RFQ - 005c - Specification of MEP Work

Palembang City Sewerage Project Employer’s Requirements: Specification
Part 3: General Technical Specifications
SECTION 2: GENERAL MECHANICAL

2-1 DESIGN REQUIREMENTS
2-1.1 Design Criteria
All plant shall consist of standard commercial equipment proven in actual service conditions on
similar duties, processes and environments. Particular attention shall be taken in the design to
ensure ease of installation, operation, inspection and maintenance, minimum corrosion and
wear, durable, safety of operation and cleanliness of the surrounding areas. Standard
replacement parts shall be readily available locally in the country of installation.
2-1.2 Operating Conditions

The design of equipment and materials shall be governed by the need for long periods of service
without frequent maintenance and attention being necessary. All equipment shall be capable of
operating continuously for 24 hours per day, 365 days per year over the full operating range and
plant design life across the full range of climatic conditions specified in the associated
datasheets.
2-1.3 Design Life

The mechanical, and any electrical, instrumentation and controls Plant supplied shall be suitable
for continuous unattended operation and shall be designed for ease of access for cleaning,
inspection, maintenance and removal of components and automatic start-up and shut down.
The mechanical Plant supplied shall be suitable for the specified operating conditions and shall
be designed and constructed for a minimum operating lifespan of 20 years.
Any controls Plant supplied shall be suitable for the specified operating conditions and shall be
designed and constructed for a minimum operating lifespan of 10 years.
The mechanical, electrical and controls Plant shall be able to operate continuously for up to
24 hours per day, 7 days a week without operator attendance and shall be designed to
accommodate intermittent operation, with multiple start/stop operations over the day.
2-1.4 Design Loads

Design loads for mechanical equipment shall be for the most adverse combination of loading
and shall include, but may not necessarily be limited to the following:
i. Dead loads
ii. Live loads
iii. Thermal loads
iv. Wind loads – including cyclone strength winds on equipment while full or empty
v. Earthquake loads
vi. Pressure induced loads
vii. Loads applied by machine action (e.g. torque)
viii. Acceleration or deceleration (inertia) loading (e.g. braking forces)
ix. Impact loads
x. Loading produced by expansion or contraction of materials of construction
xi. Loading produced by material spillage or abnormal operation (e.g. conveyor spillage onto
included walkways, blocked chutes)
xii. Loading produced during the course of plant maintenance (e.g. resting equipment on
included platforms)
xiii. Loading occurring during transport and construction
Status: Issued for Bidding 58 Invitation for Bids No.: 01/PT.IPAL/08/2019

Equipment shall be designed in accordance with AS/NZS 1170.

Equipment shall be designed to accommodate the maximum loading(s) to which it may be
reasonably subjected during its design life, without the risk of equipment damage or risk of injury
to personnel.
Where equipment is driven by a prime mover(s), e.g. an electric motor or other prime driver form,
it shall be designed to accommodate the maximum torque that the prime mover(s) can produce.
2-1.5 Fatigue
Equipment shall be designed for a fatigue life at least equal to the plant design life when applying
maximum operating loads unless otherwise specified. Design loads for fatigue failure analysis
shall be determined from those loads applied to, or produced by, a machine whilst operating at
its maximum rated capacity assuming the machine’s prime mover(s) is operating at its maximum
continuous rating, unless otherwise specified.
2-1.6 Equipment Safety

General
All equipment shall be designed to afford maximum protection and a safe working environment
for operating personnel and must comply with the relevant Workplace Health and Safety Act and
Regulations currently in force.
Grilles, bars or mesh shall be provided behind covers where moving equipment may be reached.
Alternatively, interlocks shall be provided to stop equipment in the event that covers are opened.
Fire protection facilities shall be provided to meet the requirements of the relevant Work Cover
Authority, the relevant Fire Brigade, Indonesian code standards (SNI) and regulations (UU, PP,
Permen PU, Kepmen PU).
A risk assessment approach is required when designing access for maintenance purposes and
also during installation or replacement of equipment.
Equipment Safeguarding
The safeguarding system shall be designed in accordance with the requirements of relevant
association standards with respect to the nature of the machinery and the category attributed to
the safety-related parts of the control system.
Fixed (non-interlocking) guards shall be provided:
i. To prevent personnel from contact with the hazardous parts of the machine
ii. Where the parts of the machine to be guarded do not require access by the machinery
operators in order to operate the machine or attend to frequent lubrication, adjustment or
other regular duties required to maintain the machine in operation.
Interlocking guards shall be provided:
i. Where operators need to access hazardous parts of the machine frequently in order to
operate the machine or perform regular tasks required to maintain the machine in operation
ii. If operators cannot be protected from risk by fixed guards, keeping hazardous parts out of
reach etc.
Indications shall be provided of the status of all interlocking guards and alarms when interlocking
guards are open.
Where interlocking guards are provided the machine control system shall include control mode
selections for auto, manual and maintenance mode operation as required.
Emergency stop devices shall be provided on all machines, in locations within easy reach of
personnel situated in the operating or maintenance positions associated with the machine.
Manual suspension of the stop-function of the movable guards may be necessary where an
“INCHING” mode operation of the machine is required for maintenance while personnel are
within the hazardous area. Such suspension of the stop function shall be fully discussed with
operations and maintenance personnel prior to construction.

