) unbalanced stress effects.
5.2.3 Materials
1 Screws shall be manufactured from mild steel, to BS 970 Part 1.
2 Screw covers shall be as sub-clause 9
3 Top and bottom bearing shall use life lubricated ball bearings
4 Fasteners. These shall be stainless steel, BS 970 type 316S31, except for those securing the
bearing stub shafts to the screws. These shall be to BS 4395 and BS 4604
5 Coating system. This shall consist as follows for the screw. Alternative coating systems shall
be to the approval of the Engineer.
(a) two component polyamide cured zinc epoxy primer, dry film thickness (DFT) 40
microns
(b) two component micaceous iron oxide pigmented polyamide cured epoxy sealer, DFT
50 microns
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(c) two coats of two component high solids polyamine cured epoxy coating, each coat
DFT 200 microns
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(d) the steel shall be blast cleaned to ISO SA 2½ with a blasting profile of 40 -70
microns
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(e) the remainder of the components shall be painted as Section 8.

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5.2.4 Fabrication
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1 Components shall be fabricated as described in the following paragraphs.
2 Screw pumps
(a) screw pumps shall be of fabricated welded construction and consist of a mild steel
screw operating in an inclined steel trough liner which shall be grouted into a concrete
channel.
(b) screws shall be electric motor driven through a heavy duty speed reducing gearbox
(c) screws shall consist of a robust mild carbon steel tube onto which are welded two or
more cold formed helical mild steel blades to make a continuous spiral, with stub
shaft housings at the ends
(d) screw pumps deflection shall be limited to the screw length between bearing supports
divided by 360 in accordance with the value given in BS 5950 Part 1 tables, or the
screw manufacturer’s recommendations
(e) tubes shall have a minimum wall thickness of 9 mm or greater, if required, to limit the
deflection in accordance with the above
(f) welds shall be continuous fillets on each side of each blade, except when crossing a
tube weld, which shall be continuous seam welds parallel to the tube axis
(g) circumferential welds for joining tubes shall not occur at a greater distance than 20%
from the extremities of the finished tube. If possible they shall be at the lower end of
the tube
(h) blades shall have a minimum thickness of 12 mm
(i) the tips of the blades shall be reinforced by means of a stainless steel strip 60mm wide
and of the same thickness as the screw. This shall be welded onto the side of the
blade, with full penetration weld
(j) the stub shaft housing at each end of the centre tube shall effect a gradual reduction in
diameter and shall be weldable steel castings, to BS 6460 1979 equal. The stub
shafts shall be steel forging to BS 970 Part 1; 1972 or equal and the fastenings to the
housings shall not under any circumstances be subject to cyclical stressing. The stub
shaft shall be readily removable from the housing prior to transport and readily
replaceable at site. The stub shaft housing at each end should be sealed and equipped
with an accurately machined face to which the stub shaft forgings are bolted
(k) the whole assembly, with the stub shafts bolted on, shall be placed in a lathe and
machined true after all the welding has been completed, except for the helix edge
reinforcement strips
(l) pumps shall be equipped with a side rail or splash plate which shall extend the full
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length of the trough and around 230 of the circumference. The splash plate shall be
fabricated from G.R.P
(m) sufficient tolerances should be provided throughout screws, associated bearings and
transmissions to permit thermal movement of units due to ambient and operating
temperatures.
(n) all welding shall be by welders coded to BS 4871 and BS EN 287
(o) all welding procedures shall confirm to BS 4870 and BS EN 288.
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3 Bearings
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(a) screws shall be supported at the top by a self aligning double spherical ball or roller
bearing designed to accommodate the required axial and radial loads
(b) thrust shall be transferred from the shaft to the bearing by means of a thrust ring.
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(c) facilities should be provided for adjustment of bearings to permit realignment of the
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screw if necessary
(d) bearing supports shall be of fabricated steel or cast iron and shall be of adequate area
to transmit all live and dead loads to the concrete structures supporting them
(e) a minimum of four holding down bolts shall be provided for each support
(f) screws shall be supported at the bottom by ball bearings. The bottom bearing housing
and mounting shall be designed to withstand radial and axial forces including any upward
forces due to buoyancy during emergency sump level conditions. A sensing probe for
any water entrainment on the bottom bearing housing shall be provided.
(g) the two halves of the bearing shell shall be identical, so that they can be interchanged
to equalise wear
(h) seals shall consist of multiple split packing glands and labyrinth arrangement to
protect the seals from any debris in the pumped medium. It shall be possible to
renew the seals without removing the stubshaft, or supporting the screw.
(i) alternatively the bottom bearing may comprise of an eco-friendly lubricated for life
bearing, fully self aligning in all three axis. No grease lines shall be provided. Te lower
bearing housing shall be suitable for continuous or intermittent operation when
submerged or running in air. The lower bearing housing shall be specifically designed
to exclude the pumped liquid and shall contain not less than two lip seals running in a
hardened section of the shaft. Confirmation that the lip seals are compatible with the
lubricant (pumped liquid) shall be provided.
(j) an external stationary split cast iron shroud shall be provided to prevent detritus
damaging the bearing and seal
(k) an external stationary split cast iron shroud shall be provided to prevent detritus
damaging the bearing and seal
(l) bearings shall be rated for an L10 life of at least 100,000h in accordance with
BS 5512.
4 Gearbox
(a) the screws shall be coupled to heavy duty totally enclosed, robust and oiltight speed
reducing gearbox rated for continuous duty, having the output shaft at right angles to
the input shaft
(b) gearboxes shall be designed to operate continuously at the required angle of
inclination, and shall have adequate oil capacity to avoid frequent attention and shall
be equipped with a level indicator with maximum and minimum levels clearly marked
(c) backstops shall be fitted to prevent reverse rotation of the screw when the motor is
de-energised. This may be contained within main gearboxes, or be fitted externally in
the form of a suitable brake
(d) gearmotors in lieu of separate motor and gearbox are not acceptable
(e) gearboxes shall be rated as AGMA standards, quality class 12 or higher, to handle
the shock loadings appropriate to the prime mover, and shall be suitably derated to
allow for frequency of operation, ambient temperature and running time
(i) the minimum calculated life under normal operation shall exceed
100 000 h as AGMA standards
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(ii) adequate cooling facility for the gear box shall be provided. Cooling system
equipments from the gear box manufacturer shall be procured.
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(iii) cooling fins on the gearbox and/or fans shall not be permitted.
(f) transmissions shall be capable of the withstanding maximum torque
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generated by the prime movers and shall be rated either 1.5 times the power needed
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to drive the gearbox at its specified capacity or 1.1 times the motor Kw rating, which
ever is greater
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(g) gearboxes shall be directly driven through flexible couplings or `V' belt transmissions,
as specified
(h) pump drives fitted with belt transmissions shall have a means for increasing the
screw speed to achieve a future increase in capacity of not less than 10 %
(i) belts shall be rated at 1.5 times the Kw rating of the motor, and shall be oil, heat
and static resistant.
(j) access for inspection purposes shall be allowed for in the design of the gearbox
castings.
5 Drive motors
(a) the drive motor shall be a totally-enclosed fan-cooled unit as Section 1

(b) the motor and transmission shall be continuously rated and of adequate capacity to
meet the power requirement of the pump
(c) the motors shall be foot mounted near the gear box and supplied with slide rails
where necessary for the adjustment of belt tension
(d) motors shall be designed to operate continuously at the required angle of inclination
(e) motors shall have power rating 1.15 times greater than the power required to
drive the pump at its specified capacity, or be rated to drive the pump in emergency
conditions, which ever is greater.
6 Bed Plate
The drive motor and gearbox shall be mounted on a substantial fabricated steel mounting
bed plate. The base of the fabrication shall be suitable for mounting on a horizontal concrete
mounting plinth. The fabrication shall be stress relieved when all welding is complete and
prior to machining. The bed plate shall be provided with Tee slots for bolts to facilitate
removal of the motor without lifting clear of studs or other protrusions.
7 Couplings
Two types of coupling shall be fitted on the screw pumps, as follows:

(a) coupling between gearbox and screw pump. This shall be a flexible multipin and
bush, rated as the gearbox. It shall include the following features:
(i) not less than six driving pins and bushes. The bushes shall have an inner
sleeve to allow rotation in the pin. The pins shall all be shouldered
(ii) bosses shall be a tight fit in the shafts and shall be secured with hand fitted
keys
(iii) couplings shall be machined balanced matching sets.
(b) the coupling between the motor and gearbox shall be of the fluid coupling type to
instantaneously protect the motor and gearbox should the screw become suddenly
arrested in rotation. The coupling shall be fully rated to transmit the motor full load
power without exceeding normal working temperature. The fluid coupling shall be
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rated to take account of the specified climate conditions and shall be tested and
adjusted for static and dynamic balance. It shall incorporate the following features:
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(i) the weight of the coupling shall only be taken on the motor shaft providing the
motor shaft and bearing are adequate for the load without significant lift
reduction. Alternatively, a separate support bracket shall be provided.
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(ii) a flexible element between the coupling output shaft and the gearbox input shaft
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shall be provided. Bosses shall be a tight fit on shafts and secured with hand –
fitted keys.
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(iii) the casing shall be fitted with filler plugs and fusible plug for high fluid temperature
protection in event of the screw pump becoming suddenly arrested in rotation.
(iv) internal bearings shall be adequately lubricated and all seals shall be efficient.
(v) the fluid used shall be inhibited against foaming oxidation and rusting and suitable
for operating in the ambient temperature range as specified.
(vi) the filling of the coupling shall be carefully regulated to suit the torque
characteristics of the Screw and Gearbox Unit during both the starting and running
conditions.
(vii) the slip of the fluid coupling shall be taken into consideration when sizing the
Screw Pump.
8 Screw Channel Covers
(a) Insulated covers in glass reinforced plastic material shall be provided over all screw
pumps. The manufacturer shall be a specialist firm approved by the Engineer.
(b) Covers shall be manufactured using unsaturated polyester resin with a corrosion
resistant layer on the underside of an approved resin of the vinyl ester type.
(c) The top (or main) laminate shall be reinforced in the proportions 35% “E” glass as
chopped strand mat to 65% resin.
(d) The first intermediate (or internal) insulating layer shall be of polyurethane foam or
polystyrene 50mm thick.
(e) The second intermediate (or internal) layer shall be reinforced in the proportion of 10%
“E” glass as chopped strand mat to 70% resin (with 20% filler). This layer shall have a
minimum thickness of 0.1mm and a maximum thickness of 1.25mm.
(f) The lower, corrosion resistant, layer shall be reinforced in the proportion 10% “C”
glass veil or polyester tissue of 90% resin, this layer shall have a minimum thickness of
0.75mm and a maximum thickness of 1.00mm.
(g) The total thickness of the internal and the corrosion resistant layers shall be 2.0mm.
(h) The lower face of the corrosion resistant layer shall have a smooth surface finish as
produced by contact with a mould.
(i) The upper surface of the top layer shall be provided with a non-slip finish as produced
by dusting the surface of the laminate with silica sand as soon as the resin has set to a
soft gel and removing surplus sand after 24 hours.
(j) To prevent weathering the covers shall be treated by painting or the addition of
approved additives to the resin, to provide ultraviolet protection and to give a final
colour to be approved by the Engineer.
(k) Covers shall consists of individual units not exceeding 30kg in weight. All joints and
fixings shall be made using stainless steel fittings and corrosion resistant gaskets all to
the approval of the Engineer. Fixings shall be such that individual units can be
removed and replaced from above.
(l) Covers shall be capable of withstanding vertical loads of + 750 kg/m2.
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(m) Lifting handles shall be manufactured from stainless steel to BS 970 Part 1, Grade
316 S31 and the fixing shall pass through the cover such that the handle and/or fixings
can be readily replaced. Handles shall not be part of, or cast into, the covers.
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9 Trough Liner
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(a) Screw pumps shall be mounted in steel troughs supplied and installed by the
Contractor. The Contractor shall provide all necessary brackets and fixings for the
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adequate installation of the trough within the channel.

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(b) The Contractor shall be responsible for the final alignment of the trough to provide the
correct clearances, and for the grouting-in of the trough.
(c) The Screw Pump trough shall be a leak free mild steel fabrication of not less than
5mm thickness formed to give the correct clearances to the Screw Pump.
(d) The trough shall extend between the pump inlet well and the discharge channel without
distortion. The Contractor shall provide all necessary end and intermediate
fixing/support brackets.
(e) The trough shall be so shaped as to avoid ‘wedges’ between screw and side walls and
to provide for return of any excess liquid or solids without interference with pump
rotation.
(f) GRP side profiles pieces shall be provided to contain the pumped liquid on the high
water level side of the screw axis. The profiles shall be fixed to the steel trough and the
channel side wall using approved stainless steel fixing bolts, to maintain a small
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clearance around approximately 230 of the screw circumference.
inspections and tests have been conducted before shipment from the factory
(a) inspection of all welds and 100% radiographic testing for full penetrated welding/butt
welding and 100% Magnetic Particle Inspection (MPI) or Dye Penetration Inspection
(DPI) for filet welding as AWS D1.1 requirements
(b) static deflection test (unloaded)
(c) measurement of coating system thickness

(d) testing of motor as required by Section 21.
1 The Contractor shall provide, from the specialist manufacturers of the screw pump
equipment, all the spares and tools required during the commissioning and maintenance
periods as specified in Part 1, including those required below.
2 Special tools, if required for normal operation and maintenance, shall be furnished with the
equipment.
3 The following spare parts shall be provided for each pump size:
Bottom bearing 1 set

Lubricant pump system 1 set
Gearbox bearings and gaskets 1 set
Belt drives 1 set
Top bearing 1
Coupling rubbers 1 set
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Torque release coupling 1
Bearing seals 1 set
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Rupture discs 2 sets

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5.3.1 Installation
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1 The Contractor shall arrange to have the manufacturer or supplier of the equipment furnished
under this Part provide the services of competent factory-trained personnel to supervise the
installation and initial operation. Installation of all assemblies and components shall be in
accordance with the details indicated on the approved shop drawings and the printed
instructions of the manufacturer.
1 The Contractor shall operate each pumping unit over the entire designated operating range.
The operation over the entire range shall be free of vibration and noise.
2 The screw shall be run dry and the following monitored over a 1 day period:
(a) motor power consumption

(b) gearbox, top and bottom bearing temperature
(c) lubricant temperature
(d) Backstop temperature.
3 The screw shall be run with water in and the following monitored over a 7 day period
(a) water flow rate or depth of water the screw is immersed

(b) motor power consumption
(c) gearbox and top bearing temperature
(d) lubricant temperature

(e) backstop temperature
4 At the end of the 7 day period the Contractor shall change the lubricants and filter in the
bottom bearing lubricant system and the gearbox. The oils shall be analysed for any
contaminants at an accredited laboratory. After a further 3 months the contractor shall return
and sample the oil in the both systems. These shall be analysed as above. If excessive levels
of contaminants are present in the oil, then the Engineer will instruct the Contractor to take
action accordingly.
5 The lubricants shall be changed at the end of the guarantee in all the rotating elements of the
screw pumps. These shall be analysed as above for contaminants.
END OF PART
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Part 06: Surge Control System
6 SURGE CONTROL SYSTEM ........................................................................ 2
6.1 GENERAL ...................................................................................................... 2

6.1.1 Scope 2
6.1.2 References 2
6.1.3 System Description 2
6.1.4 Submittals 3
6.1.5 Quality Assurance 3
6.1.6 Warranty 4
6.2 PRODUCTS ................................................................................................... 4
6.2.1 Design Conditions and Performance Characteristics 4
6.2.2 Materials 4
6.2.3 Fabrication 5
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6 SURGE CONTROL SYSTEM

6.1 GENERAL
6.1.1 Scope
1 The Part specifies the requirements for the design, manufacture, construction, installation,
testing and commissioning of complete surge protection systems, including flywheels, surge
vessels, compressors, air valves and necessary accessory items.

This Section
Part 1, General
Part 2, Submersible Pumps
Part 3, Centrifugal Pumps
Section 1, General
6.1.2 References
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BS 449, ......................The use of structural steel in building
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BS 729 (ISO 1459, 1460, 1461) Hot dip galvanised coatings on iron and steel articles
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BS 1387 (ISO 65) .......Screwed and socketed steel tubes and tubulars and for plain end
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tubes suitable for welding or screwing to BS 21 pipe threads

BS 1571 (ISO 1217) ...Testing of positive displacement compressors and exhausters
BS 2872,.....................Copper and alloy stock and forgings
BS 3601 (ISO 2604) ...Specification for carbon steel pipes and tubes with specified room
temperature properties for pressure purposes
BS EN 1092,..............Circular flanges for pipe, valves and fittings
BS 5304,.....................Code of practice for the safety of machinery
ASME VIII Div. 1, ........Boiler and Pressure Vessel Code, Design and Fabrication of Pressure
Vessels
6.1.3 System Description
1 Hydraulic Design. Surge control devices are to be provided where necessary at all pumping
stations. The Contractor shall assume no inertia assistance from any air valves fitted. Air
valves will not be accepted as a primary means of surge suppression. Flywheels may be
used. In the case of multiple pumping mains separate surge suppression systems shall be
provided for each main. The design shall include for the worst case i.e. surge conditions
existing when the system is pumping at maximum rate and a power failure occurs. Surge
analysis shall be based on the friction factor used for new pipelines. Pump manufacturer
shall carry out surge analysis for the whole system including the pipe work within the
pumping station.
2 System Design. The following types of system may be used for surge protection:
(a) flywheels. These shall be used where there is sufficient reserve capacity of liquid in
the wet well or surge tower {see (b)} at all times to allow the flywheel to continuously
recharge the main with liquid
(b) surge towers. Their use is only applicable when the total head developed by the
pump is low
(c) hydropneumatic atmospheric surge vessels. Their use is only applicable when the
static head in the rising main is low. They shall incorporate a dip tube and a float air
valve which allows air in and out of the vessel depending on the liquid level in the
vessel.
(d) bladder type pressure vessels. Their use is only applicable when no negative
pressures occur in the main in either a surge condition or normal operation
(e) hydropneumatic surge vessels with compressors. Their use is only applicable where
there is a substantial static head in the rising main
3 Air Valves. Air valves shall be installed on the rising main as specified or required to optimise
the hydraulic efficiency of the main. They shall comply with Section 8 Part 5.
6.1.4 Submittals
1 In addition to the submittal requirements of Part 1 of this Section, the Contractor shall submit
data and information as the following paragraphs.
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2 Design Data:
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(a) Hydraulic Calculations. The Contractor shall submit a complete computer

based hydraulic transient analysis showing the performance of the surge control
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system under various model scenarios. Normal operating modes and the sudden
shut down of the pump following a power failure shall be simulated. The program
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shall have the facility to model the characteristic of the different manufacturer’s air
and reflux valves, and any other proprietary equipment
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(b) structural calculations. Structural calculations for the design of the pressure vessel
and its supports shall be provided.
3 Shop drawings: Shop drawings shall be provided for the fabrication and erection of the whole
system, including air compressors, air valves, surge vessels. Layout drawings, pressure
vessel calculations, schematic drawings and electrical drawings shall be provided.
Catalogue pages, manufacturers’ detail instructions, templates and installation methods shall
be provided.
documentation required by Part 1 of this Section on the surge protection system in the
operation and maintenance manuals. A copy of the surge analysis and site tests as
described below shall also be included. Documentation for the compressors in accordance
with BS 1571 shall be provided
6.1.5 Quality Assurance
1 Both the Company carrying out the surge analysis and the software used for the computer
transient analysis shall have a proven record in surge analysis. Software used shall be a
recognised water industry standard.
2 The Contractor shall employ Third Party Agency (TPA) to oversee the design, fabrication and
testing of pressure vessels as defined in PD5500. The independent testing authority shall
report direct to the Engineer.
6.1.6 Warranty
1 In addition to the guarantee requirements of Part 1 of this Section, the Contractor shall
ensure that the Company carrying out the surge analysis provides a warranty of the
performance of the entire surge protection system. This shall not in any way relieve the
Contractor of his contractual obligations.
6.2 PRODUCTS
6.2.1 Design Conditions and Performance Characteristics
1 Unless specified otherwise in the particular Project Specification, transient surge pressures
shall be limited as the following paragraphs.
2 Positive (over) pressure - Positive surge pressures shall not exceed the design pressure of
the pipeline, taking into account any de-rating for temperature. The rating of pipeline
restraints and thrust blocks shall be considered in limiting the positive pressure.
3 Negative (under) pressure - Negative surge pressures shall not exceed the following:
(a) GRP, asbestos cement, and cement lined ductile/cast iron and steel-limit 1 metre of
vacuum (-1 metre)
(b) Bitumen lined ductile/cast iron and steel-limit 3 metres of vacuum (-3 metres)
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(c) uPVC, ABS, HDPE, MDPE - limit 3 metres of vacuum (-3 metres).
4 Stress cycling. Certain types of plastic pipeline can fail prematurely due to duty cycling.
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Where the pump start/stop cycling is likely to be high this should be considered.
5 Pipeline Manufacturer’s Recommendations. In all instances the recommendations of the

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pipeline manufacturer with respect to positive and negative pressures and stress cycling
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must be followed. Pipeline seals must be included in these recommendations.

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6 Surge Vessels. These must be designed, inspected and tested in accordance with PD 5500
Code 2 with a 2.0 mm corrosion allowance Design pressure ratings shall be 1.25 times the
greatest pressure the vessel will be subject to. Vertical vessels shall be used wherever
possible for sewage. Any supports or plinths shall designed for the vessel to be completely
full of liquid.
7 Surge protection equipment shall be chosen in the following order of preference:
(a) flywheel – to be used in all cases where high head is involved to protect against valve
slamming,
(b) surge vessel
(c) combination of flywheel and surge vessel
6.2.2 Materials
1 Surge Towers. If these are constructed in concrete, then Section 8 shall apply. If in the
same material as the pipeline, then the specifications applying to the pipeline shall apply.
2 Surge vessels. These shall be constructed from steel in accordance with PD 5500.
3 Coatings. Surge vessels shall be coated internally with an epoxy paint system of minimum
thickness 300 microns. The system shall be proven in use in this application. The external
coating system shall be in accordance with paint system in Section 8 Part 8.
6.2.3 Fabrication
1 Flywheels. These shall comply with the requirements of Part 3.
2 Surge Towers (stand pipes). These may be constructed in concrete, G.R.P or steel. The top
of the tower shall be vented back to the wet well or through a suitable de-odouriser. An
emergency overflow shall be provided, routed to a drain. They shall be capable of
withstanding the maximum pressure generated by the pumps or surge transients, assuming
the tower is full of liquid. Means shall be provided for draining the tower and cleaning it out.
3 Hydropneumatic Atmospheric Surge Vessels. These shall be constructed in steel as

specified above for surge vessels. They shall include the following features:
(a) facility for draining the vessel. If possible, this shall be using the pressure pipeline
(b) manway access if the vessel is large enough to accommodate this, or inspection
hatch for cleaning the vessel out
(c) air/float valve on top of the vessel. This shall be readily accessible for cleaning and
maintenance
(d) vent back to the wet well or a suitable drain for the above valve
(e) pressure gauge with isolating cock to measure the maximum and minimum pressures
(f) flanges shall be to BS EN 1092 PN 16.
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4 Bladder Type Pressure Vessels. These shall be constructed in steel as specified above for
surge vessels. They shall include the features (a) (b) (e) and (f) described in 3 above and in
addition the following:
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(a) food grade iso-butyl rubber bladder. This shall have a guaranteed life of three years
in contact with the liquid pumped and at the specified temperatures
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(b) bladder pressurisation valve and gauge. This is for recharging the bladder. Access
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ladders/platforms shall be provided as necessary.

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5 Hydropneumatic Surge Vessels with compressors. The vessel shall be constructed in steel
as specified above. The vessel shall include the features (a) (b) (e) and (f) described in 3
above and in addition the following:
(a) liquid level gauges

(i) tubular glass, liquid-level gauges with 20 mm tube outside diameter shall be
provided. The minimum viewing length shall be 600 mm per gauge. Sufficient
gauges shall be provided to view the entire operating range of water levels in
the pressure vessel. Threaded 20 mm connections shall be provided. Isolation
valves with ball checks shall be provided to prevent loss of liquid upon gauge
breakage. Valves shall be of an offset pattern with integral bonnet. Valve
bodies shall be bronze. A drain cock shall be provided on the lower valve.
Valves shall have pressure ratings of 1.5 times the maximum surge pressure
anticipated, or NP 16, whichever is greater
(ii) flanges shall be provided, NP 16 for the maximum and minimum level probe
locations, respectively.
(b) safety relief valves. These shall comply with the PD 5500 and shall be
capable of passing air and water. Valves shall have a bottom inlet and side outlet.
The inlet shall incorporate a calibrated spring set to allow the valve to open at the
vessel design pressure.
(c) air pipework. Air piping shall be galvanised to BS 729 and conform to BS 1387 or
BS 3601, of a minimum of 25 mm diameter. A brass ball valve shall be
provided as a block valve at the pressure vessel. Brass check valves shall be
provided in the air line. All shall be rated for 16 bar.
(d) air compressor assembly

(i) the compressor unit shall be self-contained and consist of a single-acting, two-
(ii) stage, if necessary, air-cooled, reciprocating-type compressor motor with V-belt
drive and regulation, on a fabricated steel skid. Valves shall be of stainless
steel and shall be easily removed or inspected without use of special
tools.
(iii) the compressor shall be driven by an electric motor which shall comply with
Section 21
(iv) the air inlet filter silencer shall be of the dry replaceable cartridge type
(v) the compressor shall shut down at unsafe oil level and shall not restart without
adding oil
(vi) if necessary, the compressor shall be provided with finned tube, air-cooled
intercooler to remove the heat of compression. The compressor shall have an
automatic centrifugal starting unloader valve which will cause the pressure in
the compressor cylinders to be vented to atmosphere upon compressor
stopping, thereby allowing the compressor to start against minimum load
(vii) rotating parts shall be guarded in conformance with BS 5304
(viii) the oil sump on each compressor shall be fitted with a valve and drain
extension pipe of sufficient length to enable the oil to be drained without spilling
over the base. Sumps containing 1.0 or less may be fitted with a capped pipe.
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(e) automatic air volume control system
(i) the automatic air volume control system, in conjunction with pressure vessel-
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mounted sensor probes and the air compressor unit, shall control the air/water
ratio in the hydropneumatic pressure vessel and maintain the air/water ratio
within a range compatible with the surge control system design and established
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system static and maximum operating pressures

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(ii) contacts shall be provided for remote indication of excessive high or low water
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level in the vessel. Capacitance type level probes with a probe well
plumbed to the side of the hydropneumatic vessel shall be provided as
Section 10. A control panel with all necessary controls, relays and time delay
circuits to actuate the air add/vent solenoid valves, and signal a high or low
tank water level shall be provided.
(f) Solenoid Valves
(i) solenoid valves of sizes 5 mm through 40 mm for air service shall have forged
bronze bodies to BS 2872 with Teflon seats. Internal plunger, core tube,
plunger spring, and cage assembly shall be stainless steel BS 970 Part 1
316S12. Solenoid enclosures shall be IP 68. Valve actuators shall be 240Va.c.
Seals shall be Teflon. Valves shall have a maximum operating pressure and a
maximum differential pressure of 16 bar. Solenoid valves shall be energised to
open.
inspections and tests have been conducted at the factory and submit to the Engineer prior to
shipment.
2 Surge Vessels. These shall be inspected and tested in accordance with ASME VIII Div.1
sewer class (Welding, Non Destructive Testing (NDT), Hydro test, etc.)
3 Compressors. These shall be inspected and tested in accordance with BS 1571.
4 Motors and control panels. These shall be inspected and tested as described in Section 21.
5 Control System. This shall be inspected and tested as described in Section 10.
1 The Contractor shall provide from the specialist manufacturers of the surge equipment all the
spares and tools required during the commissioning and maintenance periods as specified in
Part 1, including those required below.
2 Special tools, if required for normal operation/or maintenance of any component of the surge
control system, shall be supplied with the equipment.
3 Air Valves. A complete seal/gasket set shall be provided for each air valve installed.
4 Control panels and control systems.
5 Compressors.
6.3.1 Installation
1 All equipment shall be installed and commissioning in accordance with the manufacturer’s
recommendations and under the supervision of the surge control system supplier’s factory
trained personnel.
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1 Surge protection system performance shall be verified by field tests at pumping rates
specified for each pressure main and for power failure at the maximum pumping rate. The
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surge control system supplier shall provide a chart recorder and pressure transducer system
to develop a permanent record for each pressure main test.
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END OF PART
Part 07: Lifting Equipment
7 LIFTING EQUIPMENT ................................................................................... 2
7.1 GENERAL ...................................................................................................... 2

7.1.1 Scope 2
7.1.2 References 2
7.1.4 Submittals 3
7.2 PRODUCTS ................................................................................................... 3
7.2.1 General 3
7.2.3 Davits 4
7.1.1 Monorail Travelling Hoists 4
7.2.4 Cranes 5
7.2.5 Manually Operated Chain Blocks 5
7.2.6 Electrically operated Rope Lifting Hoist 6
7.2.7 Mechanical Components 7
7.2.8 Electrical Components 8
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7.3.2 Site Tests 10
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7 LIFTING EQUIPMENT
7.1 GENERAL
7.1.1 Scope
1 This Part specifies the requirements for the design, manufacture, construction, installation,
testing and commissioning of hoists, monorails, bridge cranes trolley assemblies, davits and
‘A’ frames.

Section 1, General
7.1.2 References

ASME B30.9 ------------ Synthetic round sling endless
ASME B30.10 ---------- Cranes, hooks
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BS 466 (ISO 4301, 8306) -- Power driven overhead travelling cranes, semi-Goliath and
Goliath chain for general use
BS 729 (ISO 1459, 1460, 1461)-- Hot dip galvanised coatings an iron and steel articles
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BS 449 ------------------- The use of structural steel in building

BS 466, Power driven overhead travelling cranes.
BS 302 (ISO 2408) ---- Stranded steel wire ropes
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BS 2853 ----------------- The design and testing of steel overhead runway beams
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BS 2902 ----------------- Higher tensile chain slings

BS 2903 ----------------- Higher tensile steel hooks
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BS 2903,----------------- Higher tensile steel hooks for chains, slings, blocks and general
engineering purposes
BS 3032 ----------------- Higher tensile steel shackles
BS 3114,----------------- Alloy steel chain, grade 80. Polished short link calibrated load chain
for pulley blocks
BS 3243 ----------------- Hand-operated chain blocks
BS 3243,----------------- Specification for hand operated chain blocks
BS 3551,----------------- Alloy steel shackles
BS 4942,----------------- Short link chain grade (T) 8
BS 4941 (IEC 292) ---- Specification for motor starters up to and including 1000 V a.c and
1200 V d.c.
BS 5304,----------------- Code of practice for safety of machinery
BS 5714,----------------- Method of measurement of resistivity of metallic materials
BS 5744,----------------- Code of practice for safe use of cranes
BS 6231,----------------- PVC-insulated cable for switchgear and control gear wiring
BS 6346,----------------- PVC-insulated cables for electricity supply
BS 6405,----------------- Non-calibrated short link chain (grade 30) for general engineering
purposes
BS 2573 (ISO 4301) -- Rules for the design of cranes
BS 6994,----------------- Steel shackles
BS 7121,----------------- Code of practice for safe use of cranes
BS 7613,----------------- Hot rolled quenched and tempered weldable structural steel plates
BS 7668,----------------- Weldable structural steels. Hot finished structural hollow sections in
weather resistant steels
BS 7671,----------------- Requirements for electrical installations
BS 4942 (ISO 1834, 1835, 3075-3077) Short link chain for building purposes
BS 6994 (ISO 2415) -- Steel shackles for lifting purposes
BS EN 287 -------------- Approval testing of welders for fusion welding

BS EN 288 -------------- Approval of welding procedures for metallic materials
BS EN 1492-1 ---------- Flat woven webbing slings
BS EN 10113 ----------- Hot-rolled products in weldable fine grain structural steels
BS EN 10155 ----------- Structural steels with improved atmospheric corrosion resistance
BS EN 10210 ----------- Hot finished structural hollow sections of non-alloy and fine grain
structural steels
BS EN 13414-2 -------- Specification for information for use and maintenance to be provided
by the manufacturer
BS EN 13414-1 -------- Slings for general lift services
BS EN 60947 ----------- Low voltage switch gear and control gear.
ISO 4309/3481 Part 2 Methods of measuring the performance of laboratory electric

resistance furnaces.
ISO 2903 ---------------- ISO metric trapezoidal screw threads tolerances
ISO 7592 ---------------- Calibrated round steel link lifting chains
1 General. Lifting equipment shall be provided as required to remove equipment for

replacement and/or maintenance purposes. The design shall ensure safe access is provided
for the operation of the lifting equipment. Overhead cranes may also be required to grant
access for maintenance of roof mounted equipment such as light fittings, fans, and shall be
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designed to facilitate this. Davits shall only be used to lift submersible pumpsets and other
equipment from wells. Lifting equipment shall be supplied with all the necessary spacers,
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clamps, harnesses, slings, D links and eye bolts to lift any of the installed plant. Guards shall
be provided in accordance with Part 1.
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7.1.4 Submittals
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2 Design data. Complete structural calculations of crane and monorail member and
component sizing and design, shall be submitted, as required by BS 2573, BS 2853 and the
building requirements.
3 Shop Drawings. These shall be submitted as required by Part 1. Lay-out drawings shall
clearly show the lifting height of the equipment and clearances in relation to other equipment
and structures where the largest items are lifted.
4 Test certificates shall be submitted as required under factory inspection and testing.
5 Operation and maintenance manuals and instructions. The Contractor shall include all the
documentation required by Section 1 on the lifting equipment in the operation and
maintenance manuals. A copy of the design data, factory and site tests shall be included in
the manuals.
7.2 PRODUCTS
7.2.1 General
1 Hoist monorails, bridge cranes, davits and ‘A’ frames shall include all equipment,
appurtenances and auxiliaries to make the lifting equipment fully operational and capable of
performing under the specified load conditions.
2 Lifting systems, including hoists, as far as feasible, shall use the standard components of one
manufacturer to simplify maintenance.
3 Nameplates shall be permanently attached to the monorail hoist and bridge crane hoist
assemblies. The lifting capacity shall be stencilled on in tonnes in both Arabic and English on
each side and shall be clearly legible from the working level.
4 Warning signs in the Arabic and English languages shall be provided to the approval of the
Engineer and affixed to the bottom lift blocks or pendant controllers.
1 Cranes and lifting equipment shall be suitable for indoor or outdoor installation, as
designated.
2 The high ambient temperature in which lifting equipment and particularly cranes may be
required to operate shall be taken into consideration, particularly with respect to the electrical
load ratings of motors, switchgear, resistors, cables and wiring, as well as mechanical heat
sources such as brakes, bearings and gearing. Due allowance shall be made for possibly
higher temperatures than the maximum recorded shade temperature near the roofs of
buildings, if the lifting equipment is mounted in a building, or for the effect of direct sunlight if
mounted externally.
3 Design of travelling monorail hoist and bridge crane hoists and incidental accessories shall
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be based upon the use of a factor of safety of 5, structural beans shall have a factor of safety
of 2 with capacity load on all mechanical parts of the system. The factors of safety shall be
based upon the ultimate strength of the material used. The equipment shall be of ratings and
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sizes designated in the Project Specification.
4 Lifting equipment shall be rated for the load of the heaviest installed item of plant, and
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designed such that one man can operate it without difficulty.

