FGV Bulkers SDN BHD

FGV BULKERS SDN BHD
FABRICATION, INSTALLATION, PAINTING, TESTING AND

COMMISSIONING STAINLESS STEEL WATER LINE, TWO (2) UNIT
MULTISTAGE PUMP C/W PRESSURE SWITCH AND ELECTRICAL WORKS
AT KUANTAN BULKING INSTALLATION (KBI) FOR FGV BULKERS SDN BHD
SCOPE OF WORKS
1. The works cover the requirements for the fabrication, installation, painting,
cleaning, testing and commissioning of water line at Kuantan Bulking
Installation (KBI) in accordance with the drawings and specifications
provided.
2. The following works are required: -
(A) SUPPLY OF TWO (2) UNIT VERTICAL MULTISTAGE

CENTRIFUGAL PUMPSETS
i. Supply, delivery to site, testing, painting, commissioning and guarantee

of two (2) unit of vertical multistage centrifugal pumpsets as per
specification.
ii. The pump and electric motor shall be completely mounted and correctly
aligned complete with flexible coupling.
iii. The purchaser will notify the Supplier on completion of installation of
the pumpsets and ready for testing and commissioning the pump.
iv. Details specification of vertical multistage centrifugal pump.
 Design of pump Vertical Multistage Centrifugal Pump

 Approved brand Grundfos
 Type To be advised by vendor
 Rated Capacity 60m3/hr
 Head 60 m
 Fluid medium Water
 Material of Stainless steel pump head & base
construction
Stainless steel shaft
 Motor 11.0 kW / 50 Hz
 RPM of pump 2924
v. GENERAL
Catalogues and technical literature shall be supplied together with the

quotation.
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vi. DELIVERY PERIOD
To be advised by Supplier. Preferably not more than one (1) month from
date of order.
vii. TESTING AND COMMISSIONING
After the pumpsets installed by the employer the supplier must testing
and commissioning the pumpsets at the employer sites to the satisfaction
of the employer.
viii. GUARANTEE
The design, materials and workmanship of the pumpset shall be

guaranteed against defects for a period of 12 months from the date of
commissioning.
(B) PUMP INSTALLATION (CIVIL, MECHANICAL & ELECTRICAL)
1. The works cover the requirements for supply of labour, materials, hand
tools and all else necessary equipments to carry out supply and install
work of two (2) unit vertical multistage centrifugal pumpset in KBI area.
The works shall be completed with the modification and installation of
new piping, fittings, y-strainer, expansion joints and valves as per
drawings attached and engineer’s instruction.
2. The Contractor is expected to discuss all technical information required

with the employer and make a site visit and be familiar with the location
where the pumps and laying cable will be installed before submitting the
written quotation.
3. The following works are required in accordance to the scope of works as

per drawings attached and engineer’s instruction:-
4. Supply of labour, materials, hand tools and all necessary equipment to

carry out install works of two (2) unit of vertical multistage centrifugal
pumpset in KBI area:-
a. To construct new pump foundation c/with 5 mm chequered plates

lining with minimum height of 3 inches as per drawing and
engineer’s instruction. (The concrete foundation height will suit at
site upon installing the pumpset)
b. To install two (2) unit of vertical multistage centrifugal pumpset in
the KBI as per drawing and engineer’s instruction.
c. Supply of materials, fabrication and installation of the stainless
steel pipelines, fittings, valves, pipe support, etc. to the new
pumpset as per drawings and engineer’s instruction.
d. To fabricate, supply and install two (2) no. inverter starter panel
c/w 150 Amp MCCB, overload relay, contactor, ammeter,
voltmeter, CT, pressure switch, indicating light, push button, metal
clad and one (1) lot internal wiring.
e. Supply, lay and termination of 1 x 4C x 25mm² PVC/SWA/PVC
copper cable c/w cable gland, cable lug, support bracket where laid
underground/overhead with GI cable tray from main panel to
pumpsets.
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f. Remote start/emergency stop push button station using 1 x 3C x
1.5mm² PVC/SWA/PVC copper cable lay underground/ GI cable
tray c/w bracket.
g. Supply, delivery and install of remote start/emergency stop push
button c/w bracket, support, pole and other necessary accessories.
h. Supply and install galvanized iron (G.I) 4” cable tray for the laying
of the above cable in (d) & (e) above c/w GI support and bracket.
i. The cable offered shall indicate a cable size label on the cable outer
layer. Cost shall include on supply cable ladders/trays, bracket,
supports etc. where laid overhead and excavation, backfilling and
resurface with good floor finish for the underground cable
installation.
j. The heavy duty inverter starter must be rated to suit rating of the
pump supplied and made of copper.
k. All contactors for motor starters shall be rated at AC4 duty (or 1.5
times the AC3 rating) for the motor output rating specified.
l. The starter panel shall finished with epoxy powder spray painting
and oven baked.
m. Cable length is only an approximation the contractor must measure
at site to determine the accurate cable length.
n. All cable trays/ladders shall be hot-dipped galvanized and supports,
bracket, etc. shall also be hot-dipped galvanized.
(C) PIPING WORKS
1. Scope of works:
a. Installation of one (1) nos. 150mmØ sch10 stainless steel water

pipelines from incoming water near water meter to water tank at
Kuantan Bulking Installation (KBI) complete with fittings, valves,
pipe supports, concrete footing, etc as shown in the Drawing No:
KBI/WATERLINE/01/2021, KBI/WATERLINE/02/2021,
KBI/WATERLINE/03/2021 and KBI/WATERLINE/04/2021.
b. Installation of one (1) nos. 100mmØ sch10 stainless steel water

pipelines from water tank to header at Kuantan Bulking Installation
(KBI) complete with fittings, valves, pipe supports, concrete footing,
etc as shown in the Drawing No: KBI/WATERLINE/01/2021,
KBI/WATERLINE/02/2021, KBI/WATERLINE/03/2021 and
KBI/WATERLINE/04/2021.
c. Installation of one (1) nos. 100mmØ sch10 stainless steel water

pipelines from water tank to vertical multistage centrifugal pumpset
and from pumpset to header at Kuantan Bulking Installation (KBI)
complete with fittings, valves, pipe supports, concrete footing, etc as
shown in the Drawing No: KBI/WATERLINE/01/2021,
KBI/WATERLINE/02/2021, KBI/WATERLINE/03/2021 and
KBI/WATERLINE/04/2021.
d. Installation of one (1) nos. 75mmØ sch10 stainless steel water

pipelines from header to air compressor and boiler at Kuantan
Bulking Installation (KBI) complete with fittings, valves, pipe
supports, concrete footing, etc as shown in the Drawing No:
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e. Installation of one (1) nos. 75mmØ sch10 stainless steel water
pipelines from header to Pumphouse B at Kuantan Bulking
Installation (KBI) complete with fittings, valves, pipe supports,
concrete footing, etc as shown in the Drawing No:
f. Installation of one (1) nos. 75mmØ sch10 stainless steel water

pipelines from header to Pumphouse C at Kuantan Bulking
g. Installation of one (1) nos. 75mmØ sch10 stainless steel water

pipelines from header to office building at Kuantan Bulking
h. Installation of one (1) nos. 100mmØ sch10 stainless steel header at

Kuantan Bulking Installation (KBI) complete with fittings, valves,
pipe supports, concrete footing, etc as shown in the Drawing No:
i. The fabrication and installation of the following shall be included

under this item: -
 Tee guide bars in every tee joints as per engineer’s instruction

and drawing provided.
 Supply and fabricate to tie up new water pipeline to existing
water pipeline as per engineer’s instruction. Works included to
do modifications works to complete installations.
j. All the necessary pipe shoes, supports and materials required for the
complete installation of the above system shall be provided by the
Contractor.
2. All piping works including valves, fittings and supports indicated on the
drawings shall be installed. Pipe supports are to be provided in
accordance with the Employer’s specifications as shown in the drawings
or if not specified to be specified by the Contractor. The Contractor is
to supply details of pipe supports specified by them for approval by the
Employer.
3. All pipes and fittings shall be pre-cleaned using circular wire-brushes

before installation. Every butt-welded joint shall be tested for weld
penetration using a gauging plate and all excessive weld penetration
shall be rectified before further installation.
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4. The Contractor shall then test and commission the water pipeline. The
work is including of proper handover, manpower support until
completion.
5. All underground cables must be installed inside a poly pipe or GI pipe.

All cable tray supplied must be hot-dipped galvanized c/w 1 inch GI
angle iron on both its sides. All cable termination to panel box, motor,
actuator and etc. are inclusive of stainless steel/brush cable gland IP65.
6. All cable/armoured cable using Mega Cable include 1 meter each of

steel band PVC coated to fixing the cables with galvanized bolt & nut.
7. Stainless steel panel box are include stainless steel panel lock.
8. Tagging, labeling and numbering of panel box, cables and etc. with
appropriated material are included in this quotation.
9. On completion of installation and welding works, all steel pipes, fittings,

supports, etc. shall be painted as described under Clause D (7).
10. The Contractor shall provide all welding materials, bolts and nuts,
jointings and gasket, plants and all other materials such as pipes,
valves, fittings, nipples, unions, etc. which are required for the
completion of the works as stated above.
11. The Employer shall supply the Contractor with the sizes and quantity of
material i.e. pipes, valves, fittings and etc.
12. The Contractor is advised to measure and check the quantity of pipes,
fittings and materials required as the quantity of materials to be supplied
by the Employer is only an estimate of the actual requirement. The
Contractor is also advised to visit the site to check for himself the extent
of works required and to clarify with the Employer all doubts and
uncertainties before submitting his quotation.
13. The Contractor shall provide all the other necessary materials, tools,
plant and any other equipment which would be required for proper
execution and completion of the Works as stated in Clause 1.
14. The Contractor shall take delivery of the materials to be supplied in

parts or in whole from the Employer’s designated stores which shall be
sited inside Kuantan Bulking Installation, FGV Bulkers Sdn Bhd. If the
designated store is sited more than 25 km radius of FGV Bulkers Sdn
Bhd, any extra transport cost incurred by the Contractor shall be borne
by the Employer. The amount of extra cost involved shall be mutually
agreed between the Employer and the Contractor.
15. Loading and transporting of the materials at the employer’s designated

stores shall be the responsibility of the Contractor.
16. Once the Contractor has taken delivery of the material, he shall be
responsible for the material and shall, in the joint name of the employer
and Contractor insure with an insurance Company the material up to
the value of its market price against loss, damage or destruction by fire,
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lightning, earthquake and theft from the date of delivery to the date on
which the Works is accepted by the Employer.
17. The Contractor shall be responsible for the handling and delivery of the
material to site once he has taken delivery of the materials from the
Employer.
18. The Contractor shall bear all expenses in the cutting of materials
supplied by the Employer to suitable lengths for transportation from the
Employer’s designated stored to the site.
19. After completion of site work, the Contractor shall clean up the site and
remove all debris resulting from his work and leave the area in a
condition that is acceptable to the Engineer.
20. The contractor should visit the site in his own interest and seek any
clarification he needs to enable him to submit a realistic offer, as once
the quotation has been accepted, no variation from the drawing will be
considered, unless specifically authorized in writing by the Engineer and
no claims for extras will be entertained.
(D) TECHNICAL SPECIFICATIONS FOR PIPES, FITTINGS &

FLANGES.
1.1. Standards
Stainless Steel welded pipes in : ASTM A312 Grade 304 Sch10

accordance to
Stainless Steel butt welded : ASTM A403 WP304 Ansi B16.9

fittings in accordance to
Stainless Steel stub ends : JIS A182-F304
Stainless Steel Flanges : ANSI B16.5 Class 150

: Slip-on type
Seamless Carbon Steel pipes in : API 5L Grade B Schedule 40 (STD)

accordance to or any other acceptable international
standards
Seamless Carbon Steel fittings in : ANSI B16.9 made from material

accordance to ASTM-A234 Grade WPB
Carbon Steel Flanges : ANSI B16.5 Class 150

: Slip-on type
1.2. Ends of Pipes and Fittings
The ends of the pipes shall be beveled for joining and butt welding in
accordance to the relevant standards for pipe installation.
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1.3. Welding Seam of Stainless Steel Pipes and Fittings
The height of the internal welding seams for the welded pipes and fittings
shall not exceed 0.3mm.
The internal welding seams shall be factory rounded off and smoothened if
their height exceeds 0.3mm as pigging operation of pipes are required.
All pipes and fittings that do not comply with the above specification will be
rejected.
1.4. Country of Origin & Manufacture
Stainless Steel pipes

and fittings : Malaysia.
Seamless Steel pipes (API) : Japan, South Africa (Tosa), Brazil

(Mannesmann), USA, Argentina
(Siderca).
Seamless Steel fittings (Ansi) : Japan, Thailand (Benken), USA
Carbon Steel flanges : Japan, Europe
Offers from all other countries of origin/manufacture will not be considered.
1.4.1 All standards and related specifications shall be of the latest issue
date and shall include all addenda, revisions and supplements
thereto.
1.4.2 U-bolts for pipe sizes 75mm N.B. and below shall be fabricated from
8mm dia. solid round rods and hot-dipped galvanized.
2. Fabrication and Erection
2.1 Pipeline shall be erected in as neat and orderly a manner (in groups or banks
wherever applicable) as is consistent with satisfactory supporting
arrangements for easy operation and maintenance. All piping equipment and
fittings requiring regular attention of the operating and maintenance
personnel shall be made readily accessible. Also, adequate clear working
spaces shall be provided around the equipment which requires frequent
servicing.
2.2 The fabrications and erection of the pipes and fittings shall be in accordance
with the following standards :-
 Piping system for Petroleum Industry : BS 3351
 Class II Metal Arc Welding of Steel Pipelines

and Pipe Assemblies for Carrying Fluid : BS 2971
 Welder approval : BS 2971
2.3 All standards and related specifications shall be of the latest issue date and
shall include all addenda, revisions and supplements thereto.
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2.4 All conflicts between requirements for this specifications and related
standards and drawings shall be referred to the Employer for clarification in
writing prior to the purchasing and processing of materials and the
installation of the materials.
2.5 Unless otherwise indicated on the Drawings, all pipe to pipe joints shall be
butt welds. Single fillet weld sleeve joints are not permitted. All pipe ends
shall be properly prepared for butt joinings.
2.6 Branches provided by the Employer shall either be screwed or butt welded
fittings. The Contractor shall grind the internal bores of the branches and
tees to a taper to match their bores with those of the adjoining pipes prior to
joining. Where the branches are not supplied for the construction of pipeline
where pigging operations are not carried out, the Contractor shall fabricate
the branches with pipes supplied by the Employer. Those fabricated
branches shall be properly reinforced in accordance with the requirements of
applicable standards and shall be the “set on” type. The branch pipe shall be
prepared so as to permit full penetration welds. Preparation of welding
technique and cutting shall be in accordance with applicable standards. The
minimum angle of branches shall be 45 degrees but angles of 90 degrees is
preferred.
On 200mmØ and 250mmØ pipelines used for handling vegetable oil where
pigging operations are carried out, branches shall only be fabricated from
standard butt-welding fittings.
2.7 Joints shall be properly supported and aligned as accurately as is practicable

by jigs or clamps so that the joint is relieved of all extraneous loads during
welding. The alignment shall be preserved during welding and the clamp
shall not be removed until at least half the root run has been completed and is
uniformly distributed around the circumference of the joint.
2.8 Slip-on flanges shall have their bores machined to match the external
diameter of the pipe. Flange bolt holes shall not exceed 1/32” of the bolt
diameter. Welding neck flanges shall have their bores machined to match the
nominal inside diameter of the pipe and shall have ends prepared suitable for
welding.
2.9 Flanges shall be aligned as accurately as is practicable. Flanged joints shall

be fitted up so that the gasket contact faces bear uniformly on the gasket and
then made up with relatively uniform bolts stress. The flanges shall be even
parallel and sufficiently rigid not to be distorted by the bolt load. The flange
bolts shall be tightened, working at diametrically opposite nuts alternatively.
The bolts shall extend fully through their nuts.
2.10 The Contractor shall ensure that before all pipes to pipes or pipes to fittings
are welded together, the butt welding ends are properly beveled. Where end
beveling is required, the bevel shall be shaped by machine or other approved
shaping methods to obtain a reasonably smooth surface suitable for welding
and free from tears, shear drags, scale and grease. All welding faces and
adjoining surfaces for the distance of at least ¼” from the edge of the
welding groove shall be thoroughly cleaned before jointing.
2.11 After fabrication, all loose scales, weld spatter, slag, sand and other foreign
material shall be removed from the piping.
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2.12 Weld defects may only be repaired with the written permission of the
Engineer. All defects shall be removed by flame or arc grouting, grinding,
chipping or machinings. All repair welds shall be preheated and postheated
as originally required and the basic principle of the same welding procedure
initially used shall be employed as far as possible. All repairs shall be at the
Contractor’s expense and the defective piece shall be retested in accordance
with the provision of these specifications.
2.13 Should any pipe be required to be bent or formed, it shall be done by any hot
or cold method permissible by radii and material characteristics of the pipe
being bent. It may be bent to any radius which will result in a bent arc
surface which is free of cracks and substantially free of buckles. Pipe bends
shall have a smooth curve with a minimum ovality of thinning. Differences
between diameter measured on major or minor axes shall not exceed 5% of
the outside diameter of the pipe. Wall thickness of the pipe after bending
shall not be less than 87½% of the nominal wall thickness.
2.14 For screwed pipework, extreme care shall be taken to avoid overtightening of
screwed joints during installation.
2.15 All sections of welded pipe shall be closed by use of a night cap when not
being worked on or at the end of each day’s work or on the occasion of any
stoppage of work to prevent entrance of small animals or foreign matter and
shall not be re-opened until work has resumed.
2.16 Oil resistant gasket such as Tombo No. 1000 or equivalent approved type
shall be used. The gaskets shall be able to withstand services temperature up
to 150 deg F and pressures up to 150 psi saturated steam. Nicks, dents or
gouges on the flange surfaces are to be avoided to enable the gasket to
provide a good seal.
2.17 Basket strainers with stainless steel screen fabricated from stainless steel
perforated sheet shall be supplied as per drawing provided. The strainer shall
have baskets which are easily removable for cleaning. The maximum clear
opening of the screens shall be 3mm.
3. Weldings
3.1 Unless otherwise ordered, welding and heat treatment shall be in accordance
with BS 2971 as appropriate for the pressure and temperature to which the
pipe will be subjected to. Best quality electrodes with filler material suitable
for the pipe material joints shall be used at all times and their makes shall be
employed and shall have previously undertaken selected tests as described in
BS 2971. Quality welding requirements shall be maintained throughout the
contract.
3.2 The use of backing rings is prohibited.
3.3 The following requirements and dimension shall apply to preparation and
weld runs :-
3.3.1 In all cases, the fusion passes shall be smooth, free from defects and
together with the adjoining pipes shall be thoroughly cleaned, free
from all scale, rust, oil, grease, paint or other foreign matter.
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3.3.2 Butt welding reinforcement shall be uniform and not less than 1/16”
or more than 1/8” in heights and shall merge smoothly into the pipe
surface without undercut.
3.3.3 Fillet welds shall be regular in form and without undercut.
3.3.4 Root penetration shall not exceed 1/16” for all pipes.
3.3.5 Initial root runs shall not show lack of penetration or non fusion.
3.4 Parts to be jointed together shall be carefully aligned and tack welded
together so that the final welded assembly will conform to the required
dimensions within reasonable tolerances. Tack welds of sufficient number
and suitable proportions to hold the parts in space during ordinary handling
shall be made. Small tack welds i.e. between ½” to ¾” in length penetrating
to the bottom of the groove and free from cracks and other deposition faults
may be included in the first pass provided they have been made by a qualified
welder with electrodes of the same quality required for the first pass.
3.5 The Contractor shall ensure the weld soundness on all layers of weld. All
welds shall be visually examined externally for faults and irregularities.
3.6 The Contractor shall exercise care in ensuring that successive layers of weld
are uniformly distributed around the joints to avoid excessive stress
concentration. Each layer of deposited weld shall be thoroughly cleaned
prior to the deposition of the following weld metal layer. Surface defects
found shall be chipped or ground out.
3.7 THE CONTRACTOR IS TO SUPPLY QUALIFIED PIPE WELDERS

(MINIMUM 5 YEARS’ EXPERIENCE) AND A RESUME OF THE
WELDERS’ EXPERIENCE AND WELDING QUALIFICATIONS ARE TO
BE SUBMITTED FOR THE EMPLOYER’S APPROVAL.
4. Draining and Pigging
4.1 The internal bores of butt welded fittings, bends and tees used on the pipes
that require pigging shall be ground to a taper of 1 : 4 to ensure that the
bores of the fittings match the bores of the pipes at the joints.
4.2 On the pipes that require pigging, all equal tee and branch connections over
100mm NB are to have internal guide bars welded over the branch opening as
indicated on Drawing No. BPT/03/025. Guide bars shall be spaced not more
than 65mm apart.
4.3 Every weld in the pipes that require pigging shall be hand gauged. After each
additional length of pipe has been welded, it shall be gauged over its entire
length including the preceding circumferential and branch welds with a gauge
consisting of 2 steel discs rigidly fixed to a shaft of the following
dimensions:-
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Diameter of Distance Between
Size
Steel Disc Disc
300mm NB 295mm 610mm
The gauge shall be coupled to an extension of adequate length. The

gauge shall slide freely through the pipe and joints in either direction
without binding or catching when operated by hand.
All internal projection causing fouling or interference shall be

ground or scraped off until the gauge is able to slide freely.
4.4 Pigging
4.4.1 After installation and completion of pressure testing of the

pipes that require pigging, the pipes shall be cleaned and
drained of water as described below.
4.4.2 The pipes shall be flushed with water until it is flowing from
the lines in a clean state.
4.4.3 A cleaning pig shall be passed through the water filled lines
using compressed air as the driving medium for at least three
passes with the cleaning pig bypass plug open, after which
the plug shall be closed and a minimum further three passes
made or until such time as the water being displaced shall be
in a clean condition and the foreign matter immediately
preceding the cleaning pig shall not exceed 25 gm.
4.4.4 The gauging pig shall then be passed through the water filled
lines using compressed air as the driving medium for at least
3 passes. The gauging pig shall pass through the line on 3
consecutive passes with not more than 10% variation on the
time taken from launching to receiving.
4.4.5 Once the gauging of the system has been accepted, a

polyurethane foam pig shall be continuously blown through
the lines to remove all residual water from the system until
such time as not more than 500 c.c. of water is removed from
the receiving trap and foam pig.
5. Threading
5.1 Unless specified to the contrary, pipe threads shall be male taper
threads. Threading of the pipes or attachments shall be done after
bending, forging or heat treatment but before testing. Threads shall
be concentric with the outside of the pipe and shall conform to BS21.
5.2 Threads shall be cut with new sharp dies to ensure good quality form
and finish.
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5.3 Threaded joints shall be made up with Teflon (PTFE) jointing tape.
15mm wide tape shall be used for pipe sizes up to and including
50mm NB and 25mm wide for pipe sizes over 50mm NB.
6. Pipework, Testing and Inspection Procedure
6.1 All piping tests shall be witnessed and approved by the Engineer or
his representative.
6.2 Where piping system to be tested mate up to equipment or piping

which cannot be included in the test, these items shall be isolated
from the piping by means of spades or similar pieces appropriate to
the service and usage.
6.3 Test pressures and procedures shall generally be as detailed in the