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5 Hooks and load chains shall reach to the floor of the lowest level.
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6 Lifting equipment installations shall comply with BS 5744 and BS 7121.
7.2.3 Davits
1 Davits and sockets shall be fabricated from fully welded mild steel, to BS 7668, BS 7613, BS
EN 10155, BS EN 10013, galvanised and protected in accordance with BS 729 and Section
8.
2 Davits too heavy to manhandle shall consist of a davit arm, with removable pillar, and rotating
removable jib arm.
3 Davits shall have a roller thrust bearing swivel for the upright pillar, with a locking
mechanism.
4 Sockets shall be cast-in, unless bolted sockets are specified, or it is not possible to fix cast-in
sockets. A rubber socket plug with a stainless steel chain shall be provided to prevent sand
ingress when the davit is not in use.
7.2.4 Monorail Travelling Hoists
1 Each hoist shall comprise a manually operated geared travelling pulley block complete with
steel runway beams, “A” frame supports where specified and all accessories including slings
and spreaders.
2 Pulley blocks shall be manually operated up to a height of 6 to 8 m. Above 8 m electric

hoists shall be provided.
3 The runway beams shall be designed, tested and certified in accordance with BS 2853.
4 The blocks shall run on the lower flange of the runway beam and shall be of the spur geared
close haul type.
5 The blocks shall be complete with a geared travelling trolley and shall be capable of being
easily removed from the trolley without the necessity for dismantling. The operating chain for
the longitudinal motion of the trolley shall extend to within 600 mm of the floor.
6 Load chain collection boxes shall be provided.
7 Monorail systems shall not be used for loads exceeding 2000 kg.
7.2.5 Cranes
1 Cranes shall comprise end carriages and bridge units to be bolted together on site, during
erection.
2 Cranes shall be single girder or double girder as designated.
3 All exposed moving parts of the drive mechanisms shall be fitted with safety guards wherever
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possible, in accordance with Part 1.
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4 The bridge girders, end carriages and crab structures of the crane shall be designed and
constructed in accordance with all the relevant requirements of BS 466 and BS 2573. With
the crane operating under maximum service load, the stress in any operating component
shall not exceed the permissible values stipulated in Part 1 of BS 2573. The crane
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manufacturer shall supply all the information required in Appendix B of BS 466.

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5 The main bridge girders shall be plate or box girder designed as compound beams with the
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rails for the crab track secured on the top flange.
6 Jacking points and tie downs shall be provided for both bridge and crab.
7.2.6 Manually Operated Chain Blocks
1 The hoisting wheel shall be grooved and pocketed to receive the load chain. The load chain
shall be stainless steel chain Grade 80 to BS 3114.
2 Hand chains shall be to Grade 30 BS 6405 or better.
3 Chain guides shall be provided to ensure effective guidance of the load chain into the load
chain wheel pockets. A stripper shall be provided to ensure effective disengagement of the
load chain from the load chain wheel.
4 The idler wheel scores shall be so shaped as to avoid twisting the chain as it passes round.
The pitch diameter of the idler wheels shall not be less than 16 times the size of the chain,
unless they are so shaped as to avoid a bending action on the link.
5 The load chain anchorage, associated fittings and framework at the slack end shall be rated
at 2.5 times the maximum tension in the load chain when the working load limit is being lifted.
Any link used for connecting the load chain to a terminal fitting shall be of the material
specified for the chain and heat treated to provide mechanical properties and strength
equivalent to those of the load chain.
6 The hook shall be made from high grade forged stainless steel complying with BS 2903 ‘C’
type and provided with a safety catch. The hook shall be supported on a ball thrust bearing
to allow free swivelling under full loads.
7 The sheaves of the hook block shall be guarded to prevent a hand or fingers being trapped.
8 The crab hoisting gear shall be such that one man is capable of easily raising the maximum
load.
9 A galvanised mild steel chain collecting box shall be incorporated.
10 A reliable and effective braking and locking arrangement shall be provided.
11 Lifting blocks supplied for lifting equipment from wet wells shall be of stainless steel and shall
include the facility for obtaining a fresh lift on the equipment lifting chains at 1 metre intervals.
7.2.7 Electrically operated Rope Lifting Hoist
1 All hoists above a height of 8 m shall be electrically operated.
2 The hoist rope drum shall be of high quality cast iron with left and right hand spiral grooves to
accommodate the hoist rope in one layer. As far as possible, the drive gearing shall be fixed
directly to the rope drum to obviate high torsional stress in the drum shaft. The rope shall be
securely clamped to the drum.
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3 The hoist drum shall incorporate a wire rope rewind system and guides to prevent the hoist
rope skipping and damaging the lay.
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4 The hoist braking system shall be of the automatic electro-mechanical fail safe type which,
when the current is cut off or fails will automatically arrest the motion and hold at rest any
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load up to and including the rated load. The system shall safely control the lowering of the
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same load form the highest to the lowest point of lift and shall not allow any slippage of the
suspended load to occur when the ‘Raise’ motion is initiated.
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5 The hoist rope shall be a flexible wire rope specially designed for usage with cranes and in
accordance with BS 302, with a safety factor of not less than six times the maximum tension
induced by the safe working load.
6 The crane hook shall be of high grade forged steel trapezoidal section in accordance with BS
2903, ‘C’ type. The hook shall be supported on a ball thrust bearing to allow free swivelling
under full loads and shall also be fitted with a safety catch. The safe working load shall be
marked in the hook in accordance with BS 2903.
7 The sheaves of the hook block shall be guarded to prevent a hand or fingers from being
trapped between the sheaves and the in-running rope.
8 A limit switch shall be fitted to prevent over hoisting. This shall be self-resetting, closing
automatically when the hoist motor is put in reverse.
9 Brakes shall be well protected from oil and grease leakage or spillage, and from adverse
effects of atmospheric condensation or dust. A simple and easily accessible means of
carrying out adjustment for wear of the shoes or linings shall be provided for all brakes.
10 Automatic brakes, operating when the drive motor stops shall be supplied for the long and
cross travel motions.
7.2.8 Mechanical Components
1 End Carriage
(a) both end carriages of electrically operated cranes shall be powered either by a
duplicate geared motor drive, or by a single motor unit and a layshaft system.
Longitudinal and cross traverse motions shall be provided on the crane such that the
operation is speedy without impairing safety in working. The longitudinal and traverse
motions shall be operated by means of hand chains extending to within 600 mm of
the operating floor. The hoisting and lowering chains shall be of the same length.
The hook and load chain shall be such that the hook will reach to the lowest floor
level. The operating chain for the longitudinal motion of the crane shall be suitably
positioned to enable the operator to move the unit easily, without dragging the
operating chains over the control panels or other equipment
(b) the runner wheels shall be of cast steel, with double flanges, mounted on roller
bearings, or fitted with phosphor-bronze bushes running on hardened steel axles.
2 Crab Unit(s)
(a) the crab frame shall be in accordance with BS 466 and shall provide a strong rigid
framework for the hoist and cross-travel machinery mounted thereon. The placement
and layout of mechanical and electrical items shall facilitate easy inspection, service
and maintenance of the motors, reduction gearing and braking system
(b) the runner wheels shall be of cast steel with double flanges and mounted on roller
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bearings. Gearing shall be of totally enclosed type with machine cut gears. Bearings
shall be ball or roller.
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3 Endstops. Resilient or spring type buffers shall be provided on all runway/cross beams and
crane rails. Where carriages are equipped with electric travel the endstops shall be provided
with limit switches at the end of each direction of travel.
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4 Crane Rails. These shall comply with BS 449 and BS EN 10155 The line of the rails shall not
vary by more than 3mm throughout the whole length of travel. Whenever possible, rails shall
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be one piece. Where rails are to be jointed this shall be by electrical induction welding.
5 Access Platforms And Ladders
(a) safe means of access shall be provided for examination and maintenance of the
crane or other equipment only accessible from the crane. Guards shall be fitted
where possible under the crab and long travel motor and gearbox assembly to
prevent persons on the ground being endangered by falling objects during
maintenance
(b) all ladders, platforms and access ways shall comply with Section 8. Open mesh
flooring shall not be used. Access ways shall be not less than 800mm wide. The
platforms and access ways shall be securely fenced with double tiered guard rails and
steel ‘toe boards’ or ‘kicking plates’.
6 Painting. This shall be in accordance with Section 8.
7 Materials. Steel used for the fabrication of the lifting equipment shall comply with BS 449, BS
7613, BS 7668, BS EN 10113, BS EN 10155 and BS EN 10210 as applicable. Welding
procedures shall comply with BS EN 287 and BS EN 288
7.2.9 Electrical Components
1 Motors
motors shall comply with the Part 1 of this Section and Section 21 except they shall be rated
for 150 starts per hour (Duty type S7) for not less than one hour with a shaft
output power at least 15% greater than the maximum power which will be required for
operation and testing of the crane in the ambient temperature specified, at the
maximum rated load.
2 Control Gear
(a) a triple pole isolating switch with HRC fuses shall be provided at ground level for
each lifting assembly. This switch shall be lockable in the ‘OFF’ position only and
shall be provided with a Yale type lock and three keys. The switch shall have a label
marked ‘CRANE ISOLATING SWITCH’ in English and Arabic.
(b) starters and controllers for the crane motors shall be designed and constructed in
accordance with the requirements of BS 466, BS 4941, BS EN 60947 and
section 21. All control circuits shall operate at 110 volts
(c) mechanically and electrically interlocked reversing contactors shall be provided for
each motion including speed control of the hoist. Accelerating contactors shall cut out
the rotor circuit resistance of the motor in steps with suitable delays. Contacts shall
be adjustable and renewable
(d) controller and resistors shall be rated such that temperatures do not exceed the limits
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specified in BS 4941 during operation of the crane under maximum temperature
conditions. Starting resistors shall have not less than a ‘ten minute’ rating. Speed
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control resistors shall be one hour rated

(e) the control gear and cabling shall be suitable for ‘inching’ i.e. many repeated small
movements at both creep and normal speed, in any direction of motion
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(f) the starters and controllers shall be housed in well constructed sheet steel panel
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cabinets of not less than 2mm thick, sprayed and painted with an anti-condensation
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paint. The enclosures shall be protected against dust and damp to classifications
IP 54. Starting resistors shall be mounted in a ventilated section of each control
cubicle. The resistors shall all be fitted with terminal bars. The control cubicles shall
be provided with lockable hinged access doors, also interlocked with the main
isolating switch.
3 Controls
(a) the long-travel, cross-travel and slow and normal speed hoist motions of each crane
shall all be controlled from the lowest level by a pendant push button station. The
controls shall operate on a low voltage system supplied by a double wound isolating
transformer. Both primary and secondary sides of the transformer shall have HRC
fuse protection. One pole of the secondary winding shall be effectively earthed
(b) push button controls shall be of the pendant type with ‘hold-on’ type push buttons
automatically returning to the ‘off’ state on release of the button. Push buttons shall
be provided for ‘SLOW -UP’, SLOW DOWN’ ‘NORMAL UP’, ‘NORMAL DOWN’,
‘LEFT’, ‘RIGHT’, ‘FORWARD’ AND ‘REVERSE’. A larger size red ‘Emergency Stop’
button shall initiate tripping of the control gear main circuit breaker and automatic
application of the brakes on all motions. Re-closure of the main circuit breaker shall
be initiated by a separate ‘Reset’ button also on the pendant. The pendant shall be oil
tight polyethylene, totally enclosed to IP65, shockproof, and shall be suspended
from the crab unit. The voltage at the pendant shall not exceed 55 volts to earth
(c) limit switches shall be provided for all motors at the end of each direction of travel
(d) infrared or radio remote control shall be provided, where specified, or if necessary for
safe operation of the crane. Two battery packs with battery charger, sensors, sensor
connecting cables with clips, receiver and decoder shall be provided. Adequate
sensors shall be provided at each level (minimum three) to ensure continuous control
in all zones of operation. If radio is used then approval shall be obtained by the
Contractor for the frequencies used.
4 Cables wiring and earthing
(a) an insulated conductor system shall be provided for electrically powered cranes
supply. The insulated conducted system shall be of the type where each phase is
individually insulated and supported on a metal support. The type where all
conductors are contained within a single extruded or moulded insulation will not be
permitted. A ‘festoon’ insulated cable system shall be provided for the cross-travel
supply
(b) the wiring and earthing of the cranes shall conform to BS 466. Cables and wiring
shall be of 600/1,000 volt grade PVC insulated cables in accordance with BS 6231
and BS 6346. Wherever possible, the cables shall be run in screwed heavy gauge
galvanised steel conduit. All cable ends shall be clearly labelled with identification of
the appropriate terminals
(c) the selection installation and testing of cables and wiring shall be in accordance with
BS 7671 except that maximum current ratings shall be raised
by a factor of 1.4 times the rating for continuous duty obtained (after applying all
necessary de-rating factors for high ambient temperature, grouping and
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disposition form of installation, etc). The up-rating factor of 1.4 is based on the one
hour motors specified for crane operation
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(d) the crane structure, tracks, motor frames and metal cases of all electrical equipment,
including metal conduit and cable guards, shall be earthed in accordance with
BS7671.
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1 The Contractor shall secure from the lifting equipment manufacturer certification that the
following inspections and tests have been conducted on each lifting equipment at the factory,
and submit to the Engineer prior to shipment.
2 Cranes shall be inspected and tested in accordance with the requirements of BS 466 with the
difference that the “Tests on Purchaser’s Premises” (Clause 54) shall also be carried out in
the manufacturer’s works and witnessed by the Engineer.
3 The works tests shall include overload tests during which a 25% overload shall be lifted by
the hoist at the middle of the crane span and sustained under full control whilst it is moved up
and down at both normal and creep hoist speeds. Whilst still under overload the crab unit of
each crane shall be operated form end to end of its travel.
4 The mechanism and controls for the long travel motions shall be tested under light running
conditions without moving the crane.
5 Tests on manually operated cranes and hoists shall comply with the above insofar as they
are applicable.
6 Control panels, motor and any factory installed wiring shall be inspected tested in accordance
with Part 1 of this Section and Section 21.
1 Two years supply of spare parts and lubricants shall be supplied for each lifting device
supplied.
7.3.1 Installation
1 Lifting equipment shall be installed in accordance with the requirements and instructions of
the manufacturer. If specified in the Project Specification, the lifting equipment manufacturer
shall provide a representative to supervise the installation and testing.
7.3.2 Site Tests
1 After erection cranes and hoists shall be inspected, tested and certification provided by a
qualified independent crane testing specialist in accordance with the requirements of Clause
54 of BS 466 and the tests witnessed by the Engineer. Hand cranes shall be similarly tested.
2 Electrical equipment shall be tested in accordance with the requirements of Section 21
END OF PART
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Part 08: Electric and Pneumatic Actuators
8 ELECTRIC AND PNEUMATIC ACTUATORS ............................................... 2
8.1 GENERAL ...................................................................................................... 2

8.1.1 Scope 2
8.1.2 References 2
8.1.4 Submittals 2
8.2 PRODUCTS -ELECTRIC ACTUATORS ........................................................ 3
8.2.1 General 3
8.2.2 Motors 4
8.2.3 Controls 4
8.2.4 Actuator Mounting 5
8.3 PRODUCTS -PNEUMATIC ACTUATORS .................................................... 6
8.3.1 General 6
8.3.2 Cylinder Actuators 6
8.3.3 Diaphragm Actuators 6
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8.3.4 Solenoid Valves for Pneumatic Actuators 7
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8 ELECTRIC AND PNEUMATIC ACTUATORS
8.1 GENERAL
8.1.1 Scope
1 This Part specifies the requirements for the design, manufacturer, construction, installation,
testing and commissioning of electric and pneumatic actuators for valves and penstocks.
2 Related Parts and Sections are as follows:

This Section
Part 1, General
Part 4, Pipe installation
Part 5, Valves Penstocks and Appurtenances
Part 8, Protective Coatings and Painting
8.1.2 References
1 The following standards are referred to in this Part:

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BS 5501 (IEC 79) .......Electric apparatus for potentially explosive atmospheres

BS 5793 (IEC 534) .....Industrial process control valves
BS EN 60534..............Industrial control valves
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PNEUROP .................(European Committee of manufacturers of compressors, vacuum

pumps and pneumatic tools) Recommendations
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1 Actuators shall be capable of extended and continuous operation under conditions specified
in Section 1 and at the specified valve operating pressure. Submersible actuators, if
required, shall operate at the specified temperature.
8.1.4 Submittals
2 Design Data. This shall include calculations justifying the sizing of valves and actuators for
the hydraulic and system requirements.
3 Shop Drawings. Complete shop drawings for each type of actuator shall be provided,
including:
(a) specifications for materials of construction of actuators and all appurtenance

(b) wiring diagrams
(c) ratings for actuator torque, power input, cylinder or diaphragm pressures, motor
ratings and enclosures, operating speeds, and other information requested by the
Engineer
(d) actuator dimensions.
4 Operation and maintenance manuals and instructions. These shall be provided for each type
of actuator, including:
(a) list of lubricants

(b) lubrication instructions
(c) complete assembly and wiring diagrams
(d) results of all tests specified above and carried out on site
1 One set of manufacturer’s recommended spare parts for two years shall be provided for each
actuator.
2 One set of cover screws, gaskets, ‘O’ rings and ram seals shall be provided for each
actuator.
3 Two years’ requirement of consumable supplies shall be provided for operation and
maintenance of all actuators.
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8.2 PRODUCTS -ELECTRIC ACTUATORS
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8.2.1 General
1 Electric type actuators shall include the motor, heaters, operators unit gearing, limit switches,
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torque switches, declutch lever, auxiliary handwheel, reversing starter, switches, mechanical
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position indicator, and accessories as required.

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2 The valve and gate actuator motor and all electrical enclosures shall be waterproof, IP 67, as
a minimum unless explosion proof, to BS 5501, EEXD II BT4, or submersible, IP 68 is
specified.
3 When specified, a hammer blow mechanism, that travels sufficiently enough to allow the
motor to reach full speed before imparting a hammer blow, to start the valve or gate in motion
in either the closing or opening direction, shall be incorporated.
4 The power gearing shall consist of helical gears of heat-treated steel, and worm gearing of
hardened alloy steel. All power gearing shall be grease lubricated with high speed parts on
anti-friction bearings.
5 It shall be possible to remove the motor operator from the valve and gate without taking the
valve or gate out of service.
6 The valve actuating speed shall be at 300 mm per minute unless specified otherwise.
7 Pneumatic type actuators shall include the cylinder or diaphragm actuator, solenoid valves,
pneumatic positioners, pressure gauges, manual testing station, and other accessories, as
designated to provide a complete, functional actuator.
8.2.2 Motors
1 Motors shall be totally enclosed non-ventilated construction with Class F insulation with
temperature rise limited to Class B, and shall comply with Part 1 of this Section and
Section 21.
2 Available operating torque shall be at least two times the valve manufacturer's maximum
torque requirements. The motor shall be designed specifically for use on valve operation,
having high torque capacity coupled with low inertia.
3 The motor shall be of sufficient size to open or close a valve against the maximum specified
differential pressure when the voltage drop at the motor is 10 % of the nominal voltage.
4 Electrical power to the motor shall be 3 phase, 50 Hz, 415V for 0.4 kW or larger and 1 phase,
240V, 50Hz, for smaller than 0.4 kW.
5 The motor shall be pre-lubricated and all bearings shall be of the anti-friction type.
6 Motor rating shall be continuous duty unless otherwise designated.
7 Heaters and thermostats shall be provided for high humidity conditions.

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8 Electrical and mechanical disconnection of the motor shall be possible without draining the
actuator grease or lubricant
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8.2.3 Controls
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1 Each actuator shall be equipped with a reversing starter, control relays, 2-position limit
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switches and torque limiting switches.

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2 Additional position, limit switches, hand-off-auto switch, open-auto close hand switch, open,
close, stop push-button switches, position indicating potentiometer, position indicating lights,
electric braking or a position controller, or both, shall be provided for the specified analogue
signal input, unless otherwise specified.
3 Position limit switches shall be double pole, double throw and provided for both open and
close positions of travel. They shall be connected directly to the valve through continuous
gearing and follow its position at all times. Switches shall be rated 10 amps at 240 V a.c.
The actuating point shall be adjustable over at least 50 % of the travel.
4 Torque limiting switches shall be provided and be responsive to the mechanical torque
developed in seating, backseating, or by obstruction. The torque switch shall operate a
calibrated dial integrally mounted and directly related to the torque output of the operator.
Torque control accuracy shall be within ± 5 %. The use of torque wrenches for calibration will
not be required.
5 Reversing starters shall include a reversing contactor, mechanical and electrical interlocks,
and thermal overload relays as required. The contactor shall break all lines to the motor. All
controls shall operate on 110 V.a.c.
6 Push-button switches (open-stop-close) shall be located for ease of accessibility. The

controls shall be arranged for remote operation by isolated momentary or continuous contact
switches rated not less than 2 A at 240 V a.c. Terminals shall be wired such that open and
close operation only is possible by appropriate external connections.
7 The hand-off-auto switch shall select between local (HAND) and remote (AUTO) control for
open, close, stop operation. In the OFF position both local and remote controls shall have no
effect.
8 For all modulating duty operations a 4-20 mA convertor shall be provided, powered internally
from a 24 V supply, to transmit the valve position remotely.
9 Position indicator lights shall be at least 2 W, green lens for open, red lens for close; shall be
interchangeable and located near the push-button switches. Both shall light when the valve
is between open and closed limits.
10 Additional position limit switches shall be fully adjustable, of the same rating, and driven in
the same manner as the other limit switches provided.
11 The position controller shall utilise an independent position feedback potentiometer and shall
accept a 4-20 mA d.c. signal for modulating the valve position, unless otherwise specified.
The final positioning accuracy shall not be less than 1 % of position specified by the signal. A
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damping circuit shall prevent overshoot in excess of 2 % for a full-scale step input. The
controller may be separately housed but must be of the same class as the actuator housing.
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Power shall be derived from the actuator power supply.
8.2.4 Actuator Mounting

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1 Special mounting requirements, such as shaft and neck extensions, shall be provided as
shown on the Contract Drawings, and as required for safe operation.
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1 The Contractor shall secure from the actuator manufacturer certification that each actuator
has been performance tested at the factory and individual test certificates shall be supplied
for each actuator. The test equipment shall simulate a typical valve load and the following
information shall be recorded, and included with the test certificate.
(a) current at maximum torque setting

(b) torque at maximum torque setting
(c) test voltage and frequency
(d) flash test voltage
(e) actuator output speed or operating time
2 In addition, the test certificate shall display details of specifications such as gear ratios for
both manual and automatic drive, closing direction, wiring diagram code number, remote
position transmitter resistance and interposing relay voltage, etc.
8.3 PRODUCTS -PNEUMATIC ACTUATORS
8.3.1 General
1 The available instrument and operating air pressures and quality are as specified in the
particular Project Specification. Pressure reducing valves shall be provided where required
for each actuator.
2 Direct mounted pneumatic positioners shall be provided for each valve, mounted on the
valve, unless specified otherwise. Positioners shall provide 0.1 to 1 bar (gauge) output.
Electronic output of 4 to 20 mA shall be provided
3 Wrench or handwheel operated manual override shall be provided for each actuator, unless
otherwise specified. The force to operate these shall not exceed 25 Kgf.
4 Throttling manual override shall be provided for actuators where specified.
5 Where potentiometers are specified for positioning cylinder actuators they shall be 1000 ,
mounted, enclosed and provided with double pole double throw position indicating switches.
6 Test points shall be provided at each actuator to allow an external supply of compressed air
to be connected to checked the operation of the actuator and the position indicator.
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7 Where required fail-safe actuators (fail open or fail closed, as required) shall be provided
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8 Pressure gauges for pneumatic signal and operating air supply links shall be provided.
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9 A filter shall be provided for each pneumatic actuator, unless specified otherwise.
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10 Special mounting requirements, such as shaft and neck extensions shall be provided as
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shown on the Drawings.
8.3.2 Cylinder Actuators
1 Cylinder actuators shall be as follows:
(a) type: double acting cylinder, unless otherwise specified or shown. In compliance with
BS 5793, BS EN 60534 and PNEUROP recommendations as applicable
(b) actuator cover : cast iron or steel, complete with gaskets and seals, internally coated
with epoxy
(c) piston : cast iron or steel, epoxy coated
(d) piston rod : chrome plated carbon steel
(e) solenoid control valves shall be provided with mountings and piping
(f) actuators shall be suitable for operation at 5-7 bar, unless designated otherwise. Test
pressure shall be 10 bar
8.3.3 Diaphragm Actuators
1 Diaphragm type actuators shall not be provided for valves larger than 150 mm nominal
diameter unless approved by the Engineer. They shall confirm to the standards in Part 8.3.2
1(a).
2 Diaphragm actuator construction shall be as follows:
(a) diaphragm case and mounting hardware: cast iron, steel, or stainless steel;
aluminium is not acceptable
(b) diaphragm : flexible neoprene or Buna N
(c) spring : enclosed and corrosion resistant.
8.3.4 Solenoid Valves for Pneumatic Actuators
1 Solenoid valve actuators shall be as follows, and to the standards in Part 8.3.2. 1(a) above
(a) electrical characteristics : 240 or 110 V a.c., 50 Hz, single phase

(b) enclosure : IP 68, unless otherwise designated
(c) rated for continuous operation
(d) fitted with spring return unless otherwise specified
(e) the inlet shall be normally open or normally closed as required by the control system.
1 Electric and pneumatic actuators shall be installed and commissioned in accordance with
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manufacturer’s instructions.
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2 The tests listed under Part 8.2.5 shall be repeated at site. In addition the actuator
performance shall be tested as part of the control system.
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END OF PART
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Part 09: Odour Control Equipment - Carbon Type
9 ODOUR CONTROL EQUIPMENT-CARBON TYPE ...................................... 2
9.1 GENERAL ...................................................................................................... 2

9.1.1 Scope 2
9.1.2 References 2
9.1.4 Submittals 3
9.1.5 Warranty 3
9.2 PRODUCTS ................................................................................................... 4
9.2.1 General 4
9.2.2 Materials 4
9.2.3 Fabrication 5
9.2.4 Accessories 6
9.2.5 Centrifugal Fan 6
9.2.6 Electrical Control Panel 8
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9.3.1 General 8
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9 ODOUR CONTROL EQUIPMENT-CARBON TYPE

9.1 GENERAL
9.1.1 Scope
1 This Part includes the requirements for the design, manufacture, construction, installation
testing and commissioning of force ventilated and passive odour control equipment.

This Section
Part 1, General
Section 1, General
9.1.2 References
1 The following standards or revised/updated versions are referred to in this part:

ASTM D2862 ..............Test Method for Particle Size Distribution of Granular Activated Carbon
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ASTM D3467 ..............Test Method for Carbon Tetrachloride Activity of Activated Carbon
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BS 848,.......................Fans for general purposes

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BS 3749......................E glass fibre woven roving fabrics for the reinforcement of polyester
and epoxy resin systems
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BS 5000 (IEC 34, 72)Rotating electrical machines of particular types or for particular
applications
BS 3496 (ISO 1888) ...E glass fibre chopped strand mat for the reinforcement of polyester
BS 5345 (IEC 79) .......Code of practice for selection, installation and maintenance of
electrical apparatus for use in potentially explosive atmosphere
BS 7671......................Requirements for electrical installations
BS 6105 (ISO 3506) ...Corrosion resistant stainless steel fasteners
BS 2782 (ISO 174, 181, 307, 8618) Methods of testing plastics
BS 6339 (ISO 6580) ...Dimensions of circular flanges for general purpose industrial fans
BS EN 779, Particular air filters for general ventilation
1 Performance Requirements
Concentration of hydrogen sulphide : 500 ppm unless otherwise specified in project
specification
Other Contaminants:
Mercaptans : trace only
Amines (mono/di/tri) : 10 ppm
Ammonia : 50 ppm
Sulphide Concentration in Solution : 50 mg/l

Removal of hydrogen sulphide gas : 99.8 %
and ammonia
Removal of amines : 95 %
Removal of mercaptans : No requirement
2 The ventilation for force ventilated systems will operate continuously.
3 Air shall be supplied into the wet well to dilute the air/gas mixture via a fly screened inlet.
2 The deodorisation equipment shall operate continuously.
4 The sizing and design criteria for the system are given in the particular Project Specification.
5 The odour system shall be designed for indoor or door out installation as shown on the
Contract drawings and as specified.
9.1.4 Submittals
1 In addition to the requirements of Part 1 of this Section, the Contractor shall provide
information and data as described in the following paragraphs.
2 Design data providing the following information:
(a) calculations to justify the sizing and life of the carbon bed(s) at the concentrations
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given
(b) calculations to justify the sizing of the fan(s) if forced ventilated odour control
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equipment is used
(c) user certificates
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3 Shop Drawings providing the following information:

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(a) product data

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(i) fibreglass resin manufacturer’s technical data on composition and

characteristics of resin for fibreglass items including hydrostatic and burn tests
(ii) manufacturer’s technical data on other equipment used
(iii) carbon specification including test reports
(b) dimensional layout of stack and all equipment used
(c) fan test data as BS 848.
4 Samples:
(a) vessel and duct GRP, pre-filter mesh, activated carbon.
5 Operation and maintenance and instruction manuals including:
(a) odour reduction site test report(s) as specified in Part 9.3.2

(b) the documentation in 3 and 4 above.
9.1.5 Warranty
1 The Contractor shall obtain from the Odour Control System manufacturer a warranty that his
system meets the specified odour level reduction criteria, and life for the carbon bed. This
does not in any way alter the Contractor’s guarantee under the Contract.
9.2 PRODUCTS
9.2.1 General
1 All units shall be designed to operate continuously in temperatures up to 55 C with 100 %

condensing humidity and to reduce odours to an unobjectionable and unobtrusive level, and
shall consist of one of the following types, as specified.
(a) passive deodoriser. This system will be used for totally enclosed areas without
forced ventilation where positive displacement occurs. The passive deodoriser
system shall operate as a free-standing unit suitable for outside use in the conditions
prevailing at site and shall contain pre-filter cells, activated carbon filter cells or loose
activated carbon and all necessary appurtenances. Access to the filters shall be
quick and easy without the requirements of special tools for replacement of carbon,
cells and pre-filters. The design of the entire unit shall be such as to ensure a
minimum of maintenance time
(b) forced ventilation deodoriser system. The deodoriser shall contain pre-filter cells,
activated carbon filter cells, or loose activated carbon, fan unit, a vent stack and all
necessary appurtenances. Access to the filters shall be quick and easy without the
requirements of special tools for replacing carbon, cells and pre-filters. The design of
the entire unit shall be such as to ensure a minimum of maintenance and operating
timing.
2 Activated Carbon Support System. This shall be one of two types

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(a) removable carbon cell type filters. Carbon filters shall be of the rechargeable cell
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(b) type with stainless steel or moulded GRP frames and perforated faces riveted
together. The filter cells shall be arranged to give a counter current multiple pass
system with the lowest filter taking the heavy load. When the lowest filter is spent it
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shall be removed and higher filters moved down to replace the one beneath and a new
filter fitted in the highest position. Two additional complete sets of carbon filters shall
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be provided as a minimum
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(c) bulk carbon system. The odour control unit forms a receptable for the granular
activated carbon which is placed in, either manually or using a proprietary
mechanical vacuum device.
9.2.2 Materials
1 Deodoriser Unit and Ducting: These shall be of chemical and ultraviolet light resistant GRP
using water resistant ‘E’ glass chopped strand mat or woven glass fabric to BS 3496 and BS
3749. All surfaces and exposed edges shall be gel coat/flow coat covered using resin to
BS 3532. Alternatively the deodoriser unit and ducting may be manufactured in uPVC or
polypropylene/selmar and wrapped externally with G.R.P, generally as above. All fittings
shall be stainless steel and sealing strips shall be neoprene. The units shall have smooth
semi-gloss finish in white and shall be fully weatherproof.
2 Moisture Eliminator. These shall be incorporated in each duct. They shall be manufactured
from corrosion resistant materials and shall incorporate drain facilities and access panels for
cleaning. They shall incorporate a baffle arrangement with air cooling.
3 Prefilters. Prefilters shall be of washable urethane or polypropylene knitted wool to BS EN

779 designed as a particle and moisture barrier. The unit shall have an access plate for easy
removal of prefilters. They shall be fabricated such that:
(a) maximum efficiency is not less than 95%, based on test dust No. 2
(b) maximum air velocity is 2.5 m/s at the design airflow
(c) the clean filter resistance does not exceed 90 Pa
(d) filters do not sag, flutter or be obstructed by contact with other filters or duct surfaces
(e) the size shall be not less than 600 mm x 600 mm x 45 mm thick
(f) corrosion resistant drain valves are provided
(g) there are no void areas or short-circuiting
4 Activated carbon. This shall be as follows:
(a) removable cell type units. Carbon granules shall be coconut based and impregnated
with potassium iodide, size 5-10 BS mesh. The cells shall be adequately filled and
sealed to prevent short circuiting. Cells shall be rechargeable.
(b) bulk carbon filters. The activated carbon shall be virgin granular, derived from
bituminous coal, vapour-phase type, chemically impregnated with sodium hydroxide,
and suitable for control of sewage odours. Sufficient activated carbon shall be
provided to fill the adsorber to the full bed depth as designed by the odour control
system manufacturer. The carbon shall have the following performance
(c) specifications:
Carbon Substrate
CC1 4 Number percentage by weight (ASTM D3467), 60
Iodine number, minimum 1000
Mean particle diameter 3.7 mm
Percent ash maximum 8 percent
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Impregnated Carbon
(1)
Apparent density minimum 0.55 g/cu cm
Hardness number, minimum 95
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(2)
Moisture, maximum 15 percent
Maximum head loss (Pa) at 0.254 m/s linear
(3)
velocity (through a dense packed bed) 1450 Pa/bed of 900 mm
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(4)
H2S breakthrough capacity, minimum 25 g H2S removed/100 g of carbon
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notes:
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(1) as determined by ASTM D2862 on a dry basis. The delivered apparent density
shall range from 0.55 to 0.64 g/cu cm
(2) calculated on a total product basis
(3) dense packing as defined by procedure for apparent density determination
where a glass 100 ml graduated cylinder is filled through a funnel with 24 mm
inside diameter stem at a uniform rate not exceeding 1 ml/s. Pressure drop is
measured across a 900 mm deep carbon bed, at least 125 mm in diameter
(4) the determination of H2S breakthrough capacity shall be made by passing a
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moist (85 % R.H.) air stream containing 1 % H2S at a rate of 1450 m /min
through a 20 mm diameter by 230 mm deep bed of uniformly packed activated
carbon and monitored to 50 mg/l breakthrough. Results are expressed in g H2S
removed per g of carbon
(5) the carbon supplied shall be of a type chemically regenerable in-situ by the use
of up to 48 % sodium hydroxide for a minimum number of five times, or
regenerated by water if appropriate.
5 Fittings and fasteners. Fittings shall be stainless steel BS 970 Grade 316S31, fasteners shall
be stainless steel BS 970 Grade 316 S31 and BS 6105.
9.2.3 Fabrication
1 Carbon adsorbers shall be fabricated such that the vessel walls are not used to transfer any
vertical loads to the foundations or vertically support any portion of the carbon support
system. The carbon support system shall be removable for vessels of 1 m diameter or less
and shall be constructed of materials resistant to corrosion or deterioration under the service
conditions specified.
2 Four bed activated carbon units shall be horizontal, cylindrical vessels utilizing vertical media
beds and provided complete with supports and anchoring system, all nozzles, and access
hatches. Units shall be complete with access platform and ladder, support saddles, flanged
inlet and outlet nozzles, grounding rods, carbon bed monitoring system, and manways and
sample ports as specified.
3 Vessels shall be constructed in accordance with BS 4994 category III or equivalent.
9.2.4 Accessories
1 Each carbon adsorber vessel shall include the following accessories:
(a) manometer: This shall be provided to continuously monitor the pressure drop
across each carbon bed
(b) sample probes: each vessel shall have three 40 mm diameter sample probes
per bed which shall extend into the bed a minimum of 300 mm. The sample probes
shall be adequate to provide suitable extraction of carbon samples from the carbon
bed. The sample probes shall extend outside the vessel wall and shall be isolated
with a uPVC ball valve
(c) grounding rod: a stainless steel rod shall be provided to adequately ground
each carbon bed
(d) H2S monitor: one portable hydrogen sulphide monitor shall be provided for each
adsorber vessel to detect hydrogen sulphide concentration via a colour coded
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detector card. The housing shall be a weatherproof enclosure which also
allows easy replacement of detector cards
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(e) PVC-u drainage valves and 20 mm diameter pipework routed back to the wet well to
drain off any condensate/regeneration liquid from the prefilters
(f) PVC-u drain valve and 20 mm diameter pipework routed back to wet well to drain off
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(g) air tight covers with gaskets to facilitate easy removal of carbon cells or loose carbon
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(h) three PVC-u air sample probes which extend outside vessel walls and are fitted with
PVC-u isolating valves
(i) gaskets: 3 mm thick full face constructed of neoprene or equal
(j) lifting and holding down lugs
2 An inlet shall be fitted to the wet well to allow fresh air to be drawn in. This shall be of GRP or
PVC-u construction with an insect screen.
9.2.5 Centrifugal Fan
1 The fan shall be centrifugal, belt-driven type constructed from corrosion resistant fibreglass
reinforced plastic or stainless steel with vibration free mountings. The fan shall be capable of
the performance specifications as shown below:
(a) unit capacity : as designated

(b) static pressure : 3000 Pa, or as required
(c) operating temperature : 0 - 70 C
(d) Motor : high efficiency, 415 V, 3 phase, 50 Hz IP 55;1500 rpm, power as required,
rated for zone 2 use with methane gas (BS 5345), to BS 5000.
2 Exhaust fans shall be suitable for continuous 24-hour operation and shall be non-
overloading. Each fan shall operate such that no point on the fan curve requires more than
the rated motor power.
3 The fan housing, flanges and backward curved impellers shall be constructed of flame
retardant GRP laminate or stainless steel, capable of resisting continuous fume temperatures
of 70 C. The manufacturer shall state the type of resin used and confirm that it shall
perform satisfactorily under the operating conditions. All interior surfaces exposed to the
corrosive air stream shall be resin rich.
4 Wheel and shaft assemblies shall be statically and dynamically balanced to a maximum of
0.5 m displacement prior to assembly and every fan test run prior to shipment.
5 Fans shall comply with BS 848 and be provided with the following standard features:
(a) drive assembly: belts shall be oil, heat and static resistant type, sized for
continuous duty. Shafts shall be constructed of heavy duty steel turned, ground and
polished, keyed at both ends
(b) bearings: heavy duty, self-aligning, pillow block bearings, with grease fittings
(c) shaft seal: a fibreglass and neoprene shaft seal shall be placed where the shaft
leaves the housing along with a viton shaft slinger between the seal and wheel on belt
drive units
(d) bases: heavy gauge hot rolled steel, epoxy coated.
(e) the fan shall be provided with the following accessories:
(i) flanged and drilled inlet and outlet to BS 6339
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(ii) drain
(iii) access door
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(iv) vibration isolation system

(v) belt and shaft guard as Part 1
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(vi) earthing as QGEWC requirements and BS 7671

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(f) flexible connectors:

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(i) flexible connectors shall be installed on the fan inlet and outlet to dampen
axial, lateral, and vibrational duct movement
(ii) the flexible connector shall be resistant to the corrosive gases being processed
and shall be able to withstand  3750 Pa. The flexible connector shall be
minimum 30 mm long.
6 Dampers:
(a) (a) suitable sized dampers shall be provided as follows:

(i) balancing damper between the fan outlet and the carbon adsorber inlet
(ii) isolation dampers at each carbon adsorber outlet.
(b) (b) the dampers shall be provided in accordance with the following specifications:
(i) the dampers shall be flanged and drilled to withstand 3000 Pa
(ii) flange mount channel frame shall be vinylester with reinforced bearing pad
(iii) the blade thickness shall be as required by the damper manufacturer
(iv) the bearings shall be moulded plastic material
(v) fibreglass axles shall extend full length of blade and 150 mm beyond frame
(vi) the unit shall be equipped with a full circumference blade seal to limit leakage
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to less than 1 m /m min at 3000 Pa
9.2.6 Electrical Control Panel
1 A prewired, preassembled electrical control panel shall be provided for the odour control
system as specified in the Project Specification. The control panel shall contain pushbuttons,
indicating lights, fan motor starters, alarms, and other controls for a complete automatic
system. The panel shall be wired suitable for connection to 415 V a.c., 3 phase, 50 Hz
source. The panel shall comply with Part 1 of this Section and Section 21.
1 The Contractor shall secure from the equipment manufacturers certification that the following
factory tests have been carried out, and submit to the Engineer prior to shipment. Fibreglass
vessels shall be tested as follows:
(a) hydrostatically tested prior to shipment, with water to the top of the
vessel for a minimum of 24 h
(b) the water must be contained with no visible signs of leaks or excessive wall deflection
(c) a minimum of two burn tests of cutouts, from areas where access doors or piping
cutouts are required, to verify glass resin ratio.
2 Activated carbon shall be tested as Part 9.2.2.4
3 Fans shall be tested as required by BS 848, Part 1 and 2.