BS 3351.
6.4 The Contractor shall be responsible for the proper administration of

all tests, test records and inspection requirements of this
specification including the codes, standards, rules and regulations
specified herein. He shall maintain an accurate records of all tests
carried out for the duration of the Contract. Test records details shall
include date of test, identification of the piping tested, test fluid, test
pressure and approval by the Engineer.
6.5 The Engineer shall be responsible for the approval of all tests and in
addition, he may exercise his discretion in calling for any further
tests as may be required from time to time.
6.6 Where prefabricated piping has been shop tested and approved,
further system tests may be required in accordance with this
specification, at the discretion of the Engineer.
6.7 Prior to testing pipework, all loose foreign material such as scale,
sand, weld spatter, etc. shall be removed and all lines flushed clean.
6.8 All shop hydrostatic tests shall be made with clean water. Salt or
brackish water must not be used.
6.9 All instruments that may be adversely affected by pressure or foreign

materials i.e. scale, grit, weld slag, etc. shall not be inserted during
testing. Temporary plugs or blank flanges shall be provided by the
Contractor to close off the connections as required.
6.10 Steel piping generally shall be tested with water in accordance with
the code and test pressure of 1.5 times the designed operating
pressure subject to a maximum of 225 psig.
6.11 The compressed air system shall also be tested with water in
accordance with the above procedure.
6.12 The Contractor may, if he chooses, to carry out a preliminary air test
at not more than 25 psig pressure prior to the hydrostatic test to
locate major leaks.
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6.13 The hydrostatic pressure test shall be maintained for a sufficient time
at the discretion of the Engineer to determine the leaks in the system.
6.14 All pressure gauges, equipment, materials (including water) and

other facilities shall be provided by the Contractor for the tests. The
Contractor shall be responsible and shall bear all expenses in the
transporting of the water from the source of supply to the pipes to be
tested.
6.15 All gaskets used as spades for closing off piping or equipment for the
testing or erection purpose shall be replaced by new materials for
commissioning.
6.16 All repairs or additions made to pipes which have undergone

pressure testing, the Engineer may at his discretion call for the piping
to be re-tested.
7. Painting
7.1 The Contractor shall provide all materials and workmanship

necessary for the painting of all pipes and fittings. Equipment not
installed by the Contractor, valves and moving parts shall not be
painted.
7.2 Systems may be shop or site painted. However, for shop painted
system, all defects shall be touched up before handling over.
7.3 Any fees necessary for Statutory Approval e.g. Scaffolding, shall be
the Contractor’s responsibility.
7.4 All paint supplied and used by the Contractor shall be of good
quality and shall be stored in a dry place. No defective paint shall be
used.
7.5 Surfaces to be painted shall be dry and free from oil, grease, dirt and
rust and suitably prepared for application of paint to avoid any
likelihood of adhesion problems. Paint shall not be applied when the
Relative Humidity is 85% and above.
7.6 In all cases where parts will be inaccessible after shop assembly,
they shall be prepared and full system applied before assembly.
7.7 Site hardware, gratings, equipment or accessories removed by the

Contractor to gain access to any area shall be reinstalled by him
immediately after completion of work in the particular area.
7.8 Where the shop painted coat has been damaged exposing the metal
surface, the Contractor carrying out the site painting shall rectify
same before handing over. The affected area shall be scraped and
edges of the damaged paint shall then be beveled with sandpaper.
The patches of new paint shall overlap the old by at least 50mm all
round.
7.9 All surfaces prior to painting shall be hand and power tool cleaned.
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7.10 All deposits of oil, grease, dirt and foreign matters, fluxes and fume
deposits adjacent to weld runs, shall be removed by solvent cleaning
or fresh water washing.
7.11 All loose rust and millscale shall be removed by means of

handscraper, chipping hammer, hand or power wire brushing, power
grinders, power impact tools, etc. This process shall be continued
until all visible rust, non adherent millscale and millscale readily
loosened by the impact tool(s) are moved. All residue, dust and
loose material resulting from the above shall be removed from the
surface.
7.12 Tools shall be used in such a way as to leave no burrs, sharp edges or
cuts on the surface. Excessive power wire brushing shall be avoided
as detrimental burnishing of the surface may occur.
7.13 All pipes and fittings shall be painted in accordance with the colour
scheme to be provided by the Engineer.
7.14 All pipes, fittings and supports shall be given two (2) coats of
epoxymastic paints of an approved quality at 100 DFT per coat,
followed by one (1) coat of polyurethane of an approved quality of
50 - 60 DFT per coat.
7.15 For underground pipings, in addition to two (2) coats of coal tar
epoxy paints of an approved quality at 125 DFT per coat, these
underground pipings shall be wrapped with one layer of DENSO
TAPE at all underground sections and up to a height of 0.5 metre
above ground level at both ends of the pipes when they exit from the
ground.
7.16 The following brands of paint is approved for usage in the above works
:-
 KCC (Korea) - Koremastic 500/Koretane 300
 Jotun (Sweden) - Jotamastic 87/Hardtop AS
 Nippon (Japan) - Copon 8048/Nippon Polyurethane
7.17 All surface preparation and application of paint shall be subjected to

inspection by the Engineer for compliance with this Specification
and the paint manufacturer’s recommendations.
7.18 In addition to visual inspection, each paint coat shall be tested for its
film thickness by means of a wet and/or dry film thickness gauge.
The tests shall be carried out at points nominated by the Engineer.
7.19 Work rejected by the Engineer shall be rectified at the Contractor’s

expenses.
14
(E) SPECIFICATIONS OF VALVES AND GAUGES FOR TANKS AND
PIPELINES
1.0 Gate Valves
1.1 Full Bore Stainless Steel and Cast Steel Gate Valves
a) All valves to be supplied under this group shall be robustly

constructed of high grade materials combining proven design
features with modern manufacturing techniques generally in
accordance to BS 1414 and API 600 Class 150 flanged to Ansi
B16.5 Class 150 and drilled.
Other specifications :
 Stainless Steel 304 valve trim materials
 Outside screw rising stem type
 Solid wedge type
 Maleable iron or steel handwheel
b) Only proven brands will be considered such as Kitz. In this

context, valves manufactured in the Republic of China, Taiwan
and Korea are not acceptable. Manufacturer’s Certificate and
proof of the country of origin of the valves supplied will have to
be submitted at time of delivery of valves.
2.0 Ball Valves
2.1 Reduced Bore Stainless Steel Ball Valve

features with modern manufacturing techniques and screwed
ends to BS21.
 Floating ball
 Lever operation
 Seat material shall be reinforced PTFE
 Service rating of 100 psig compressed air at 50°C
b) Only proven brands will be considered such as Kitz, Hisaka or

JC. In this context, valves manufactured in the Republic of
China, Taiwan and Korea are not acceptable. Manufacturer’s
Certificate and proof of the country of origin of the valves
supplied will have to be submitted at time of delivery of valves.
2.2 Full Bore Carbon Steel Floating Ball Valve

features with modern manufacturing techniques generally in
accordance to API 6D Class 150, flanged to Ansi B16.5 Class
150 and drilled.
15
 Valves operation with lever handle for 6”Ø size and below
and gear-operated for 8”Ø size and above
 Seat material shall be reinforced PTFE
 Full bore and suitable for pigging operation
b) Only proven brands will be considered such as Kitz, Hisaka, or

JC. In this context, valves manufactured in the Republic of
China, Taiwan and Korea are not acceptable. Manufacturer’s
Certificate and proof of the country of origin of the valves
supplied will have to be submitted at time of delivery of valves.
3.0 Check Valve
3.1 Stainless Steel and Cast Steel Swing Check Valve
Valves to be supplied under this group shall be in accordance to B.S.

1868 Class 150 or its equivalent with their latest amendments,
revisions and supplements thereto. These valves shall be flanged in
accordance with Ansi B16.34 Class 150 and drilled.
 Stainless Steel 304 valve trim materials
 Approved Brand : KITZ
3.2 DISCO Non-Return Valves
Valves patented fixed centering lugs for easy alignment between

flanges and optimum guidance of valve disc.
 Body : Stainless Steel

 Approved Brand : Gestra
4.0 Pressure Gauge
4.1 Stainless Steel Pressure Gauge
Pressure gauges of bourden tube construction shall conform to

BS1780 : Part 2 or its equivalent and shall be of minimum 4”dia.
type. For pressure gauges the scale value shall be ranging from 0 – 8
bar with units marked in bar and psi. For compound gauges, the scale
values shall be ranging from -1 to 5 bar with units marked in mm Hg,
bar and psi.
 Stainless Steel 304 gauge materials
 Fluid medium – Palm Oil, vegetable oils & Biodiesel
 Size ½” BSPT end connection
16
5.0 General
5.1 The valves specified and described under Clause 1.0, 2.0 & 3.0
above will be fitted in line pipes for conveyance of palm oil and
other vegetable oils. Line pipes will be of API 5L Grade ‘B’
Schedule 40 (STD) grade or ASTM A312 Grade 304 Schedule 10.
5.2 Bodies
Valves bodies are to be generously proportioned and shall have

flanged ends, unless otherwise stated. Seat rings are to be firmly
secured in the bodies to prevent them becoming loose under all
normal service conditions.
5.3 Material of Construction
All parts in contact with the fluid medium to be conveyed shall not
be made of copper or its alloy.
5.4 Pressure Temperature Rating (Steel Valves)
Pressure-temperature rating shall be in accordance with Ansi

B16.34 or BS 1560.
(F) TECHNICAL SPECIFICATIONS FOR ELECTRICAL WORKS
SECTION A – MAIN SWITCHBOARDS AND GENERATOR

SWITCHBOARD
1. GENERAL
The switchboards as detailed in the accompanying drawings shall be

supplied, installed, connect-up, tested and commissioning into service by the
Contractor including all termination incoming and outgoing cables works.
2. GENERAL CONSTRUCTION
All the switchboards indicated on the relevant drawings shall be suitable for
floor-mounting, free-standing or wall mounting as the case may be, dead-
fronted type, metalclad, cubicle board, fitted with the required number of
circuit breakers, isolators, switch fuses, fuse-switches, necessary instruments,
protection devices, indicating lamps, contactors, current transformer,
busbars, internal interconnected wiring, transformers, cable end-boxes and
all other items necessary to effect completion of the switchboards.
The switchboards shall each consist of the required number of sheet steel
enclosures for mounting all the items of electrical equipment and
components as required. The structural work of the cubicles shall comprise
welded or module type M.S. angles with boxes, cable glands, terminal blocks
and other relevant items. Each cubicles shall be enclosed on the front, sides,
rear and top with removable M.S. sheet panels of not thinner then the
following gauges :-
17
 Front Panel : No. 12 SWG
 Rear, Side & Top Panel : No. 14 SWG
The controlling circuit breaker or isolator for switchboard shall be mounted

in its own separate cubicle and shall be completely isolated from the rest of
the components on the switchboard and all incoming “live” terminals and
conductors shall be fully insulated by means of insulated paneling, sleeving
or other approved means in such a manner as to prevent accidental touch of
the “live” metal parts or conductors of the incoming supply cable from its
point of entry to the switchboard to the incoming terminals of the circuit
breaker or controlling isolator.
3. BUSBAR
Busbar and busbar connections to switching devices in the switchboards

shall comprise high-conductivity, tinned copper bars of current rating and
sufficient cross-sectional areas to cater for the current ratings stated on the
relevant drawings. The rupturing capacity of the busbars on the main M.V.
Switchboard shall be 31MVA at 415V, 3-phase, 50H, A.C. (43.3KA., A.C.
symmetrical interrupting rating at 415V). Whilst the busbars for the others
sub-switchboard shall have a minimum A.C. symmetrical interrupting ratings
as stated on the Schematic Diagrams. The temperature rise as required by
B.S. 159 : 1957 and busbar markings, clearances between busbars, other
current-carrying conductors and the structural frame works of the
switchboards shall be in accordance with the requirements of B.S. 158 :
1961.
“Phase” and “Neutral” busbars shall be of similar cross-sectional areas in

each cast. Busbar supports shall be of the heavy duty type, fabricated from
porcelain or other non-hygroscopic insulating material or approved type and
of adequate mechanical strength. The busbars shall be so spaced within each
switchboard so as to be installed in parallel or edge-to-edge disposition.
4. INTERNAL CONNECTION & WIRING
PVC-insulated cables of appropriate current ratings and voltage grades to

suit the various circuits concerned, shall be utilized for interconnecting
switching devices, instruments, relays and other relevant circuits within each
switchboard. All such cables shall be nearly bound and cleated to frame
supports by means of approved-type PVC binding strips or saddles, using
non-corrosive type screws or bolts & nuts. Termination of PVC
interconnecting cables shall be by means of soldered type or compression
type copper lugs fitted to either end of each cable-run and these, in turn, shall
be fastened to busbars and terminals of switching devices, instruments and
other items of electrical equipment by means of suitable brass bolts, brass
washers, steel spring washers and brass nuts with lock-nuts. Where the
current ratings of interconnecting circuits within the switchboards are too
high to permit the use of PVC insulated cables, copper busbar
interconnections may be used in lieu of the cables provided that clearance
between the framework and other busbars within switchboard meet the
requirements of B.S. 158-1961. Terminations of interconnecting busbars
shall be well tinned before being connection in position.
18
5. EARTH CONTINUITY
Each switchboard shall be fitted with a built-in earth-continuity, thinner

copper busbar of not less than 25mm x 3.2mm cross-section and which shall
extend throughout the full length of each switchboard. Each switchboards
framework, main earthing lead, incoming and outgoing feeder earthing leads
shall be securely bonded to its earthing busbar.
6. TERMINATIONS
All incoming and outgoing feeder cables to each switchboard shall be

provided with appropriate cable end-boxes and/or brass terminal glands and
terminal blocks, to suit the types and sizes of such cables as stated in the
relevant schematic diagrams accompanying this document.
7. LABELS
Black ivoring labels with white lettering engraved thereon (PVC, adhesive-
type labels shall not be accepted) shall be provided and fixed immediately
below or on panels of switching devices, stating details of the circuits
controlled by such devices. In addition, a main label with 25mm high
lettering engraved thereon and stating the designation of the switchboard
concerned, shall be provided and fitted on the top panel of each switchboard.
8. TROPICALISATION
Each switchboard with all its components shall be fully tropicalised and
suitable for used in an ambient temperature of 90 deg. Fahrenheit under very
humid, tropical conditions.
9. PAINTING
Each switchboard shall be well cleaned and derusted, after which it shall be
treated internally and externally with two (2) coats of an approved-type anti-
corrosive paint. The switchboard shall be finished with two (2) coats of
stove-enameled paint in matt-finish, dark battleship grey. After each
switchboard is delivered to the site and installed in position with the
connection of all incoming and outgoing feeder cables completed, all
scratched or chipped portions of paint work shall be resprayed with the same
colour finish in such manner as to present a clean surface, free from patches
or blemishes.
10. MANUFACTURER’S TESTS
Prior to the delivery of each switchboard to the site, the switchboard shall be
tested at the Manufacturer’s Workshop in accordance with the requirements
of Jabatan Bekalan Elektrik Malaysia. The results of such tests shall be
submitted by the manufacturer to them for registration. The Contractor is
required to submit four (4) copies of the Manufacturer’s Tests Results,
together with four (4) copies of the Jabatan Bekalan Elektrik Malaysia letter
of registration of each switchboard, to the Engineers for distribution to the
various parties concerned. It shall be the responsibility of the Contractor to
ensure that each switchboard is properly registered and accepted by the
Jabatan Bekalan Elektrik Malaysia before commissioning into service same
19
and no claims for compensation from the contractor resulting from
modification works required by the Jabatan Bekalan Elektrik Malaysia on
such switchboards before acceptance is given, shall be entertained.
11. CIRCUIT BREAKERS, FUSEGEAR & ISOLATORS
11.1 Air Circuit Breaker (ACBs)
Where ACBs are specified on the Drawings the ACBs conform to

the following requirements :
a) Each ACB shall be a metalclad, T.P. manually-operated

(unless where stated on the Drawings as being electrically
operated type), withdrawable type, suitable for flush-
mounting in switchboards, distribution boards or control
panels.
b) A bolted-type, solid “neutral” link shall be provided and

fitted in the same compartment as its relevant ACB.
c) The ACBs shall match the current and voltage ratings stated
on the relevant Schematic Diagrams and be manufactured in
accordance with B.S. 862 : 1959 or B.S. 4752 : 1971. The
rupturing capacities (in MVA) or symmetrical interrupting
ratings (in KA.) stated against each ACB on the relevant
schematic Diagrams shall be based on a 415V, 3-phase, 4-
wire, 50H, A.C. supply rating and all ACBs supplied for the
contract works shall be not less than the rupturing capacities
or interrupting ratings stated on the said diagrams.
d) Each ACB shall be fitted with a shunt-trip device and

provided with C/T-operated, magnetic overcurrent trips on
all 3-poles (i.e. on all 3 “Phase” of the electricity supply) and
fitted with adjustable settings. Provision shall also be made
for external connections to automatic or manual devices
operating in conjunction with the ACB’s shunt-trip device.
e) Every ACB, shall be fitted with interlocking facilities to
prevent closing of the ACB in its withdrawn position. A
mechanical “On/Off” indicator shall be built-in with the
mechanism of the ACB’s operating handle and provision for
padlocking the handle in the “Off’ position shall also be
made.
f) All test and setting required by TENAGA NASIONAL

BERHAD is to be carried out by Contractor and the cost of
such tests deemed to have been included in the quoted sum.
11.2 Moulded Case Circuit Breakers (MCCBs) and Miniature Circuit

Breakers (MCBs)
Where MCCBs and MCBs are required to be provided and

installed for switchboards, control panels or distributions boards
for the contract works, the contractor shall supply and install all
such MCCBs and MCBs which meet the following requirements :-
20
a) Each MCCB and MCB shall be of the all-insulated,
moulded, T.P. or D.P. or S.P. (where stated on the relevant
Schematic Diagrams), non-withdrawable type, suitable for
flush-mounting in the switchboards, distribution boards or
controls panels.
b) A bolted-type, solid “Neutral” link shall be provided and

fitted in the same compartment as its relevant MCCB or
MCB.
c) The MCCBs and MCBs shall match the current and voltage
ratings of the circuits they control and as stated on the
relevant schematic Diagrams. In additional, the MCCBs and
MCBs shall be suitable for the symmetrical interrupting
rating as stated on the relevant Schematic Diagrams in
Kiloamperers (KA.) at 415V., 50H., A.C.
d) MCCBs shall be manufactured in accordance with B.S. 3871

: Part 2 : 1966 and MCBs shall comply with the
requirements of B.S. 3871 : Part 1 : 1965. In addition, they
shall be of makes approved for use by the Jabatan Bekalan
Elektrik Malaysia.
e) All MCCBs and MCBs shall be thermal magnetic type with

increase time characteristic for protection against overload
and short circuit currents, operating on all poles of the
supply and suitable for the current rating stated on the
relevant Schematic Diagram. The tripping device shall be so
designed as to prevent “Single-phasing” of the supply (in
case of D.P. and T.P. breakers only) should a fault occur on
any one “Phase” of the supply.
f) Where it is stated on the Schematic Diagrams that shunt-trips

are required for certain MCCBs or MCBs such devices shall
be provided and built-in with the relevant breakers, with
provision being made “tripping” of the MCCBs or MCBs.
g) Every MCCB or MCB shall be provided with a mechanical

“ON/OFF” indicator operating in conjunction with the
operating handle of the circuit breaker. A facility for
padlocking the operating handle of the MCCB or MCB in
the “OFF” position shall also be provided.
11.3 Fusegear Units (Fuse-Switches & Switch-Fuses)
Where it is required for fusegear units to be utilized on

switchboards and elsewhere in this Contract Works, the Contractor
shall supply and install such units which shall conform to the
following requirements :-
a) Each fuse-switch or switch-fuse unit shall be of the S.P&N.,

or D.P. or T.P&N., metalclad type as stated on the relevant
Schematic Diagrams. Where the units are required for
installation in switchboards, distribution boards and control
21
panels, they shall be suitable for flush-mounting in the
boards or panels. Individual units installed on walls,
frameworks of machines or equipment, or on brackets and
stands, shall be housed in their own metalclad or cast-metal
alloy casings which shall be of the dust and oil-tight type,
with facilities for cable entries and exists.
In outdoor locations, or in areas where water or dampness is

always present, the casings of the units shall, in addition to
being dust and oil-tight, be made weatherproof with facilities
for the entry of incoming and outgoing cables.
b) The moving contacts of fusegear unit shall be of the heavy-

duty, silver plated, quick-break/quick-make type, irrespective
of the effort applied to the operating handle. Fixed contacts
shall be of the spring loaded, self-aligning, silver plates type,
mounted on an insulating panel of high mechanical strength
and with excellent electrical insulating properties. All fixed
contacts shall be fully shrouded and all shrouds shall be
moulded from material which posses good electrical
insulating and self-extinguishing properties, so that the
shrouds give full protection from accidental touch during
fuse replacement or maintenance and assist in ARC control
to give longer contact life.
c) All fusegear units shall be manufactured in accordance with

B.S. 3815 : 1959 and be of makes approved for use in
Malaysia by the Jabatan Bekalan Elektrik.
d) Mechanical “ON/OFF” indicators shall be fitted to fusegear

units for operating in conjunction with their respective
operating handles. Operating handles shall be provided with
facilities for padlocking the handles in their “OFF” position.
In addition, fusegear units shall be provided with built-in
interlocking arrangements whereby, their respective covers
or door may not be opened when the operating handles are in
the “ON” position.
e) HRC fuse-links of current ratings stated in the relevant

Schematic Diagrams shall be provided for all fusegear units.
All HRC fuse-links shall conform to the requirements
described below.
11.4 Isolators
Where isolators are required for installation on switchboards and

elsewhere in the contract works, they shall be metalclad type
S.P&N., D.P. or T.P&N. types as indicated on the Schematic
Diagram. Units used for switchboards shall be of the flush-
mounting type and suitable for mounting on cubicle-type
switchboards. The units shall conform to B.S.S. 861 : Part I : 1955
and B.S.s. 861 : Part II : 1966 where applicable and shall be of the
“ON LOAD” type, fitted with heavy duty contacts, generally
constructed in the same manner as for fusegear units described
under Sub-clauses above. Mechanical “ON” and “OFF” indicators
22
shall be fitted to the units for operation in conjunction with their
respective operating handles.
Operating handles of all isolator units shall be fitted with facilities

for padlocking their handles with “OFF” position and the units
shall be provided with interlocking arrangements whereby their
respective unit covers may not be opened when the switch handles
are in the “ON” position.
12. HRC FUSE-LINKS
12.1 Where it is required for HRC fuse-links to be fitted to fuse-gear

units, cut-outs, distribution fuse boards and other similar current
protection devices to be installed for the Contract Works, the
Contractor shall supply and install HRC fuse-links affording close-
excess current protection which shall enable them to operate
within four (4) hours at 1.5 times the designed load currents for the
circuits which they protect. Such HRC fuse-links shall be those
complying with B.S. 88 : Part 2 : 1987 and fitted with fuse-links
marked to indicate a Class “Q1” fusing factor.
12.2 HRC fuse-links used for 13A fused plug tops complying with B.S.
1363 : 1967 shall be of 13A current rating and manufacturing to
B.S. 1362 : 1953.
13. EARTH FAULT RELAYS
Where earth fault (E/F) relays are to be provided for earth-fault protection of
electrical circuits and feeders as shown on the Schematic Diagrams, the
Contractor shall supply and install such units conforming to the following
requirements :-
13.1 The E/F or IDMT relay shall operate in conjunction with circuit
breakers controlling the electrical feeders or circuits concerned.
13.2 Each relay shall be of the unrestricted, attracting armature type