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1 The Contractor shall provide from the equipment manufacturer’s all the spare parts and tools
those below. In addition, sufficient activated carbon shall be provided for the complete
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operation of the odour removal system for two years of operation.

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2 The following tools and shall be provided in addition to any others required:
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(a) sampling tool

(b) plastic container for shipping carbon samples.
3 The following spare parts shall be furnished as a minimum requirement, in addition to any
additional spare parts required for two years of operation.
Item Quantity
Complete Centrifugal Fan (1)
Sets of V-belts (2)
Sets of bearings (2)
Shaft seals (2) (if fitted)
Carbon (1) Supplies guaranteed for two years operation
Prefilter set (2)
9.3.1 General
1 If required by the Project Specification, the Contractor shall furnish from the odour control
system supplies the services on site of a factory trained service technician or engineer. He
shall inspect the equipment installation, advise and assist with commissioning and train the
Employer’s operations and maintenance personnel.
2 The odour control system shall be installed in accordance with manufacturer’s written
instructions, by suitably qualified and experienced personnel.
1 Vessel Test. The above water test shall be repeated on site after installation.
2 Fans shall be tested as required by BS 848 Part 1 and shall be installed in accordance with
BS 848 Part 5.
3 Odour Vessels Test: The Contractor shall test as follows:
(a) the odour control system to certify that it meets requirements after completion of the
installation
(b) all odour testing conducted by the Contractor in the presence of the Engineer
(c) the odour control system test shall be conducted after all the air systems are tested
and balanced. Separate H2S tests shall be conducted on each odour control system
(d) the H2S tests shall be repeated at the end of the maintenance period
with the equipment in full operation during the time of year determined by the
Employer to have greatest odour problems, using the actual gas levels.
(e) the hydrogen sulphide test shall comprise as follows:
(i) hydrogen sulphide (H2S) concentrations shall be measured using a calibrated
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portable H2S analyser
(ii) if instructed by the Engineer, bottled H2S gas shall be used to determine if the
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specified H2S performance requirements are met

(iii) each test: three sets of samples shall be taken over an 8 h period:
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 each test shall consist of an inlet and outlet H2S test

 the supplier shall be responsible for supplying the H2S for the bottled H2S
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testing
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 the three H2S levels to be tested shall be selected by the Engineer.

(f) if the odour control system fails to meet the performance criteria, it shall be the
Contractor’s responsibility to make all the modifications necessary to improve
performance at no cost to the Employer. The Contractor shall pay for all additional
testing required to verify that performance criteria are being met
(g) final acceptance of the system will only be possible after successful completion of
this testing
(h) documentation for all the testing shall be submitted to the Engineer.
END OF PART
Part 10: Odour Control Equipment - Scrubber Type
10 ODOUR CONTROL EQUIPMENT-SCRUBBER TYPE ................................. 2
10.1 GENERAL ...................................................................................................... 2

10.1.1 Scope 2
10.1.2 References 2
10.1.4 Submittals 3
10.1.5 Warranty 4
10.2 PRODUCTS ................................................................................................... 4
10.2.1 General 4
10.2.2 Scrubbers 5
10.2.3 Fans 7
10.2.4 Recirculation Pumps 8
10.2.5 Chemical Feed Pumps 9
10.2.6 Chemical Storage Tanks 10
10.2.7 Rotameters 11
10.2.8 WYE Strainer 11
10.2.9 Sump Overflow Trap 11
10.2.10 Acid Supply Connection 12
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10.2.11 Pressure And Vacuum Gauges 12
10.2.12 Pressure Switches 12
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10.2.13 Drench Showers 12

10.2.14 Water Softener 12
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10.2.15 Control Panel 13

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10 ODOUR CONTROL EQUIPMENT-SCRUBBER TYPE

10.1 GENERAL
10.1.1 Scope
1 This Part specifies the requirements for the design, manufacture, construction, installation
testing and commissioning of odour scrubber systems and related auxiliary equipment.

This Section
Part 1, General

Section 10, Instrumentation Control and Automation
10.1.2 References
1 The following standards or revised/updated versions and other documents are referred to in
this Part:
BS 848,.......................Fans for general purposes
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BS 1646 (ISO 3511) ...Symbolic representation for process measurement control functions
and instrumentation
BS 2782 (ISO 181, 174, 307, 8618) Methods of testing plastics
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BS 3496 (ISO 1888) E glass fibre chopped strand mat for the reinforcement of polyester and
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epoxy resin systems

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BS 3749......................E glass fibre woven roving fabrics for the reinforcement of polyester
BS EN 1092...............Circular flanges for pipes valves and fittings
BS 4994......................Design and construction of tanks and vessels in reinforced plastics
BS 5000 (IEC 34,72) Rotating electrical machines of particular types or for particular
applications
BS 5345 (IEC 79) .......Code of practice for selection, installation and maintenance of
electrical apparatus for use in potentially explosive atmosphere
BS 5512 (ISO 281) .....Methods of calculating dynamic load ratings and rating life of rolling
bearings
BS 6105 (ISO 3506) ...Corrosion resistant stainless steel fasteners
BS 6339 (ISO 6580) ...Dimensions of circular flanges for general purpose industrial fans
BS 7671......................Requirements for electrical installations
1 Performance requirements:
concentration of hydrogen sulphide (unless specified otherwise) : 500 ppm
other contaminants:
Mercapatans : trace only

Amines (mono (di/tri) : 10ppm
Ammonia : 50ppm
Sulphide concentration in solution : 50 mgl
Number of air changes per hour in ventilated
volume : 4 minimum. More if Contractor deems
necessary.
Removal of hydrosulphide gas and ammonia : 99.8%
Removal of amines : 95%
Removal of mercapatans : No requirement
The above criteria are for domestic sewage of a quality normally encountered in Qatar.
Highly septic sewage or sewage from industrial sources will need special analysis and the
possible addition of a sulphuric acid stage or a separate sodium hydroxide stage.
2 The scrubber shall be the counterflow, packed bed tower type.
3 Sodium hydroxide 20 % w/w (NaOH) and sodium hypochlorite 12 % w/w (NaOCl) are to be
used as the scrubbing reagents for removing hydrogen sulphide from the odour source. For
some installations with ammonia levels above 30 ppm or other industrial chemicals, addition
of a sulphuric acid 20 % w/w (H2SO4) stage will be necessary. Operation of the scrubber
shall be automatically controlled (with manual override capability) as follows. A single speed
fan activated by a manual start/stop push-button switch, draws odorous air through the
packed beds of the scrubber. The selected recirculation pump (a standby is to be provided),
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also activated by a manual start/stop pushbutton switch, circulates scrubber liquors through
the packed beds. Sulphuric acid (if used), Sodium hydroxide and sodium hypochlorite are
added to the scrubber liquor via metering pumps. Sulphuric acid must be added separately
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in another stage. These pumps are controlled through set points on analysers for pH for
H2SO4 and NaOH and Redox (oxidation reduction potential) for NaOCl. Chemical is added
until the highest set point on the analyser is reached. The recirculation pumps shall be
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interlocked with the metering pumps so that in automatic mode, recirculation pump failure will
cause shut down of metering pumps. Pressure switches shall initiate change over to the
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standby Flow switches (rotameters) shall initiate change over to standby on low flow fan.
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4 The final control involved in the scrubber is water makeup to replace both “bleed” scrubber
liquor and evaporative losses. This is to be achieved with a capacitance type liquid level
element and a solenoid valve on the supply line fed from the water softener.
5 Scrubber liquid is bled off continuously so that the potable water added is sufficient to
maintain the salts in solution.
6 The odour scrubber system shall be designed for indoor or outdoor installation as shown on
the drawings and specified.
7 The chemical storage and feed system shall be designed for outdoor installation.
8 A duplex ion exchange water softener shall be fitted on the potable water supply line, with
booster pumps if necessary.
10.1.4 Submittals
1 In addition to the requirements of Part 1 of this Section, the Contractor shall provide data and
2 Design Data providing the following information:
(a) calculations to justify the sizing of the fans, packed bed, pumps and chemical storage
tanks
(b) calculations as required by BS 4994 category III pertaining to the construction of the
scrubber and chemical storage tanks
(c) structural calculations for foundations and guy wires or any other external means of
support, taking into account wind loadings
(d) user certificates.
3 Shop Drawings providing the following information:
(a) product data

(i) fibreglass resin and plastic liner manufacturer’s technical data on composition.
Characteristics of resin and liner including hydrostatic and burn test
(ii) manufacturer’s technical data on other equipment used
(b) dimensional layout of stack and all equipment used
(c) fan test data as BS 848 Parts 1 and 2.
4 Instrumentation:
(a) complete layout and wiring diagrams of unit control panels.

(b) complete process and instrumentation diagrams drawn in accordance with BS 1646
5 Samples
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(a) vessel and duct GRP and liner, packed media.
6 Operation and maintenance and instruction manuals including:

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(a) odour reduction field test report(s) as specified in Part 10.3

(b) the documentation in Clauses 2, 3 and 4 above in Part 10.1.4.
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10.1.5 Warranty
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1 In addition to the guarantee requirements of Part 1 of this Section, the Contractor shall
ensure that the odour control scrubber equipment manufacturer be responsible for the proper
performance and warranty of the odour control system. The system shall be designed and
guaranteed to meet the odour removal requirement as outlined in this specification.
2 Warranties and guarantees by the suppliers of various components in lieu of single-source

responsibility by the scrubber manufacturer will not be accepted. The Contractor shall ensure
that the scrubber manufacturer is solely responsible for the warranty.
3 The scrubber manufacturer must state in his proposal the guaranteed removal efficiency of
the scrubber, based on the gas inlet concentration.
10.2 PRODUCTS
10.2.1 General
1 Those items of the scrubbers and fans specified to be constructed of fibre glass reinforced
polyester resin shall have approximately 25 % glass reinforcement with a 75 % resin content
and conform to the following:
(a) the polyester resin shall be ortho and isophtalic polyester vinylester resin to BS
3532
(b) reinforcing material shall be a commercial grade of glass fibre water resistant type ‘E’
chopped strand mat or woven glass fabric to BS 3496 and BS 3749
(c) surface finish shall be a gelcoat flow coat isophtalic resin to BS 3532. All drilled, cut
or otherwise exposed edges shall be sealed with polyester resin
(d) all materials, fabrication procedures, manufacturing tolerances, workmanship, tests,
and product quality shall conform to BS 4994
(e) the scrubbing towers and chemical storage tanks shall include conductive resin strips
behind weld lines, and nozzle fitting joints, to enable a full spark test to be carried out,
both in the factory and subsequently on site
(f) Each scrubbing tower and chemical storage tank shall have a corrosion resistant
welded thermoplastic liner of either PVC-u or polypropylene. If PVC-u is used it shall
be annealed after fabrication and welding.
10.2.2 Scrubbers
1 The scrubber shall be single or dual stage vertical, counter-current design, packed tower
type.
2 The scrubber shall contain in the main packed bed a minimum depth of 3 m of nominal
50 mm size filamentous toroidal helix shaped or spherical type packing, having a free volume
2 3
of 95 %, with 28 m of surface area per m of packing. Packing is to be randomly dumped
into the scrubber; structured type packing is not acceptable. Material of construction is to be
polypropylene. Pressure drop per metre of packing shall not exceed 15 mm water column.
3 The scrubber shall include an entrainment separator/demister, internal spray piping or liquid
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distribution as recommended by the specialist scrubber packing manufacturer, packing,
packing supports, lifting and hold down lugs.
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4 All liquid handling nozzles, external to the vessel, shall be flanged to NP16. Gas handling
nozzles shall be of the dimensions as outlined in BS 6339. Couplings shall be fully flanged,
NP16. Minimum projection of nozzles shall be 150 mm.
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5 Scrubber nozzles and appurtenances shall include:

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(a) make-up water inlet

(b) hydrochloric acid supply connection
(c) overflow
(d) sump drain
(e) scrubber liquor recirculation inlet (to spray header)
(f) scrubber liquor recirculation outlet (to pump suction)
(g) pH probe mounting
(h) Redox probe mounting
(i) level sensor mounting connections with stilling well
(j) a minimum of three manholes with neoprene gaskets (for servicing spray nozzles,
packed bed, and scrubber sump)
(k) four GRP tie down lugs or base flange
(l) mounting brackets for scrubber recirculation piping
(m) stainless steel guy wires as necessary
(n) gas sampling points on inlet and outlet to the scrubber. If necessary, both shall be
piped using 12 mm piping to a convenient point for use of a hand held hydrogen
sulphide monitor.
6 The scrubber tower shall be capable of operating at the design flow rate with a maximum
static pressure loss of 75 mm water column. The packing depth, recirculation rate, and
recirculation solution shall be designed to meet the required efficiency.
7 The scrubber housing and internal structural members shall be fabricated of GRP, and shall
be not less than 5 mm thickness. External reinforcing ribs, if required for pressure or vacuum
conditions or wind load, shall be suitably designed and installed not more than 1 m apart.
Colour shall be white.
8 An internal moisture entrainment separator section shall be furnished with each unit which is
to consist of 300 mm deep packed bed. The demister shall be capable of removing not less
than 99 % of the entrained moisture of the air exiting the scrubber, consisting of droplets
10 m and larger.
9 Packing support plates for the main bed shall be manufactured from polypropylene having
40 mm by 40 mm square openings and being 40 mm deep. Packing support plates for the
entrainment separator section shall be manufactured from polypropylene, having a minimum
84 percent open area , or same as above. Any internal supports required shall be of the
same material as the shell. Support plates are not required for chevron blades.
10 The scrubbing liquid distribution system shall be the spray type of manufacturer’s standard
design, sized for the flowrates required and taking into varying air delivery rates of +10 %.
No liquid distributors shall be permitted. Spray headers shall be placed at the manufacturer’s
recommended distance above the packing. Material of construction shall be chlorinated
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polyvinyl chloride (PVC-C), NP16. Spray nozzles shall be spiral design, full cone type,
constructed of PVC
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11 The scrubber shall be designed with a minimum of 600 mm of shell height between the gas
inlet and bottom to act as an integral sump. The sump shall hold a minimum of two minutes
supply of scrubbing liquid. The sump shall be furnished with a level sensor as specified
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herein.
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12 No internal wetted metal bolts, or components are permitted. All external bolts and fasteners
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including anchor bolts and flanged bolts shall be BS 970 316 stainless steel. Stainless steel
anchor bolts guy wires and clips shall be provided by the manufacturer.
13 The scrubber shall be supplied with integral mounting lugs and pipe supports for the (PVC-C)
scrubber liquor recirculation piping. Mountings shall be designed with consideration for pipe
inlet and outlet connections. Pipe supports shall be non-metallic channels and straps.
14 The scrubber shall be equipped with a differential pressure gauge on the inlet and outlet
ductwork which shall be installed so that abnormalities that may occur in the scrubber can be
visually detected. The scrubber shall have pressure taps located below the main packed bed
and above the entrainment separator, and the gauge shall be mounted on a scrubber shell.
The differential pressure gauge shall include instrument traps, and valve manifolds to permit
testing and zero setting of the gauge. Plastic tubing equipment with PVC condensate traps
shall connect the high and low pressure taps. The gauge shall have a 100 mm round face.
15 Redox and pH probes for analysing the contents shall be located in the scrubber sumps. The
probes and analysers shall provide the chemical feed control as described herein. The
probes shall meet the following specifications:
(a) range : pH probe : 0-14 pH : Redox probe; 0-1000 mV

(b) stability :  01.% per 24 hours, non-cumulative
(c) wetted materials sensor Liquid crystal polymer body
(d) accuracy/ sensitivity  0.1 pH unit : Redox probe : ± 1 mV
0
(e) temp. limits 65 C
(f) pressure rating 0-350 kPa

(g) interconnect cable manufacturer’s standard
(h) each probe shall be supplied with a two wire transmitter and analyser
(i) the analyser shall be microprocessor based with a 4 digit display, with dual
programmable high/low set points, contacts. Alarm conditions shall be indicated on
the instrument by front panel LED’s with auxiliary alarm contacts. Automatic or
manual temperature compensation shall be selectable, with the option to display the
process temperature. A data logging system for high/low signals shall be
incorporated. Set-up, alarm and control functions shall be accessible on the front
panel
(j) each probe shall be provided with a protector or well as recommended by the
manufacturer
(k) the manufacturer shall supply all necessary hardware and wiring for installation of
probe and analyser.
16 The sump liquid level sensor shall be a capacitance type liquid level probe with a Teflon
coated probe element and integrally mounted cast iron or epoxy coated enclosure. The probe
shall be a dual-point sensor, for high and low liquid levels. On low liquid level, an electrically
operated solenoid valve shall open and allow scrubber make-up water to flow into sump. The
valve shall close when high set point is reached. Low-low level shall simultaneously sound an
alarm in the control panel and shut off the recirculation pumps. Probe shall be inserted in
type 316 stainless steel stilling wells mounted externally of the scrubber.
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17 All instrumentation mounted inside the scrubber tower or tanks shall be intrinsically safe.
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10.2.3 Fans
1 Duty/standby fans shall be provided for each scrubber unit. Each fan shall have a single
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speed motor with the capacity and power to deliver the required volume of air against the
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total pressure losses in the air intake, duct collection systems, packed bed, mist eliminator
and ductwork to the fan and exiting out of the stack.
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2 The fan shall be centrifugal, belt-driven type constructed from corrosion resistant fibre glass
reinforced plastic or stainless steel, with vibration free mountings. The fan shall be capable
of the performance specifications as shown below:
(a) unit capacity : as required

(b) static pressure : 3000 Pa, or as required
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(c) operating temperature : 0 -70 C
(d) Motor : high efficiency, 415 V, 3 phase, 50 Hz IP 55; 1500 rpm power as required,
rated for zone 2 use with methane gas (BS 5345), to BS 5000, 1500 rpm.
3 Exhaust fans shall be suitable for continuous 24-hour operation and shall be non-
overloading. Each fan shall operate such that no point on the fan curve requires more than
the rated motor power.
4 The fan housing, flanges and backward curved impellers shall be constructed of flame
retardant GRP laminate or stainless steel, capable of resisting continuous fume temperature
0
of 70 C. The manufacturer shall state the type of resin used and confirm that it will perform
satisfactorily under the operating conditions. All interior surfaces exposed to the corrosive air
stream shall be resin rich.
5 Wheel and shaft assemblies shall be statically and dynamically balanced to a maximum of
0.5 m displacement prior to assembly and every fan test run prior to shipment.
6 Fans shall comply with BS 848 and be provided with the following standard features:
(a) drive assembly: belts shall be oil, heat and static resistant type, sized for continuous
duty. Shafts shall be constructed of heavy duty steel turned, ground and polished,
keyed at both ends
(b) bearings: heavy duty, self-aligning, pillow block bearings, with grease fittings
(c) shaft seal: a fibreglass and neoprene shaft seal shall be placed where the shaft
leaves the housing, along with a viton shaft slinger between the seal and wheel on
belt drive units
(d) bases: heavy gauge hot rolled steel, epoxy coated
(e) the fan shall be provided with the following accessories:
(i) flanged and drilled inlet and outlet to BS 6339
(ii) drain
(iii) access door
(iv) vibration isolation system
(v) belt and shaft guard as Part 1
(vi) earthing as QGEWC requirements and BS 7671
(f) flexible connectors:
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(i) flexible connectors shall be installed on the fan inlet and outlet to dampen
axial, lateral, and vibrational duct movement. Flexible connectors shall be
installed at each fan inlet and outlet
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(ii) the flexible connector shall be resistant to the corrosive gases being processed
and shall be able to withstand  3750 Pa. The flexible connector shall be
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minimum 30 mm long.
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7 Dampers:
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(a) suitable sized dampers shall be provided as follows:

(i) balancing damper between the fan outlet and the scrubber inlet
(ii) isolation dampers at each fan inlet and outlet
(b) the dampers shall be provided in accordance with the following specifications:
(i) the damper shall be flanged and drilled to withstand 3000 Pa
(ii) the blade thickness shall be as required by the damper manufacturer
(iii) the bearings shall be moulded plastic material
(iv) fibreglass axles shall extend full length of blade and 150 mm beyond frame
(v) the unit shall be equipped with a full circumference blade seal to limit leakage
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to less than 1 m /m min at 3000 Pa.
10.2.4 Recirculation Pumps
1 Pumps shall be of the direct coupled, single stage, end suction, horizontal, back pullout
corrosion resistant, centrifugal type.
2 Impellers with integral shaft sleeves shall be balanced semi-open fibre glass reinforced resin
polyester or PVC-C.
3 The pump casing shall be a resin injected hot press moulded fibre glass reinforced polyester
or PVC-C. The casing shall be free standing supported by heavy duty non-metallic feet.
Suction and discharge nozzles shall be NP16 flanges.
4 The shaft shall be constructed of 316 stainless steel of sufficient diameter to assure rigid
support of the impeller to prevent excessive vibration.
5 The bearing housing shall be constructed of cast iron, machined with precision pins of
tongue-and-groove construction to ensure permanent alignment.
6 Bearings shall be of the anti-friction, oil lubricated, ball type and enclosed in a cast iron, oil-
tight bearing frame. Bearings shall have a minimum L-10 rating of 20,000 hours under full
load continuous 24-hour duty. Bearings shall be oil lubricated. The pump shall be equipped
with constant level oiler.
7 The shaft seal shall be mechanical, EPDM/carbon/ceramic. Seal water shall be provided if
necessary.
8 Pumps and motors shall be bolted to a common GRP baseplate. Pumps shall be grouted in
place with epoxy grout.
9 Pumps shall be directly coupled to the motor with a suitable spacer type coupling and guard.
10 Duty/standby change over shall be by means of a low flow switch mounted in the liquor feed.
11 Motor:
(a) each pump shall be provided with a horizontal squirrel cage induction, totally
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enclosed fan cooled motor, of sufficient power such that no point on the pump
curve requires more than the rated power of the motor furnished
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(b) each motor shall be suitable for 415 V, 3 phase, 50 Hz continuous 24-hour operation
and shall conform to the requirements of Part 1 of this Section and Section 21.
10.2.5 Chemical Feed Pumps

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1 The pumps shall be of the hydraulically balanced double diaphragm type, wherein a
measuring piston reciprocates within a cylinder and causes hydraulic oil to deflect a flat
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diaphragm. The diaphragm shall be supported throughout the entire pumping stroke. The
hydraulic oil system shall include a means to automatically relieve excess hydraulic pressure,
makeup oil and bleed-off vapours. Mechanically operated devices are not acceptable. The
chemical metering head shall include a diaphragm cavity moulded into the head material, or
have other intrinsic design features to prevent diaphragm damage during restricted inlet
conditions. The pump shall have a flow-through liquid path from bottom to top. The
diaphragm shall be capable of sealing under full head bolt torque limits without stressing the
diaphragm. Pump heads shall be polyproylene and diaphragms PTFE.
2 The metered liquid shall enter the metering head at the bottom and exit at the top through
alumina-ceramic disk or ball type check valves. These may be gravity seating or spring
loaded to meet service conditions. Valve assemblies shall be replaceable without threading.
Valve seats, shall be of Viton, gaskets shall be PTFE.
3 The pump mechanism shall have flooded lubrication using a common oil with the hydraulic
system. It shall not contain auxiliary lubricator mechanisms. The pump mechanism shall be
sealed from direct contact with the outside atmosphere and shall be suitable for operation in
ambient conditions of 55 C without the use of heating or cooling devices. Manual capacity
adjustments between 0 and 100 % shall be accomplished while the pump is idle, or
operating, by simply changing the piston stroke length. A minimum of 400 adjustment
increments shall be available. Stroke adjustments shall provide positive, repeatable settings
within ± 0.25 % over the entire pumping range. Pump delivery shall be repeatable within ±
1 % accuracy over a 10 to 1 range.
4 Pump bearings shall be heavy duty ball or tapered roller type designed for an L10 life of at
least 50,000 hours in accordance with BS 5512.
5 Each pump shall have an integral pressure relief valve to prevent damage to the pump or
piping in the event of a downstream pipe blockage.
6 Pumps shall be capable of operating continuously with liquids at 40° C.
7 Each pump specified herein shall be driven by a squirrel cage induction motor suitable for
operation on a 240 V, single phase, 50 Hz power supply, and meeting the requirements for
electrical motors as specified in Part 1 of this Section and Section 21. Motors shall be direct
coupled to the pumps, with flexible couplings.
8 Each pump discharge shall include a back pressure valve designed to create a constant back
pressure without chatter or cycling. Parts in contact with the pumped liquid shall be suitable
for use with H2SO4, NaOH and NaOCl as specified herein. A PTFE diaphragm shall seal
the spring and bonnet from the product. The diaphragm shall seal on a replaceable seat and
shall ensure tight shutoff at zero flow.
10.2.6 Chemical Storage Tanks
1 The storage tanks shall be of lined laminated construction, designed and fabricated in
accordance with BS 4994 category III, and shall provide safe, sound, and leak-proof storage
at atmospheric pressure for the specified liquids. Lamination thickness specified in the
standards shall be considered minimum thicknesses.
2 Tanks shall be constructed of a welded PVDF, PVC-u or polypropylene liner and contact-
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moulded translucent reinforced plastic resin. As a minimum, tank construction shall consist of
a 50 m resin-rich exterior mat, a middle layer mat to develop the necessary strength, and a
250 to 300 m resin-rich nexus veil interior and a minimum 3 mm thick plastic liner.
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3 Tanks, anchors, and supports shall be designed for exterior installation that shall withstand a
horizontal wind load without movement or damage. Tanks shall also be designed for a
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concentrated dead load at the top of the tank of 500 kg. Tanks shall include hold-down
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anchors. Anchors shall be designed to hold the tank against an uplift pressure of 2 m of
water column. Tanks shall be designed for pneumatic tanker loading.
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4 Factory-applied insulation shall be provided for all storage tanks. Insulation shall be 50 mm
thick and shall provide a maximum coefficient of thermal conductivity (K Value) of 0.4
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kg.cal/h/m /C. Insulation shall be protected by an additional fibreglass laminate built up to a
minimum thickness of 0.4 mm. This protective laminate shall include expansion joints
spaced to preclude damage due to thermal expansion. A lip shall be provided at each joint to
prevent moisture from entering. The exterior laminate shall also include a pigmented
protective gel coat in a colour to be selected by the Engineer. Loose insulation shall be
packed into the gusset around the pipe neck at each tank nozzle, and shall be taped to
provide a weatherproof seal.
5 A permanently attached encapsulated paper or stainless steel tag shall be affixed to the
outside laminate covering the insulation. This label shall contain the following information:
(a) manufacturer
(b) corrosion-resistant liner
(c) type of liner reinforcement
(d) chemical to be stored
(i) concentration
(ii) maximum specific gravity
(iii) maximum temperature
(e) exterior resin
(f) tank capacity

(g) date of manufacture.
6 The tanks shall include the fittings and appurtenances shown on the drawings and described
herein:
(a) hinged, top-mounted access manway (800 mm diameter) with non-slip walkway and
316 stainless steel ladder cage, and handrailing
(b) conical gusseted, flanged connections for fill, inlet, outlet, drain, vent and
overflow. All shall be minimum 75 mm diameter. The overflow shall be piped into
the tank bund to prevent splashing. Connections shall be located as shown on the
Drawings. Flange face and bolting shall be in accordance with NP 16
(c) low level probes shall be fitted in each tank to stop the dosing pumps in the event of
low level being detected. Suitable gasketed covers shall be provided for these
probes
(d) screened vent. The vent shall be sized for release of air during tanker offloading
(e) anchor and lifting lugs
(f) A visual cat and mouse type liquid level gauge shall be provided on each tank, or
alternatively a hand operated pneumatic bubbler.
7 Tanks shall be segregated in bunds. Bunds shall have individual capacities equal to 1.1
times the tank full volume. Alternatively tanks of a proprietary design with integral bunds may
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be provided.
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10.2.7 Rotameters
1 General. Rotameters shall be provided as shown on the drawings and specified herein.
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Rotameters shall include a plastic housing or frame. Rotameters shall include a flow indicator
suitable for indoor installations. All wetted parts and fittings shall be 316 stainless steel,
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except O-rings. Meters shall have a minimum rangeability of 10:1.

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2 Make-up Water. Rotameters shall include a dial flow indicator, 316L or plastic, suitable for
high pressure, high temperature flow indication. The metering float shall be magnetically
coupled to an indicator housed in a fully gasketed, reinforced fibreglass case. Accuracy shall
be plus or minus 5 % of full scale. A stainless steel control valve shall be provided for
precise regulation of liquid flow rate.
3 Seal Water (if used) and recirculation pump rotameters shall be armoured purge meter type
with magnetically coupled indicator used for low flow, high pressure, and high temperature.
Accuracy shall be plus or minus 10 % of measuring flow rate. Rotameter shall include a
12 mm stainless steel needle valve.
10.2.8 WYE Strainer
1 Wye strainer shall be installed on the potable water, recirculation and dosing pump feeds,.
Strainers shall have a PVC body with type 316 stainless or PVC strainers with 0.8 mm
perforations.
10.2.9 Sump Overflow Trap
1 A trap shall be provided on the scrubber sump overflow line to prevent air inflow through the
scrubber.
10.2.10 Acid Supply Connection
1 The scrubber shall be equipped with a nozzle for addition of a dilute acid solution to the
sump. A 50 mm PVC ball valve and 50 by 100 mm funnel shall be installed for this.
10.2.11 Pressure And Vacuum Gauges
1 General. Pressure gauges shall be of the stem-mounting type.
2 Construction. Gauges shall be of the bourdon tube or bellows type with 270  clockwise
pointer travel. Dials shall be white with black numerals. Dial size shall be 100 mm. Panel
mounted gauges shall have round bezels for flush mounting and rear connection, others shall
have a stem-mounting bottom connection. Connections for all gauges shall be male 12 mm
threaded with square wrench flats. Wetted parts shall be compatible with the process fluid.
Cases shall be impact resistant plastic. Accuracy shall be ±0.5 % of span.
3 Chemical Seal. The gauge shall be furnished with a diaphragm seal. The diaphragm seal
shall have a 316 stainless steel (minimum) top and bottom housing and a 316 stainless steel
diaphragm welded to the top housing. When the process fluid is not compatible with 316
stainless steel, the manufacturer shall provide a diaphragm seal compatible with the process
fluid. The process connection shall be a 20 mm threaded connection with a flushing
connection. The fill fluid shall be silicone.
10.2.12 Pressure Switches

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1 Pressure switches shall be operated by a brass bourdon tube actuating a switch. Switches
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shall be single pole double throw, rated at 4 A, 240 V a.c., 50 Hz, and have deadband
adjustable up to 100 % of switch range. The adjustable operating range shall be 1 mPa, with
calibrated dials and two pointers indicating set and reset points. Enclosures shall be IP 65.
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2 Pressure switches shall be fitted in the dosing and potable water booster pump lines to effect
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changeover from duty to standby pumps.