(unless otherwise stated on the Schematic Diagram) and be
operated through a set of four (4) current transformers of current
ratio, burden and class as stated on the Schematic Diagram.
13.3 The relay units shall be suitable for either flush-mounting or

surface-mounting on switchboard or control board panels and
manufactured in accordance with B.S. 142 : 1966.
13.4 Every E/F or IDMT relay shall be fitted with a hand-reset type,
mechanical flag indicator and provided with adjustable settings
having a range of 10% to 40% of the secondary current rating of its
relevant current transformer.
14. CURRENT TRANSFORMER
14.1 Current transformer (C/Ts) supplied and fixed by the Contractor in

Switchboards or control panels for the operation of ammeters,
power factor indicators, earth-fault relay and magnetic overcurrent
23
tripping devices of circuit breakers, shall be of the type with
appropriate current ratios, burdens and classes as indicated on the
Schematic Diagrams.
14.2 All current transformer shall be of correct dimensions for fixing in

busbars and shall be manufactured to B.S. 3938 : 1973.
15. MEASURING INSTRUMENTS
Wherever instruments for measuring or indication are required to be

incorporated in switchboards, control panels or distributions boards for the
Contract Works, the Contractor shall provide such instruments conforming to
the followings requirements :-
15.1 All instruments shall be provided with square dials and be flush-
mounted in their respective switchboards and control panels.
15.2 The instruments shall be manufactured to the relevant B.S. or other

Standard approved by the Jabatan Bekalan Elektrik Malaysia for
the Main M.V. Switchboards, the instruments shall be fitted with
144mm x 144mm frames. In all other control boards and
switchboards, dial frames of instruments mounted thereon shall be
96mm x 96mm size.
15.3 Voltmeters
Each voltmeter shall be of the M.I.S.C. type, be of suitable voltage

range to suit the circuit concerned and of a high degree of accuracy
the Voltmeter shall be connected in circuit with a 6-position
selector switch and protective cut-outs fitted with HRC fuse-links.
15.4 Ammeters
Each ammeter shall be of the M.I.S.C. type, be of suitable range to

suit the current rating of the circuit. It is meant to operate on
through current transformers. It shall have a high degree of
accuracy and be connected to three (3) busbar-connected under
Clause above and of the correct ratio, burden and class as stated on
the relevant Schematic Diagram. The Ammeter shall also be
connected in circuit with a 4-position, selector switch.
15.5 Power Factor Indicators
Each power factor indicator shall be of the M.I.S.C. type and be

suitable for measurement of 3-phase, 4-wire, unbalance loads
through current transformers (for the voltage coil circuit
protection, HRC, fuse-links shall be used). The indicator shall be
scaled to read from 0.5 capacitive to 1 and from to 0.5 inductive
circuits.
24
16. INDICATOR LAMPS
Where indicator lamps are shown on the Schematic Diagrams for installation
on switchboards and control panels, the Contractor shall supply and install
such lamps to meet the following requirements :-
16.1 All indicator lamps shall be of the transformer operated type and
be suitable for flush-mounting in their respective boards or panels.
16.2 Lenses for indicator lamps shall be of durable quality glass and
coloured to suit the colours stated on the relevant Schematic
Diagrams (for “Phase” indication of the electricity supply, “Red”,
“Yellow” and “Blue” coloured lenses shall be used to indicate
“Red”, “Yellow” and “Blue” phase of the electricity supply,
respectively.
17. CONTACTORS
Where contactors are indicated in the Schematic Diagrams for the Contract
Works, the Contractor shall provide and install such contactors to meet the
following requirements :-
17.1 The contactors shall be suitable for panel-mounting within the

compartments of their respective switchboards, control panels and
distribution boards.
17.2 The contactors shall be of the heavy-duty type, be suitable for

operation on inductive or capacitive holds and be manufactured in
accordance with B.S. 775 : Part I : 1969 or any other equivalent
Specification for contactors approved for use in Malaysia by the
Jabatan Bekalan Elektrik Malaysia.
17.3 The operational life for the contactors shall not be less than 9
Million (9,000,000) operations and be mechanical duty or
utilization shall be Class IV, with a Making and Breaking Category
of A4 as specified under B.S. 775 : Part I : 1969.
17.4 Contact surfaces shall be silver-lated and protected against dust

and accidental contact of “live” parts. For larger current ratings,
contacts are preferred to be of the twin-break type. Auxiliary
contacts, where required in the Schematic Diagrams, shall be fitted
to the contactors units.
17.5 Contactor armatures shall be centrally located to ensure balance

operation and equalized pressure. Armature bearings shall be of
the self-cleaning type. Operating coils shall be of the voltages and
frequencies stipulated in the Schematic Diagram for each contactor
and means shall be provided for easy removals and replacements
of the coils.
17.6 Where contactor are required to be installed outside switchboards

or control panels, they shall be housed in dust-proof, pressed-steel
or cast-metal casing fitted with hinged, lockable doors and be
suitable for wall-mounting or exposed to weather conditions or to
25
the constant presence of water or dampness, they shall be
accommodated in cast-metal casing of weatherproof construction.
All casings for contactor units shall have provision for the entry
and exit for circuit cables wired in conduit or cables of the
armoured multi-core type, as the case may be.
18. TIME SWITCHES
Where time switches are required in the Contract Works for automatic time-
controlled operation of lighting and other circuits, the Contractor shall
provide and fix such switches in switchboards or control panels, or
distribution boards (wherever as indicated on the Schematic Diagrams) to
conform to the following requirements :-
18.1 The time switches shall be of the synchronous type, fitted with 36-
hours spring reserves and 24 hours dial switches (switches to be
provided with adjustable levers for two “ON” and two “OFF”
operation.
18.2 The switches shall be suitable for flush-mounting on switchboard or

control panels and be suitable for operation on a 240V., single phase,
50H., A.C. supply.
18.3 The operation D.P. contacts of the time switches shall be rated at not
less than 10A, for operation in circuit with operating coils of
switching contractors. Means shall also be provided for test or
manual operation of the time switches.
19. AUTOMATIC POWER FACTOR CORRECTION PANEL
19.1 The Contractor shall supply and install and automatic power factor
correction panel at the main M.V. switchboards. The panel shall
from part of the Main M.V. switchboards, with its cubicle
construction, arrangement of busbars, internal components,
interconnections, small wiring and paint finish generally conforming
to the requirements of the Main M.V. switchboards.
19.2 The Automatic Power Factor Correction Panel shall generally

comprise the following components :-
a) A main T.P.&N., MCCB of current and voltage ratings and

symmetrical interrupting rating as stated on the schematic
diagram, for controlling the incoming electricity supply to
the Power Factor Correction Panel.
b) A flush-mounted type, automatic power factor regulator unit,

suitable for the number of switching steps of operation as
indicated on the relevant, ring-type current transformer
(current ratio, burden and class as stated on the schematic
diagram).
c) The required number of capacitor units to form the capacitor

bank (rating of each capacitor and the quantity to form the
capacitor bank shall be as stated on the schematic diagram),
26
which shall be built-in with the cubicle of the Automatic
Power Factor Correction Panel. Each capacitor unit shall be
manufactured to BS comprising a vertically-arranged stack
of flattened roll capacitor elements of high purity aluminium
foil, separated with multiple layers of high grade dielectric
tissue. The steel container shall be internally lined with a
high-grade insulating board. Each capacitor unit is to be
fitted with a built-in discharge resistance network which
shall ensure that the capacitor is fully discharged in not more
than a minute after the electricity supply is de-energized.
The terminals of the capacitor unit shall be of glade ceramic
or other approved insulating material. The capacitor’s
element shall be impregnated with a suitable non-
inflammable impregnate and the whole shall be hermetically
sealed within the container.
d) The required number of contactors to switch in the capacitor

units. The contactors shall be of the voltage and current
ratings stated on the relevant schematic diagram and
conform to the requirements of clause of this specification.
e) 3 nos. – “phase” indicator lamps to indicate the state of the

incoming electricity supply to the Automatic Power Factor
Correction Panel.
f) The required number of indicator lamps to indicated the

operation of the contactors for switching in the capacitor
units (one indicator lamp per contactor is required.
g) One lot of terminal blocks, all necessary internal PVC,

wiring connections and engraved ivorine labels.
h) 1 no. Main Earthing busbar of high-conductivity tinned

copper of not less than 3.2mm x 25mm cross-section.
20. MISCELLANEOUS EQUIPMENT FOR SWITCHROOMS
The following item of equipment shall be supplied and installed by the

Contractor for switchroom, switchboards and Electrical Riser Duct Rooms :-
20.1 Main Switchboard Room
The items of equipment shall be supplied and installed for this

switchroom shall be as follows :-
a) 1 no. Regulation-type, “DANGER” notice to be positioned

on the Sub-Switchboard.
b) 1 no. Regulation-type, “NO ADMITTANCE” notice to be

positioned on the outside face of the door to the Switchroom.
c) 1 no. Regulation-type, shock treatment card, to be hung in a

prominent position on the wall of the switchroom.
27
d) 1 set “AS FITTED” schematic Diagrams of the electrical
installation for the entire complex, to be hung in a prominent
position on the wall of the switchroom.
e) 1 no. 0.6 metre wide x 10mm thick, rubber insulation mat

which shall be the full length of the switchboard and shall be
spread on the floor in front of the switchboard.
20.2 All Electrical Rooms
For each of these rooms, the contractor shall supply and install on
the outside face of the room’s door a Regulation-type “NO
ADMITTANCE” and “DANGER” notice boards.
SECTION B – DISTRIBUTION BOARD/MOTOR CONTROL CENTRE
1. ELECTRICAL SUPPLY
1.1 The electrical supply to the DB will be a nominal 415-Volt, 4-wire, 3-phase
and neutral service.
2. RATINGS
2.1 The DB shall comply with BS 5486 Part 1.
The DB shall have a certified busbar system and incomer switch rated for a
fault level of 43K Amp for one second or better.
2.2 The busbar system shall be rated to carry the full load current, based on the
maximum rating ALL outgoing compartments as per drawing.
2.3 The main switch shall be rated to break the full load current of DB, based on
the maximum rating of ALL outgoing compartments.
2.4 Individual compartment switches shall be rated to break the full load current,
based on the maximum rating of that compartment.
2.5 All cables shall be rated to carry continuously the full current value of their
protective devices.
3. MATERIAL
3.1 All materials shall be new and of best quality.
3.2 All materials shall be manufactured to the relevant British Standard or

equivalent standards applicable to Malaysia.
3.3 There shall be no deviation from the nominated manufacturers and type of
equipment referred to in this specification.
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4. DB ARRANGEMENT
4.1 The DB shall be self supporting, free standing with provision made from
securing to the floor.
4.2 The DB shall be arranged for both front and rear access to compartments and
for cabling to compartments.
The busbars shall be accessible from the front and rear.
4.3 The DB shall be suitable for top and bottom cable entry.
4.4 The DB shall be arranged such that additional tiers may be readily added to
at least one end, for future extension.
4.5 The DB manufacturer shall offer the option of providing the Main incomer,
Switch and metering at either end of the unit to suit the customer’s
requirement.
4.6 The DB shall have a removable plinth.
4.7 The busbars shall run along the top section of the DB with vertical droppers
at each tier.
The busbar system shall be fully shielded from other section of DB.
5. DB CONSTRUCTION
5.1 The DB shall be constructed to BS 5486 Part I and shall be protected to UP

54 as detailed in IEC Publication 144.
5.2 The plinth shall be demountable and may a single assembly to provide a rigid
and straight base for the mounting of the DB sections.
The plinth shall be of welded construction from heavy gauge steel,

approximately 150mm high.
The plinth shall be provided with suitable securing holes for floor fixing.
The outer faces of the plinth shall provide a flush face, to match the outer
faces of the DB.
5.3 The construction of the DB shall be of sheet steel, having a minimum

thickness of 1.5mm generally and 2.0mm for pillars and main frame.
The DB shall be of welded construction with flush front design and radiuses
corners and edges.
5.4 Removable gland plates of minimum thickness 3mm shall be provided on top
of the DB to accommodate all cabling requirements.
5.5 Provision shall be made within the DB for the termination of bottom entry
cables.
29
5.6 Each compartment, whatever its function, shall be fully segregated from
adjacent compartments, to confine damage due to an internal fault.
Any barriers used to effect this segregation shall be of non-flammable

material.
5.7 The DB shall be provided with lifting eye bolts to facilitate handling. A set
of blanking bolts, to replace the eye bolts, shall be supplied by the DB.
Manufacturers for fitting by the Electrical Contractor.
5.8 Where provisions are made for extending busbars and cable ways, for future
additions to the DB, cutouts shall be fitted with screw-fixed cover plates.
5.9 Between each tier of starter compartments, a front access cable way shall be
provided, adequately sized to permit the installation of cables to all
compartments. Access between cable ways and equipment compartments
shall be made via adequately-sized openings fitted with blind grommets.
5.10 Provision shall be made for the routing of wiring between compartments in
different tiers.
5.11 Each compartment containing equipment shall have an access door.
Doors shall have exposed chrome hinges or concealed hinges, which permit
the door to open through 90 or greater.
Door fitted with interlocked switches shall have quick-release catches. Other
doors shall be secured by door handles.
All doors shall be fitted with locks, which shall have the same key differ.
5.12 All other access openings shall be fitted with removable covers fixed by
chrome screws.
6. FINISH
6.1 All steelwork shall be degreased, given an anti-corrosion treatment, primed,

undercoated and top coated with high quality stove enamel.
6.2 An internal steelwork shall be finished gloss white.
6.3 All external steelwork shall be finished semi-gloss paint approved by the
Engineer.
Note : That a high quality pigment is required for this colour to ensure a
good cover.
7. BUSBARS
7.1 In addition to the requirements of Section 3.0 and 5.0 the following shall
apply :-
(i) The busbar system shall consist of air-insulated single copper bars for
three phases and neutral and shall be suitable for extension at one or
both ends.
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(ii) Barriers shall be fitted to all horizontal and vertical busbar
intersections.
(iii) The busbars are to be fully shielded from all other sections of the
panel.
(iv) All bars are to be fitted with colour-coded markers for easy
identification of phases and neutral.
8. EARTHING
8.1 A copper earth bar sized to BS 5486 Part 1, Appendix B, is to be installed

internally along the entire length of the top section of the DB and shall be
suitable for extension in conjunction with the busbars.
8.2 External earthing studs suitable for the connection of an earthing tape shall
be provided on top of the DB, at both ends. These earthing studs shall be
directly bonded to the DB main earth bar.
8.3 From the main earth bar in the DB, vertical earth bars shall be installed and
bonded to each individual equipment compartment. An earthing stud shall
be provided in each compartment.
8.4 At each equipment compartment the door and removable equipment plates
are to be bonded to the compartment earthing stud by means of suitably-sized
greed/yellow PVC insulated flexible copper cable.
8.5 All gland plates are to be bonded to the main earth bar in each DB by means
of suitably-sized greed/yellow PVC insulated flexible copper cable.
9. MAIN INCOMER
9.1 The DB shall have a main isolating switch with 3-phase double break action,
rated to break a load in excess of the sum of the rating of all outgoing
compartments. A solid bolted neutral link of like rating shall be mounted in
the same compartment.
9.2 The main incoming power supply to the DB shall be wired via the main
contacts of the isolating switch. All terminals shall be fully shrouded.
9.3 Adequate provision shall be made for installing the incoming supply cables
to the isolating switch. All terminals shall be fully shrouded.
9.4 The main outgoing terminals of the isolating switch shall be bolted directly
to the busbar system.
9.5 The door for the main isolating switch compartment shall be mechanically
interlocked to prevent the switch being closed with the door open and the
door being opened with the switch closed.
9.6 The “ON” and “OFF” positions of the isolating switch shall be clearly
marked and the switch shall be pad-lockable in the “OFF” position.
31
10. INSTRUMENT COMPARTMENT
10.1 The DB shall have an instrument compartment located adjacent to the main
isolating switch compartment.
10.2 The instrumentation shall comprise a door-mounted ammeter with 3-phase

and neutral selector switch and a door-mounted voltmeter with LINE-LINE
and PHASE-NEUTRAL selector switch.
10.3 The ammeter shall be ranged to the maximum load plus overscale.
The ammeter shall be operated from current transformers, with 1-amp

secondaries located on the busbars in the main isolating switch
compartments.
10.4 The voltmeter shall be ranged 0 – 500 volts with red indicator lines on the
scale at 240 volts and 415 volts.
The voltmeter supply shall be derived from primary fuse carriers, bolted to
the main busbars via secondary fuse carriers located in the instrument
compartment.
The phase fuse carriers shall be black and shall be fitted with HRC fuse
links, with suitable discrimination between primaries and secondaries.
The neutral carriers shall be white and shall be fitted with solid copper links.
11. STARTERS
11.1 Starter shall have a separate compartment.
11.2 Starter compartment shall be designated with a maximum rating value.
All equipment and wiring within a compartment shall be sized to the

maximum rating of that compartment with the exception of fuses, overload
heaters and ammeters, which shall be sized to suit the rating of the associated
motor.
11.3 The starting arrangement for standard starters shall be decided by the
Engineer.
11.4 Clearing working space shall be allowed in all starter compartments for
wiring, maintenance and replacement of parts. In particulars, full allowance
shall be made for the installation and termination of field wiring at the
terminal blocks. With all wiring complete, each item of equipment shall
remain fully accessible.
11.5 Starter equipment shall be mounted within the compartment housing. Only
“through the door” equipment shall be located on doors.
11.6 Starter compartment shall have a double break, 3-phase, MCCB complete
with rotary handle.
The switch shall be sized to break the maximum load for which the
compartment can be rated.
32
The main incoming terminals of the switch shall be bolted directly to the
supply busbars.
Auxiliary contacts shall be provided to isolated all additional incoming

power sources.
The switch shall be mechanically interlocked with the compartment door, to

prevent the switch being closed with the door open and the door being
opened with the switch closed.
The “ON” and “OFF” positions of the isolating switch shall be clearly
marked and the switch shall be pad lockable in the “OFF” position.
All terminals shall be fully shrouded.
11.7 Starter shall have a Contactor and Contactors to suit the starting
arrangements for which it is designed.
Contactors shall be double break magnetically operated with three main

contacts and sufficient auxiliary contacts to suit the control system involved.
Contacts shall be suitable for AC3 Class II operation and shall be sized to the
maximum rating of the compartment.
Contactor coils shall be suitable for operation at 240 Volts 50Hz.
11.8 Starter compartment shall have an overload relay.
The overload relay shall be the directly-connected thermal type or the C/T
operated thermal type as recommended by the manufacturer.
All thermal relays shall be 3-phase combined thermal overload and single
phasing preventor type, with manual reset.
Thermal overloads shall be arranged for hand resetting after opening the
compartment door.
Operation of the overload relays shall de-energize the starter contactor and
illuminate trip indication lamp.
11.9 Starter compartments with which ever specified shall have a thermistor
protection relay.
Thermistor protection relays shall be arranged for hand resetting, after

opening the compartment door.
Operation of the thermistor protection relay shall de-energize the starter

contactor and illuminate the trip indication lamp.
11.10 Starter compartment whichever specified shall have a door-mounted

ammeter, ranged to suit the full load current of the associated motor and with
an overscale facility, to allow for starting loads.
33
A red pointer, adjustable from the front, shall be incorporated in the ammeter
design.
All ammeters shall operate from the yellow phase, via current transformers
having lamp secondary windings where applicable.
Current transformer shall have a minimum burden rating of 2.5 VA and shall
be arranged for the connection of an external current indication circuit.
11.11 Starter compartment shall have a red, door-mounted, stop push button and a
green, door-mounted starter push button for local operation of the drive
motor.
11.12 Starter compartment shall have a door mounted, 3 position selector switch
for local manual and remote manual selection.
11.13 Starter compartment shall have a red door mounted indicator light,
illuminated when the motor is running and a clear door mounted indicator
light, illuminated when the starter control circuit is in a trip condition.
11.14 Starter compartment shall have a terminal rail for the connection of outgoing
and incoming wiring.
The voltage applicable to each group of terminals shall be clearly labeled.
All terminals shall be fitted with identification markers.
Terminals which remain energized when the compartment isolator in

switched “OFF” shall be fully shrouded and warning labels shall be fitted.
Terminals shall be of the screw clamp type for cables up to 50 sq.mm and
stud type for cables over 50 sq.mm.
When sizing terminals full allowance shall be made for field wiring sized to
accommodate volt drop.
11.15 Additional equipment associated with motor control may be housed in the
M.C.C. i.e. Variable Speed Control Units, Transformers for Auto-
Transformer Starting.
Where this equipment cannot be accommodated in the associated starter

compartment it shall be located in an adjacent compartment.
When separate compartments are used door interlocking or full shielding and
warning labels shall be fitted.
Full allowance shall be made for heat output from additional equipment
when designing the M.C.C.
12. SUPPLY SWITCHES
12.1 Each switch provided for the purpose of feeding a supply to an external load
shall have a separate compartment.
12.2 Each switch compartment shall be designated with a maximum rating value.
34
All equipment and wiring within a compartment shall be sized to the
maximum rating of that compartment, with the exception of the fuses, which
shall be sized to suit the rating of the load.
12.3 Each switch compartment shall have a double break, 3 phase, MCCB.
The switch shall be sized to break the maximum load for which the
compartment can be rated.
The main incoming terminals on the switch shall be bolted directly to the
supply busbars.
The switch shall be mechanically interlocked with the compartment door, to

prevent the switch being closed with the door open and the door being
opened with the switch closed.
The “ON” and “OFF” positions of the switch shall be clearly marked and the
switch shall be pad-lockable in the “OFF” position.
All terminals shall be fully shrouded.
12.4 Each switch compartment shall have a door mounted ammeter, ranged to the
maximum rating of the fuse switch.
All ammeters shall operate from the yellow phase via current transformers
having 1 amp secondary windings where applicable.
12.5 Each switch compartment shall have a terminal rail for the connection of
outgoing wiring.
Terminals shall be of the screw clamp type for cables up to 50 sq.mm and
stud type for cables over 50 sq.mm.
When sizing cables full allowance shall be made for field wiring sized to
accommodate volt drop.
The terminals shall be cabled to the fuse switch and neutral link.
a) Internal Wiring
All internal wiring shall be installed complete.
(i) Wiring shall be carried out in single core flexible copper, PVC
insulated cable, rated for operation at 600 volts.
Wiring shall be correctly sized for the duty involved with a

minimum size of 1.5 sq.mm. (30/0.25mm dia.) for control wiring
and 2.5 sq.mm (50/0.25mm) for power wiring.
(ii) Wiring shall be installed in plastic trunking or loomed and secured

to the fabric of the panel, by straps or saddles.
Particular attention shall be paid to the location and protection of

cables installed to hinged doors. Such cables shall be fully
sleeved and shall be clear of the compartment edges and of
35
equipment inside the cubicle with the door in the “open” and
“closed” positions.
(iii) Wiring shall be installed to the following colour codes :
415 volt phase wiring - to appropriate phase colour :