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3 A pressure drop transmitter shall be fitted in the ducting to effect changeover from duty to
standby fans.
10.2.13 Drench Showers
1 One or more drench showers shall be provided by the chemical storage tanks, as specified.
2 Showers shall be operated by a walk-on platform with stainless steel operating linkages and
a stainless steel stay open valve which locks open.
3 The shower deluge shall be provided by gravity from a tank mounted above the shower with
an in-line or tank mounted thermostatically operated heater, fitted with 30 mA RCD
protection.
4 The shower shall incorporate an emergency eye/face wash fountain with a flexible hose
5 The shower shall be complete with a light and emergency shower/eye wash signs.
10.2.14 Water Softener
1 These shall be dual cylinder water softeners, rated for continuous output with an integral
meter initiated water power regeneration. The softener shall use a fine bead resin bed in
conjunction with a brine solution. The softener shall be rated for 28 days use without the salt
storage being replenished.
2 A water storage break tank shall be provided to feed the softeners via duty/standby water
booster pumps.
10.2.15 Control Panel
1 A prewired, preassembled electrical control panel shall be provided for the odour control
system, as specified in the particular Project Specification
2 The panel shall be supplied complete with all equipment and accessories, including the
following:
(a) motor control switches and indicating lights for the fans, recirculating pumps chemical
metering pumps, pH and Redox analyser/controllers
(b) interlocks between recirculating pumps, chemical metering pumps, and sump level
control. Interlocks between pH and Redox analyser/controllers, chemical metering
pumps, and the make-up water solenoid valve and level controls
(c) selector switches for manual or automatic operation
(d) an annunciator with volt-free contacts for remote signalling, as required in the Project
Specification.
3 Additionally the panel construction and components shall meet the requirements of Part 1 of
this Section, Section 21 and shall be suitable for connection to 415V 3 phase 50Hz.
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1 The Contractor shall secure from the equipment manufacturers certification that the following
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factory tests have been carried out, and submit to the Engineer prior to shipment.
2 Fibreglass vessels shall be tested as follows:

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(a) hydrostatically tested prior to shipment, with water to the top of the vessel for a
minimum of 24 hours
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(b) the water must be contained with no leaks or excessive wall deflection.
3 Fans shall be tested as required by BS 848, Parts 1 and 2
4 One pump of each size supplied shall be factory tested. Where multiple units are provided,
only one of each size and type shall be tested. Dosing pumps shall be tested in accordance
with BS 5316 Part 2, recirculation pumps to BS 5316 Part 1.
1 The Contractor shall provide from the equipment manufacturers all the spare parts and tools
those below:
2 In addition, sufficient chemicals shall be provided for the complete operation of the odour
removal system for 2 years of operation.
3 The following spare parts shall be furnished as a minimum requirement, in addition to any
additional spare parts required for two years of operation.
Item Quantity
Fan
Complete Centrifugal Fan (1)
Sets of V- belts (2)
Sets of bearing (2)
Shaft seals (2) (if fitted)
Scrubber
main packing (100 %) (for 1 bed)
spray nozzles (1) (set)
moisture separator packing (5%) (of total)
Dosing pumps
diaphragms (8)
Disk check valves and sets (8)
Pump gaskets and ‘O ‘ rings (8) (complete sets)
Pumps and motors (2)
Recirculation Pumps
Impeller (2)
Seals (8)
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Pump and motor (1)
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10.3.1 Installation
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1 The Contractor shall ensure the supplier of the odour control system furnishes the services
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on site of a factory trained service technician or engineer. He shall inspect the equipment
installation, advise and assist with commissioning, and train the Employer’s operations and
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maintenance personnel.
2 The odour control system shall be installed in accordance with manufacturer’s written
instructions, by suitably qualified and experienced personnel.
1 Vessel and tank tests. The above water tests shall be repeated on site after installation.
2 Fans shall be tested as required by BS 848 Part 1 and shall be installed in accordance with
BS 848 Part 5.
3 Odour System Test: The Contractor shall test as follows:
(a) the odour control system to certify that it meets requirements after completion of the
installation
(b) all odour shall be testing conducted by the Contractor in the presence of the
Engineer
(c) the odour control system test shall be conducted after all the air systems are tested
and balanced. Separate H2S tests shall be conducted on each odour control system
(d) the H2S tests shall be repeated at the end of the maintenance period
with the plant in full operation during the time of year determined by the Employer to
have greatest odour problems, using the actual gas levels generated by the pumping
stations
(e) the hydrogen sulphide test shall comprise as follows:

(i) hydrogen sulphide (H2S) concentrations shall be measured using a calibrated
portable H2S analyser
(ii) if instructed by the Engineer, bottled H2S gas shall be used to determine if the
specified H2S performance requirements are met
(iii) each test: three sets of samples shall be taken over an 8 h period:
 each test shall consist of an inlet and outlet H2S test
 the supplier shall be responsible for supplying the H2S for the bottled H2S
testing
 the three H2S levels to be tested shall be selected by the Engineer.
(f) if the odour control system fails to meet the performance criteria, it shall be the
Contractor’s responsibility to make all the modifications necessary to improve
performance at no cost to the Employer. The Contractor shall pay for all additional
testing required to verify that performance criteria are being met
(g) final acceptance of the system will only be possible after successful completion of
this testing
(h) documentation for all the testing shall be submitted to the Engineer.
END OF PART
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Part 11: Screening Equipment
11 SCREENING EQUIPMENT ........................................................................... 2
11.1 GENERAL ...................................................................................................... 2

11.1.1 Scope 2
11.1.2 References 2
11.1.3 Submittals 2
11.2 PRODUCTS ................................................................................................... 2
11.2.1 General 2
11.2.2 Brush Screen 3
11.2.3 Band / Escalator Screen 3
11.2.4 Rotary Raked Bar Screen 4
11.2.5 Semi Rotary Raked Bar Screen 4
11.2.6 11.2.6 Step Screen 5
11.2.7 Straight Bar Screen 5
11.2.8 Covered Skip Containers 6
11.3 SCREENINGS TRANSFER SYSTEMS ......................................................... 6
11.3.1 Screening Trough 6
11.3.2 Conveyor Belt 6
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11.4 SCREENING WASHER/COMPACTORS ...................................................... 7
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11.4.1 Screening Washer/Compactor 7

11.4.2 Washer/Dewaterer 7
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11.5 GEAR REDUCER .......................................................................................... 8

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11.6 MOTORS ....................................................................................................... 8

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11.7 CONTROLS ................................................................................................... 8

11.8.2 Testing 8
11 SCREENING EQUIPMENT
11.1 GENERAL
11.1.1 Scope
1 This part specifies the requirement for the design, manufacture, construction, installation,
testing and commissioning of screening equipment.

Section 1 General
Section 8 Sewerage
Section 10 Instrumentation, Control and Automation
Section 13 Building Electrical Works
Section 21 Electrical Works
11.1.2 References
BS EN 10084, ...........Case hardening steels
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List of ‘Approved Suppliers’ prepared by the Public Works Authority
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11.1.3 Submittals
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1 In addition to the requirements of Part 1 of this Section, the Contractor shall reconfirm the
information provided in the Technical Submission Schedules submitted with his Tender.
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11.2 PRODUCTS
11.2.1 General
1 Screens shall be complete with all the necessary ancillary equipment and with screenings
washing and compacting facilities.
2 The screens shall be fitted with an automatic cleaning mechanism, which shall remove the
screenings adequately and positively into a screenings transfer system to the screenings
washing equipment without risk of spillage. The transfer system shall be totally enclosed and
be fitted with bolted removable access cover sections.
3 Unless otherwise stated in the Contract Documents the Contractor shall make his own
assessment of the amount of screenings that will be produced by his equipment and the
design of the screenings handling system shall be sized accordingly.
4 In all cases the screens shall be protected by a torque limiting device in addition to the motor
overload protection. Rake parking switches shall also be provided and in each case the
electrical circuit information for each device shall be provided with drawings for approval.
The screening equipment shall not immediately restart on removal of the obstruction but
shall be manually reset at the control panel.
5 The screen aperture shall be as stated in the Contract Documents.

6 All moving parts of the screen shall have oil impregnated, sintered bronze or grease
lubricated bearings. In the case of the latter, individual stainless steel feed pipes and flexible
polyurethane tubes to the bearings shall be fed from a manifold that shall be located in a
convenient position outside any guards on the screen. A manual grease feed pumping
system shall be incorporated.
7 The screen framework and components shall be designed to resist both hydraulic and drive
mechanism loads during normal running and all modes of failure. Screen rake mechanism
shall be arranged such that the minimum number of moving parts will remain immersed
when the screen is in the parked position.
8 The complete headgear shall be enclosed within a removable glass reinforced plastic splash
hood and a hinged door shall be provided to give visual inspection of the screens. The hood
shall incorporate air admittance valves.
9 The plant shall be controlled by PLC suitable for SCADA and telemetry connection and shall
incorporate a Human Machine Interface (HMI) within a dedicated Motor Control Centre
(MCC).
10 The screen shall be manufactured from stainless steel Grade 316 S31 to BS 970-1(partially
replaced by BS EN 10084), unless otherwise stated.
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11 Limit of position indication shall be incorporated into the drive mechanism by means of
proximity switches protected to IP68.
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11.2.2 Brush Screen

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1 The screen shall comprise perforated stainless steel Grade 316 S31 to BS 970-1 (partially
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replaced by BS EN 10084), or moulded polyurethane panels with 6mm apertures. .

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2 The rotating brush shall incorporate adjustment arrangements to optimise brush

effectiveness and reduce brush wear. Brush adjusters shall be fitted with either locknuts,
stiff nuts or stop retainers to prevent disengagement of the brush resulting in consequent
damage of the screen plates.
3 The screening panels shall be bolted to the framework using stainless countersunk bolts.
Edge clearances shall not be capable of trapping screenings and in any event shall not
exceed 5mm.
4 The screen shall be provided with a brush wiper mechanism to ensure the complete removal
of screenings from the brush.
11.2.3 Band / Escalator Screen
1 Travelling Band / Escalator Screens shall not be permanently secured to the screen
chamber walls. Location fixings shall be positioned at coping level for ease of access.
2 Screens to be housed in enclosed structures shall be manufactured in sections to facilitate

removal from the chamber making due allowance for the maximum height available.
3 Where the size of the screen permits, the screen may be hinged such that it can be tilted out
of the chamber for maintenance purposes.
4 The screen shall consist of a moving band of screening panels supported above coping level
on two cast iron sprockets mounted on a horizontal headshaft supported in self aligning roller
bearings. The headshaft shall be mounted on machined guides to allow for adjustment to
compensate for chain wear. Tension screws shall be provided and shall be manufactured
from stainless steel.
5 The main chain shall comprise links, bushes, pins and rollers and shall be self-lubricating by
immersion in the flow. The links shall carry the mesh panel support frame and shall be fixed
with stainless steel set screws. The chain shall run in curved guides at the bottom of the
channel. Sprockets shall not be used to return the chain at the bottom of the channel.
6 The mesh panels shall be constructed of perforated stainless steel Grade 316 S31 to BS
970-1 (partially replaced by BS EN 10084), or moulded polyurethane, and provided with
elevators to raise the screened material to the cleaning point. Woven panels shall not be
used for screening sewage. The panels shall be designed to withstand full differential head
across a fully blinded panel.
7 A sealing plate shall be provided between the outer edge of the mesh panels and a sealing
angle bolted to the walls of the screening chamber. The plate shall enclose the chain guide
on the upstream side of the screen to prevent debris fouling the chain. Sealing strips shall
be provided between adjacent mesh panels to maintain the screening aperture when panels
articulate around the bottom curve of the chain guide.
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8 Spray jets shall be provided within the head section to remove the screenings from the mesh
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into a debris collecting trough. The spray pipe feeding the jets shall be provided with a
washout valve fitted with a hose connection to facilitate flushing of the system. A rotating
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brush shall be provided immediately after the spray jets to remove fibrous material that has
interwoven between the mesh apertures. The brush shall be easily renewable and fixed by
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stainless steel set screws.

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9 The spray jet water shall be applied at the correct quality and pressure to efficiently remove
all screenings during one pass of the panels.
10 Chain driven screens shall be provided with chain tensioners and have provision for manual
adjustment in the event of chain stretching.
11 Tracked carriages shall also be provided with wheel adjustment so that engagement in the
channels of the track can be optimised.
11.2.4 Rotary Raked Bar Screen
1 Rotary curved bar screens shall be raked by a shaft mounted rake mechanism revolving
continuously through 360o. The rotation of the cleaning rake shall clean the radius of the
stationary bar rack and elevate screenings to a discharge point at the top of the rack. At this
point a wiper mechanism shall ensure that the rake is cleared of all screenings before
continuing its cycle.
11.2.5 Semi Rotary Raked Bar Screen
1 Semi rotary curved raked bar screens shall comprise a single cleaning rake which by means
of a pivoting linkage describes a rotary path along the stationary curved rack, disengages at
the top of the screen rake and re-engages at the bottom of the rack.
2 At the top of the rack a wiper mechanism shall ensure that the rake is positively cleared of all
screenings before continuing its cycle.
3 This type of screen may also be hydraulically operated.
11.2.6 11.2.6 Step Screen
1 Step screens shall not be permanently secured to the screen chamber walls. Location
fixings shall be positioned at coping level for ease of access.
2 Screens to be housed in enclosed structures shall be manufactured in sections to facilitate

removal from the chamber making due allowance for the maximum height available.
3 Where the size of the screen permits, the screen may be hinged such that it can be tilted out
of the chamber for maintenance purposes.
4 The screen shall consist of a series of self cleaning screening bars in a staircase
configuration. Every other bar shall be fixed in a rigid structure and the remaining bars shall
form a robust moveable framework that shall revolve in a reciprocating motion to lift the
screenings step by step to the top for discharge.
5 A sealing plate shall be provided between the outer edge of the screen and the walls of the
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screening chamber. The plate shall enclose the drive mechanism on the upstream side of
the screen to prevent fouling by debris. Chain drives, if used, shall incorporate means of
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adjustment to compensate for chain wear. Tension screws shall be provided and shall be
manufactured from stainless steel.
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6 The screen shall be designed to prevent blockage at the base by grit or stones and shall be
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constructed of stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN

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10084).
11.2.7 Straight Bar Screen
1 The straight bar screen may be vertical or inclined and shall comprise a stationary bar rack
or grid which is automatically cleaned by one or more power operated rakes.
2 The screen bars shall be at the centres as specified in the Contract and fabricated from
stainless steel to BS 970, Grade 316 S31 (partially replaced by BS EN 10084).
3 The screen may be front or back raked. In the case of reciprocating rake machines, the
rakes shall clear the bars on the down stroke and engage positively with screen bars prior to
the upward stroke. A wiper mechanism shall ensure that the rake is cleared of all screenings
before continuing its cycle.
4 The cleaning rake shall be jam proof type, chain driven, suitable for either front or back
cleaning, and shall be formed of stainless steel with teeth of adequate length and section
bolted on for easy replacement.
5 Chain driven screens shall be provided with chain tensioners and have provision for manual
adjustment in the event of chain stretching.
6 Tracked rake carriages shall also be provided with wheel adjustment so that engagement in
the channels of the track can be optimised.
11.2.8 Covered Skip Containers
1 Covered skips shall be suitably sized and fabricated from steel sheets of sufficient thickness
to withstand full volume of screenings or grit loading and the stresses of movement and
dumping of the screenings and grit.
2 The shape and dimensions of the skip containers shall be compatible with the configuration
of the screenings and grit dewaterers so that discharge to the skip containers occurs without
spillage. The skips shall have a nominal length of 3.6m, nominal width of 1.8m and nominal
liquids capacity of 3.6m3 and shall be suitable for use with Government of Qatar standard
skip transporting vehicles.
3 Skip containers shall have rubberised castor wheels, with a minimum wheel diameter
150mm.
4 Skip containers shall be epoxy coated in accordance with Section 8, with a minimum of at
least 3 epoxy coats.
5 Covered skips shall be interchangeable between the screens and grit removal applications.
6 Skips shall be subject to a 5 year replacement guarantee under regular use by the Client,
provided that the skips are not subjected to misuse.
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11.3 SCREENINGS TRANSFER SYSTEMS
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11.3.1 Screening Trough

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1 Screenings shall be discharged from the screens into a screening trough for water borne
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transfer to the washer/compactors. The trough shall be made of minimum 6 mm thickness

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stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084) plate with
bolted removable access cover sections.
2 Water for flushing the screenings from the screen discharge collection point to the
washer/compactor shall be 6mm screened sewage, treated sewage effluent or potable water
as specified in the Contract. Screened sewage shall only be used with the approval of the
Engineer and the Contractor shall take all necessary measures to eliminate odour release
and to treat any odours that are released.
3 The trough shall be supplied with two inspection ports having dimensions of approximately
100 mm by 500mm. A 25 mm pipe flushing connections shall be provided at each end of the
drainage collecting trough to allow washing/cleaning of the trough.
11.3.2 Conveyor Belt
1 Conveyor belts shall be of 3-ply standard endless conveyor belting (joints to be vulcanised),
reinforced with fabric between plies of width 800mm and a thickness of 20mm (upper ply-
contact surface 7mm, middle ply 8mm and bottom ply 5mm thickness). This conveyor shall
be incorporated with SS side plates, doctor blades, troughing and stainless steel return
idlers, adjustable tail pulley and a motorized head pulley permitting rotation in both
directions. The conveyor shall be mounted on stainless steel frame work.
11.4 SCREENING WASHER/COMPACTORS
11.4.1 Screening Washer/Compactor
1 Screenings compactors shall consist of an inlet hopper, high energy washing zone, screw
compactor, electric motors and reduction gear drive unit, discharge pipe, drain connections
and water spray system. The whole unit shall be factory assembled and tested prior to
shipment. The unit shall be designed to wash faecal and organic matter from the screenings
before compaction and discharge through a chute suitable for use with a standard skip.
2 The washing impeller and its drive unit shall be hinged from the tank for ease of
maintenance.
3 A drain shall be installed at the lowest point of the wash tank, be fitted with a knife valve and
shall be piped, together with the wash water overflow, to a local drain point.
4 The dewatering compartment shall be a screw compactor operating in a trough with

maximum 6mm diameter perforations for drainage. The compactor screw shall be fitted with
a hard wearing brush on the periphery of the screw blades to ensure free drainage is
maintained. The brush shall be arranged to allow adjustment for wear.
5 The compactor will have a minimum capacity as required by the volume of screenings
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expected to be produced by the contractors proposed screens and will be designed to
provide compacted screenings with a maximum moisture content of 50% and a maximum
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faecal content of 5%.

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6 The compactor screw shall be constructed of stainless steel flights welded to a stainless
steel solid shaft. The screw shall extend a minimum of 600mm beyond the end of the
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dewatering zone. The pressing zone shall be a cylindrical stainless steel pipe rising towards
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the discharge chute. Stainless steel shall be Grade 316 S31 to BS 970-1 (partially replaced
by BS EN 10084).
7 The discharge pipe shall be made of stainless steel and shall use long-radius fittings
designed to avoid any jamming of the partially dewatered/compacted screenings. The
discharge pipe shall be easily disassembled to clear blockages and shall terminate in a
position or manner such that a standard skip can be easily removed from below it.
11.4.2 Washer/Dewaterer
1 Washer/dewaterers shall be of the two stage brush and perforated plate type and fabricated
from stainless steel with removable GRP access covers.
2 The first stage, (washing stage) shall contain the rotating brush assembly fitted with four
polypropylene brushes, and the second stage, (dewatering stage) shall contain a rotating
rubber roller assembly fitted with four tensioned rollers.
3 The screening panels shall be manufactured from stainless steel with 3mm perforations.
4 The machine shall be complete with integral inspection walkway, access ladder and
handrailing, the walkway width being 900mm minimum. Where duty and standby machines
are specified a common walkway may be sited between the machines, however the
machines must be of sufficient height to allow discharge of the screenings into a common
skip.
5 The filtrate shall collect in the bottom of the machine and discharge through a NP16 flanged
outlet of 100mm n.b. A 100mm n.b. overflow outlet, flanged to NP16 shall also be provided
above the centre line of the machine. Pipework shall be of stainless steel.
11.5 GEAR REDUCER
1 The screens and washer/compactors shall be powered by an electric motor and gear
reducer.
2 The gear reducer shall include anti-friction bearings with high overhung load properties and
oil-seal, double-lip, high temperature synthetic riding on precision ground shaft, to minimise
leakage possibilities. The speed reducer shall be enclosed in a cast iron weatherproof
casing. Gears shall be made of hardened and heat treated forged steel. The gear reducer
shall not be overloaded under any normal operating conditions and shall be designed for
heavy-duty service. The gearing shall be oil lubricated.
11.6 MOTORS
1 Motors shall have Class F insulation and be rated for continuous duty operation. They shall
conform to the requirements of Section 21 of the specification and the recommendations of
the manufacturer.
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2 Motors shall be sized so that under maximum continuous loading the motor rated power is a
minimum of 50 % greater than the driven load.
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11.7 CONTROLS
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1 All necessary controls shall be incorporated in an FBA as described in Section 21.

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2 The controls shall include all the necessary relays, starters, timers, indicators, breakers,
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switches and fuses and all other electrical accessories required to make the system
complete and perfect in every way.
1 The equipment delivered to Site shall be examined by the Engineer to determine that it is in
good condition and in conformance with the approved working drawings and certification. All
equipment shall be installed in strict accordance with Part 1 of this Section 9.
11.8.2 Testing
1 Test Procedures shall be in accordance with Part 1 of this Section 9 and the particulars of
the Contract.
END OF PART
Part 12: Grit Removal Equipment
12 GRIT REMOVAL EQUIPMENT...................................................................... 2
12.1 GENERAL ...................................................................................................... 2

12.1.1 Scope 2
12.1.2 References 2
12.1.3 Submittals 2
12.2 PRODUCTS ................................................................................................... 2
12.2.1 General 2
12.2.2 Hydro Dynamic Separator 3
12.2.3 Vortex Grit Separator 3
12.2.4 Cross Flow Grit Removal 4
12.2.5 Screw Grit Classifier 5
12.2.6 Reciprocating Rake Grit Classifier 6
12.3.2 Testing 6
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12 GRIT REMOVAL EQUIPMENT
12.1 GENERAL
12.1.1 Scope
testing and commissioning of grit removal equipment.

Section 1 General
12.1.2 References
BS 970 (ISO 683) .......Wrought steels for mechanical and allied engineering purposes.
BS EN 10084 .............Case hardening Steels
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12.1.3 Submittals
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12.2 PRODUCTS
12.2.1 General
1 Grit removal equipment shall comprise vortex grit separators, sized to achieve the specified
operating criteria and each shall operate in conjunction with a grit classifier.
2 The Contractor shall make his own assessment of the amount of grit which will be produced
by his equipment and the design of the grit handling systems shall be sized accordingly.
3 Grit separators shall be complete with all necessary ancillary equipment and controls.
(MCC).
5 An interlock shall be provided between the grit removal device and the grit classifier.
12.2.2 Hydro Dynamic Separator
1 The grit separator shall be designed to efficiently remove grit from waste water inflows to
protect downstream components of the Treatment Plant. They shall utilise the special
characteristics of controlled hydro dynamic flow, to separate settleable solids and operate at
high hydraulic loadings to minimise facility space requirements.
2 The separator shall have no moving parts and require no maintenance. Grit separation shall
be accomplished entirely by the unit geometry and hydraulic flow regime. The tangential
inlet and overflow design shall ensure that vortex flow develops and that no short circuiting
through the unit can take place.
3 The flow shall enter through the tangential bottom inlet pipe, spiral and rise through the
separator, flows through the annular opening created by the conical section and the overflow
floor, over the overflow weir and out through the de-gritted overflow pipe or channel.
4 Grit and other settleable solids shall drop to the sloped bottom and be concentrated into the
unit sump. The concentrated grit shall be removed from the sump using a grit pump or airlift
pump.
5 A tangential inlet shall induce a vortex flow pattern within the separator hence creating ideal
conditions for the potential currents of a vortex funnel. The resulting flow patterns shall be
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well defined and low in turbulence leading to favourable conditions for grit settling.
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6 A conical section extending into the interior of the vessel shall be used to stabilise the
secondary currents and increased the boundary surfaces to induce further grit settling.
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7 The collected and concentrated grit in the sump shall be pumped to a screw classifier which
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shall be used to wash and classify the grit in order to minimise organic solids concentrations
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in the grit discharge.
8 All internal parts and weirs shall be stainless steel Grade 316 S31 to BS 970-1 (partially
replaced by BS EN 10084).
12.2.3 Vortex Grit Separator
1 The circular tank grit trap shall be supplied complete with geared motor, gearhead assembly,
impeller drive tube, impeller, air blower and airwash/airlift assemblies.
2 The grit trap shall be designed such that the headloss is less than 7mm. The design shall be
capable of removing grit from screened sewage and depositing grit into the grit classifier.
3 The grit removal chamber shall have inlet and outlet separated by greater than 270o of the
tank periphery. There shall be a sloping floor connecting the upper and lower sections.
4 The grit removal device shall be fitted with a rotating impeller. The impeller shall be
manufactured in two halves and shall be clamped to the drive tube when fully assembled.
The stub shaft should not have any supporting bearings under the water and should be
hanging from the gear head assembly.
5 The impeller shall be fitted with four fixed blades set at an angle of 30o and provide sufficient
washing action to prevent lighter solids entering the classification gap between impeller and
grit hopper whilst allowing settled grits through for collection.
6 The impeller blades shall create a slight upward flow in the central zone of the upper
chamber whilst leaving the outer annulus of the upper chamber quiescent to allow grit
settlement.
7 The impeller shall be driven by a helical geared motor with a service factor of 2.0 or greater.
The geared motor shall be fully weatherproofed and shall be oil lubricated and the drive shall
incorporate a slewing ring bearing and helical spur gearing transmission. Torque limiter to
be provided for protecting the drive unit.
8 An airwash/airlift assembly shall be provided to facilitate grit washing and removal. The
assembly shall consist of an airlift pump discharge pipe, minimum 100mm diameter, with
airwash and airlift headers. Separate air supply lines consisting of minimum 38mm diameter
pipe shall connect to the airwash and airlift header. The airwash header shall discharge an
adequate quantity of air for air washing of the collected grit. Each air delivery line shall
terminate above the drive gear head and connected to a three way ball valve, minimum
38mm diameter, with automatic operation.
9 The Contractor shall supply a displacement blower and pipework to provide air for the
airwash/airlift operation. The blower shall have the capacity to provide sufficient quantities of
air at the required pressure to ensure efficient operation of the airwash/airlift system.
10 All internal parts and weirs shall be stainless steel Grade 316 S31 to BS 970-1 (partially
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replaced by BS EN 10084).
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12.2.4 Cross Flow Grit Removal
1 Cross Flow Grit Removal Equipment shall be designed to achieve an optimum sewage
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velocity to enable the complete satisfactory settlement of the specified fine grit particles.
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2 Each arm assembly shall be equipped with a sufficient number of scraper flights such that
they will be capable of removing up to 50 mm of grit from the floor of the grit settlement tank
into a grit sump.
3 The Contractor shall supply and install all the equipment necessary for its operation inclusive
of bridge, scraper arms, drive assembly, inlet guide vanes, tubes, pipes, grit pump and
fixings etc.
4 The plant shall be designed for installation in a circular flat-bottomed tank.
5 The approach velocity into the detritor shall be 1.2m/s with a maximum horizontal velocity
across the tank not exceeding 0.3m/s unless stated otherwise in the Contract Documents.
6 The inlet shall span the diameter of the tank and be equipped with inlet deflectors which shall
evenly distribute the flow across the whole width of the tank. The deflector support
channels, spindles and sleeves complete with concrete guide vanes shall be supplied and
installed by the Contractor.
7 The bridge structure shall be constructed from stainless steel section braced together. The
beams shall be designed to withstand the total loadings imposed by the bridge and its
associated equipment plus a super-imposed load of 250kg/m2 (equivalent to two men)
without exceeding a total deflection of 1/360 of the bridge span.
8 The access walkway shall comprise stainless steel non-slip floor plates fixed to the bridge
structure and supporting double row handrailing which shall comply with Section 8 Part 6.
9 The centre bearing assembly shall be designed to withstand the total loading of the rotating
scraper arms and other forces associated with the plant in operation.
10 The scrapers shall be driven by a motor/gearbox unit, directly or via a chain drive. In both
cases a torque limiting device shall be supplied to initiate safe plant shut down should a
blockage occur.
11 The peripheral speed of the scraper arm shall not exceed 5m/min.
12 The scraper arms, blades and shaft shall be fabricated from stainless steel and shall
incorporate a scoop at the extreme end to assist in the sweeping of the deposited grit into a
grit sump, or into the classifier hopper, depending on the system design.
13 Duty and standby grit pumps shall lift the grit into the classifier hopper.
12.2.5 Screw Grit Classifier
1 Each grit separator shall have an individual grit classifier. However, the grit delivery
pipework shall be arranged such that if one classifier is out of operation, e.g. for
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maintenance, its associated separator can be connected to another classifier.
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2 The grit classifiers shall be capable of handling the water and grit removed from the grit
separators at the rate discharged by the grit air lift or grit pump.
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3 The grit classifiers shall be a free standing units of the helical screw type which shall
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efficiently deposit dry organic free grit to a skip positioned beneath the discharge chute.
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4 A wash water supply shall be connected into the classifier to assist with washing the grit.
The units shall be provided with a valved washout drain at the lowest point which shall be
piped, together with the wash water overflow, to a local drain point.
5 The screw drive unit shall be mounted at the upper end of the screw trough. The whole of
the unit shall be guarded over its whole length.
6 The screw conveyor shall use a shaft-less screw resting on wearing surfaces. The screw
device shall not have a submerged end bearing.
7 The screw shall be formed in stainless steel Grade 316 S31 to BS 970-1 (partially replaced
by BS EN 10084) plate of 8mm minimum thickness and the trough of a similar metal in 6mm
plate.
8 The wearing surfaces in the screw trough shall be easily replaceable and formed of high
density polyethylene (HDPE).
9 The screw shall be fitted on one bearing placed in the drive unit. The bearing shall be a
combined thrust and radial type sufficient to accommodate the total axial and thrust loading.
10 The screw conveyor shall have adequate accessibility for maintenance.

12.2.6 Reciprocating Rake Grit Classifier
1 Reciprocating rake grit classifiers and cleaning mechanisms shall comprise a multiple-rake
reciprocating mechanism mounted within the cleaning channel constructed parallel to the
direction of flow and integral with one side of the cross flow grit settlement tank. The
mechanism shall be inclined and deposit clean grit into the collecting skip positioned below
the grit discharge. The discharge point shall be above Top Water Level. The grit shall be
separated from the organic matter by the washing action of the reciprocating rake and
suitable means of returning organic matter to the collecting tank shall be provided, together
with the necessary built in pipework, screen and washwater pump.
2 The rake and blades shall be fabricated from stainless steel section and shall be suspended
from the drive unit by connecting rods and bell cranks.
3 The classifier shall be driven by a motor/gearbox unit with torque unit switch via a crank
mounted on the output shaft; balance weight arms, secondary output shaft; bellcrank and
rake hangers.
4 The entire reciprocating mechanism shall be totally enclosed to prevent accidental contact
and release of odours.

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12.3.2 Testing
the Contract.
END OF PART
Part 13: Aeration Equipment
13 AERATION EQUIPMENT .............................................................................. 2
13.1 GENERAL ...................................................................................................... 2

13.1.1 Scope 2
13.1.2 References 2
13.1.3 Submittals 2
13.2 PRODUCTS ................................................................................................... 2
13.2.1 General 2
13.3 SHAFT ROTOR AERATORS ........................................................................ 3
13.3.1 Rotor Aerators 3
13.3.2 Aeration Tank Baffle 4
13.3.3 Vertical Shaft Surface Aerators 4
13.3.4 Floating Aeration Devices 4
13.4 SUBMERSIBLE AERATION DEVICES ......................................................... 5
13.5 AIR BLOWERS OR COMPRESSORS .......................................................... 5

13.5.1 General 5
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13.6 AIR PIPEWORK............................................................................................. 5
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13.6.1 Intake Ducting 5

13.6.2 Discharge Pipework 6
13.6.3 Blower Manifold 6
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13.6.4 Air Supply Main 7

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13.6.5 Distribution Pipework 7

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13.6.6 Flow Control and Isolation 7

13.7 AIR DIFFUSERS............................................................................................ 8
13.7.1 General 8
13.7.2 Fine Bubble Air Diffusers 8
13.7.3 Tubular Membrane Diffusers 8
13.7.4 Plate Membrane Diffusers 9
13.7.5 Coarse Bubble Air Diffusers 9
13.8.2 Testing 10
13 AERATION EQUIPMENT
13.1 GENERAL
13.1.1 Scope
testing and commissioning of equipment to dissolve oxygen into liquids using air.

Section 1 General
Section 8 Sewerage
13.1.2 References
BS 3170 .....................Specification for flexible couplings for power transmission
BS EN 10084 .............Case hardening steels
BS EN 779 .................Particulate air filters for general ventilation
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13.1.3 Submittals
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13.2 PRODUCTS
13.2.1 General
1 The works shall be complete with the appropriate number of air blowers, pipework, fittings,
valves, diffusers, control equipment and all the necessary ancillaries to make the plant
complete.
2 The aeration devices selected by the Contractor shall be based on achieving maximum
oxygen transfer efficiency for the design liquid depth. The minimum oxygenation rate in clean
water shall be 2.0 kgO2/kW.h at 20ºC
3 Upon selection of a particular aeration device the Contractor shall provide sufficient test data
demonstrating the oxygen transfer efficiency of the aeration device at the design liquid
depth. Tests shall have been carried out in accordance with the requirements of the
American Civil Association standard “Measurement of Oxygen Transfer in Clean Water” test.
If the contractor is unable to provide evidence that their equipment has been tested in this
way the Contractor shall undertake an oxygen transfer test in clean water in accordance with
the American Civil Association standard at an approved testing laboratory.
4 The sizing and number of aeration devices shall be dependent upon the oxygenation
requirements of the process.
5 The Contractor shall supply the Engineer with all supporting design calculations and criteria
used to determine the type and size/no. of aeration devices selected for approval.
(FBA).
7 The Contractor shall design, supply and install the optimum number and configuration of air
blowers to give the best whole life cost and maintain the integrity of the process.
8 The Contractor shall provide standby facility at all control valves and shall, insofar as is
possible, design and select the valves to be identical to rationalise maintenance.
9 Stainless steel shall be Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084)
unless otherwise stated.
13.3 SHAFT ROTOR AERATORS

13.3.1 Rotor Aerators
1 The rotor shall be suitably sized for the process requirements up to a maximum of 9 metres
in length. The rotor shall be suitable for immersion at depths of 0-300mm
2 The rotor shaft shall be of stainless steel sealed at both ends and suitably strengthened
along its length to minimise the effects of torsion.
3 The shaft shall be supported at the drive end and non-drive end by cylindrical roller bearings.
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4 Stainless steel aeration blade elements shall be equi-spaced around the circumference and
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along the length of the drive shaft.
5 In order to minimise the effects of clogging of the aerator, the aeration blades shall be fixed
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6 The aeration blades should be positioned such that pulsating torque transferred to the drive
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shaft, caused by the action of their immersion in the process liquid, is prevented.
7 The drive unit shall comprise a helical geared reduction gearbox. Design of the rotor/drive
unit shall prevent contamination of the drive unit from sludge thrown by the rotor.
8 Splash type lubrication of the gears shall be facilitated by means of an oil bath.
9 Shaft bearings shall be protected against water ingress by the provision of rubber lip seals.
10 Bearings shall be roller or angular contact type, designed for a B10 life expectancy in excess
of 100,000 hours.
11 Steel foundation plates shall be provided beneath the drive mechanism suitable for fixing by
anchor bolts.
12 Power transmission from the reduction gearbox to the rotor shall be via a flexible coupling.
The coupling shall be designed to minimise the transmission of vibration from the rotor to the
drive unit. The flexible coupling shall be in accordance with B.S.3170.
13 The end of the rotor shaft shall be fitted with a split pattern self aligning bearing assembly.
14 The bearing unit shall consist of a cast iron housing and grease lubricated heavy duty double
row roller bearing with lip seals. Locking collars shall be provided.
15 The rotor unit shall be fitted with GRP splash guards which shall be positioned along the full
length of the rotor between the top of the rotor and the underside of the walkway.
16 GRP covers shall be provided for the drive unit, bearings and end bearing assembly.
13.3.2 Aeration Tank Baffle
1 An aeration tank baffle shall be provided to direct surface velocities downwards thus
maintaining the necessary flow velocities for the depth of tank specified in the contract.
2 The baffle shall cover the full width of the tank and be fabricated from stainless steel.
3 The baffle shall be provided complete with all necessary fixing bolts and brackets.
13.3.3 Vertical Shaft Surface Aerators
1 The aerator shall comprise a central deflector/cone complete with profiled blades. The aerator
shall be of all-welded construction. Alternatively the impeller shall be the centrifugal screw type
comprising a central shaft to which a spiral vane is fully welded along its length
2 The aerator impeller shall be fabricated from stainless steel.
3 Cross baffles for use with the aerator impeller shall be fabricated from stainless steel and shall
be of all-welded construction suitable for bolting to the aeration tank floor.
4 In order to promote mixing of the process liquid and to avoid short circuiting, up-draught tubes
shall be fitted below the aerator impeller.
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5 Up-draught tubes shall be manufactured from stainless steel or GRP and be suitable for bolting
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to the tank floor via adjustable mounting brackets.
6 Stainless steel tie rods suitable for bolting to the tank structure shall be provided complete with
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7 The drive shaft shall be fully welded construction manufactured from steel tube and plate.
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8 The drive shaft shall be connected to the reduction gearbox via a fixed coupling.
9 The drive unit shall comprise a helical geared reduction gearbox.
10 The drive unit shall be fitted with a 3 phase high efficiency motor complying with the
requirements of Section 21.
11 Where specified by the contract the drive motors shall be suitable for variable speeds via
frequency invertors.
13.3.4 Floating Aeration Devices
1 Where specified vertical shaft type aerators shall be mounted on a floating raft.
2 The raft shall be manufactured from stainless steel box section. The structure shall be suitably
braced for rigidity and interconnections between cross members shall be demountable
3 The raft shall be supported in the process media by use of suitably sized Polyethelene drum
buoyancy aids, or equal approved by the Engineer, which shall be bolted to the raft framework.
4 The raft assembly shall be restrained within the tank structure by means of a minimum of three
stainless steel guy ropes complete with turnbuckles.
13.4 SUBMERSIBLE AERATION DEVICES

1 The aerator shall comprise the following:
(a) Submersible Motor

(b) Impeller
(c) Venturi and / or Diffuser
(d) Air Inlet pipe
(e) Base Support
2 The submersible motor shall be in accordance with Section 21 of this specification.
3 The impeller shall be a turbine type manufactured from stainless steel and suitably profiled to
promote agitation of the media.
4 Where specified by the Contract agitation of the process media shall be by use of a submersible
centrifugal pump which shall be in accordance with Part 3 of this Section 9.
5 The diffuser assembly shall be manufactured from corrosion resistant materials and be rigidly
secured to the drive assembly frame.
6 The diffuser profile shall ensure uniform distribution of the aerated liquid.
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13.5 AIR BLOWERS OR COMPRESSORS
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13.5.1 General
1 Air blowers or compressors shall comply with Section 14 of this Part 9.

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13.6 AIR PIPEWORK

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13.6.1 Intake Ducting
1 The air supply to the blowers will be provided from the air inside the blower room. Individual
air intake ducting shall be supplied for each blower for this purpose.
2 The ducting shall be of stainless steel Grade 316 S31 to BS 970-1 (Partially replaced by BS
EN 10084) supported from the blower room floor and shall include two filters (1 No.coarse
and 1No.fine), silencer and air intake.
3 The combined efficiency for particle removal by the two filters shall suit the requirements of
the blowers and the aeration diffusers selected, but shall not be less than EU4. The filters
shall be of the pad or dry pocket type. The filter enclosures shall be fabricated from stainless
steel and shall be designed for ease of access to the filter elements for
inspection/replacement without dismantling the ductwork.
4 The silencer shall ensure that the noise level described for the blowers shall not exceed
75dBA at one metre. It can be a separately mounted unit or mounted on the common
baseplate with the blower assembly. The casing shall be fabricated from stainless steel
Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084), and shall be approved by the
Engineer. Only reflective or reactive type silencers are to be used. Absorptive or dissipative
silencers shall not be used.
5 The blower room air intakes shall be mounted directly to the wall and shall comprise a fixed
blade weather and sand trap louvre complete with bird screen. The louvre shall be designed
to exclude rain and sand from entering the building. The intake shall be fabricated from
stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084), or a suitable
non-corroding material as approved by the Engineer.
6 Filters shall be tested in accordance with BS EN 779 at the manufacturer's works.
13.6.2 Discharge Pipework
1 Each blower shall be provided with individual discharge pipework, which shall be connected
to a common manifold. The discharge pipes shall be supported from the blower plant room
floor.
2 Discharge pipework shall be stainless steel Grade 316 S31 to BS 970-1 (partially replaced by
BS EN 10084). The supports shall be of steel galvanised after fabrication.
3 Each discharge pipe shall be provided with a suitably sized blow-off valve, non-return valve
and isolation valve.
4 The blow-off valve shall be an actuated butterfly valve and shall be fitted with an exhaust
silencer. The discharge from the silencer shall be at least 2 metres above floor level and
shall be directed vertically upward or mounted in the horizontal plane. The silencer shall
ensure that the noise level of the exhaust does not exceed the level described for the
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blowers.
5 The non-return valve shall be of the wafer check type.

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6 Butterfly valves shall be provided for isolation of the individual pipelines. They shall be
gearbox driven to suitably limit the rate at which the operator can shut off the valve. The
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valves shall be capable of being operated with the operator standing at floor level.
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13.6.3 Blower Manifold

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1 The blower discharge pipework shall tee into the manifold. The manifold shall be installed in
the blower plant room and shall be supported from the floor. The manifold shall be sized for
the duty blowers operating simultaneously delivering air at their maximum output.
2 A valved tapping shall be provided for the fitting of a pressure transducer for monitoring the
pressure within the manifold.
3 If necessary, a silencer shall be installed within the manifold to ensure that the noise level
outside the building, transmitted via the pipework, does not exceed 75dB(A). This shall be
based on the duty blowers delivering at their normal rated output.
4 The manifold shall be fabricated from stainless steel Grade 316 S31 to BS 970-1 (partially
replaced by BS EN 10084). The supports shall be of steel, galvanised after fabrication.
5 Automatic condensate drain traps shall be installed at any location where water can collect in
the discharge pipework/manifold assemblies.
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6 The blower manifold and any other above ground air pipework that exceeds 60 C surface
temperature shall be insulated.
13.6.4 Air Supply Main
1 A supply main shall be provided and shall connect the blower house manifold to the
distribution pipework. The main shall extend from the blower house to the treatment process
units.
2 The supply main shall be sized for the duty blowers operating simultaneously delivering air at
their maximum output and the velocity shall not exceed 20 m/s.
3 A dirt pocket with an automatic condensate drain trap shall be installed to collect and drain
water at the lowest position on the main. A chamber for access to this condensate drain trap
shall be provided.
4 The main shall be laid to an even grade sloping back to the condensate trap.
13.6.5 Distribution Pipework
1 Distribution pipework shall be made from stainless steel Grade 316 S31 to BS 970-1
(partially replaced by BS EN 10084).
2 Additionally, the gauge of the pipes to which the diffusers are to be fitted shall be sufficient to
allow the use of screw fit aeration disc base plates and to withstand local forces generated at
the joints by the flow of effluent over the discs.
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3 The pipework grid shall be broken down into sections, which shall be indicated on the
Contractor's drawings.
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4 Coupling seals shall be manufactured from a rubber compound suitable for long-term
immersion in aerated effluent. If push-fit connections are used they shall be of a design that
inhibits the removal of the spigot piece once inserted into the socket.
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5 Pipework shall be fixed to the concrete floor of the process units by means of stainless steel
pipe supports fixed by means of stainless steel anchor bolts. Pipe supports shall provide a
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means of fine adjustment of the level of the aeration grid.
6 Pipework supports shall be sufficiently numerous to support the grids without sagging and to
allow the pipework to resist mechanical, hydrodynamic and hydrostatic loads without
generating excessive loading in the pipework.
7 The maximum air velocity in any portion of the air distribution pipework shall not exceed 20
m/s. When selecting connections, consideration shall be given to heat, internal and external
corrosion, expansion and contraction and resistance to all normal and abnormal forces.
8 Each diffuser array shall be provided with condensate drains and purge pipes which shall be
taken above TWL and be accessible from walkways. Protection against siphoning of effluent
into the air main shall be provided. Self-sealing diffusers shall not be considered to meet this
specific requirement.
13.6.6 Flow Control and Isolation
1 Each aeration zone shall be provided with a flow modulation valve to control the flow of air
into each zone as required by the process. The valves shall be of an eccentric plug or iris
type with a linear characteristic across their design flow range.
2 Each aeration zone shall be provided with an isolation valve. Valves shall be of a gate or
butterfly type.
3 Each aeration zone shall be aerated by a series of arrays of diffusers via a dropper. Each
dropper shall have provision for measuring and adjusting the air flow rate to balance the air
flows in the correct proportions over the area of the pocket to maintain adequate mixing.
4 The provisions for measuring and adjusting the air flow rate on each dropper shall be linked
to the SCADA system to achieve remote monitoring and adjustment of each individual
dropper.
13.7 AIR DIFFUSERS

13.7.1 General
1 The size and number of diffusers selected shall provide the necessary oxygen required by the
process.
2 Particular attention should be paid to the number of diffusers selected in order to avoid "dead"
areas within the aeration zone.
3 The diffusers shall be evenly spaced along the floor of each tank and shall provide an air
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flow rate of not less than 2.2 m /hr per m of tank surface area
4 Manufacturers test certificates shall be provided clearly stating the required air flow rate
necessary to achieve even flow distribution through the diffuser.
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13.7.2 Fine Bubble Air Diffusers
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1 Diffusers shall be installed on the distribution pipework. Diffuser holders shall be

manufactured from materials compatible with the distribution pipework. The diffusers shall
be selected for long service with a minimum replacement period of 10 years. Diffusers that
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can be cleaned in situ will be preferred.

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2 The materials of the diffuser shall be non-biological and resistant to sewage and its by-
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products and the membrane shall be manufactured from EPDM. The membrane
perforations shall be formed such that tearing of the material is minimised. The diffusers
shall be fitted with either integral non-return valves, or similar system, which are capable of
automatically sealing and preventing water ingress into the air piping if the air pressure falls.
3 The maximum air flow rate through each diffuser shall not exceed the rated design flow for
3 2
the diffuser or 175m /hr of air at standard conditions per m of effective membrane area,
whichever is the lower.
13.7.3 Tubular Membrane Diffusers
1 The aerator shall consist of the following:
(a) Membrane holder complete with air distribution holes.

(b) Membrane
(c) Clamping rings
2 The membrane holder shall be manufactured from stainless steel.
3 The membrane properties shall be as 13.7.2.2 above.
4 The membrane holder shall incorporate an integral check valve to prevent backflow of process
media into the diffuser grid pipework.
5 The membrane holder shall be fixed to the distribution pipework via a threaded nipple or via
threaded pipe adaptors and stainless steel tie rods complete with stainless steel nuts bolts and
washers.
6 The membrane shall be retained to the holder via stainless steel clamping rings.
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7 The diffuser shall be suitable for operating at flow rates of 1.0 to 15.0 m /hr.
13.7.4 Plate Membrane Diffusers
1 The size and number of aeration devices selected shall provide the necessary oxygen required
by the process.
2 The aerator shall consist of the following:
(a) Diffuser trough

(b) Membrane
(c) Stiffening plate
(d) Seal
(e) Retaining Clamps
3 The diffuser trough shall be fabricated from stainless steel plate. The trough shall comprise
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suitable brackets for bolting the diffuser assembly to the delivery pipework.
4 The membrane properties shall be as 13.7.2.2 above.

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5 The membrane shall be supported by means of a stainless steel stiffening plate which shall
contain air distribution holes to uniformly distribute the air across the area of the membrane.
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6 The distribution holes shall be positioned relative to the membrane perforations such that
backflow of the process media during loss of air supply is inhibited.
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7 The membrane assembly shall be sealed into the diffuser trough by means of a profiled rubber
gasket.
8 The membrane assembly shall be retained in the diffuser trough by means of stainless steel
clamps. The number of clamps shall be dependent upon the length of the diffuser. The clamps
shall be equi-spaced along the length of the diffuser.
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9 The diffuser shall be suitable for operating at flow rates from 1.0 to 25.0m /hr.
13.7.5 Coarse Bubble Air Diffusers
1 The air diffuser consists of two simple parts, the diffuser body assembly and the flexible
check diaphragm. Both parts are molded together so no separation can occur. During
aeration, the diaphragm rises allowing the air to exit through the orifice of the disk body.
When the air stops, the diaphragm is instantly seated against the diffuser body by the
pressure of the liquid, preventing backflow and clogging. The formation of the air check
diaphragm will allow double shear of the discharged air from the orifice, along with assisting
in reducing the requirements of maintaining each diffuser level for proper air distribution.
The air diffuser material shall be adequate to prevent plugging and resist brittleness or
growing of the diaphragm through absorption of chemical components in the liquids.

13.8.2 Testing
the Contract.
2 Where specified in the Contract the aeration system shall be tested as follows:
3 The aeration tank shall be cleaned of any contaminants which may inhibit successful testing.
The use of synthetic detergents for this purpose is not permitted.
4 The aeration tank shall be filled with the required test volume of potable water/final effluent.
5 The dissolved oxygen monitoring equipment shall be calibrated: at zero D.O. using water de-
aerated with sodium sulphite solution; at saturation, with aerated water after prolonged and
vigorous aeration; and at 50 % saturation, achieved by vigorously aerating water with a gas
containing 10.5% oxygen in nitrogen.
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6 Calibration results should show a linear relation between D.O. meter and concentration of D.O.
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Deviations shall require recalibration, checking of the probe including necessary refurbishment,
checking of any temperature compensation. Calibration shall be undertaken under the same
temperature conditions as those envisaged within the tank.
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7 Multiple probes shall be utilised and distributed evenly throughout the tank.
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8 Once the necessary equipment is positioned and the required volume of potable water/final
effluent is added to the tank the air saturation equilibrium concentration of D.O. shall be
checked. The water temperature shall also be measured.
9 A strong solution of sodium sulphite shall be made in warm water, if possible. The required
quantity shall be sufficient to provide 20% excess over the stoichiometric amount required for
deoxygenation. The mass of anhydrous sodium sulphite in Kg is therefore: -
Volume of tank x D.O concentration in mg/l (prior to addition of sulphite) x 7.88 x 1.5
1000
Note: excessive sodium sulphite addition will result in a longer oxygen uptake.
10 A strong solution of cobalt chloride, to act as a catalyst, should be added to the tank sufficient to
give a concentration of 0.5mg/l. The mass required is therefore:
Mass CoCl2 (g) = 2 x tank volume
11 The chemical solutions shall be distributed evenly through the aeration tank. Rapid addition at a
single point is not permitted.
12 At the start and end of each test the temperature of the water shall be measured to the nearest
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0.1 C and the barometric pressure to the nearest mm of mercury.
13 The aeration equipment shall be activated and the airflow rate, temperature and pressure
shall be closely monitored. In the case of mechanical aeration equipment the power drawn
shall be monitored.
14 The dissolved oxygen probes shall be connected to a multi channel potentiometer recorder. The
increase in dissolved oxygen levels shall be monitored until the air saturation is reached (after
approx 6/kLa hours). At 90% saturation a sample of liquid shall be taken to examine the quantity
of residual cobalt.
15 When the test liquid has reached air saturation level a sample shall be taken and the
concentration of dissolved oxygen shall be determined using the modified Winkler method.
16 The recorded concentrations of D.O. and calculated or measured values of saturation

concentrations results shall be plotted as graphs of loge of D.O. deficit against time for D.O.
values from 20 to 80% of the saturation value for each probe. The slopes of these graphs shall
be used to calculate separate values of KLa as described by the equation:
-
loge Cs - Ct =-KLa t(min 1)
Cs - Co
17 The average of the KLa values plotted shall be used to determine the KLa of the aeration
system.
18 Cs shall be calculated using the following equation:

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Cs = 468
31.6+T
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19 Following the determination of KLa and by applying the correction factor the oxygenation
capacity of the system shall be calculated using Oc = KLa.V.Cs
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20 The aerator shall be + or - 10 % of the contractors stated values for oxygenation capacity. If this
tolerance is exceeded the Contractor shall provide rectification at his own expense.
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21 Where the aeration equipment is a mechanical device the Contractor shall also demonstrate
that the minimum velocity across the aeration tank floor of 60mm/s is achieved. If this velocity is
not achieved the Contractor shall provide rectification at his own expense
END OF PART
Part 14: Air Blowers & Compressors
14 AIR BLOWERS AND COMPRESSORS ........................................................ 2
14.1 GENERAL ...................................................................................................... 2

14.1.1 Scope 2
14.1.2 References 2
14.1.3 Submittals 2
14.2 PRODUCTS ................................................................................................... 2
14.3 AIR BLOWERS .............................................................................................. 3

14.3.1 Centrifugal Blowers 3
14.3.2 Positive Displacement Blowers 4
14.4 AIR COMPRESSORS.................................................................................... 5
14.4.1 General 5
14.4.2 Reciprocating Compressors 5
14.4.3 Rotary Compressors 5
14.4.4 After Cooler 6
14.4.5 Air Receivers 6
14.4.6 Fabrication Requirements 7
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14.4.7 Booster Compressor 7
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14.5.2 Testing 8
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14 AIR BLOWERS AND COMPRESSORS

14.1 GENERAL
14.1.1 Scope
testing and commissioning of air blowers and compressors.

Section 1 General
14.1.2 References
BS ISO 10816 ...........Part 1 and Part 3, Mechanical vibration in rotating and reciprocating
machinery
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BS 1123 ....................Safety valves, gauges and fusible plugs for compressed air or inert
gas installation
BS 5169 ....................Specification for fusion welded steel air receivers
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BS 5493 .....................Code of Practice for protective coating of iron and steel structures
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against corrosion
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BS EN ISO .................Paints and varnishes. Corrosion protection of steel structures by

protective paint systems
BS ISO 1217 ..............Displacement compressors. Acceptance tests
BS1042 ......................Measurement of fluid in closed conduits
ISO 10474 .................Steel & Steel Products Inspection Documents

PD 5500 .....................Specification for unfired fusion welded pressure vessels
British Compressed Air Society's Code of Practice and the Pressure Systems and
Transportable Gas Containers Regulations 1989
14.1.3 Submittals
14.2 PRODUCTS
1 The Contractor shall assess which type and configuration of blowers or compressors that will
offer the best whole life cost benefit for use on the plant to supply the process air
requirements.
2 The number of blower/compressor sets provided shall be sufficient to ensure the full range of
process air requirements can be met and that a minimum of one standby unit for each
application is available at maximum process airflow. Blower/compressor sets shall be the
same model with the same rated capacity for each separate application.
3 The motor rating shall be rated at least 10% greater than the maximum power required
under all climatic and operating conditions.
4 Each blower/compressor set shall be provided with an acoustic enclosure and a surge
protection system. The acoustic enclosure shall limit the noise level to not more than
75Db(A) when measured at 1 metre distance from any point at the enclosure surface at any
time. The enclosure ventilation shall be designed to ensure that adequate cooling of the
blower set is maintained. Consideration should be given to ducting the enclosure exhaust
direct to atmosphere to limit the temperature rise within the blower house to a maximum of
5°C above ambient. The enclosure shall be designed to allow for ease of access to the
blower set, without the necessity to lift the complete enclosure, to allow for routine inspection
and maintenance procedures.
5 The level of vibration in each blower / compressor shall be within the limits and comply with
BS ISO 10816, Part 1 and Part 3.
6 The blower/compressor sets shall be of a proven design with at least five years operational
experience in similar applications. Where multiple units are required to meet the duty in
addition to single duty applications, the design shall be proven in applications where two or
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more units are automatically controlled to meet the varying air demand.
14.3 AIR BLOWERS

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14.3.1 Centrifugal Blowers

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1 Blower sets shall comprise of single stage centrifugal air blowers with modulating powered
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inlet and outlet guide vanes, gearbox, lubrication system, electric drive motor, and suction
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and discharge flexible stainless steel connection compensators, all mounted on a common
baseplate. The sets shall be installed on flexible machine mounts.
2 The volume flow rate from the blowers shall be modulated control on the inlet and outlet
guide vanes which shall be capable of varying the delivery rate down to 45% of the rated
output without causing the blower to go into surge when operating either singly or in parallel.
A high operating efficiency shall be maintained throughout the flow range.
3 Materials and equipments of construction shall give a design running life of at least 100,000
hours before major maintenance is necessary.
4 The impeller shall be statically balanced and the whole rotor shall be dynamically balanced.
The first responsive critical speed of the rotating assembly shall be at least 10% above the
maximum operating speed.
5 The gearboxes shall be of the parallel shaft high speed helical type. The gears shall have a
minimum AGMA service factor of 1.5. A labyrinth oil seal shall be fitted to each shaft to
prevent oil seepage from the casing under operating and static conditions. The seals shall be
designed to ensure there is no contamination of the process air.
6 Each gearbox shall be fitted with an oil level sight glass and a drain plug which shall be
readily accessible in operation.
7 The baseplate shall be provided with lifting points to allow the complete set to be handled
using chain slings.
8 Instrumentation for the safety monitoring of air blowers shall include oil temperature, oil level,
air temperature at inlet and outlet from the blower, outlet air pressure, surge conditions,
bearing temperature and vibration and motor running current. The instruments shall provide
signals for the shutting down of air blowers if unsafe conditions arise and for visual indication
of the fault. Additionally, the contractor shall provide all necessary instrumentation for
measuring the airflow from each blower.
9 Each blower shall be equipped with an inlet air filter, automatic unloading device, pressure
relief valve, pressure switch and under load (no flow) detection device to trip the blower in
case of drive/flow failure.
10 Each blower shall be performance tested at the manufacturer’s works, using the control
motors, to BS ISO 1217:1996. Air flow measurement for these tests shall be carried out in
accordance with BS 1042. Blower casings shall be works hydro-statically tested to 1.5 times
the maximum working pressure.
14.3.2 Positive Displacement Blowers
1 The blowers shall be complete with all ancillary equipment which may be required to enable
the units to operate correctly.
2 Blowers shall be air-cooled and of the double rotor positive displacement rotary type with
cast iron casings delivering oil-free air.
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3 Each blower shall be complete with an automatic unloading device, dead-weight pressure
relief valve, spring type pressure relief valve, pressure gauge, pressure switch and non
return valve of the wafer or nozzle ring check pattern.
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4 The blower speed shall not exceed 70% of the maximum designed speed or 2300 rpm
whichever is the lower.
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5 Each blower shall have an under load detection relay or other similar device to trip the
blower in the event of a drive or flow failure.
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6 The blower casing shall be high-grade cast iron adequately ribbed to assist cooling and
avoid distortion. The rotors shall be spheroidal graphite iron with integral shafting. Timing
gears shall be of nickel cast iron positively keyed to the rotor shafts, they shall be accurately
ground with close clearances to prevent interference between rotors.
7 The blower shall be fitted with an oil lubrication system for the bearings and timing gears.
The blower shall be fitted with mechanical seals to prevent the ingress of oil into the rotor
chamber.
8 The lubrication system shall include filling and drain plugs and oil level indicators visible from
outside the acoustic cover.
9 The drive between the blower and motor shall be of the vee belt or flat toothed belt type and
of approved design.
10 The complete blower assembly shall be mounted on steel section frame which shall
incorporate a blower mounting plate, motor adjustment slides and guard support brackets,
the frame is to be supported on anti vibration mounts.
11 An inlet silencer complete with replaceable filter element shall be fitted to each blower, the
silencer shall be fitted with a visual indicator to warn of filter blockage.
12 Outlet silencer shall be fitted to maintain noise levels as low as possible. A flexible coupling
shall be fitted to prevent vibration transmission to the air supply system.
13 Silencers are to be of the reactive type, absorptive type silencers will not be permitted.
14 Components likely to wear in the course of normal operation shall be capable of replacement
with readily available replacement components.
14.4 AIR COMPRESSORS

14.4.1 General
1 The design and installation of the compressed air system shall be in accordance with the
requirements of the British Compressed Air Society's Code of Practice and the Pressure
Systems and Transportable Gas Containers Regulations 1989.
2 Compressors shall be rated to achieve the duty at optimum efficiency and may be selected
from one of the following types unless otherwise specified in the particular specifications:-
(a) (a) Reciprocating Single Stage

(b) (b) Reciprocating Multi Stage
(c) (c) Rotary Screw
14.4.2 Reciprocating Compressors
1 Reciprocating Single Stage Compressors shall be of inherently oil free design. The
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compressor shall be of cast iron construction with aluminium cylinder heads and shall be air
cooled. The unit, complete with electric motor, shall be mounted on a rigid bedplate
incorporating anti vibration mountings. The drive arrangement shall be belt or shaft driven
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and shall be fully guarded. A suitable means of achieving alignment shall be provided and
where appropriate flexible couplings shall be used.
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2 Reciprocating Multi-Stage Compressors shall be as above but incorporate interstage cooling

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and be of the short stroke design for low piston speeds.

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3 Both single and multistage units shall be provided with the following:-
(a) Low oil level cut out switch.

(b) Crank case oil sight glass.
(c) Air inlet filter.
(d) Silencer complete with pressure gauge and low pressure cut out (filter blockage
protection).
(e) Pressure gauge tappings after each stage for compressors up to 15kW, and gauges
and safety valves on compressors over 15kW.
(f) Oil pressure indicator on compressors over 100kW.
(g) Final air temperature indicator on compressors over 100kW.
(h) Unloader valve unit.
(i) Air dryer system (Dehumidifier) where dry air is required.
14.4.3 Rotary Compressors
1 Rotary Screw Compressors shall be of the inherently oil free design and shall be either the
single stage or multi-stage type depending on the duty.
2 The separate stages shall be enclosed in individual housings, the male rotor being gearbox
driven whilst the female rotor is driven via a timing gear.
3 The rotor shafts shall be supported by precision made ball and roller bearings
4 Lubrication to the driving gear, bearings and timing gear shall be via an oil pump driven by
the main shaft. The lubrication system shall be complete with oil filter and cooler, pressure
gauge and fail-safe pressure switch.
5 On multi stage units air cooling shall be undertaken by an intercooler.
6 The compressor shall be motor driven via a flexible coupling and gearbox common to both
stages. A suitable means of alignment shall be provided.
7 The complete compressor set ie. compressor, motor, gearbox and associated cooling
equipment shall be supplied on a rigid bed plate suitable for floor mounting via anti vibration
mountings.
14.4.4 After Cooler
1 All types of compressor shall be fitted with an aftercooler. These shall be of the air cooled
type comprising an air to air heat exchanger. The aftercooler shall cool the process air to a
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temperature of 10 C above ambient. The aftercooler shall be fitted with an automatic
condensation drain which shall be provided with a manual bypass.
2 Delivery lines from the Compressor Sets shall be fitted with the following equipment:-
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(a) Oil trap/filter prior to entry into the air receiver. The filter shall be fitted with an auto
drain and manual by pass.
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(b) Adjustable safety valve (lockable).

(c) A solenoid valve for unloading (dependant upon compressor size) for applications
where the compressor is directly coupled to a surge vessel.
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(d) A non return valve.

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(e) A high efficiency coalescing oil filter (0.001 micron filtration).

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14.4.5 Air Receivers
1 Unless otherwise stated, one air receiver shall be provided, normally being online, but with
the capacity to be isolated from the system.
2 These shall be manufactured from fusion welded steel and shall comply with BS 5169 or
equivalent for the appropriate pressure class.
3 Air receivers greater than 1000 litres capacity shall be designed and manufactured in
accordance with PD 5500 or equivalent.
4 Each integral air receiver shall have sufficient capacity to damp out air pulses from the
compressor and to prevent pressure drops on process valve actuations.
5 The air receivers shall be connected such that the duty compressor delivers into either or, if
two air receivers are specified, both of the air receivers. Diaphragm isolation valves shall be
provided for isolating either of the receivers from the system.
6 The air receivers shall be suitable for floor mounting and shall be supplied with two
inspection ports. The inspection ports shall be of the elliptical type and pressure sealed.
14.4.6 Fabrication Requirements
1 The air compressors shall be air-cooled. The cooling air shall be drawn directly from the
ambient air, routed through the enclosure and exhausted upward through the enclosure box.
The cooling air for the motor shall be drawn directly from the ambient air.
2 The drive motors shall be directly coupled to the air end by flexible coupling.
3 The compressors shall be suitable for indoor installation.
4 Each air compressor shall have an efficient filter for cleaning intake air and micro filter after
the discharge. Each compressor shall be fitted with a silencer, which shall be sized to
prevent excessive pressure drop.
5 All instrument tappings shall be via suitable bosses welded to the tank structure. The vessel
shall be supplied with:
(a) Pressure gauge.

(b) Pressure relief valve.
(c) Drain valve.
(d) Lifting lugs.
6 The vessel shall be corrosion protected to give maintenance free service for a period of 20
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years minimum, as defined in BS 5493 (partially replaced by BS EN ISO 12944) or
equivalent and as specified in Section 8 part 8
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7 Full certification in triplicate shall be supplied with the air vessel. The vessel shall also
feature a stainless steel nameplate containing the following details.
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(a) The manufacturers’ name.

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(b) The date of manufacture.

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(c) The standard to which the vessel was built.

(d) The maximum design pressure.
(e) The minimum design pressure where it is other than atmospheric.
(f) The design temperature
(g) The test pressure
14.4.7 Booster Compressor
1 In case discharge pressure in excess of 15 bar is required, then booster compressors will be
required. Alternatively multistage piston type air compressor can also be proposed. The
booster compressor package shall comprise the following items:
(a) Booster compressor and motor mounted on common base plate.

(b) V-belt drive with guard.
(c) Oil/water separator or after cooler with automatic drainage and associated unloaded
start.
(d) Solenoid valve to close the inlet at standstill.
(e) Safety valve on the oil/water separator or after cooler.
(f) Anti vibration floor mounts.
(g) Suitably sized air receiver.

1 1 The equipment delivered to Site shall be examined by the Engineer to determine that it is
All equipment shall be installed in strict accordance with Part 1 of this Section 9.
14.5.2 Testing
the Contract.
END OF PART
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Part 15: Settlement Tank Equipment
15 SETTLEMENT TANK EQUIPMENT .............................................................. 2
15.1 GENERAL ...................................................................................................... 2

15.1.1 Scope 2
15.1.2 References 2
15.1.3 Submittals 2
15.2 MATERIALS .................................................................................................. 2
15.3 BRIDGES AND SCRAPERS .......................................................................... 3

15.3.1 Scrapers 3
15.3.2 Bridges 3
15.3.3 Walkways 4
15.3.4 Bearings 4
15.3.5 Drive Units 4
15.4 ELECTRICAL EQUIPMENT ........................................................................... 5
15.4.1 General 5
15.4.2 Slip-Ring Current Collectors 5
15.4.3 Emergency Isolator Limit Switch 5
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15.4.4 Motor Decontactor Plug and Socket 5
15.4.5 Parking Switch 6
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15.4.6 Cabling 6
15.5 ANCILLARY EQUIPMENT ............................................................................. 6
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15.5.1 Diffusion Drum 6

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15.5.2 Weir plates and scum boards 6

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15.5.3 Scum Skimmer 7

15.5.4 Scum Collection 7
15.5.5 Effluent Channel Cleaning 7
15 SETTLEMENT TANK EQUIPMENT

15.1 GENERAL
15.1.1 Scope
1 This part specifies the requirement for the design, manufacture, construction, testing and
commissioning of equipment for primary and secondary settlement tanks.

Section 1 General
15.1.2 References
BS 4 Part 1 .................Structural steel sections

BS 449 Part 2 .............Specification for the use of structural steel in building
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BS 970 ......................Wrought steels for mechanical and allied engineering purposes
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BS 7671 .....................Requirements for electrical installations. IEE Wiring Regulations.