Red, Yellow, Blue
240 volt AC phase wiring - Brown
Neutral - Black
240 volt DC - White
C/T and Signals - Grey
Earth - Green/Yellow
(iv) Internal wiring, shall be installed clear of routes intended for

external wiring.
(v) Each wire shall be fitted with a crimped connector and

identification marker at either end.
(vi) Interlock and control supply wiring between starter compartments

shall be installed in plastic trunking
(vii) located in the cable ways.
b) Labels
(i) Identification labels shall be engraved white/black/white plastic

sandwich type, securely fixed by chrome plated self tapping
screw, except for door mounted push buttons, lamps and selector
switches which, as an alternative, may be fitted with the
manufacturer’s legend plates, bearing the appropriate description.
(ii) Each DB shall have a main identification label of uniform size and
engraved in 12mm high lettering with the DB title.
(iii) Each equipment compartment shall be fitted externally with an

identification label of uniform size and engraved in 4mm high
lettering with :
 The compartment number
 The equipment title
 The equipment reference number
(iv) Each item of equipment, internal and external shall have an

identification label fixed adjacent, engraved in lettering of
minimum height 3mm, with an identification or operation
description.
Such equipment will include individual fuse holders.
(v) Each individual terminal shall be fitted with an identification

marker. Groups of terminals shall also have a voltage
identification label.
(vi) Warning labels shall be yellow/black/yellow trifoliate type

securely fixed with chrome plated self tapping screws.
36
(vii) A warning label shall be fitted to each external cover which gives
access to live parts. Minimum engraving letter height is 4mm.
(viii) Internal wiring labels shall be fitted to shields/shrouds protecting

live parts which are not isolated when the compartment switch is
the “OFF” position.
In the case of terminal rails, the warning label may also from the
protective shield.
Minimum engraving letter height is 3mm.
(ix) Exact wording of all labels shall be agreed with the customer
before label manufacture.
c) Inspections and Tests
(i) Facilities shall be provided for the customers Engineers to inspect

the M.C.C.’s during manufacture.
(ii) On completion of manufacture, facilities shall be provided for the

customers Engineers to inspect the equipment and to witness tests
which shall include :
 Insulation megger tests at 1,000 volts
 Dielectric tests at 2,500 volts for 1 minute
(Excepting equipment not suitable for this test).
 Earth continuity test
 Full functional operation test
 Primary current injection tests on meters and protective
devices
 Low voltage drop out tests
(iii) On notification of completion of manufacture, a mutually agreed

time and date shall be determined for inspection and testing.
(iv) Test Certificates are to be provided to the appropriate British

Standard, together with a typed copy of the test results.
d) Manufacturers Drawings
(i) With the qoutation, sketch arrangements showing the proposed

arrangement of each panel, overall dimensions and estimated
weights. Actual and maximum rating of each starter compartment
shall be shown.
(ii) Two weeks after order, three copies of certified drawings,

showing overall and fixing dimensions, front of panel layouts and
cubicle internal layouts.
(iii) Three weeks after order, three copies of preliminary schematic

wiring diagrams, fully detailed.
(iv) Two weeks after customers comments, three copies of certified

schematic wiring diagrams.
37
(v) Two weeks after certified schematic wiring diagrams, three copies
of certified wiring connection diagrams.
(vi) One week after final approval of certified drawings, one

reproducible copy of each drawing.
(vii) One additional set of drawing prints to be dispatched with the

panels to Site.
e) Equipment and Spares
(i) Two weeks after order, a comprehensive list of the quantities and
type of equipment items proposed for each panel, together with a
priced list of recommended spares.
(ii) Together with the issue of the certified schematic wiring

diagrams, a certified list of the quantities and types of equipment
items to be installed in each panel, containing sufficient
information for the re-ordering from the equipment manufacturers,
of any item required.
(iii) Together with the delivery of the M.C.C.’s, six copies of the
operating manuals.
SECTION C : WIRING INSTALLATION WORKS
1. CABLE-ENTRY DUCTS, ROAD-CROSSING CABLE DUCTS & R.C. CABLE

TRENCHES
1.1 All underground cable-entry pipe ducts to and underground cable-

distribution pipe ducts feeding from the buildings and reinforced concrete
cable trenches within buildings shall be provided and installed by the other
Contractor.
1.2 Wherever it is stated on the accompanying layout drawings that road-

crossing pipe cable ducts are to be provided by the Contractor, shall be
required to supply and lay in position all such road-crossing pipe ducts and
include for the cost of the same in his Contract Sum.
1.3 All road-crossing pipe cable ducts, cable-entry pipe ducts to and cable
distribution pipe ducts away from the buildings shall each be provided with a
non-corrodable draw-wire for the easy drawing-in of cables.
1.4 All cable-entry, cable distribution and cable road-crossing pipe ducts,
whether provided by the other Contractor or the Contractor, shall be
effectively sealed by the Contract (after all cables are laid in position) in
such a manner as to prevent the ingress of water, mud or dirt through the
ducts.
1.5 The Contractor shall closely liaise with the other Contractor in the laying of
all cable-entry, cable distribution and road-crossing ducts, so as to avoid any
breaking-up of concrete walls, floors, aprons and completed road surfaces at
38
a later date due to such items being installed or laid incorrectly or in wrong
locations.
2. CABLES
2.1 Cables for the internal wiring of the buildings and the external cabling
distribution sub-mains, shall be supplied and installed by the Contractor.
The Contractor shall supply and install all cables for internal and external
building as specified in the specification and drawings.
2.2 All electric cables supplied by the Contractor for the Contract Works shall be
provided with high conductivity, stranded annealed copper conductors.
2.3 Where PVC cables are specified in the contract such cable shall be
600/1,000V. grade and manufactured to B.S. 6004 : 1969 for metric sizes.
3. TYPE OF CABLE
3.1 For single-phase and 3-phase or 3-phase 4-wire, final sub-circuit wiring,
PVC insulated (PVC) cables of 600/1,000V. grade and manufactured to B.S.
6004 : 1969 shall be used. Where PVC cables are used for L.V. single-phase
or 3-hase, 4-wire sub-mains or rising mains installed on cable trays, such
cables shall be of the PVC insulated and sheathed (PVC/PVC) type of the
same voltage grade as specified above.
3.2 Where Mineral Insulated Copper Covered and PVC sheathed (MICC/PVC)
cables or Mineral Insulated Copper Covered (MICC) cables are specified on
the drawings for use in the Contract Works, such cables shall be of
600/1000V. grade and manufactured to B.S. 627 : Part I : 1969.
3.3 Wherever PVC-insulated single wire armoured and PVC Served Overall
(PVC/SWA/PVC) cables are specified on the drawings for use on the
Contract Works, such cables shall be 600/1,000V. grade for Metric Sizes and
manufactured to B.S. 6346 : 1969.
3.4 Where Paper Insulated Lead Covered and Served (PILC.&S) cables, or Paper
Insulated Lead Covered Double Steel Tape Armoured and Compounded Jute
Hessein Tape Overall (PILCDSTA.&S) cables are specified for use on this
sub-contract, such cables shall be of the M.I.N.D. type, manufactured to B.S.
6480 : Part I : 1969 and of 600/1,000V grade for all L.V. circuits.
3.5 Flexible cords used for the suspension or lampshades, connection of lighting
fittings to their wiring points and for connection of electric appliances, shall
be of the 3-core or 4-wire or 5-core, PVC-insulated type with white colour
sheaths, of Metric Sizes (300/300V) grade for single-phase circuits and
300/500V. grade for 3-phase or 3-phase, 4-wire circuits) and manufactured to
B.S. 6500 : 1969.
39
4. INTERNAL ELECTRICAL WIRING INSTALLATION & UNDERGROUND
OR UNDERFLOOR CABLING
4.1 Surface-Run Conduit Wiring
Surface-run conduit wiring with PVC cables, wherever indicated on the

Diagrams, shall be run on walls, steel structural work or on cable trays as the
case may be.
a) Conduits utilized throughout the Contract Works shall be galvanized,

heavy gauge, Class ‘B’ Screwed steel type to B.S. 1940 and latest
amendments thereof.
b) Conduit fittings and accessories shall be galvanized type and

manufactured in accordance with the relevant British Standard
Specifications. All conduit bends, including solid non-inspection tees
and elbows, shall be restricted in accordance with the I.E.E. Wiring
Regulations.
c) Conduit ends and terminations shall be provided with approved type

brass bushes in compliance with the I.E.E. Wiring Regulations. The use
of all insulated type, plastic, fibre or bakelite bushes in lieu of brass
bushes shall not be permitted.
d) For cables manufactured to British Standard “Inch” sizes, the minimum

number of cables pulled shall comply with the I.E.E. Wiring Regulations.
For British Standard cables manufactured to Metric Sizes, the minimum
number of cable to the I.E.E. Wiring Regulations.
e) Where conduits are installed directly on walls and concrete work, they
shall be fastened by means of galvanized, spacer-bar saddles and
rawlplugs at appropriate intervals in accordance with standard wiring
practice. Rawl plugs shall be drilled into walls and concrete works and
the use of hardwood plugs for installing spacer-bar saddles shall not be
permitted. Spacer-bar saddles shall be fastened by means of ground-head
brass screws and washers.
f) In the case where conduits are installed on-perforated cable trays, they
shall be fastened by means of suitable galvanized metal saddles, round-
head brass bolts, nuts and washers.
g) The Contractor shall paint all surface-run conduit with two (2) coats of
an approved type of paint after erection is completed. All conduits shall
be painted orange colour.
4.2 Concealed Conduit Installation
Wherever conduit wiring is to be concealed in the plasterwork of walls or

buried in floors, they shall be installed in chases of sufficient depth and
width to suit the sizes of conduits and parallel runs involved. Cables used for
concealed conduit rungs shall be PVC insulated type, except where wiring
runs are partially installed in conduit and partially run concealed directly in
the plasterwork of walls, they shall be of the PVC/PVC type.
40
a) Where conduits are to be concealed in the plasterwork of brickwork
walls, the Contractor is required to cut the necessary chases in the walls
for the installation of the conduits. Initial plastering of chases shall be
undertaken by the Contractor after conduits have been erected in position
by the final plastering of chases shall be undertaken by the other
Contractor.
b) Where conduit is to be buried in concrete floors, fairfaced concrete walls

and the underside of bars concrete ceilings, the conduit shall be cast in-
site with the concrete and for this purpose, the Contractor is required to
liaise very closely with the other Contractor and arrange for all the
conduits to be laid in position before the casting of any concrete floor or
wall is carried out by the other Contractor, throughout the progress of the
building construction.
c) The methods employed for the installation of concealed conduit wiring

shall generally by the same as for surface-run conduit wiring, outlined
under Sub-Clause of this section, except that conduits shall be held in
position in the respective chases by means of normal, galvanized metal
saddles and no painting of conduits before plastering or cementing is
required, except where such conduits rise from floors or emerge from
walls.
d) Rigid, concealed conduit risers shall terminate at height of approximately

30cm above finished floor levels under terminal boxes of motors or,
where this is not possible, then as near as possible to machines on which
the motors are installed. Flexible conduits with special adaptor sockets
and of similar diameters as the rigid conduits shall then be connected to
the rigid conduit terminations and continued to terminate in the terminal
boxes of motors or control panels of machines. Where concealed
conduits emerges from walls or floors to enter switchboards, control
boards, distribution boards, termination boxes, lighting fittings and
electrical accessories, the rigid conduit shall be brought-in directly to the
equipment and terminated within the equipment. Where it is not possible
for rigid conduit to terminate at equipment, then such conduit shall be
connected to flexible conduit with special adaptors and the flexible
conduit, in turn, shall terminate in the equipment. Flexible conduits used
throughout shall be of the liquid-tight type with bitumen infused paper
between two flexible aluminium tube spirals and with electrical
continuity being maintained throughout their entire lengths.
e) All conduit risers shall be painted in the same manner as described under
Sub-Clauses below of this Section.
f) All conduits shall be provided with suitable draw-wires.
4.3 Installation of PVC/SWA/PVC, XLPE/SWA/PVC and PILCDSTA. & S