Sixteenth edition
BS EN 10029 .............Specification for tolerances on dimensions, shape and mass for hot
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rolled steel plates 3 mm thick or above

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BS EN 10084 .............Case Hardening Steels

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BS EN 10113 .............Hot-rolled products in weldable fine grain structural steels

BS EN 10155 .............Structural steels with improved atmospheric corrosion resistance
BS EN 10210 .............Hot finished structural hollow sections of non-alloy and fine grain
structural steels
BS EN 12020 .............Aluminium and aluminium alloys
BS EN 60947-1 ..........Specification for low-voltage switchgear and controlgear
15.1.3 Submittals
15.2 MATERIALS
1 All reference to stainless steel shall mean stainless steel to BS970 Grade 316 S31 (partially
replaced by BS EN 10084) unless otherwise stated.
2 All reference to aluminium shall mean marine grade aluminium milled finished 6063TF alloy
to BS EN 12020.
3 All materials shall be protected against corrosion in accordance with Section 8 Part 8.
15.3 BRIDGES AND SCRAPERS

15.3.1 Scrapers
1 The tank scrapers shall be of the half-bridge rotating type or fixed bridge type as specified in
the Contract Documents.
2 Non retractable tubular steel arms shall connect the scraper blades to the drive. The
stainless steel scraper blades shall be fitted with removable heavy duty neoprene rubber or
synthetic material hard wearing strips having a minimum shore hardness of 70. They shall
be not less than 20mm thick and shall be fastened to the mechanism in such a way that the
blades may be reversed. The minimum blade life shall be 2 years. Blades shall be arranged
to form a continuous spiral across the floor and vertically up the side wall of the tank. Either
the arms or blades shall be hinged to compensate for minor variations in the tank floor and
side wall. Slotted holes shall be provided on the scraper rubber blades for adjustment
against wear.
3 The two arms of fixed bridge scrapers with any appendages shall be equally balanced
statically and be supported for rigidity using stay rods and turn buckles.
4 The scraper and its driving mechanisms shall be designed to allow for longitudinal and
vertical movements of the bridge.
15.3.2 Bridges
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1 The bridge shall be fabricated from structural steelwork to BS4 Part 1: BS449 Part 2: BS
20
EN10029: BS EN10113: BS EN10155 and BS EN10210.
2 Primary tanks bridges shall be fabricated from stainless steel or from marine grade
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aluminium. Secondary bridges may be fabricated from mild steel, galvanised and painted in
accordance with Section 8.
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3 Fixed bridges shall span the full width of the tank.
4 Rotating half bridges shall be supported at the centre of the tank using a tripod manufactured
from the same material of the bridge. The structure shall be designed to withstand the total
loadings induced by the bridge and other forces associated with the bridge and scraper
when in operation. The top plate of the support structure shall accommodate the centre
bearing assembly and diffuser drum supports.
5 The bridge shall be designed to take a uniform distribution load of 250 kg/m2 in addition to
the weight of the scraper assembly and shall be capable of satisfactory operation under wind
loads, acting horizontally and normal to the total area of exposed surfaces.
6 The maximum permissible deflection with this superimposed load shall not be greater than
1/360 of the bridge span. On removal of the load the bridge deflection shall fully recover and
return to its original mid span position on either side of the bridge.
7 The bridge design shall include provisions to adequately cope with all torsional moments that
it may reasonably be expected to encounter, with a safety factor of 2.0.
8 Fixed bridges shall be constructed with equal mass on both sides of the centre of the tank.
At each end provision shall be made in the design of the supports to allow for expansion and
contraction resulting from temperature differentials of not less than 10C beyond the
recorded maximum and minimum ambient temperatures in the region.
15.3.3 Walkways
1 The bridge structure shall have suitably rated open stainless steel or aluminium walkway the
full length of the structure and the width shall be 850mm, between handrailing.
2 Handrailing shall be manufactured from stainless steel to BS970 Grade 316 S31 (partially
replaced by BS EN 10084) or marine grade aluminium tubes with standards 1100mm above
the walkway, top rail and an intermediate rail 550mm above the walkway.
3 Toeboards 150mm high shall be fitted along both sides of the walkway.
4 Insulation shall be provided as necessary to prevent electrolytic action between dissimilar

metals.
15.3.4 Bearings
1 Fixed Bridges:
Where the feed pipe rises from the centre of the hopper the scrapers shall be supported from
the bridge on a frame around the pipe and shall have at least one steady bearing of
phosphor bronze or stainless steel at the base of the scraper frame. The inner ring of this
bearing shall be bolted to the feed pipe and the outer ring bolted to the scraper frame. All
shafts on the drive system shall have at least two bearings whatever the configuration and
as many guides as are necessary to retain stability.
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2 Rotating Bridges:
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The centre bearing assembly shall be designed to permit both horizontal rotation and vertical
undulation of the bridge structure. The slewing and trunnion arrangement shall be designed
to withstand the total loading of the bridge and other forces associated with the bridge and
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scraper in operation. Lubrication for the pivot pins, trunnions, etc. shall be provided from a
readily accessible grease nipple battery plate.
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15.3.5 Drive Units

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1 For fixed bridges a motor, flange mounted to a reduction gearbox, shall provide the drive.
The motor speed shall not exceed 1500rpm. The motor and gearbox shall be easily
accessible for maintenance.
2 Rotating bridges shall be driven by a double-wheeled drive unit mounted on the end
carriage. The end carriage shall be fabricated from mild steel and incorporate the trailing
rear-driven wheel and the leading driving wheel and shall incorporate guards covering all
wheels to protect from the possibility of wheel nip. The driving wheel shall be driven by a
motor and gearbox unit. Both wheels shall be polyurethane tyred.
3 Gearboxes and motors shall have an ingress protection rating conforming to BS EN 60947-
1: IP55 classification. Gearboxes shall have a life of 100,000 hours and be selected in
accordance with the AGMA recommendations for power calculation and service factor
application, shall incorporate filler cap/breather, dipstick or level plug and drain plug, and
have a noise level of not greater than 65 dB(A) at 1 metre distant in any direction.
4 For fixed bridge drive units the following shall apply:
(a) A drip tray, with gunmetal drain tap, shall be located under the motor and gearbox
reduction unit(s). The drip tray shall be manufactured from stainless steel not less
than 2mm thickness.
(b) Any drive required between the reduction gearbox and the scraper shaft shall be by
pinions and spur wheels or geared slewing rings as appropriate.
(c) The gearbox may be oil or grease lubricated whilst all other bearings shall be grease
lubricated. All grease lubrication pipes shall be manufactured from stainless steel
tube and be terminated at a common location on the bridge at a point which affords
operational access to enable convenient, safe lubrication and be suitably labelled.
(d) The speed of the scraper assemblies measured at the tank periphery shall be. as
follows:
Primary tanks 0.75 – 1.0m/min
Final tanks 0.3 – 2.5m/min fully variable.
(e) The drive system shall incorporate a loss of rotation monitor and an overload
protection device comprising a torque limiting coupling set at the appropriate cut out
torque. The device shall incorporate a switch and alarm indication system drawing
attention to the fact that the torque limiting device has operated.
(f) The gearbox output mechanism shall be restrained by a torque arm fitted with a
weatherproof, strain gauge type torque indicator and electro mechanical overload
contacts.
(g) Guards shall be provided fully enclosing the scraper drive mechanisms.
15.4 ELECTRICAL EQUIPMENT

15.4.1 General
1 Electrical equipment and installation shall comply with Section 21 together with the following
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supplementary clauses.
15.4.2 Slip-Ring Current Collectors

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1 All power supply, controls and signals to rotating bridges shall be fed to/from the bridge via
an underfeed slip ring collector assembly fixed to the stationary centre bearing base plate.
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2 The unit shall comprise phosphor bronze sliprings fitted with spring loaded brush-holders
complete with copper graphite brushes, housed in an overall enclosure with an IP55 rating.
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3 Current rating shall be adequate for starting and running the size of bridge drive motor
chosen by the bridge manufacturer. The assembly shall also be suitable for the transmission
of control signals.
4 The minimum voltage shall be 24v current capability, twelve circuits shall be provided as a
minimum.
5 Cable boxes shall be suitable for accepting cable from below via 25mm cable entry and exit
points.
15.4.3 Emergency Isolator Limit Switch
1 Each rotating bridge shall have an emergency isolator switch mounted on the leading edge
of the drive carriage.
2 The switch shall have an enclosure rating of IP55 and shall be operated by a touch bar
located on the leading edge of the drive carriage. The switch/touchbar assembly will
constitute an emergency stop.
15.4.4 Motor Decontactor Plug and Socket
1 The supply cable to the drive motor shall incorporate a suitably rated weatherproof
decontactor plug and socket.
2 The male section of the unit shall be connected directly to the drive motor using suitably
rated flexible cable. The female socket shall be securely supported in a position to ensure
that the latch button is readily accessible from the bridge.
15.4.5 Parking Switch
1 Each rotating bridge shall be provided with a magnetic proximity switch protected to at least
IP55 standard arranged to ensure that the bridge is parked at a fixed location on the tank.
2 On installations with bridge mounted starters, a parking selector switch must be provided
which is accessible from off the bridge.
15.4.6 Cabling
1 The Contractor shall supply and install all on-bridge cabling from the slipring collector.
Cabling shall be stranded copper 600/1000 volts grade and suitable for the application in
accordance with BS 7671 and specification Section 21.
2 The main cable from the collector shall be a single multi-core which is to be terminated at the
motor end of the bridge with an IP55 junction box. From the terminal box individual three or
two core cables shall be run to the various items of equipment included in the bridge
contract.
3 All cables shall be suitably supported along their length with approved cleats. The spacing
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centres for the cleats shall not exceed that given in BS 7671. Cleats to be of rigid PVC
secured to the bridge structure using stainless steel nuts and bolts. The bridge structure
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must be pre-drilled prior to galvanising to accept the saddle fixings. Crimped terminals shall
be used for all connections.
15.5 ANCILLARY EQUIPMENT

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15.5.1 Diffusion Drum

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1 Diffuser drums shall be constructed in glass reinforced plastic suitably strengthened and
supported from the bridge so as to be positioned in the centre of the tank.
2 The drum shall be sized to be 10% of the total area of the tank and 2m deep. The top of the
diffusion drum shall project 150mm above TWL.
3 The drum skin and flange thicknesses shall be not less than 4mm and 6mm respectively.
4 Two 180 opposed square cut outs with internal baffles above TWL shall be installed in each
drum to enable the removal of grease and sludge.
15.5.2 Weir plates and scum boards
1 'V' notch weir plates shall be supplied for bolting to the tank walls. The weir plate shall have
90o notches equi-spaced around the periphery of the tank and slotted adjustment holes.
The spacing and size of "V" notches should be determined by calculation. The maximum
discharge per notch should be 30-40m3/day to enable uniform outlet conditions.
2 The weir plate shall be 300mm deep and be fabricated from composite plastic or GRP. The
weir plate shall be pre-curved and of minimum thickness 6mm. Sealing strips shall be
provided for installation between the weir plates and the tank wall to allow for discrepancies
in the structure.
3 Scum boards and fixing brackets shall be provided on all tanks. The brackets shall be
stainless steel with stainless steel bolts and be so designed that no fixing is required to the
tank wall within 250mm of the weir level.
4 The brackets shall hold the scum board securely 500mm from the inside face of the weir
wall. The scum boards shall be manufactured from GRP, 305mm deep by 6mm thick pre-
curved and shall be positioned so that 100mm of the scum board is above water level.
15.5.3 Scum Skimmer
1 A scum skimming arm (trailing scum board) shall be attached to the bridge (for rotary bridge)
or to the scraper arm (for fixed bridge) which must maintain contact with the scum board in
all positions. The scum arm shall sweep the scum to a trumpet at the periphery of the tank
which shall automatically discharge the scum via pipework to a scum/grease trap. The blade
shall be fabricated from GRP or stainless steel and shall protrude 100mm above top water
level.
15.5.4 Scum Collection
1 Scum shall be collected in a scum box attached to the tank wall. The scum box shall be
fabricated from stainless steel and terminate with a flanged connection. Scum box flush
shall be provided suitable for operation from either the bridge or tank periphery. Not less
than two scum collection boxes shall be provided at final settlement tanks associated with
Activated Sludge Plants.
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15.5.5 Effluent Channel Cleaning
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1 Where called for in the Contract Documents a spray jet system shall be mounted on the
travelling bridge (or on an extension to the scraping mechanism in the case of fixed bridges),
to clean the outlet channel. The jets shall be fitted with hooded cover plates to prevent
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aerosols being forced upwards. A submersible sewage pump, fitted to the bridge or scraper
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extension shall supply tank effluent to the nozzles. A strainer shall be fitted to the pump. To
allow cleaning of the filter, the pump discharge shall be a flexible hose, to allow lifting of the
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pump from the bridge without dismantling the pipework.
2 Spring loaded polypropylene bristle brushes shall be supplied and arranged to assist in
cleaning of the effluent channel and weir walls without restricting effluent flow. The
assembly shall be fabricated from 316L stainless steel. Springs shall be of stainless steel.
3 Effluent channel cleaning systems shall not be installed in primary tanks unless they are fully
covered and odour controlled.
END OF PART
Part 16: Tertiary Treatment Granular Filters
16 TERTIARY TREATMENT GRANULAR FILTERS .......................................... 2
16.1 GENERAL ...................................................................................................... 2

16.1.1 Scope 2
16.1.2 References 2
16.1.3 Submittals 2
16.2 PRODUCTS ................................................................................................... 2
16.2.1 General 2
16.2.2 Filtration Rates 3
16.2.3 Nozzle Plates 4
16.2.4 Pressure Filters 4
16.3.2 Testing 6
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16 TERTIARY TREATMENT GRANULAR FILTERS
16.1 GENERAL
16.1.1 Scope
testing and commissioning of tertiary treatment granular filters.

Section 1 General
16.1.2 References
BS 970 ......................Wrought steels for mechanical and allied engineering purposes
BS 1780 .....................Specification for bourdon tube pressure and vacuum gauges
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BS 4870 .....................Specification for approval testing of welding procedures
BS 4871 .....................Specification for approval testing of welders working to approved
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welding procedures
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PD 5500 .....................Unfired fusion welded pressure vessels

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16.1.3 Submittals
16.2 PRODUCTS
16.2.1 General
1 Filters shall be of the downward flow sand type and shall include a minimum of two batteries
operating in parallel. Access to valves and pipework etc shall be constructed such that
operation and maintenance can be carried out safely and without obstruction. The
contractor shall be responsible for providing all access walkways and ladders.
2 Unless otherwise specified in the Contract Documents the filter material shall have an
effective size of 1.8mm and a uniformity coefficient of 1.5.
3 Valving, penstocks and associated pipework shall be provided on each filter for raw water
inlet, filtered water outlet, washwater inlet, washwater outlet, air scour, filter slow drain and
air after back wash. All valves shall be butterfly type and with the exception of the slow drain
valve shall be controlled automatically and shall include provision for manual operation.
Valves shall be in accordance with the valves section of this specification. Actuators shall be
electrically operated, quarter turn type. Valves and penstocks shall be positioned to allow for
manual operation from adjacent walkways. The backwash delivery manifold and air scour
delivery manifold shall be fitted with a pressure gauge to BS 1780 or equivalent.
4 Pipework shall be stainless steel, uPVC, HDPE or GRP and in accordance with Section 8 of
this Specification.
5 Filters shall be automatically backwashed using air scour blowers and washwater pumps.
6 The washwater pumps shall draw filtered water from a backwash tank, which shall
automatically be replenished following a wash cycle. The working volume of the tank shall
be equivalent to the volume of backwash water required for two complete wash cycles.
7 The backwash pumps shall be controlled to give a gradual increase in wash cycle. Control
will either be by speed control of the pump motor or by a controlled slow opening valve on
the washwater pipe. A non-return valve shall be included in the delivery pipework.
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8 The air scour pipework shall incorporate a non-return valve, which shall rise to a height
above the filter top water level, before dropping down to the filter and d an automatic drain
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valve at the lowest point to relieve the system of leakage water through the valve, to prevent
process water passing from the filter to the blower.
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9 The backwash delivery manifold and air scour delivery manifold shall be fitted with a
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pressure gauge
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10 Pressure filters shall be provided with a pressure gauge mounted on the front of the vessel
visible from the walkway.
11 Loss of media from the filters is not acceptable. The raw water inlet/washwater outlet shall
be designed to prevent the passage of media during the backwash cycle. The level of the
fluidised bed shall be well below the washwater outlet to prevent sand loss.
12 Flow measuring and recording equipment shall be provided to indicate the flow through each
filter, washwater flow and air scour flow.
13 Rapid gravity filters shall be provided with loss of head measuring instrumentation.
14 Sample taps shall be provided on the raw water inlet / washwater outlet and the filtered
water outlet pipework of each filter. The taps shall be accessible from walkways.
16.2.2 Filtration Rates
1 Filtration rates shall not exceed 7.5 m/hour for single media filtration and 12m/hour for multi-
media filtration. Sufficient capacity shall be provided to ensure that these flowrates are not
exceeded with one unit out of service and one unit backwashing.
2 The maximum allowable solid loading shall be 1.2 kg/m2 between backwashes unless
otherwise specified in the Contract Documents. Depending on the type of media selected, a
variation to the solid loading of 1.2kg/m2 may be permitted provided that reasons
substantiating the variation are clearly stated in the tender as an alternative option.
3 The maximum acceptable number of backwashes shall be ONE per filter per day during
"AVERAGE - CONDITIONS".
16.2.3 Nozzle Plates
1 Where a nozzle plate is incorporated into the design of the filter then the plate shall be
stiffened to withstand sand, surge and backwash pressure loading. Nozzle fixing access
shall be from below. Access through the nozzle plate is not permitted.
2 Where the design of the filter incorporates a nozzle plate, the underfloor section shall be
vented to prevent air pocket accumulation and subsequent major sand disturbance during
the back wash cycle.
3 Laterals and headers shall be uPVC with nozzles for water and air distribution. Support
brackets shall be Grade 316S31 Stainless Steel.
16.2.4 Pressure Filters

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1 Pressure filters shall be all steel, designed, manufactured, inspected, tested in accordance
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with PD 5500 or equivalent.
2 Longitudinal seam welds shall not cross at any intersection with circumferential welds but
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shall be offset a minimum length corresponding to 90o of shell circumference.

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3 Allowance for a vessel life expectancy of 25 years shall be made and the corrosion
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allowance shall be not less than 2.0mm.
4 Pressure filters shall be fabricated from Carbon Manganese steel, and full fabrication details
shall be submitted for approval by the Contractor. The vessel shall comprise two domed
ends with an intermediate cylindrical section. Not less than two lifting lugs shall be provided
for lifting of the complete vessel. Vessels may be vertically or horizontally mounted.
5 The inlet and outlet pipework shall be designed to the same criteria as the pressure filter
terminating in flanged connections. A drain line shall be provided complete with isolating
globe valve and flanged hose connection suitable for a flexible hose of 50mm diameter.
6 Pressure filters shall be supplied complete with associated fittings internal manhole access,
sand door, pressure gauges and air valves.
7 The sand door shall be located at the lower end of the centre cylindrical section of the filter
shell. The underfloor inspection hatch shall be located on the lower domed end of the
vessel.
8 The filter shell shall be mounted on fabricated feet for mounting on pre cast concrete plinths
on the filter room floor at a height to enable man entry into the lower inspection access
hatch.
9 Pressure filters shall be provided with a double acting large orifice air valves.
10 A 150 mm nominal diameter pressure gauge shall be surface mounted on the vessel using a
purpose made mild steel bracket welded to the vessel.
11 The man access shall be of the "T-bolt" closure type of not less than 600 mm internal
diameter with the hinge running parallel to the filter diameter and be provided in the
cylindrical section of the vessel to permit access and located such that internal launders and
bellmouths can be visually inspected without entry into the filter.
12 Both the sand door and under floor inspection hatch shall be of the flanged type and be
provided with a lifting swing davit which shall incorporate a lifting screw, so that the whole
flange cover may be lifted up and then swung out from the entry port. The davit shall be
fabricated onto the cylindrical wall of the vessel.
13 A safety/hand rail shall be located adjacent to the man-way with a fixing for a safety rope.
Each man-way access shall incorporate a traffolite warning notice permanently fixed to the
cover in view of an operative intending to access the vessel. The notice shall state
"WARNING Ensure full isolation and permit to work and depressurisation before entry”.
14 Welding shall only be carried out by Contractors' staff who are qualified and experienced to
undertake this work in accordance by PD 5500 or equivalent by reference to the following:-
(a) BS 4870 or equivalent.

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(b) BS 4871 or equivalent.
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15 The Contractor shall mark clearly with their respective safe working pressure in lettering not
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less than 80mm in height in gloss paint.

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16 A brass plate shall also be fixed to the vessels which will state:-
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(a) Name of manufacturer with address.

(b) Identification number.
(c) Client's Order number.
(d) Shell Thickness.
(e) Corrosion Allowance.
(f) Shell Diameter.
(g) Head Diameter.
(h) Head Thickness.
(i) Head Corrosion Allowance.
(j) Degree of X Ray Inspection.
(k) Tan Length.
(l) Design Pressure.
(m) Hydraulic Test Pressure.
(n) Weight.
(o) Length.
(p) Inspection Date.

(q) Inspectors Initials.
(r) S.W.P.
17 The Contractor shall allow for 100% category 1 radiographic testing.
18 The Contractor shall employ an independent testing authority to oversee the design,
fabrication and testing of pressure vessels as defined in BS5500. The independent testing
authority shall report direct to the Engineer.
19 The Contractor shall make provision for all the necessary work associated with carrying out
the Inspecting Authority's recommendations resulting through the use of PD 5500 or
equivalent in assessing design, manufacturing procedure, documentation and testing of the
vessel.
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equipment shall be installed in strict accordance with Part 1 of this Section 9, the relevant
Parts of this Section 9 for ancillary equipment installed and the manufacturer’s instructions.
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16.3.2 Testing
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1 Test Procedures shall be in accordance with Part 1 of this Section 9 and in addition those
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listed below.
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2 Unless otherwise stated in the Contract Document the performance of the filter shall be
assessed by samples taken from the following points within the works.
(a) Raw water - prior to any treatment.

(b) Individual filters outlet.
(c) Final water into storage reservoir
3 Samples are to be collected using automatic composite samplers over a period of 7 days.
Each sample shall comprise 24 No discreet hourly samples. Spot samples may also be
taken for the performance assessment by the Engineer.
4 The performance of the works will be judged to be acceptable if samples, collected during
the Tests before Completion meet all of the criteria for all the determinants listed in the
Contract Document.
5 Sample collection and analysis shall be undertaken by an approved independent laboratory

at the Contractor’s cost.
END OF PART
Part 17: Sludge Thickening & Dewatering Equipment
17 SLUDGE THICKENING AND DEWATERING EQUIPMENT ......................... 2
17.1 GENERAL ...................................................................................................... 2

17.1.1 Scope 2
17.1.2 References 2
17.1.3 Submittals 2
17.2 THICKENING AND DEWATERING ............................................................... 2
17.2.1 General 2
17.3 GRAVITY BELT THICKENER ........................................................................ 3
17.3.1 General 3
17.3.2 Polyelectrolyte Mixing System 3
17.3.3 Conditioning Tank 3
17.3.4 Drainage Section: 4
17.3.5 Machine Rollers 4
17.3.6 Drive Unit 4
17.3.7 Sludge Scraper and Lift Blades 4
17.3.8 Washwater System 5
17.3.9 Hydraulic Power Pack 5
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17.3.10 Machinery Construction and Materials 5
17.3.11 Ventilation 5
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17.4 CENTRIFUGE................................................................................................ 6
17.4.1 General 6
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17.4.2 Sludge Feed Pumps 7

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17.4.3 Sludge Discharge Arrangements 7

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17.4.5 Washwater System 8
17.5.2 Testing 8
17 SLUDGE THICKENING AND DEWATERING EQUIPMENT

17.1 GENERAL
17.1.1 Scope
1 This part specifies the requirement for the design, manufacture, construction, testing and
commissioning of sludge thickening and dewatering equipment.

Section 1 General
17.1.2 References
BS 970 ......................Wrought steels for mechanical and allied engineering purposes.

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17.1.3 Submittals
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17.2 THICKENING AND DEWATERING

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17.2.1 General
1 The approved methods of mechanical thickening of surplus sludge are:

(a) Centrifuge
(b) Gravity belt thickener
2 The approved method of mechanical dewatering of sludge is by centrifuge.
3 Sludge feed systems shall comprise feed pumps complete with electro-magnetic flowmeters,
interconnecting pipework and fittings. The number of feed pump sets shall be in accordance
with the Contract documentation but as a minimum one duty and one standby pump shall be
installed.
4 The feed pumps shall be of the progressive cavity type and shall be fitted with a mechanical
speed variator. Speed shall be automatically and manually adjustable to regulate the flow
into the thickener according to its performance and variations in the incoming sludge quality.
The pumps shall comply with the requirements of this Section 9.
5 Thickened sludge shall discharge to a thickened sludge pump and be pumped to the
digestion system unless otherwise specified. A minimum of one duty and one standby pump
shall be provided. All necessary pipework and valves shall be provided.
6 Thickened sludge pumps shall be of the progressive cavity type fitted with motors rated IP65.
The pumps shall be in accordance with the general requirements of this Section 9.
7 Access platforms and stairways shall be provided to give operators access to all items of
Plant requiring maintenance or operation.
8 Polymer preparation and dosing systems shall be provided complete with all interconnecting
pipework and fittings. The system shall be in accordance with the general requirements of
Section 22.
9 The control equipment shall comprise new FBAs that shall incorporate a PLC section
complete with Human Machine Interface (HMI) suitable for connection to SCADA and
telemetry in accordance with Section 21 of this Specification.
10 All plant and equipment shall be housed in an air-conditioned building.
17.3 GRAVITY BELT THICKENER

17.3.1 General
1 Each gravity belt thickener (GBT) unit shall be a complete package plant and the general
arrangement of each belt thickener system shall include:-
(a) Belt thickener
(b) Polyelectrolyte mixing system
(c) Conditioning tank
(d) Drive unit
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(e) Sludge scraper and lift blades
(f) Washwater system
(g) Hydraulic power pack
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(h) Ventilation
2 Sludge belt thickeners shall consist of an endless dewatering belt passing around a series of
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rollers.
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3 The design of the plant shall permit a controlled feed of sludge to be mixed with a controlled
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flow of polyelectrolyte in a mixing drum from which it shall go through a flocculation stage
prior to discharge onto the dewatering belt. The flocculated sludge shall then travel along the
belt before climbing over a ramp and discharging as a thickened sludge from a horizontal
stage of the machine.
4 The belt shall be washed automatically using final effluent, and be arranged for ease of
threading, alignment and tensioning.
17.3.2 Polyelectrolyte Mixing System
1 A non-clogging, multiple baffle mixing device shall be incorporated into the inlet of the
machine. The mixing system shall ensure intimate dispersion of conditioning polyelectrolyte
agent with the incoming sludge. The polyelectrolyte dosing position shall be both multiple
and variable to suit the type of sludge being treated.
17.3.3 Conditioning Tank
1 Mixed sludge and polyelectrolyte shall pass to a bifurcated upwardly diverging conditioning
tank, which shall be suitably sized to enable good floc formation to occur. The outlet of the
tank shall be designed such that the flocculated sludge distributes gently and evenly across
the full width of the filter belt.
17.3.4 Drainage Section:
1 The drainage section shall comprise a woven mono-filament polyester filter belt horizontally
supported on a PVC-U perforated support grid to allow rapid drainage of filtrate to a
collection system. The edges of the belt shall be raised by means of guides to prevent
sludge overflow during peak flow rates.
2 The belt weave selected shall be suitable for the sludge to be dewatered.
3 The belt shall incorporate a simple quick release to enable belt replacement to be effected
with minimal delay.
4 Blades shall be located at the entry position to the drainage section to induce drainage
furrows in the sludge blanket.
5 Drainage shall be connected into the works drainage system.
17.3.5 Machine Rollers
1 The machine shall be equipped with the following rollers:-
2 Manually adjustable tension rollers to allow pre-setting of the belt tension. The rollers shall
be mounted on the top frame member in plummer blocks fitted to manually adjustable slides.
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3 A hydraulically sleeved belt alignment roller. The alignment system shall be automatic. The
belt shall be maintained central to the roller system. Should the alignment system fail or lose
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pressure, excessive wander shall be detected by limit switches and the drive shall stop.
4 A drive roller mounted on the top frame member in plummer blocks.

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5 Plummer blocks shall be fitted with heavy-duty bearings. Bearings shall have a guaranteed
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life in excess of 100,000 hours. Auxiliary seals shall be fitted to bearings to prevent the
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ingress of water.
6 For maintenance purposes, rollers shall be easily removable from the side of the machine,
without the need to dismantle any other components.
17.3.6 Drive Unit
1 The drive roller shall be chain-driven through a set of sprockets and manually adjusted
hydraulic speed variator by an induction motor or gear motor unit.
2 Gear motors shall be suitably rated and protected.
3 Gear motors bearings shall have a guaranteed life in excess of 50,000 hours. The AGMA
service factor of the gear motor shall not be less than 1.5.
17.3.7 Sludge Scraper and Lift Blades
1 An easily replaceable sludge blade shall be positioned at an angle to the drive roller to
ensure that sludge is effectively removed from the filter.
2 An easily replaceable sludge lift blade shall be positioned on the horizontal section of the
filter belt immediately prior to the drive roller. The blade shall be capable of being locked in
or out of position, as the process requires. The blade height shall be adjustable and shall
exert a backpressure on the advancing sludge to cause it to back up over the blade and
dewater by self-weight.
3 Sludge shall fall down a stainless steel Grade 316 S31 to BS 970-1 (partially replaced by BS
EN 10084) chute directly to a thickened sludge pump.
17.3.8 Washwater System
1 The belt wash system shall consist of a high-pressure spray pipe fitted with an integral
cleaning device for cleaning nozzles without dismantling or interrupting operation. Final
effluent shall be used as washwater. The whole belt wash area shall be totally enclosed to
prevent release of spray to the atmosphere surrounding the thickener.
2 A break tank and booster pumps shall be incorporated as part of the system, if the supplied
pressure of the final effluent washwater system is not sufficient. The Contractor shall adhere
to the appropriate health and safety guidelines, relating to water borne and air borne bacteria
arising from high-pressure atomising washwater systems utilising final effluent, in his design.
17.3.9 Hydraulic Power Pack
1 An hydraulic power pack shall be supplied to provide drive and control for each GBT. This
shall be floor mounted adjacent to the thickener.
2 The hydraulic power pack shall comprise:-
(a) A hydraulic fluid tank fitted with filler cap, strainer, fluid level gauge and fluid
temperature gauge, bund and lockable drain.
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(b) An electric motor driven hydraulic pump. The pump speed shall not exceed 1500 rpm.
(c) Hydraulic accumulator, filter, pressure regulators and control valves.
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17.3.10 Machinery Construction and Materials

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1 The machine frame shall comprise structural steel channel and angle sections welded and
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bolted to form a rigid framework. The frame shall incorporate fabricated steel stops to allow
operators to view the horizontal section of belt.
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2 Filtrate troughs, filtrate tanks, conditioning tanks, etc., shall be constructed of stainless steel
plate to BS970 Grade 361 S31 or shall be of glass reinforced plastic.
3 The sides of the machine shall be enclosed within easily removable GRP or PVC-U panels.
Guards and splash plates shall be of steel or PVC-U materials. Guards shall be placed over
moving parts of the machine.
4 Scraper, thickening and furrow blades shall be of high-density plastic, to avoid damage to
the filter belt.
5 The equipment shall be self-contained, hydraulic power packs, actuating mechanisms and
drive units shall be mounted on the structural framework.
6 All steelwork other than stainless steel shall be galvanised.
17.3.11 Ventilation
1 A ventilation hood and curtain system shall be provided to isolate the thickener from the
surrounding building and ensure that high rate ventilation is concentrated on the machines.
A ventilation system shall be provided to ensure that odour/gasses are contained within the
hood. The ventilation system shall be designed for connection to an odour control unit.
17.4 CENTRIFUGE
17.4.1 General
1 Centrifuges shall be of the horizontal decanter type and consist of a high speed rotating bowl
containing a scroll conveyor. The scroll shall be designed to rotate in the same direction as
the bowl but at different speed. The bowl and the scroll shall be balanced independently.
The speed differential will be provided and controlled by using two motors with variable
speed control system.
2 The centrifuge shall be designed for use with wastewater sludges. The bowl, scroll and
bearing hub of the centrifuge shall be manufactured in duplex stainless steel SAF 2205 or
higher grade. The bowl shall be centrifugally cast. All other parts in contact with sludge shall
be constructed of stainless steel Grade 316 S31to BS 970-1 (partially replaced by BS EN
10084).
3 Inlet and outlet parts, rotating parts and wear zones shall be designed with either
replaceable wearing parts or from abrasion resistant materials. Inlet and outlet parts,
rotating parts and wear zones shall be designed such that replacement or adjustment can be
completed easily within a single working day. The edge of the screw conveyor shall be
protected by spray-on tungsten carbide alloy or tungsten carbide tiles.
4 The centrifugal force at the inner surface of the bowl shall be a minimum of 2500g for
thickening centrifuges and 2900g for dewatering centrifuges. For torque based back drive
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systems, the pond depth in the centrifuge bowl shall be adjustable through the use of
replaceable or adjustable dam plates at the liquid discharge end.
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5 The solids discharge shall be fitted with field replaceable stellite bushes.
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6 The differential speed adjustment between the bowl and the scroll conveyor shall be an
energy efficient system driven by an electric motor. Differential speed adjustment of scroll
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speed shall be infinite within the range of ± 1 to 15 rpm with an accuracy of +/- 0.05 rpm via
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an electric motor and inverter. The adjustment of the differential speed to accommodate
changes in solids content of the feed shall be fully automatic.
7 Torque experienced by the back drive shall be monitored continuously. Two stages of high
torque alarm shall be provided. Stage one shall initiate feed shut off. If the torque drops
below the torque alarm, the control system shall automatically open the feed. Stage two
high high torque alarm initiates the centrifuge shut down sequence. The centrifuge scroll
shall be kept running to clear the bowl when the decanter is slowing down under normal
shutdown or a high high alarm shutdown sequence.
8 The sludge feed tube shall be designed to allow the dosing of polymer directly into the scroll
distribution ports. The sludge inlet zone shall be low shear design to minimise floc
destruction.
9 The centrifuge shall be balanced and factory tested with a vibration level less than 5mm/s.
The centrifuge shall be equipped with rubber vibration dampers to minimise the transfer of
vibration to structures. The centrifuge shall be continuously monitored for vibration, with a
two stage alarm. Stage one shall initiate a high vibration alarm warning displayed on the
control panel and through the telemetry system. Stage two shall signal a high high vibration
alarm and initiate the automatic centrifuge shutdown sequence.
10 The centrifuge noise level shall not exceed 75 dBA when measured one metre from the
machine in any direction.
11 The bearings shall be designed for a L10 life of 100,000 hours. Bowl bearings shall be
continuously monitored for temperature with a two stage alarm. Stage one shall initiate a
high temperature alarm warning displayed on the control panel and through the telemetry
system. Stage two shall signal a high high temperature alarm and initiate the automatic
centrifuge shutdown sequence.
12 The main bearings on the centrifuge scroll and gears shall be lubricated for life.
13 The centrifugal bowl assembly and drive system shall be mounted on a base frame. The
base frame shall be able to support all the static and dynamic loading. The base frame shall
be fabricated from carbon steel with painting and corrosion protection in accordance with
Section D Part 4
14 Centrate from the centrifuges shall be discharged directly into the site drainage system.
17.4.2 Sludge Feed Pumps
1 Each centrifuge shall have a dedicated duty and standby feed pump.
17.4.3 Sludge Discharge Arrangements
1 The thickening centrifuges shall have a thickened sludge pump dedicated to each centrifuge
outlet with standby pumping facilities that can be immediately utilised for any centrifuge
without affecting the flow from any other centrifuge.
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2 Dewatered sludge from the dewatering centrifuges shall be transported by a system of
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conveyors to a sludge loading area outside the building.
3 The Contractor shall size the conveyer system to handle all dewatered sludges from the
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centrifuges at up to 25% dry solids.

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4 The conveyor system shall incorporate an adjustable high level cut out which shall inhibit
flow from the centrifuge to prevent overflow.
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5 If any one conveyor fails it must still be possible to operate the necessary number of duty
centrifuges using the remaining conveyors.
6 Emergency off buttons shall be provided adjacent to each conveyor.
7 The conveyor system installed under this contract shall permit the installation of further duty
centrifuges in future.
8 The conveyor system shall be of proprietary manufacture with the detailed arrangements,
including the controls, designed by the supplier or a specialist in such equipment.
9 The body and helical screw of screw conveyors shall be of stainless steel construction and
the system shall be heavy duty and robust in construction with ample features that will allow
for ease of operation, maintenance and repair
17.4.4 Ventilation
1 A sealed inlet and outlet arrangement shall be installed to prevent the emission of gasses
from the system into the building. The ventilation system shall be designed for connection to
an odour control unit.
2 The Contractor shall assess the need for ventilation for maintenance purposes in
accordance with the centrifuge manufacturers recommendations and provide an appropriate
system to protect personnel and equipment from harmful effects of sewage sludge gasses,
whilst the centrifuge is either not in use or is being maintained.
17.4.5 Washwater System
1 Each centrifuge shall incorporate a wash system, which shall consist of an automatically
operated injector nozzle designed to displace sludge through the process in preparation for
when the centrifuge is being shut down. A further manual hose shall be provided for manual
washing of the centrifuge during maintenance. Final effluent shall be used as washwater. A
break tank and duty/standby booster pumps shall be incorporated as part of the system.

equipment shall be installed in strict accordance with Part 1 of this Section 9, the relevant
Parts of this Section 9 for ancillary equipment installed and the manufacturer’s instructions.
17.5.2 Testing
14
1 Test Procedures shall be in accordance with Part 1 of this Section 9 and in addition those
listed below.
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2 Unless otherwise stated in the Contract Documents, performance prior to Taking Over shall
be judged against the following criteria.
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3 Sludge thickening – four spot samples shall be collected each day of the feed sludge and the
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thickened sludge over a period of 7 days. The quantity of polyelectrolyte used over this
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period shall also be recorded. The thickening plant will be considered acceptable if during
this period the thickened sludge has a dry solids content equal to or greater than stated in
the Tender Submission and the quantity of polyelectrolyte used does not exceed the quantity
stated in the Tender Submission.
4 Sludge Dewatering – four spot samples shall be collected each day of the feed sludge and
the dewatered sludge over a period of 7 days. The quantity of polyelectrolyte used over this
period shall also be recorded. The dewatering plant will be considered acceptable if during
this period the dewatered sludge has a dry solids content equal to or greater than stated in
the Tender Submission and the quantity of polyelectrolyte used does not exceed the quantity
stated in the Tender Submission.
5 Sample collection and analysis shall be undertaken by an approved independent laboratory

at the Contractor’s cost.
END OF PART
Part 18: Mixers and Stirrers
18 MIXERS AND STIRRERS ............................................................................. 2
18.1 GENERAL ...................................................................................................... 2

18.1.1 Scope 2
18.1.2 References 2
18.1.3 Submittals 2
18.2 COMPONENTS ............................................................................................. 2
18.2.1 General 2
18.2.2 Bearings (Non Static Mixers) 3
18.2.3 Sealing (Non-submersible mixers) 3
18.2.4 Balance 4
18.2.5 Rating Plate 4
18.2.6 Couplings 4
18.2.7 Guarding 4
18.2.8 Installation and Lifting Equipment 4
18.2.9 Protection from Corrosion 5
18.3 SUBMERSIBLE MIXERS ............................................................................... 5
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18.4 TANK MIXERS............................................................................................... 6
18.5 STATIC MIXERS ........................................................................................... 6

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18 MIXERS AND STIRRERS
18.1 GENERAL
18.1.1 Scope
1 This part specifies the requirement for the design, manufacture, testing and commissioning
of mixers and stirrers.