Insulated Cables
Unless otherwise stated on the drawings, the foregoing cables may be

installed in the following manner.
a) PVC/SWA/PVC and XLPE Insulated Cables may either be installed

direct in the ground or on cable trays or directly cleated to walls or on
cable racks or in concrete trenches.
41
PILCDSTA & S cables may be installed in the same manner as for
PVC/SWA/PVC cables.
b) Where such cables are laid in pre-cast concrete trenches, the cables shall
be nearly laid at the bottom of the trenches without crossing each other
except where they rise from the trenches to their respective terminal
boxes or cable end-boxes. Cables laid in concrete trenches shall be
spaced a part of each other in the manner prescribed of this section.
Where more than one layer of cables are to be laid in the same trench,
then the upper layers shall be neatly spaced and held in position by
purpose-made, hardwood cleats installed on M.S. brackets along the
walls of the trench. The spacing of cables of brackets shall be in
accordance with of the I.E.E. Wiring Regulations. For cable diameters
exceeding 40mm dia. (overall), reference shall be made to the
Manufacturers of such cables for spacing of supports. In any case,
however, the spacing of supports shall be such that there is no sag in the
cables between supports.
c) Where such cables are laid on trays, they shall be held in position by
means of purpose-made non-corrodable, non-magnetic, metal saddles of
appropriate sizes and mechanical strength. The cables shall be spaced
apart in the manner prescribed under Sub-clause 5 of this section.
Saddles shall be bolted to the trays by means of non-corrodable nuts,
bolts and washers. Only one layer of cables may be installed one each
tray and under no circumstances may two or more layers of cables be
installed on a single cable tray.
d) PVC/SWA/PVC, XLPE and PILCDSTA &S insulated cables pulled

through ducts shall be separated from each other at not less than two (2)
inches and such cables shall not be laid in parallel at a distance of 30mm
from gas, fresh or salt water pipes and pipes of various other services.
The same distance apart shall also apply for L.V. and H.T. cables or
cables of other services which are laid in parallel to each other.
e) Where PVC/SWA/PVC or XLPE or PILCDSTA &S insulated cables are

laid direct in the ground, they shall be laid in trenches or sufficient width
and depth to cater for the cable runs and cable voltage grades concerned.
L.V. cables shall be laid at a depth of not less than 0.6 metres below
finished ground level, when measured from the top surfaces of the
cables. Trenches of sufficient depth to meet the foregoing cable depth
requirement shall therefore be dug. Prior to the lying of cables in
trenches, a 50mm layer of shifted sand shall be placed at the bottom of
the trenches. The cables shall then be laid over this bedding without
crossing each other and covered over with another 50mm layer of shifted
sand, over which interlocking type R.C. cable slabs shall be laid in such
a manner as to overlap the cables at 50mm to 100mm on both sides.
The cable trenches shall then be filled up with earth in layers of 150mm
each, every layer being properly tamped before another layer is placed
over. The procedure shall continue until the trenches have been
completely reinstated.
f) No straight-through or tee joints in PVC/SWA/PVC or PILCDSTA &S

underground cable-runs shall be permitted. Sufficient lengths of cables
42
shall therefore be supplied to suit the various circuits indicated on the
drawings.
g) For cables laid directly in the ground, Regulation type reinforced

concrete cable markers shall be planted into the ground at every change
in direction of the cable route and at every 30 metres intervals along
straight runs.
h) The Contractor shall provide and connect-up all necessary brass glands
for the termination of PVC/SWA/PVC or XLPE insulated cables. In the
cast of PILCDSTA &S cables, the Contractor shall provide the necessary
cable end-boxes, black insulating compound for their respective cable
end-boxes and all such compound shall be suitable for the voltage grades
of the cables to be terminated. All other jointing materials necessary to
complete the termination of the cables shall also be provided by the
Contractor.
i) PVC/SWA/PVC or XLPE insulated cables shall be terminated by means

of compression type gunmetal or brass glands constructed to grip both
the inner and outer PVC sheath of each cable so designed that any strain
on the cable is taken by the steel wire armouring which shall be
effectively sealed between the gland itself and the other cable sheath.
j) The type of gland that the Contractor proposes to use shall be approved
by the Engineer before any termination is carried out.
k) All glands shall be weather and moisture proof complete with PVC
shrouds.
l) Compounds shall be to the manufacturer’s recommendations and the

Engineer’s approval.
m) Wherever a PVC/SWA/PVC or XLPE insulated cable is cut during the

course of installation, the open ends shall be sealed immediately by
means of a self adhesive non-hygroscopic tape in order to form an air-
tight joint. A wax water seal shall be employed beneath the tapping a
prevent the ingress of moisture between the cores. For PILCDSTA.&S
cables the open ends shall be immediately sealed with cable sealing lead.
n) Every outdoor cable end-box joint started on a particular day shall be

completed during the same day.
o) Crimped cable lugs shall be used throughout for the jointing of the
conductors of PVC, armoured cables. Lugs shall be affixed to the cable
by means of a crimping tool as recommended by the manufacturer, using
the correct pressure.
p) Where terminations are made at switchgear and other items of electrical

equipment, wire armouring shall be bonded to the casing by means of
tinned copper conductors of cross-sectional area not less than the
appropriate size of earth conductor stated in the current edition of the
I.E.E. Wiring Regulations.
43
q) The cable cores shall be taken direct into the equipment terminals,
jointed tails shall not be permitted unless with the permission of the
Engineers.
4.4 Cables in Conduit and Flexible
a) Wiring cables and flexibles shall be insulated with PVC manufactured to

the relevant British Standard and shall be delivered with the marker’s
seals intact, which shall be retained for inspection.
b) Flexible cables shall be kept to a minimum and shall comply with this
specification where applicable.
c) All flexible cords shall be rated in accordance with the I.E.E.

Regulations but the minimum size employed shall be rated at 6 amperes.
d) Connections to apparatus which operate above 80 degrees Centigrade

shall be made using silicon coated cable with a non-hygroscopic fixed
block connector.
4.5 Grouping of Cables on Trays and Cables Laid in Closed Precast Concrete
Trenches
Where installing several circuits of cables on trays or when laying several

circuits of cables in Precast concrete trenches, the Contractor shall strictly
adhere to the requirements stated below and install the cables accordingly.
For this purpose, the word : “Circuits” used in single-core cable runs shall
deem to mean pairs of cables for a single-phase, A.C. or D.C. circuit or 3
cables per circuit for a 3-phase, A.C. circuit or 4 cables per circuit for a 3-
phase, 4-wire, A.C. circuit.
a) For PVC or PVC/PVC cables laid in trays, the horizontal clearance

between circuits for single core cables shall be :
(i) Not less than 6 times the overall diameter of an individual cable
and not less than the overall width of an individual circuit except
that the horizontal clearance need not in any case exceed
150mm.
(ii) The vertical clearance between circuits is not less than 150mm.
(iii) If the number of circuits exceed 4, they have to be installed in a

horizontal plane.
b) For multi-core, PVC/PCS or PVC/SWA/PVC or XLPE or

PILCDSTA.&S insulated cables laid in trays, the horizontal clearance
between cables shall be :
c) Where multi-core cables of the trays stated above and circuits of single-
core cables stated above are installed in Precast closed concrete trenches,
the dispositions of the cables or circuits of single-core cables shall follow
the requirements laid out in the I.E.E. Wiring Regulations and multi-runs
of cables in trenches shall be de-rated in accordance with the Rating
Factors stated in the I.E. Wiring Regulations.
44
(G) GENERAL SPECIFICATIONS
1. Duty and Taxes
All prices shall be inclusive of all Government duties, surtax and sales.
2. Protection and Packaging
All valves, connectors, gauges, etc. shall be properly protected to prevent any
possible damage during transportation and storage.
3. Catalogue
Manufacturer’s catalogues indicating physical dimensions, chemical

composition and service rating of the pipes, fittings, flanges, valves,
strainers, rubber connectors, steam traps, etc. offered shall be submitted at
the time of submission of quotation.
4. Test Certificates
Manufacturer’s Test Certificate for the seamless steel pipes, fittings and door
closure shall be submitted at the time of delivery of the pipes.
5. References
A customer list comprising customers in MALAYSIA only for each brands

of items offered shall be submitted at the time of submission of quotation.
6. Drawings
The drawings provided are as follows :-
No. Title Drawing No.
1. Overall Layout of Kuantan Bulking KBI/WATERLINE/01/2021

Installation (KBI)
2. Details Layout of Waterline at Kuantan KBI/WATERLINE/02/2021

Bulking Installation (KBI)
3. Details Diagram of Waterline Connection KBI/WATERLINE/03/2021
4. Details Connection for Multistage Pump and KBI/WATERLINE/04/2021

Header
5. Details of Pipe Supports KBI/WATERLINE/05/2021
45
7. Completion Schedule
Eight (8) weeks from the date of order.
8. Duties and Taxes
All prices shall be inclusive of all duties and taxes.
9. Penalty For Late Completion Of Works
The liquidated damages for late completion of work shall be calculated at the
rate of RM2,000.00 per day subject to a maximum of 20% of the Contract Price.
46

FGV Bulkers SDN BHD

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FGV BULKERS SDN BHD

FABRICATION, INSTALLATION, PAINTING, TESTING AND

2. The following works are required: -

(A) SUPPLY OF TWO (2) UNIT VERTICAL MULTISTAGE

i. Supply, delivery to site, testing, painting, commissioning and guarantee

 Design of pump Vertical Multistage Centrifugal Pump

Catalogues and technical literature shall be supplied together with the

vii. TESTING AND COMMISSIONING

The design, materials and workmanship of the pumpset shall be

(B) PUMP INSTALLATION (CIVIL, MECHANICAL & ELECTRICAL)

2. The Contractor is expected to discuss all technical information required

3. The following works are required in accordance to the scope of works as

4. Supply of labour, materials, hand tools and all necessary equipment to

a. To construct new pump foundation c/with 5 mm chequered plates

(C) PIPING WORKS

a. Installation of one (1) nos. 150mmØ sch10 stainless steel water

b. Installation of one (1) nos. 100mmØ sch10 stainless steel water

c. Installation of one (1) nos. 100mmØ sch10 stainless steel water

d. Installation of one (1) nos. 75mmØ sch10 stainless steel water

f. Installation of one (1) nos. 75mmØ sch10 stainless steel water

g. Installation of one (1) nos. 75mmØ sch10 stainless steel water

h. Installation of one (1) nos. 100mmØ sch10 stainless steel header at

i. The fabrication and installation of the following shall be included

 Tee guide bars in every tee joints as per engineer’s instruction

3. All pipes and fittings shall be pre-cleaned using circular wire-brushes

5. All underground cables must be installed inside a poly pipe or GI pipe.

6. All cable/armoured cable using Mega Cable include 1 meter each of

9. On completion of installation and welding works, all steel pipes, fittings,

14. The Contractor shall take delivery of the materials to be supplied in

15. Loading and transporting of the materials at the employer’s designated

(D) TECHNICAL SPECIFICATIONS FOR PIPES, FITTINGS &

Stainless Steel welded pipes in : ASTM A312 Grade 304 Sch10

Stainless Steel butt welded : ASTM A403 WP304 Ansi B16.9

Stainless Steel stub ends : JIS A182-F304

Stainless Steel Flanges : ANSI B16.5 Class 150

Seamless Carbon Steel pipes in : API 5L Grade B Schedule 40 (STD)

Seamless Carbon Steel fittings in : ANSI B16.9 made from material

Carbon Steel Flanges : ANSI B16.5 Class 150

1.2. Ends of Pipes and Fittings

1.4. Country of Origin & Manufacture

Stainless Steel pipes

Seamless Steel pipes (API) : Japan, South Africa (Tosa), Brazil

Seamless Steel fittings (Ansi) : Japan, Thailand (Benken), USA

Carbon Steel flanges : Japan, Europe

Offers from all other countries of origin/manufacture will not be considered.

2. Fabrication and Erection

 Piping system for Petroleum Industry : BS 3351

 Class II Metal Arc Welding of Steel Pipelines

 Welder approval : BS 2971

2.7 Joints shall be properly supported and aligned as accurately as is practicable

2.9 Flanges shall be aligned as accurately as is practicable. Flanged joints shall

3.2 The use of backing rings is prohibited.

3.3.3 Fillet welds shall be regular in form and without undercut.

3.7 THE CONTRACTOR IS TO SUPPLY QUALIFIED PIPE WELDERS

4. Draining and Pigging

The gauge shall be coupled to an extension of adequate length. The

All internal projection causing fouling or interference shall be

4.4.1 After installation and completion of pressure testing of the

4.4.5 Once the gauging of the system has been accepted, a

6. Pipework, Testing and Inspection Procedure

6.2 Where piping system to be tested mate up to equipment or piping

6.3 Test pressures and procedures shall generally be as detailed in the

6.4 The Contractor shall be responsible for the proper administration of