Section 1 General
List of ‘Approved Suppliers’ prepared by Public Works Authority
18.1.2 References
BS 970 (ISO 683) .......Wrought steels for mechanical and allied engineering purposes.
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18.1.3 Submittals
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18.2 COMPONENTS
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18.2.1 General
1 Mixers and stirrers generally fall into the following categories:-
(a) Static In-line Mixers

(b) Submersible Shrouded Mixers
(c) Submersible Banana Blade Mixers
(d) Tank Mixers
(e) Stirrers/Flocculator Paddles
2 The mixer performance (excluding static mixers), related to its required duty and installed
media, shall be stable and the unit shall be non-overloading.
3 Contractors shall select the most economic units given the constraints of the operating
parameters and particular requirements of the specification.
4 For static mixers the pressure rating of the associated pipework shall be rated to a minimum
of 16 Bar unless otherwise stated.
5 Mixer propellers, casings and all other external parts shall be of stainless steel construction
minimum Grade316 S31 to BS970-1
18.2.2 Bearings (Non Static Mixers)
1 The axial thrust generated shall be taken by a thrust bearing arrangement or angular contact
bearings. Thrust bearing arrangements incorporated into the motor housing are not
permitted. The Contractor shall demonstrate that the bearings are suitably rated in his
submittals for approval. Setting of thrust bearings shall account for dynamic loading, albeit
setting is carried out with the machinery stationary.
2 Rolling element ball or roller bearings shall be sealed for life and shall be rated to give a
minimum life of 75,000 hours at maximum load without replacement. Bearings shall be
protected by water throwers and lip seals where appropriate. The bearing housing shall be
of the cartridge type to allow removal of the bearing without disturbing the units.
3 Plain/Bush Bearings where utilised, shall be in bronze or equal, split for easy maintenance
and positively locked to prevent rotation.
4 Bearing housings shall be of the cartridge type to allow removal of the bearing without
disturbing the units.
18.2.3 Sealing (Non-submersible mixers)
1 For soft-packed gland arrangements, packing shall be graphite impregnated PTFE, of

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approved manufacture. Asbestos based packing will not be permitted.
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2 The gland design shall incorporate the following:
(a) A tapered "lead in" at the mouth of the gland entry to facilitate packing replacement and
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obviate the risk of damage on assembly.

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(b) The surface finish of the adjacent metal parts shall be 0.4μm CLA on the shaft gland
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sleeve and 1.6μm CLA on the stuffing box bore.

(c) Where running clearances are excessive, the packing shall be protected by an
independent ring of robust material which reduces the clearance to a minimum.
(d) The packing must not be used as a bearing.
(e) All studs, dowels and adjustable nuts shall be manufactured from stainless steel.
(f) Lantern rings shall be of gun metal or bronze and shall be split for ease of removal.
3 The stuffing box shall be manufactured from cast iron of a heavy section independent of the
mixer body and shall be provided with drain holes.
4 Mechanical seals shall be employed in submersible or closed tank applications with

differential pressures greater than 17 Bar or where controlled leakage is not permitted.
5 The Contractor shall specify the type, size and material of the mechanical seal he intends to
supply. It shall be the responsibility of the mixer manufacturer to ensure that the tolerances
required by the seal manufacturer are not exceeded. Checks shall be carried out on the
mixer casing and shafting for:
(a) Shaft straightness

(b) Rotational Balance
(c) Shaft run-out
(d) Bearing clearance - lateral and radial movement

(e) Shaft tolerance and ovality
(f) Concentricity
(g) Seat squareness
(h) Coupling alignment
6 The Contractor shall ensure that the seat, face and component materials of the mechanical
seal are suitable for the media.
18.2.4 Balance
1 The whole of the rotating assembly, including locking key(s) and mixing element, shall be
dynamically balanced as an integral component. The mixing element shall also be
dynamically balanced separately and then assembled to the shaft, to form without further
adjustment, a dynamically balanced whole.
18.2.5 Rating Plate
1 Rating plates shall be fitted to all mixers, be manufactured and fixed by corrosion resistant
material (excluding brass), and include full details of the mixer including size, type and serial
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number.
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2 The weight of the mixer including motor/mounting brackets etc. shall be marked on the data
plate
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18.2.6 Couplings
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1 For large mixers, couplings shall be provided to permit the removal of drive shafts, bearings,
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etc. without removing the mixer or motor. Couplings between the thrust bearing and motor
shall be accommodated within motor/support stools.
2 Couplings shall be of the pin and buffer type unless otherwise specified.
18.2.7 Guarding
1 All machine enclosures shall be safeguarded with guards fixed to the body or motor as
practical for the application.
2 Shaft guards shall extend the whole length of the shaft.
18.2.8 Installation and Lifting Equipment
1 Independent of application, the mixer shall be positively located and secured when
operating. Methods of installation shall be one of the following methods:-
(a) Swivel Mounting (for tank mixers/stirrers) - ease of removal of the mixing element from
the media shall be facilitated by means of a swivel mounting arrangement installed on
the top of the tank. This shall incorporate an adjustment to enable off centre mixing.
(b) Guide Rail mounting (for submersible mixers) - the mixer shall be supported by the
lifting chain from a hanging point and have a sliding guide bracket of stainless steel
Grade 316 S31 to BS 970-1 (partially replaced by BS EN 10084) mounted on a vertical
guide rail. It shall be possible to remove and replace the mixer safely without lowering
the level in the sump, or leaning into or entering the sump. The guide rail and hanging
arrangement shall permit full adjustment of the depth and direction of the mixer. The
guide system shall be retained at the lower end and upper end by stainless steel
mounting brackets. Rails shall be installed to within ±05mm/m length of the vertical
with no more than +1mm -0mm tolerance between parallel rails.
(c) Direct flange mounting to a mixing tank shall preferably be from the top. Side entry
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mounting is acceptable for vessels greater than 4m . The mounting shall be designed
to enable removal through the flanged hole. Alternatively and especially for drum
applications, the impeller can be of the folding type.
2 Integral lifting brackets, shackles and lifting eyebolts shall be provided and shall be
manufactured from stainless steel with a minimum U.T.S. of 540 MN/m2, and certified by an
approved testing authority. Both bolt and hole shall be permanently marked, preferably by
punching, with the diameter and thread form used. All eyebolts shall be of the collar type
18.2.9 Protection from Corrosion

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1 The internal & external finishes shall be in accordance with Section 8 Part 8.
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18.3 SUBMERSIBLE MIXERS
1 Submersible shrouded mixers installed in open or closed topped tanks or chambers, should
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be considered for the mixing of sewage, slurries, sludges and industrial process solutions
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where there is an absence of rags and other large debris.

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2 The mixer shall be easily removable from the installed position and this shall be achieved by
means of a guide rail system which also allows depth adjustment of the unit.
3 The assembly shall be directly driven from a submersible motor through an oil casing and,
when the specified duty dictates, also via a reduction gearbox. The motor shaft shall extend
to form the drive shaft of the propeller.
4 The oil casing shall provide lubrication and cooling for the seals and create a barrier between
the motor and the media. Expansion of the oil within the sealed casing shall be contained by
an air volume. Moisture sensor shall be provided for detecting any seal failures.
5 The propeller shall be designed to deter clogging and produce high efficiency, and the
shroud shall be fitted over the propeller to improve efficiency and direct the flow from the
mixer. The shroud shall be optional and the unit shall be capable of continuous operation
without it.
6 Motor cooling shall be achieved by the surrounding media.
7 Submersible banana blade mixers shall be easily removable from the installed position and
the blades shall be manufactured from lightweight glass reinforced plastic
8 Shafts shall either be sealed from the media in which they are working or shall be
manufactured from grade 316 stainless steel. Coated shafts shall not be permitted.
9 Submersible mixer motors shall be certified for use in a Zone 1 explosive atmosphere and be
capable of working at 20m liquid depth. All other requirements for motors and shaft seals
shall be to the requirements of Section 9 Part 2 2.4 (submersible pump fabrication).
18.4 Tank Mixers
1 Tank mixers installed in open topped or closed tanks or chambers should be considered for
the mixing of chemicals, slurries, sludges, industrial process solutions where there is an
absence of rags and other debris.
2 Tank mixers and stirrers shall be easily removable from the installed position and shall be
achieved by means of a flanged connection at the top or side of the tank or, in the case of
portable mixers, by means of a positioning bracket which shall be universally adjustable as
necessary for the application.
3 The assembly shall be driven from a totally enclosed fan cooled motor or air motor through a
reduction gear box.
4 The gear box output shaft shall extend to the propeller shaft via a rigid coupling. Shaft
sealing shall be provided between the mixer and a closed tank. The motor shaft shall extend
to form the drive shaft of the gear box.
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5 Propellers shall be designed to produce high efficiency.
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18.5 STATIC MIXERS

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1 Static Mixers installed in line within pipework for the blending of liquid to liquid and gas to
liquid in waste water treatment applications shall be constructed from materials suitable for
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use with the chemicals they are associated with and shall be complete with end connections
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compatible with the mating pipework. Changes in diameter or shape relative to the adjacent
pipework shall not be permitted.
2 Mixing shall be achieved by either flow splitting, rotating and recombining, or by vortex
action. The mixer shall incorporate sufficient elements to ensure complete and homogenous
mixing across the pipe section given the specified flow variations.
3 Assuming complete and homogenous mixing, the mixer shall maximise energy efficiency to
reduce the pressure losses through the unit. A characteristic curve of pressure loss against
flow shall be provided at the tender stage.
4 Where chemical injection points are integral with the mixer, they shall be designed and
positioned to maximise the mixing efficiency. Injectors shall be manufactured from materials
that tolerate the chemicals being dosed allowing for the design pressures.
1 Installation and commissioning shall be in accordance with Part 1 of this Section 9.
END OF PART
Part 19: Chlorination
19 CHLORINATION ............................................................................................ 2
19.1 GENERAL ...................................................................................................... 2

19.1.1 Scope 2
19.1.2 References 2
19.1.3 Submittals 2
19.2 CHLORINATION SYSTEMS .......................................................................... 2
19.2.1 General 2
19.2.2 Chlorinators 3
19.2.3 Ejectors 4
19.2.4 Motive Water Pumps 4
19.2.5 Chlorine Gas Cylinders 4
19.2.6 Chlorine Gas Header 4
19.2.7 Automatic Cylinder Change-Over Module 5
19.2.8 Automatic Isolation Valve 5
19.2.9 Chlorine Gas Header 6
19.2.10 Gas Feeder 7
19.2.11 Residual Chlorine Recorders 8
19.2.12 Chlorine Consumption and Recording Apparatus 9
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19.2.13 Analyser Cells 9
19.2.14 Gas Leak Detection Equipment 9
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19.2.15 Drum and Cylinders Handling 11

19.2.16 Pipework 11
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19.2.18 Emergency Breathing Apparatus and Air Compressor 12
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19.2.19 Warning and Safety Notices 12

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19.3 ON SITE GENERATION OF CHLORINE ..................................................... 13

19.3.1 General 13
19.3.2 Salt Saturators 13
19.3.3 Brine Feed 13
19.3.4 Electrolyser 14
19.3.5 Sodium Hypochlorite Storage 14
19.3.6 Sodium Hypochlorite Dosing 14
19.3.7 Pipework 15
19.3.8 Electrical Installation 15
19.3.9 Transformer / Rectifier 15
19.3.10 Control Panel 15
19.4 ANALYSERS ............................................................................................... 16
19.5 NEUTRALISATION SYSTEMS .................................................................... 16

19.5.1 General 16
19.5.2 Neutralisation Tower 17
19.5.3 Circulating Pumping Units 17
19.5.4 Pipework and Electrical Connections 17
19 CHLORINATION
19.1 GENERAL
19.1.1 Scope
of gaseous chlorination disinfection plants.

Section 1 General
19.1.2 References
BS 970 (ISO 683) Wrought steels for mechanical and allied engineering purposes.
PWA – Chlorine Safety Guidelines – Liquefied Chlorine Gas
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19.1.3 Submittals
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19.2 CHLORINATION SYSTEMS
19.2.1 General
1 Gaseous dosing systems shall comprise pressurised and liquefied gas drums or cylinders
complete with automatic changeover equipment, gas feeders and solution injection. All gas
dosing systems shall be based upon the full vacuum and remote injection principle.
2 Unless otherwise stated the system shall comprise the following equipment:
(a) Chlorinator
(b) Ejector complete with diffuser
(c) Motive water pump
(d) Chlorine gas cylinders
(e) Chlorine gas header
(f) Automatic cylinder change-over module
(g) Remote vacuum controller for cylinders
(h) Pipework
(i) Gas feeder
(j) Dosing control

(k) Residual chlorine recorders
(l) Chlorine consumption recording apparatus
(m) Analyser cells
(n) Gas leak detection equipment
(o) Neutralisation equipment
(p) Lifting and moving facilities for cylinders
(q) Safety equipment
(r) Drench shower linked to SCADA system
19.2.2 Chlorinators
1 The Contractor shall supply and install the chlorinators, one as stand-by. The chlorinators
shall be of the floor mounted vacuum type, and provided with evaporator of suitable capacity.
The chlorinators shall feed ejectors with the adjusted dose of chlorine. A diffuser shall be
connected to each ejector.
2 All interconnecting pipes between the chlorinators and ejectors shall be under vacuum, and
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pressure must be prevented from building up in the system by means of pressure relief
valves.
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3 Chlorinators shall be designed to shut-down automatically the chlorine supply to ejectors

vacuum line at the following cases:
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(a) The water supply to the ejectors fails.

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(b) The ejectors vacuum line breaks.

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(c) The water supply pipeline accidentally shuts down due to the closing of a valve or
valves.
(d) The electric supply fails.
4 The chlorinators shall be of the compound loop system and suitable for automatic control by
signals received separately from the flowmeter and the chlorine residual controller.
5 The accurate dosing scale of the apparatus should have a ratio of about 20:1 between the
maximum and minimum dosing rates. The rate will be automatically adjusted by means of
the chlorine residual controller according to the free chlorine residual needed. Provision
shall be made for manual adjustment.
6 Best chlorine resisting materials shall be used through the whole parts of the system. The
unit shall be of modular design, free standing with all control components protected within a
rigid fibre-glass cabinet or similar.
7 The components within the cabinet shall be readily accessible from the front for ease of
maintenance and shall be easily removable for examination or changing if required.
19.2.3 Ejectors
1 The ejectors shall be of the aspirator type to give maximum efficiency in mixing the chlorine
with the water. The ejector water supply must be designed to suit the maximum rated output
of the chlorinators offered.
2 Each ejector shall be connected to a diffuser for regular distribution of the chlorine solution at
the injection point.
3 The ejectors shall be separated from the chlorinators to give flexibility of placing the
chlorinators in their rooms and to inject the chlorine solution by the ejectors at the injection
point.
19.2.4 Motive Water Pumps
1 The Contractor shall supply and erect electrically driven boosting pumps. The pumps shall
be connected in parallel to supply water to the ejectors.
2 Motive water pumps shall be multi-stage, stainless steel, ring construction and provided on a
duty/standby basis. Pumps shall be provided complete with isolation valves, reflux valves
and delivery pressure gauges. Suction and delivery pressure gauges shall be provided on
each pump and downstream of flow control valves where flow splitting is provided.
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3 A filter shall be fitted to each suction pipeline.
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4 The discharge and manometric head of each pumping sets shall be chosen to suit the
working conditions of the ejectors at their maximum rated output.
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5 The pumps shall be of the centrifugal type with high efficiency. Each pump shall be directly
coupled to a totally enclosed air cooled electric motor, the motor shall be complete with its
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starter, rated for continuous running (24 hours) with class (F) insulation.
6 The pumps impellers, shafts, diffusers (if any), shall be made of stainless steel.
7 Ammoniator motive water systems shall be provided complete with base exchange water
softeners, complete with local salt saturator for regeneration or from bulk salt saturators if
employed at the site. The water softener shall be dual auto-rotation element units complete
with auto-timers and regeneration controller.
19.2.5 Chlorine Gas Cylinders
1 Where specified in the Contract the Contractor shall supply chlorine gas cylinders of the
pattern and size specified.
19.2.6 Chlorine Gas Header
1 The Contractor shall provide a suitable manifold and header system to convey gas from the
cylinders via the changeover panel to the associated gas feeder.
2 The pipework shall include flexible connectors, isolating valves, interceptor traps, gas filters
and all necessary mild steel pipework.
3 Each header shall be complete with electric heater. The heater shall be of suitable power to
prevent the freezing of chlorine gas when its flow rate through the header is maximum.
4 On drum chlorine systems, a combined liquid trap and gas filter shall be provided complete
with a self-regulating heater.
5 Pipework and valves shall be designed and constructed to withstand the pressure and
corrosive nature of the gas. Welding, if used, shall be to the relevant British Standard or
equivalent for pipework conveying corrosive liquids under pressure. Suitable isolating valves
and couplings shall be provided to each major item of plant to facilitate removal for
maintenance. Pressure testing of the pipework and valves shall be carried out by the
contractor to the approval of the Engineer, and shall comply with the relevant British
Standard or equivalent.
6 Each header shall be suitable for connecting two chlorine drums of capacity one ton each.
19.2.7 Automatic Cylinder Change-Over Module
1 Where specified in the Contract the Contractor shall supply and erect an automatic
changeover panel which will change from duty gas supply to standby in the event of low
pressure on the duty supply. The changeover panel shall include duty/standby indication,
bottle change required, and the pressure of gas in the duty cylinder.
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2 The changeover panel shall be mechanically operated and be complete with pressure
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reducing valves to prevent re-liquification of the gas and changeover valve block heater.
The line between the changeover panel and the gas feeder incorporate individual failsafe
vacuum gas regulator valves.
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3 The automatic change-over module shall not permit a return to the initial source until the
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secondary source is exhausted.
4 The Contractor shall also supply a remote vacuum controller for each cylinder on duty to
shut-down the cylinder on indication of loss of vacuum.
19.2.8 Automatic Isolation Valve
1 The discharge from drums shall be protected by an automatic isolation valve system. The
system shall either be a proprietary system, or it shall comply with the following Clauses.
2 The automatic control of the isolation valve system shall be from the gas leak detection
equipment.
3 For gas leak testing purposes, a remotely mounted manual opening facility shall be provided
for each isolation valve. These shall be spring return push buttons with engraved labels
"Press and Hold to Open Drum No 1 (No 2) Valve" and shall be incorporated into a
shutdown control panel (mounted in a safe area) with the following features.
(a) Lamp (Green)-Drum No 1 Valve Open

(b) Lamp (Green)-Drum No 2 Valve Open
(c) Hand/Off/Auto Selector-Drum No 1 Valve
(d) Hand/Off/Auto Selector-Drum No 2 Valve
(e) Push Button-Press and Hold to Open Drum No 1 Valve

(f) Push Button-Press and Hold to Open Drum No 2 Valve
(g) Push Button-Reset System
4 The isolation valve shall be a two way PTFE taper plug valve suitable for use with dry
chlorine. The body shall be of LCB carbon steel and plug of monel metal.
5 The automatic isolation valve shall be a spring return, giving fail safe operation in the event
of loss of air supply.
6 The Contractor shall be responsible for the air supply to the valve. The supply line shall
incorporate a moisture trap and drain located as near as possible to the electrically operated
solenoid valves to be used for isolation valve control.
7 The solenoid valves shall operate from a 110 volt 50 Hz electricity supply and shall be
mounted outside the control box. Valve terminal enclosures shall be fully shrouded and
fitted with a propriety cable compression gland. Final connection to these valves shall be via
short lengths of flexible multicore cable from an adjacent termination box.
8 The air supply to the automatic isolation valves shall be suitably rated nylon tubing supported
in 25mm PVC conduit.
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9 A sufficient length of tubing shall be provided adjacent to the automatic isolation valve in
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order to facilitate maintenance and valve height adjustment.
10 The connections to the automatic isolation valves shall be 2 No special elbows with a 3/4"
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BSP female rotary union for connection to the existing drum valve and a 3/4" BSP male taper
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for connection to the isolation valve are required for this purpose.
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11 A 3/4" male/male nipple shall be provided on the upstream side of the isolation valve for
connection to the gas header pipework system.
12 The pneumatically operated isolation valves shall be supported in a manner which facilitates
adjustment in three planes to relieve the pipework connections adjacent to the valve of the
weight of the valve and actuator.
13 The Contractor shall supply and install a robust tubular guard rail to protect the vulnerable
valve and pipework arrangement on the discharge side of the drum from swinging drums.
14 The framework shall be fabricated in mild steel tubular sections and painted in accordance
with Section 8 Part 8 the Specification.
15 The frame floor anchor plates and holding down bolts shall be designed to withstand an
impact from a swinging chlorine drum.
16 The guard railing may be utilised for the support of the automatic isolation valves.
19.2.9 Chlorine Gas Header
1 The Contractor shall provide a suitable manifold and header system to convey gas from the
cylinders via the changeover panel to the associated gas feeder.
2 The pipework shall include flexible connectors, isolating valves, interceptor traps, gas filters
and all necessary mild steel pipework.
3 Each header shall be complete with electric heater. The heater shall be of suitable power to
prevent the freezing of chlorine gas when its flow rate through the header is maximum.
4 On drum chlorine systems, a combined liquid trap and gas filter shall be provided complete
with a self-regulating heater.
5 Pipework and valves shall be designed and constructed to withstand the pressure and
corrosive nature of the gas. Welding, if used, shall be to the relevant British Standard or
equivalent for pipework conveying corrosive liquids under pressure. Suitable isolating valves
and couplings shall be provided to each major item of plant to facilitate removal for
maintenance. Pressure testing of the pipework and valves shall be carried out by the
contractor to the approval of the Engineer, and shall comply with the relevant British
Standard or equivalent.
6 Each header shall be suitable for connecting two chlorine drums of capacity one ton each.
19.2.10 Gas Feeder
1 Chlorine shall be dosed via duty/standby gas feeders, of the all vacuum/remote ejector
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principle.
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2 The gas feeder shall dose gas automatically in proportion to flow, chlorine levels, super or
residual whichever may be applicable.
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3 Gas feeders shall be located such that access for maintenance is unobstructed. Rear
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access is acceptable providing a minimum of 1 metre free space is available for egress in
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emergencies.
4 The gas feeder shall incorporate the following features:
(a) Positive Gas Shut Off - in the event of loss of vacuum, gas shall be prevented from
entering the system.
(b) High Level Vent - in the event of gas vent, gas shall be directed to a high level external
non-hazardous area.
(c) Vacuum Gauge - indicating system vacuum state.
(d) Flowmeter - indicating as flow thorough feeder.
5 Microprocessor based process controllers shall provide automatic control, changeover

monitoring and transmission facilities for disinfection control. The unit shall not be
susceptible to memory corruption during normal electrical supply transients and shall be
protected by a stabilised power supply.
6 The unit shall provide a continuous display of the actual chlorine residual and also indicate
set residual parameters on demand. A separate readout shall also be provided to give
operational data including alarm settings etc.
7 Each unit shall be provided complete with its own residual signal transmitter.
8 An integral printer shall provide the following status data on its respective system, on
demand or at pre set intervals.
(a) Date
(b) Time
(c) Residual chlorine levels
(d) Water Flow
(e) Gas Flow
(f) Alarm Conditions (high and low residual)
9 In addition a 4-20 mA analogue signal shall be provided to drive a pen of a three pen
recorder (the two other pens being driven from the two other controllers associated with its
respective pumping system). The pen recorder shall be a 7 day circular recorder and each
pen shall be arranged to operate at different radii despite have similar residual chlorine
levels. The recorder shall be wall mounted adjacent to the chlorination equipment.
10 The residual chlorine of the effluent shall be measured, indicated and controlled. It is
required to supply and erect two chlorine residual sampling, measuring and controlling units,
one as stand-by. Each unit shall be mounted with the chlorinator in one panel.
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11 The residual chlorine measuring unit shall be of the amperometric type with suitable bi-
metallic electrodes to measure free available residual chlorine.
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12 The electrodes shall be continuously cleaned by a suitable mechanical means. The

electrodes shall be stationary and not to be allowed to move during the continuous cleaning
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operation.
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The measuring cell shall be designed to measure “free available” chlorine. The signal
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generated in the measuring cell shall be fed to the recorder for recording. The measuring
cell assembly contain equipment for regulating the pressure, flow and pH of the sample
water before being passed through it.
14 The instrument shall include control components to provide automatic control of residual
chlorine by adjusting the feed rate of chlorinators.
15 The sampling and measuring components shall be complete with all necessary pipe work,
sampling pumps, valves and fittings.
19.2.11 Residual Chlorine Recorders
1 The measured values of residual chlorine shall be automatically recorded by residual

chlorine recorders. It is required to supply two recorders (one as stand-by).
2 The recorders shall be of the servo type which receive the residual chlorine signals from the
residual measuring unit.
3 These signals shall be current proportional to the residual chlorine. The current shall then be
indicated and recorded by the conventional self-balancing amperometric recorder head on a
suitable diameter weekly inkless (pressure sensitive) chart.
4 The recorder shall have the same range for residual chlorine as the residual measuring
apparatus, which is from “0” to 2.0 mg/lit.
5 The reading of residual chlorine shall be transferred to the chlorine apparatus.
19.2.12 Chlorine Consumption and Recording Apparatus
1 Duty and standby continuous measurement and totalising chlorine consumption measuring
and recording apparatus shall be provided.
19.2.13 Analyser Cells
1 Sampling point shall be selected by the Contractor and agreed with the Engineer. The
Contractor shall include in his supply individual analyser cells. These units shall be supplied
with buffer pump and container together with pressure switches and sample/by pass
facilities.
2 The filter shall be mounted outside the unit in a convenient location and in a way which does
not require dismantling of the access cover.
3 Sufficient buffer solution shall be provided for preliminary testing and tests before
completion.
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4 The system shall provide for triple validation of the analyser cells and supply lines.
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5 Residual Chlorine analyzers shall be used to monitor the amount of free residual chlorine in
final effluent/irrigation water. Each residual chlorine analyzer system shall comprise of a
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sensor, transmitter, buffer solution and other accessories. The analyzer should be provided
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with a flow regulating/isolation valve, sample flow indicator (VA type) „Y‟ strainer and
associated pipework, skid mounted and installed in a GRP enclosure. The analyzer shall
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have a maximum response time of ten seconds for step change of 90%.
6 Transmitter shall comprise 3½ digits LCD, have a measurement accuracy of ±2%. These
shall be fields selectable from 0-0.5 to 0-20 mg/l. complete width. Automatic compensation
for temperature. They shall have an isolated 4-20 mA d.c. output, and be suitable for surface
mounting or digital signal if a data bus is specified. The enclosure shall be protected to IP66.
7 The sensor shall be of the Amperometric type sensor with flow through installation, and be
complete width with an internal temperature sensor for automatic compensation. The sensor
shall be complete with bottle of buffer solution and interconnecting cable.
19.2.14 Gas Leak Detection Equipment
1 Drum stores, bottle stores and chlorinator rooms shall be provided with a gas sensing alarm
system.
2 Each store/room shall be provided with sensors mounted in positions to achieve maximum
effectiveness with chlorine sensors mounted at a low level. Multiple sensors shall be
provided in larger stores/rooms where single sensor may not effectively sense all leaks.
3 Alarm control panels shall be mounted in a safe area outside the rooms, and shall operate
via an integral battery back up system. Where available, the system may be powered from a
central uninterruptable Power Supply (UPS) system.
4 Alarm control panels shall incorporate:
(a) Meter displaying the concentration of the gas leak in mg/l.

(b) Warning lamps or LED's for each gas sensor to indicate:
(c) 1st stage leak at 3.0 mg/l
(d) 2nd stage leak at 10.0 mg/l
(e) Alarm/control contacts for:
(f) Controlling Drum Shutdown Systems (where applicable)
(g) Controlling Ventilation Fans
(h) Controlling Door Access Warning Lamps
(i) Signalling to Central Control Room or SCADA System
(j) Signalling to a Site Telemetry Outstation
(k) Instrument fault lamp or LED and warning contact.
(l) Audible/visual warning device.
(m) Power 'ON' or instrument 'HEALTHY' lamp or LED.
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5 The automatic Chlorine drum change-over system shall be arranged to change from the duty
drum to the standby drum when the 1st stage leak level of 3.0 mg/l is reached. Further drum
change-over shall be inhibited until the system is manually reset.
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6 Chlorine drums shall be automatically isolated when the 2nd stage leak level of 10 mg/l is
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reached and the evaporators shall continue operating until the gas pressure reduced to zero.
Once isolated, drums shall remain isolated until the system is reset and the drum automatic
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isolation valves manually re-opened. Operation of the automatic isolation system shall
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initiate a works shut down.
7 Ventilation fans in the affected room shall automatically be switched ON when the 1st stage
leak level of 3.0 mg/l is reached. Ventilation fans in the affected room shall automatically be
switched OFF when the 2nd stage leak level of 10.0 mg/l is reached. If the leak level falls
below the 1st stage leak level, the ventilation fans shall continue to run on for 10 minutes
before stopping.
8 Each access door to stores or rooms shall be provided with warning lamps to permit or
prohibit entry. A green lamp shall indicate that it is safe to enter, at leak levels below the 3.0
mg/l threshold: A red lamp shall indicate that a 1st or 2nd stage leak has been detected.
Each lamp box colour shall be provided with a minimum of two lamps so that a single lamp
failure does not render the indication in-operative.
9 Each building containing a store or room shall be provided with an external flashing/rotating
beacon coloured RED and an audible warning device. The audible device shall produce an
output of 106dB(A) at 1 metre and shall remain sounding until such time as the alarm is
accepted/cancelled, and it shall self cancel after 5 minutes. The flashing/rotating beacon
shall remain operational whilst 1st or 2nd stage leak persists.
10 The location of the external flashing/rotating beacon shall be such that it is readily visible to
persons entering the site via the main access route.
19.2.15 Drum and Cylinders Handling
1 The Contractor shall provide a travelling crane complying with Part 7 of this Section 9 as
stated in the Particular Specification.
2 Drums shall be moved using a roller system. Each roller shall comprise a set of four
trunnions which shall be used as a method of positioning the outlet valves of the drums and
also for spacing and supporting the drums. The trunnions shall be fixed to steel I-beams,
which shall be fixed rigidly to the floor of store.
3 Cylinders shall be set in racks and provided with positive restraint clamps. These clamps
shall be either profile clamps or chain restraints which prevent movement of the cylinders
from the stored position.
4 The handling system shall be designed so that it is not possible to pass a hoisted drum over
a drum in use.
5 The Contractor shall supply one weighing balance for weighing of the chlorine cylinders.
The balance shall be of the spring type with three (3) tons measuring capacity.
19.2.16 Pipework
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1 The Contractor shall provide and install all pipework and valves etc. necessary for the
complete installation for the chlorination equipment system.
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2 2 Pipework shall be provided with the necessary valves, bends, tees and unions for easy
dismantling. Pipework materials should be provided in accordance with the chlorination
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equipment manufacturers recommendations and shall comply with international industry

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standards. Typically uPVC pipe will be used for water and chlorinated water and carbon
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steel for liquid chlorine.
3 3 All pipework shall be neatly laid and securely fixed in position. Similarly all valves shall be
securely fixed, clearly numbered and labelled in accordance with the operating instructions.
4 4 Pipework shall be clean, dry and free from oil and grease and shall not be cleaned with
organic solvents.
19.2.17 Ventilation
1 Drum stores, bottle stores, and chlorinator rooms shall all be provided with forced ventilation
systems, design to produce at least 6 volume changes of air per hour, and arranged to
provide a negative pressure within the rooms.
2 Automatic control of the extract fans shall be from the gas leak detection equipment.
3 Manual control of the fans shall be provided from a safe area outside the rooms. Manual
control shall be available regardless of the action of the gas leak detection equipment. The
manual control shall be arranged so that it is not possible for ventilation fans to be turned off
when the automatic system is calling for the fans to be turned on.
4 Extract grills and fans shall be positioned at a low level with the fan exhaust arranged to
discharge the vented gas away from pedestrian walkways and roadways. If necessary,
ducting to a point above building eaves level shall be provided to achieve this, subject to
approval by the Engineer.
5 Intake grills shall be positioned at a high level and arranged so that the entire contents of the
room are fully replenished with fresh air when the extract fans are running.
19.2.18 Emergency Breathing Apparatus and Air Compressor
1 The Contractor shall supply Masks with air bottles (cylinders) to allow for working in
contaminated air for 30 minutes. Their size shall be according to requirements of personnel
dealing with chlorine gas. They shall be stored in cupboard.
2 The Contractor shall supply a motor driven portable air compressor. The compressor shall
be mounted on a carriage with 2 pneumatic tyred wheels and handles for trailing. Also it
shall be provided with an air reservoir of ample capacity. The set (air compressor and air
reservoir) shall be complete with safety valves, pressure gauges, valves, piping and
necessary safety devices.
3 The air intake shall be from the free atmospheric air.

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4 The compressor shall be provided with suitable connection to allow for filling the air bottles
(cylinders) of the masks. The compressed air must be free of any lubricating oil traces.
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5 The capacity of compressor shall be enough to fill the air bottle of the mask-up to its working
pressure in 5 minutes.
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19.2.19 Warning and Safety Notices

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1 The Contractor shall provide and fix engraved labels with white lettering 20mm high on a
Red background. Externally mounted labels shall be provided with a stainless steel
backplate for added support. The labels shall be:
(a) External to the gas store:

WARNING:
CHLORINE AND SULPHUR DIOXIDE STORE
DO NOT ENTER WHEN WARNING LIGHT
AND ALARM IS ON
(b) Internal to the Gas Store, in a prominent location:
WARNING
IF ALARM SOUNDS ALL
PERSONNEL MUST VACATE
THIS DRUM STORE
2 The Contractor shall display first aid advice in Arabic & English and protective clothing for
personnel who deal with chlorine equipment. As a minimum notices shall say:
Chlorine is a highly irritating gas immediately affecting the eyes, nose, throat and chest.
Anyone so affected must be removed to fresh air and medical treatment sought.
3 Warning lamps with alarm to be provided at the entry to the evaporator room and chlorinator
room for alerting the personnel in case of a gas leak. Lamps shall indicated
Red > 9 ppm chlorine

Yellow >3 - 9 ppm chlorine
Green < 3 ppm chlorine
19.3 ON SITE GENERATION OF CHLORINE
19.3.1 General
1 Sodium hypochlorite generation, batching, dosing and dechlorination shall be automatically

controlled. The Transformer/Rectifier and control panel shall be located in a separate room
from the electrolyser and hypochlorite storage tanks where mounted internally. The location of
plant within the generation room shall take into account local zoning restrictions.
2 Generation rooms shall be provided with either one full wall free air ventilator or automatic
forced extract air systems. High level ventilators shall be provided.
19.3.2 Salt Saturators
1 Salt saturators shall be provided for the storage of fully saturated salt solution (brine). The total
storage capacity shall be not less than 1 month‟s consumption at maximum works output. The
salt saturators shall be approved with regard to FDA Regulations for use of non-toxic materials.
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2 The saturators shall be rated for the peak salt consumption requirement of overnight generation
of sodium hypochlorite and incorporate an internal suction discharge limiter to prevent tracking
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of partially saturated salt solution. The units shall be supplied and installed complete with the
filter bed gravel and first salt fill on foundations prepared by the Civil Contractor to the
Contractors requirements. The saturators shall be suitable for outdoor use.
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3 The saturators shall include

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(a) Inlet and Outlet connection manifolds.

(b) Tanker charging connection and manifold.
(c) Overflow to drain.
(d) Vent pipe complete with dust arrester
(e) Upper and lower level manway inspection points.
(f) Shrouded inlet float valve.
(g) Surrounding bund of not less than 110% of the Saturator Volume.
(h) Visual indication of salt level
19.3.3 Brine Feed
1 Brine feed through the electrolyser to the hypochlorite storage tank shall be provided on a
duty/standby basis. Fixed speed, manually adjustable stroke pumps shall be suitable for this
application.
2 The feed line shall be fitted with a flow monitor and a sampling point for brine testing. The
contract shall include a brineometer for this purpose.
19.3.4 Electrolyser
1 Rating of the electrolysers shall be dependant on the requirement for generation of sodium
hypochlorite during the off peak period. Multiple electrolysers shall be provided to achieve the
required capacity. Standby shall be provided by either one spare unit or 25% of the capacity
which ever is the greater, held in store at the site.
2 The anode/cathode is a consumable item within the generation package. Manufacturers offer a
five year guarantee with regard to life consumed during a five year cycle of operation. The
Contractor shall transfer this guarantee to the Purchaser which shall become effective from the
date of the Take-Over. The Contractor shall therefore ensure that the current density value is
commensurate with a five year cycle of operation.
3 The electrolysers shall be rack mounted such that access to all connections is within view of
maintenance staff. Disconnection and replacement shall be possible without associated
pipework disturbance.
4 Hydrogen release from the electrolysers shall be manifolded for transportation with the sodium
hypochlorite for high level discharge in the hypochlorite storage tank. The sodium hypochlorite
feed line shall incorporate a flow switch, for process shut-down in the event of low flow, a
temperature switch for over temperature shut down of the process and a sample point for
sodium hypochlorite sampling.
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5 Any equipment which is in the defined Potentially Explosive Atmosphere shall be selected in
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6 The water feed to the electrolyser shall be 'softened' as required via duty/standby water
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softeners with automatic changeover.

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7 A heat exchanger shall be included with the electrolyser to transfer heat generated in the
product to the incoming diluted brine solution in order to maximise the overall efficiency of the
unit. Where this may not be sufficient, pre-heating with an electric immersion heater shall be
provided.
19.3.5 Sodium Hypochlorite Storage
1 The sodium hypochlorite storage tanks shall be provided on a duplicate basis. The capacity
shall be sufficient for 48 hours consumption at the maximum works output. The tank shall be
suitable for external application and shall include forced ventilation for hydrogen dispersion.
The tank(s) shall be installed in bund(s) of not less than 110% of the tank volume.
2 Duty/Standby ventilation fans shall be provided to supply air into the storage tank for high level
discharge with dispersed hydrogen from the gaseous space above the stored liquid. Flow
sensors shall monitor fan operation and shut down the generation process in the event of low
flow detection.
19.3.6 Sodium Hypochlorite Dosing
1 Dosing of sodium hypochlorite shall be via duty/standby dosing pumps. Control of the pumps
shall be related to the flowrate through the works chlorine disinfection requirements, and
residual requirements.
2 Overall control of the whole system shall be by means of a programmable logic controller (PLC)
which shall be configured so that failure of the PLC shall not result in danger to personnel or
equipment.
19.3.7 Pipework
1 All pipework fittings and valves associated with the generation equipment shall be rigidly fixed
and supported, pipe routes over floor areas shall be adequately protected against accidental
damage.
19.3.8 Electrical Installation
1 The electrical installation shall be in accordance with Section 21 of this specification.
19.3.9 Transformer / Rectifier
1 A duty transformer/rectifier shall provide low voltage DC for the electrolyser. The unit shall be
free standing, the input shall be 415V, 3ph, a.c., output should not be greater than 24V dc with
full wave rectification.
2 The unit be in accordance with the specification Section 21 and be capable of operation in
ambient temperatures up to 500C. Cooling shall be via natural convection ventilation.
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3 The rectifier shall include:-
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(a) A dc voltmeter
(b) A dc Ammeter
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(c) A dc Centre zero voltmeter

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(d) Lockable input isolator

(e) Main input contactor
(f) On/Off push buttons
(g) Hand/Off/Auto selector
(h) Current level setting
(i) Mains "on" lamp
(j) DC "live" lamp
(k) Hours run meter
4 All status and alarms shall be provided at the signals and alarms marshalling box.
19.3.10 Control Panel
1 A control panel shall be mounted adjacent to the Transformer/Rectifier to provide overall system
control. The panel shall be in accordance with Section 21 - Factory Built Assemblies of
Switchgear and Control Gear.
2 The Panel shall include indication and control equipment for the process.
3 In particular the following alarms shall be provided locally and at the signals and alarms
marshalling box:-
(a) Improper voltage

(b) Rectifier failure
(c) Protection voltage failure
(d) Storage tank low level
(e) Low/high electrolyte temperature
(f) Low electrolyte level
(g) Low air flow
(h) Bund flood
(i) Low water flow
19.4 ANALYSERS
1 Residual Chlorine analyzers are used to monitor the amount of free residual chlorine in final
effluent/irrigation water. Each residual Chlorine analyzer system comprises of a sensor,
transmitter, buffer solution and other accessories. The analyzer should be provided with a flow
regulating/isolation valve, sample flow indicator (VA type) „Y‟ strainer and associated pipework,
skid mounted and installed in a GRP enclosure. The analyzer shall have a maximum response
time of ten seconds for step change of 90%.
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2 Transmitter shall comprise 3½ digits LCD, have a measurement accuracy of ±2%. These shall
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be fields selectable from 0-0.5 to 0-20 mg/l. complete width. Automatic compensation for
temperature. They shall have an isolated 4-20 mA d.c. output, and be suitable for surface
mounting. The enclosure shall be protected to IP66.
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3 The sensor shall be of the Amperometric type sensor with flow through installation, and be
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complete width with an internal temperature sensor for automatic compensation. The sensor
shall be complete with bottle of buffer solution and interconnecting cable.
19.5 NEUTRALISATION SYSTEMS
19.5.1 General
1 The neutralisation system shall include the following:
(a) Neutralisation tower.

(b) Circulating pumping units.
(c) Air exhaust system.
(d) Caustic soda ash enough for two (2) times use.
(e) Necessary pipes, fittings, valves.
(f) Necessary electric connections.
2 When the concentration of the chlorine gas in the air reaches four (4) mg/lit, by volume, the
chlorine leak detectors shall operate the neutralization system.
3 Caustic soda solution prepared at the bottom part of the neutralization tower shall be sucked by
the pumps and delivered to the spraying nozzles at the top of the tower. In the same time
contaminated air shall be delivered to the lower part of the tower by the extraction fans. Contact
shall happen, between the contaminated air and the caustic soda solution, through the contact
rings and the neutralized solution shall be collected back at the bottom of the tank. The process
shall continue until the concentration of the chlorine gas in air becomes normal. The neutralized
solution shall be drained out from the lower part of the tower and another volume shall be
prepared to be ready for emergency cases.
19.5.2 Neutralisation Tower
1 The tower shall be made from reinforced fibre glass. The neutralizing solution shall be prepared
at the bottom of the tower by using of caustic soda ash. In the upper part of the tank, the
spraying system with its nozzles shall be installed.
2 Porcelain or P.V.C. rings shall be placed on certain brackets inside the tower for increasing the
contact area between the contaminated air and the sprayed neutralization solution.
19.5.3 Circulating Pumping Units
1 One duty and one stand-by pump shall be used to circulate, the neutralization solution from the
bottom of the tower to the spraying installations.
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2 The pumps shall be of discharge and head to suit the supplied installations.
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3 The pumps shall be manufactured from suitable materials to withstand the corrosion action of
the handled media.
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19.5.4 Pipework and Electrical Connections

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1 The price of neutralization system shall include all air ducts, caustic soda pumps, pipes and
electric connections required. Air ducts shall be of uPVC complete with necessary valves and
fittings.
2 The caustic soda pump suction and delivery pipes including valves and fittings shall be of PVC.
END OF PART
Part 20: Washwater Systems
20 WASHWATER SYSTEMS ............................................................................. 2
20.1 GENERAL ...................................................................................................... 2

20.1.1 Scope 2
20.1.2 References 2
20.1.3 Submittals 2
20.2 PRODUCTS ................................................................................................... 2
20.2.1 General 2
20.2.2 Washwater Booster Set 2
20.3 TESTING ....................................................................................................... 3
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20 WASHWATER SYSTEMS
20.1 GENERAL
20.1.1 Scope
of washwater systems.

Section 1 General
20.1.2 References

BS 1123 .....................Safety valves, gauges and fusible plugs for compressed air or inert
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gas installation
BS 5169 .....................Specification for fusion welded steel air receivers
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PD 5500 ....................Specification for unfired fusion welded pressure vessels

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ISO 10474 ..................Steel & Steel Products Inspection Documents

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20.1.3 Submittals
20.2 PRODUCTS
20.2.1 General
1 The wash water system shall be capable of delivering a supply of final effluent wash water to
the plant at the rate recommended by the manufacturers of the proprietary equipment plus a
minimum of 6 l/s at 4 bar(g) with any two hydrants open and all process water requirements
being meet simultaneously.
2 The design shall ensure that the hydrant pressure does not exceed 5 bar. Pressure
reducing valves may be utilised for this purpose.
20.2.2 Washwater Booster Set
1 The wash water system shall comprise a minimum of one duty pump and a standby pump,
pressure vessel with adjustable differential pressure switches, interconnecting pipework and
valves, and a terminal panel. The motor starters and controls shall be part of a FBA. The
pumps shall be provided with a duplex-strainer in the suction piping to prevent any debris
from entering the system.
2 The pressure vessel shall be adequately sized to keep the maximum number of pump starts
under the worst conditions to 15 per hour. The pressure vessel shall incorporate a butyl-
rubber diaphragm to contain the water and shall be charged with nitrogen or another
approved inert gas.
3 The vessel shall be of welded construction and in accordance with the relevant British
Standards or ASME VII Div 1, and shall be complete with all necessary fixtures and fittings
and shall include the following:-
(a) Inspection manhole single or double bridged, according to size, which shall seat on
pressure.
(b) Flanged inlet and outlet connections.
(c) System compound pressure gauge of the diaphragm type.
(d) Safety valve, to relieve excess air pressure in tank to atmosphere.
(e) 50mm drain connection with valve.
4 The vessel shall be high quality epoxy coated inside and out after all manufacture has been
completed, and shall be suitable for the maximum working pressure required by the process.
5 The upper dome of the vessel shall be fitted with a suitable spring loaded pressure relief
valve, which shall be arranged to commence to open at 110% of the maximum system
working pressure, and be fully open at 120% of this pressure.
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6 The pressure vessel, which shall be of vertical or horizontal construction, shall be mounted
on a minimum of four mounting feet, to raise the vessel off the base plate a distance of not
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less than 300mm.
7 The vessel shall be fitted with a 150mm diameter pressure gauge, connected such that it
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reads the air pressure in the vessel and thereby indicating the pressure in the system.
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8 There shall be provided for the vessel a manually operated air release valve, to enable the
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system to be depressurised to atmosphere before the system is drained and to enable the
vessel to be recharged.
9 Pressure switches shall be robustly constructed and suitable for the arduous duties involved,
and shall be fully adjustable over their working range, together with adjustable differentials.
20.3 TESTING
1 1 Testing of the vessel to the recommended Code of Practice shall be carried out at the
manufacturers works, and a test certificate shall be issued. The working and test pressures
shall be stamped onto the outside of the vessel such that they are clearly visible.

END OF PART
Part 21: Miscellaneous Equipment
21 MISCELLANEOUS EQUIPMENT .................................................................. 2
21.1 GENERAL ...................................................................................................... 2

21.1.1 Scope 2
21.1.2 References 2
21.1.3 Submittals 2
21.1.4 General 2
21.2 PROGRESSIVE CAVITY PUMPS.................................................................. 2
21.2.1 General 2
21.2.2 Pump Design 2
21.2.3 Macerator/Muncher 3
21.3 END SUCTION PUMPS ................................................................................. 3
21.3.1 General 3
21.3.2 Casing 4
21.3.3 Shaft and Impeller 4
21.3.4 Gland Plate 4
21.3.5 Bearings 5
21.3.6 Pump Performance 5
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21.4 PRESSURE FILTERS AND STRAINERS ...................................................... 5
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21.4.1 Pressure Filters 5

21.4.2 Basket Strainers 6
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21.5 POLYMER PREPARATION AND DOSING SYSTEMS .................................. 6

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21.5.1 General 6
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21.5.2 Wetting and Dispersing Device 7

21.5.3 Flocculent Storage Tanks 7
21.5.4 Dosing Pumps 7
21 MISCELLANEOUS EQUIPMENT
21.1 GENERAL
21.1.1 Scope
of miscellaneous items of equipment.

Section 1 General
21.1.2 References
BS 970 (ISO 683) ----- Wrought steels for mechanical and allied engineering purposes
BS 3170 ----------------- Specification for flexible couplings for power transmission
BS EN 10084 ----------- Case hardening steels

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21.1.3 Submittals
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21.1.4 General
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1 The plant shall be complete with electric motors, starters and switchboards, cabling,
accessories, valves, piping, holding down bolts, lubricators, appendages and connections to
make the plant complete and perfect in every part and detail.
2 There shall be included all necessary stairs, ladders, platforms etc. to provide permanent,
fixed safe and easy access for the maintenance of every item of plant.
21.2 PROGRESSIVE CAVITY PUMPS

21.2.1 General
1 Each pump shall be capable of pumping sludge with a dry solids content 50% greater than
the design percentage of solids.
2 It should be noted that macerators/munchers might be required in certain applications.
3 The design of the installation shall allow the pump rotor to be removed from the installed
pump body without the need to remove the pump casing from its installation.
21.2.2 Pump Design
1 The pumps shall be of the horizontal rotary type, for abrasive service provide hard chrome
plated tool steel, for corrosive service provide hard chrome plated SS316 S31 having an
abrasion resistant helical rotor operating in a resilient, synthetic rubber stator, suitable for the
handling of the sludge.
2 The pumps shall be of robust construction throughout suitable for the arduous conditions
involved when pumping sludge, and shall be capable of working for long periods without
requiring maintenance attention.
3 The rotor speed shall not exceed 400 rpm and provision shall be made for easy inspection of
the rotor.
4 The pumps may be direct driven or belt driven and the motors shall be mounted beside the
pumps.
5 The pumps and motor shall be mounted on a robustly constructed baseplate which shall
incorporate, if belt driven, a positive belt tensioning device and shall be arranged such that
access for inspection and maintenance is not unduly restricted or hindered by pipework
connections etc.
6 For belt driven pumps, the drive between the pump and motor shall be by Vee Belts and
shall be rated such that with half the number of belts broken the remaining belts can transmit
the full driving power required by the pump at maximum duty.
7 The belt drive and pulleys shall be completely protected by suitable guards easily removable
for inspection.
8 Each pump shall be supplied with a spring loaded pressure relief valve, the discharge of
which shall be separately piped back to the suction pipework. To allow an increased head
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for main clearing purposes the valves shall be arranged to relieve at 45 metres head or at
the maximum head under which the pumps may operate, whichever is the lower.
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9 The pumps shall be arranged with “suction on gland” and the suction body shall be fitted with
a flushing connection from the wash water system.
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10 The Contractor shall provide and install all necessary pipework and valves from wash water
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system to the pumps.

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11 Calculations for sizing the pumps shall be supplied with the offer and when tested at the
maker’s works, the pumps shall give results that conform to the said calculations.
21.2.3 Macerator/Muncher
1 Macerators if required shall be installed upstream of each pump and shall be able to handle
an equivalent flow.
2 The macerator/muncher shall comprise a slow speed, high torque, parallel shaft grinder.
3 The macerator/muncher shall ensure that the progressing cavity pumps are protected from
and can adequately cope with the diverse materials likely to be encountered in the sludge.
21.3 END SUCTION PUMPS

21.3.1 General
1 End suction pumps may be close horizontally coupled to the motor as a single compact unit
or independent of the motor.
2 The pumps shall be continuously rated and designed for an operating life of 20 years without
major overhaul. Components likely to wear in the course of normal operation shall be
capable of replacement with readily exchangeable components.
3 The pump casing and other parts in contact with the liquid shall be suitable for the duties
involved.
4 Close coupled pumps shall be directly coupled to the drive motor through a rigid coupling
and end thrusts accommodated in the motor bearings. The motor shall be flanged and
spigotted for correct alignment, it shall be fitted with jacking bolts to ease removal.
5 Independent pumps shall be coupled to the drive motor through a flexible coupling which
shall not be capable of transmitting end thrust to the motor.
6 The rotating unit must be removable type from the pump casing without disturbing the
suction and delivery piping and the motor. A spacer type flexible coupling shall be used for
power transmission.
21.3.2 Casing
1 The pump casing shall be of duplex stainless steel and be abrasion resistant, capable of
taking shock loads and incorporate lifting eyes for removal of the pump. It shall be designed
and correctly formed to provide the highest efficiency and absence of turbulence and shall
be flanged and spigotted for correct location and jointing.
2 Readily replaceable back and front casing wear rings shall be provided, unless otherwise
specified the casing wear rings shall be stainless steel Grade 316 S31 to BS 970 Part 1 and
the wear rings shall be locked to prevent rotation by dowels or other similar approved
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method.
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3 The pump casing shall be complete with integrally cast feet and lifting points.
21.3.3 Shaft and Impeller

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1 The shaft shall be of stainless steel of minimum Grade 316 –S31 to BS 970-1 and of ample
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diameter to withstand all stresses imposed.

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2 Where shafts are exposed to the process fluid and where they pass through the sealing
gland they shall be fitted with positively driven stainless steel sleeves Grade 316-S31 to BS
970-1, which shall extend through the stuffing box.
3 The impeller shall be made of duplex stainless steel DIN 1.4517 and be of robust
construction and be machined where possible with the water passages and blades filed and
scraped, to produce smooth surfaces so that rags and stringy matter will not adhere. It shall
be provided with auxiliary back blades to reduce the pressure at the mechanical seal and
prevent the ingress of solids and abrasive matter. Hydraulic balance holes shall not be
provided and the impeller shall be tested and adjusted for static and dynamic balance. The
impeller shall be fitted to the drive shaft by a fitted impeller key and secured by a contoured
nut, provided with a positive locking arrangement. Impellers are to be provided with
renewable wear rings. Impeller wear rings shall be stainless steel Grade 316 S31 to BS 970
Part 1. The shaft shall be fully protected from contact with the pumped liquid.
4 The pump shall rotate in a clockwise direction when viewed from the suction end. The
rotating element shall be in balance and designed so that the maximum operating speed is
not less than 30 per cent below the first critical speed and there is no tendency for any part
to unlock due to possible reversal of rotation.
21.3.4 Gland Plate
1 The gland plate shall be flanged and spigotted for correct alignment, it shall be fitted with
jacking bolts to ease removal from the pump casing.
2 The gland plate shall be fitted with a cartridge type mechanical seal. The gland stuffing box
shall be designed for soft gland packing as an alternative.
3 The mechanical seal selected shall be suitable for the pump duty and the media being
pumped, the seal shall be water lubricated and shall not in normal use permit any controlled
leakage from the pump.
21.3.5 Bearings
1 Independent pumps shall be fitted with an external shaft bearing assembly. It shall positively
locate the shaft so that on reassembly the shaft and impeller are in true alignment within the
rotating unit and it shall be provided with locating dowels and jacking bolts to ease removal.
2 Bearings shall be generously rated and sized to take all thrust and radial loads and to ensure
satisfactory and stable running under all conditions of operation, they shall be to ISO
standard with SI unit dimensions. Bearings shall be of anti-friction type designed for an L10
life of at least 100,000 hours in accordance with BS 5512. The bearings shall be arranged for
oil or grease lubrication.
21.3.6 Pump Performance
1 The pump head/flow characteristic curve shall be stable, rising steadily to closed valve head
and non-overloading. The closed valve head shall be a minimum of 110% of the maximum
duty head
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2 Where the maximum duty is met by parallel pump operation, a single pump shall be capable
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of operation without run-out or overloading.
3 The Contractor shall make his own assessment of the friction losses under all operating
conditions.
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4 The pump quantity/power characteristics shall be stable and non-overloading such that the
maximum power absorbed under any condition remains at least 10% less than the rating of
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the motor.
5 Characteristic curves for the pump shall be supplied with the Tender to a large scale which
shall show the capacity of the pumps when pumping singly at minimum and maximum head.
Where two or more pumps are installed discharging through the same pumping main, the
characteristic curves shall include the system curves for all combinations of pumps. Curves
showing pump efficiency and kW loading shall also be included. Where pumps are supplied
with variable speed drives provide pump curves for minimum and maximum speed with
pump efficiency and kW loading at intersections of the system curve.
6 When tested through their complete range of workable heads at the maker’s works, the
pumps shall give results which conform to the curves submitted with the Tender
21.4 PRESSURE FILTERS AND STRAINERS

21.4.1 Pressure Filters
1 Automatic self cleaning filters shall be specifically suitable for use with organic contaminants.
Cleaning shall be by a hydraulically powered suction scanner, automatically activated when
the differential pressure across the filter reaches an adjustable level, nominally 3.5m.
2 The filter body and all internal parts, including flanges, shall be stainless steel Grade 316S31
to BS 970-1 (partially replaced by BS EN 10084). The screen shall be 150 micron mesh size.
The flushing line shall be connected to the works drainage system.
3 The control system shall feature a fail-safe timer to prevent continuous flushing due to
malfunction. The filter shall not flush when the system or pumps are not working.
4 All the filters shall have isolation valves in the suction and delivery side for easy
maintenance. The controller for the filters shall be equipped with a timer and pressure
differential control unit.
5 Pressure gauges shall be connected to suction and delivery side of each filter, pressure
switches shall be mounted in the electric control panel in an isolated compartment.
6 Input and output flanges dimensions shall be in accordance with BS EN 1092 PN 16.
21.4.2 Basket Strainers
1 The strainer shall be of the duplex in-line basket flanged type, of compact design and shall
incorporate large filtration areas giving low pressure drops.
2 The body and cover will be of cast iron to BS EN 1561 grade 250 or equivalent, and shall
be fusion bonded epoxy coated internally and externally with a minimum thickness of 300
microns. Flanges shall be PN16 to BS EN 1092.
3 Internal parts shall be of stainless steel Grade 316S31 to BS 970-1 (partially replaced by BS
EN 10084) or equivalent.
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4 The filter shall be 920 microns mesh inserted into a perforated plate basket.
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5 Strainers shall be suitably rated for all working and test delivery pressures.
6 A differential pressure switch shall be connected between the inlet and outlet of the filter, and
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if the pressure drop across the filter is exceeded by 50% (or other value recommended by
the Manufacturer and agreed with the Engineer) a lamp on the panel shall indicate “filter
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blocked” and operation of the system shall be disabled.

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21.5 POLYMER PREPARATION AND DOSING SYSTEMS

21.5.1 General
1 A polyelectrolyte make-up, storage and dosing system shall be provided. The system shall
be sized to provide the polyelectrolyte requirements of the sludge thickening system as
designed by the Contractor and provide an adequate storage period of the necessary raw
materials
2 The Contractor shall provide a facility for dosing by direct injection into the pipework, of pre-
prepared polyelectrolyte, upstream of the conditioning tanks. The facility shall be manually
selected via a gate valve and capable of being isolated from the dosing system.
3 The dry granule storage hopper shall be fabricated of stainless steel and shall have a 25kg
minimum capacity. The hopper shall be mounted on the polyelectrolyte feeder and shall be
provided with supports. The hopper shall be provided with a low-level alarm.
4 The hopper shall be enclosed by a stainless steel cabinet with a tubular heater fitted inside
to prevent condensation and maintain polyelectrolyte in a dry condition.
5 The transfer of granules into the hopper shall use a vacuum system designed to operate with
1 tonne bulk bags.
6 The dry granule transfer equipment for the transfer of dry polymer from hopper to wetting
device shall include the following: -
(a) A granule feeder with single screw discharge. The granule feeder outlet shall be fitted
with a heater to prevent condensation.
(b) A stainless steel funnel to direct the granules from the screw discharge into an air lift
venturi. The funnel shall be fitted with a sieve.
(c) A centrifugal air blower to provide a high velocity air stream. The motor shall be totally
enclosed with a degree of enclosure protection appropriate to the equipment. The
level of protection shall not be less than IP55.
(d) An air dehumidifier.
(e) A venturi granule injector to feed the granules into the air stream.
(f) An anti-static connecting hose.
7 All stainless steel parts shall be Grade 316 S31 to BS 970-1 (partially replaced by BS EN
10084)
21.5.2 Wetting and Dispersing Device
1 Wetting and dispersing devices shall ensure that every granule of polyelectrolyte delivered
by the air stream is wetted and dispersed into the make-up tank. No conglomerates of
polyelectrolyte shall be produced. The spray heads shall be of stainless steel Grade 316 S31
to BS 970-1 (partially replaced by BS EN 10084) and shall be fitted with a water pressure
gauge and a control pressure switch. Potable water shall be used
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2 The Contractor shall provide the Engineer with design calculations to demonstrate that he
has made all reasonable endeavours to optimise the use of water on works processes.
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3 For the polyelectrolyte system, the Contractor must install a break tank of sufficient water
capacity to allow batch polymer to be mixed for one day’s use.
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4 The Contractor shall design the polyelectrolyte break tank with optimal spare capacity and
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shall impose a strict regime of control to suppress any peaks and troughs of the water
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demand pattern.
21.5.3 Flocculent Storage Tanks
1 Flocculent storage tanks shall be fabricated from glass-reinforced plastic or steel reinforced
glass fibre and shall include the following: -
(a) Slow speed propeller or turbine mixer.

(b) Level electrodes to control solenoid valves, air blower, mixer, screw feeder and dosing
pumps.
(c) Mounting for wetting and dispersing device.
(d) Flanged inlet, outlet, drain and overflow connections.
(e) Removable covers.
(f) Sight glass.
(g) Tank contents gauge with analogue output to SCADA system.
21.5.4 Dosing Pumps
1 Duty and standby chemical metering pumps shall be provided complete with all pipework,
valves and any necessary metering arrangements. The output of the pumps shall be
variable by means of hydraulic variator or adjustable speed drive depending on pump type
selected, so as to get accuracy in the dosing rate.
2 Flow meter (analogue-mechanical type) shall be installed in the delivery line of the pump to
get the chemical flow rate.

END OF PART
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Part 22: Ventilation Systems
22 VENTILATION SYSTEMS ............................................................................. 2
22.1 GENERAL ...................................................................................................... 2

22.1.1 Scope 2
22.1.2 Noise Level 2
22.1.3 Inlets and Outlets 2
22.2 VENTILATION SYSTEMS ............................................................................. 2
22.2.1 Ventilation Rates 2
22.2.2 Wet Well Ventilation/Process Area Ventilation 3
22.2.3 Dry Well Ventilation 3
22.2.4 Motor Room Ventilation 4
22.2.5 Fans 4
22.2.6 Fan Motors 4
22.2.7 Ducting 4
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22 VENTILATION SYSTEMS
22.1 GENERAL
22.1.1 Scope
1 This part specifies the particular requirement for the ventilation systems for sewerage and
sewage treatment installations. This section is to be read in conjunction with Section 22.
Where there is conflict then the requirements of this Section shall prevail.

Section 1 General
Section 22 Air Conditioning, Refrigeration and Ventilation
22.1.2 Noise Level
1 The noise level due to ventilation and air conditioning equipment shall be no greater than
sound power level 65dB(A) at one metre.
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2 The Contractor shall include for sound absorbers and anti-vibration mountings as necessary.
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22.1.3 Inlets and Outlets

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1 All inlets and outlets through the roof shall be fitted with approved GRP or Aluminium cowls
and bird screens. All inlets and outlets through walls shall be fitted with demountable
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aluminium louvers. All materials used for external fittings shall be highly resistant to ultra-
violet light.
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2 All louvers shall be of the sand trap type and shall be fitted with internal sand filters and
mosquito screens.
22.2 VENTILATION SYSTEMS

22.2.1 Ventilation Rates
1 The minimum number of air changes per hour shall be:
Toilets 12
Stores 12
Workshops 15
Garages/Car park areas 12
Messes (two speed) 6 – 20
Motor Room 10 – 20
Dry Well 20
6 when covered rising to 20 prior to and
Covered areas containing untreated sewage
during man entry
22.2.2 Wet Well Ventilation/Process Area Ventilation
1 Ventilation equipment shall ensure that at all times the wet well area is not hazardous to
operators, during operation or shut down of the pumping plant. It should be noted that the
gases given off by sewage may include methane (marsh gas), carbon dioxide, nitrogen,
oxygen, hydrogen, hydrogen sulphide, water vapour and other constituents. In naturally
ventilated wet wells/process area levels of hydrogen sulphide of up to 100 ppm are common
and concentrations in excess of 400 ppm have been measured. Methane concentrations
above the lower explosive limit are possible. This should be borne in mind when designing
the ventilation system and odour control systems.
2 The system shall be capable of treating the specified H 2S concentration such that the
operating mean H2S level in the well does not exceed 3 ppm. Removable cell type
deodorisers shall not require filter replacement in a period less than 6 months. Bulk carbon
deodorisers shall not require carbon regeneration in a period less than 2 years. Pelletised
activated caustic or water regenerable carbon shall be used for the bulk type deodorizer
units.
3 Where H2S levels are likely to exceed 20 ppm, a chemical scrubber of other suitable pre-filter
shall be provided before a carbon filter.
4 The system shall operate on the principle of forced draught ducted outlet/natural ducted
inlets and account shall be taken of the fact that the gases to be handled have differing
specific gravities. The high and low level ducted inlets and outlets should span the width of
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the wet well so that there is a constant sweep of clean air across the wet well.
5 A complete fan/motor assembly shall be provided as a spare. This shall include the fan
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housing on the bulk carbon deodorisers.
6 On bulk carbon deodoriser systems a flow switch shall be fitted into the extract ductwork to
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actuate an alarm on the annunciator in the event of failure of the extract system.
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7 In the event of failure of the wet well ventilation red rotating beacon, high intensity, alarm
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lights shall be illuminated adjacent to each wet well access door.
8 The extract shall be through a Deodoriser unit as specified elsewhere to remove obnoxious
smells.
9 Warning labels worded as follows in English and Arabic shall be fitted at each alarm light
location.
WARNING
DO NOT ENTER WHEN RED LIGHT IS ON
NO NAKED LIGHTS AT ANY TIME
10 Two identical systems shall be provided, each capable of providing 60% of the overall design
requirement for ventilation.
11 The treated air shall be discharged into the atmosphere via a stack which shall extend above
the height of the building.
22.2.3 Dry Well Ventilation
1 The system shall operate on the principle of forced draught outlet/ natural ventilation inlet via
the stairways and other apertures.
2 Fans shall be of the double motor type having a standby motor which comes into operation
should the duty motor fail. Alternatively two complete fans and motors shall be provided and
installed to act as duty and standby.
22.2.4 Motor Room Ventilation
1 The system shall operate on the principle of forced draught outlet/ natural ventilation inlet via
inlet louvers. All inlet louvers shall be fitted with 2" thick metallic washable filters. Access
shall be provided for cleaning/changing filters.
2 Fans shall be of the double motor type having a standby motor which comes into operation
should the duty motor fail. Alternatively two complete fans and motors shall be provided and
installed to act as duty and standby.
22.2.5 Fans
1 Fans shall be of the axial flow or centrifugal types suitable for handling air of high humidity
and having concentrations of hydrogen sulphide.
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2 They shall be of non ferrous construction or be protected with suitable epoxy resin coatings.
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3 Odour Control fans shall be constructed entirely from stainless steel Grade 316 S31 to BS
970-1 (partially replaced by BS EN 10084) or fibreglass reinforced plastic of vinyl ester resin.
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4 For deodorizer fan units, bearings shall be of the roller or ball type and shall be mounted
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using adaptor sleeves and plumber blocks with provision for lubrication. Sealed bearings
shall be used for small fan units in dry well/motor room ventilation system.
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22.2.6 Fan Motors
1 Fan motors shall be suitable for continuous operation in hot, humid atmospheres at an
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ambient temperature of up to 55 C at 100% humidity.
2 The degree of protection shall be IP55 and for the wet well a classification of Ex N IIA T3 or
better is required.
3 All motors shall comply with the section of this Specification headed "Motors" insofar as it
applies.
22.2.7 Ducting
1 Ventilation ducting shall be of GRP, Reinforced uPVC or Stainless Steel to BS 970, Grade
316 S31. Material thickness, stiffening and joint arrangements shall not be of a standard
lower than those set out in the Chartered Institution of Building Services (C.I.B.S), Guide
(Section B3) 1983 Edition.
2 Ducting shall be complete with all necessary supports. Galvanised or stainless steel nuts
and bolts shall be used for all ducting joints and all supports and brackets shall be
galvanised. All supports, ducting, brackets and fixings in wet wells shall be stainless steel as
specified elsewhere.
3 Ducting shall be sized so that the air velocity within the ducts shall not exceed 5.5 metres per
second.
4 Flexible connections and anti-vibration mountings shall be provided as necessary between

the ductwork and fans and provision shall be made for thermal expansion.
5 Where ducts pass through the roof or floor slab the gap shall be sealed with polystyrene or
similar approved material. Wood is not acceptable.
END OF PART
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09 0 Mechanical and Electrical Equipment Combined

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QCS 2014 Section 09: Mechanical and Electrical Equipment Page 1

Part 01: General

1.2.7 Anchors and Sleeves 16

1.2.9 Drive Units 16

1.2.12 Electric Motors 18

1.1.2 Related Works

1 The following standards or revised/updated versions are referred to in this Part:

BS 89,.........................(IEC 51) Direct acting indicating analogue electrical measuring

instruments and their accessories

BS 4142, ....................(ISO 1996/2/3) Method of rating industrial noise affecting mixed

BS EN ISO 9000, ......Quality management and quality assurance standards

BS EN 60947, ............Low voltage switchgear and control gear

BS EN 10084, ............Case hardening steels. Technical delivery conditions

BS ISO 10816, Part 1,

AWS D1.1, ................Steel structure welding code

List of „Approved Suppliers‟ prepared by the Public Works Authority

Programme (4) 7 days

60 days after Contract

Manufacturing programme 30 days before start of

4 Material and Product Data

include drawings of any templates required for the installation work.

equipment, maintenance, access requirements and loadings due to equipment

7 Testing and Commissioning Submittals

(i) description of temporary procedure facilities, including drawings and sketches

(v) re-test/check result

devices as required, types conforming to the approved procedure plans. All

8 Operation and Maintenance Manuals and Instructions - General

Consultant, Contractor, sub-contractors, manufacturers and agents. The date the

(c) general equipment description

sufficient detail to facilitate dismantling and re-assembly

numbers relating to power circuit diagrams

networks, systems etc.

1.1.5 Quality Standards

1.1.6 Manufacturer’s Experience

1.1.7 Factory Inspection

1.1.8 Factory Tests and Test Certificates

1.1.9 Shipment, Storage and Handling

3 Equipment and materials shall be handled in accordance with manufacturer‟s

1.1.10 Adaptation of Equipment

delays from the preparation of such revised drawings.

requirements, equipment warranty shall cover:

(a) faulty or inadequate design

1.1.12 Job Conditions

1.1.13 Approved Manufacturers and Subcontractors

1.1.14 Hydraulic Sump Model Testing

1.1.15 Sewage Characteristics

ductile iron unless otherwise specified.

4 Structural steel shall be as specified in Section 8, 16 and 17.

9 Safety guards shall be of stainless steel of Grade 316S31 to BS 970-1.

treated with linseed oil varnishes shall not be used.

1.2.4 De-rating Due to Climate Conditions

4 Cast molybdenum steel shall be to BS 3100 Grade B unless otherwise specified.

1.2.6 Equipment Bases and Bedplates

1.2.7 Anchors and Sleeves

lamination or other lining material shall be terminated on the equipment secured.

1.2.8 Safety Guards

1.2.9 Drive Units

15 Lubricants shall be suitable for the temperatures encountered in service conditions.

1.2.12 Electric Motors

commissioning of motors shall be in accordance with Section 21 unless otherwise agreed

1.2.13 Pressure Gauges

3 Pressure gauges shall be always kept calibrated as QCS Section 10 requirements.

1.2.14 Nameplates and Data Plates