The machine safeguarding system shall include provisions for the isolation and dissipation of all
energy sources; electrical energy, fluid pressure, gravity etc associated with the machine.
Guards
The size of the guards shall be sufficient to cover the area of protection required to the extent
that an operator can view the covered area but cannot contact the hazardous parts of the
machine through the guard nor reach or climb around the guard to do so.
The anthropomorphic data (human body measurements) for the design of the guards shall be
taken from AS 4024.1704.
Guards shall be constructed of rigid, impact resistant, corrosion resistant material and securely
fixed either to the machine frame, surrounding fixed surface or floor by fixings of adequate
strength, spacing and number to ensure that guards remain secure under any foreseeable
loading. Fixing shall be by means of mechanical fasteners or clamps, welded or bonded joints
or other means suited to the application. Self-tapping screws shall not be used to secure guards.
Pursuant to clause 6.3.4 of AS 4024.1601, each guard assembly shall be designed such that
process material cannot easily become lodged in it, and for easy cleaning.
Guards shall be suitable to facilitate manual installation and removal, and shall be hinged where
practicable. Any single guard panel (dimension or mass) shall not be more than 2.0 metres in
length or 20 kilograms in weight. Movable hinged guards or removable sections of fixed guards
shall be designed to be of a suitable size and weight to permit ease of handling/operation. If
possible, operating forces shall be reduced by the use of springs, counterbalances or gas struts.
Movable guards shall be interlocked.
Plugged tachometer holes shall be provided in guards at pulley shaft centres.
Guards shall not foul any moving components of the equipment.
Guards attached to equipment handling hazardous substances (e.g. chemical dosing systems)
shall be transparent to allow personnel to detect leaks before they are removed/opened.
Appropriate workplace health and safety warning signs complying with AS 1319 shall be fastened
to all equipment.
Fixed Guards
Fixed guards shall be provided in accordance with the requirements of AS 4024.1601 for a Fixed
Guard (Non-Interlocking). Fixed guards shall be bolted and require the use of tools for removal.
Interlocking Guards
Where interlocking guards are required the design criteria for these guards shall be as follows:
i. Designed in accordance with the requirements of AS 4024.1601 for an interlocked fixed or
movable guard as required.
ii. At least one fastener on each guard shall be a locking device as defined by clause 4.6.2
and 6.4.10 of AS 4024.1601. The locking device shall be an electrically interlocked safety
latch.
iii. Pursuant to clause 6.1.2 of AS 4024.1601:
iv. An interlocking guard, when unlocked, shall allow as free and unobstructed access as is
technically possible to the machine assembly for cleaning and maintenance or other task
required
v. The guard assembly when fixed in place shall allow safe and ergonomic access for
operating the machine
vi. Lubrication points covered by closed guards shall be brought outside the guard with remote
operated lubrication lines
Pursuant to clause 6.1.4 of AS 4024.1601 the stop function activated when any guard is unlocked
shall stop all material and energy feed into the machine including all its immediate upstream
process and energy sources.
Pursuant to clause 8.4 of AS 4024.1601 each guard shall be painted Safety Yellow and a sign

shall be affixed to the outside reading “HAZARD – MOVING MACHINERY. Lock guard in place
for normal production operation.”
Safety signs
Supply and install all safety and warning signs as required. Safety signs shall comply with
AS 1319.
The signs shall warn of potential hazards and assist in preventing accidents and give operational
and emergency procedures for potentially hazardous situations. Signs shall provide warnings
where equipment may start automatically, where equipment may move without warning and
where other potential hazards may occur (e.g. chemical storage areas).
Warning sirens and beacon lights shall be installed for equipment where there is a hazard, such
as when equipment starts automatically or when equipment fails to start.
The contents of piping, conduits and ducts shall be identified as per AS 1345. Arrows shall be
provided to show the direction of flow.
Fail safe
All items of equipment shall be designed for safe operation.
Machinery shall be designed to ensure that the plant will remain in a safe condition in the event
of any failure in part of the machinery or its associated safeguards, control circuits or its power
supply.
2-2 TECHNICAL REQUIREMENTS

2-2.1 Materials
General
All materials necessary for the work shall be supplied in accordance with this section of the
Specification.
All pipes, fittings and other materials shall be of the best quality and fit for purpose. They shall
conform to the requirements of the latest relevant Standards.
All materials supplied shall be new and shall be suitable for its intended duty and its associated
environment, with appropriate abrasive and corrosion resistance.
Materials and equipment shall include all machinery, equipment and components which form a
part of the works.
All materials and equipment shall be:
i. of a duty rating appropriate to the application;
ii. suitable for the purpose;
iii. proven in service;
iv. suitable for installation in the spaces allocated with suitable access and clearances for
normal and long term maintenance requirements;
v. compatible with other materials and equipment to be used in the works;
vi. in compliance with the Conditions of Contract;
vii. supported by appropriate servicing facilities and locally available spare parts;
viii. corrosion resistant;
ix. wear resistant.
Where products of alternative manufacturers are proposed, their acceptability and approval must
be obtained. Materials and equipment supplied must meet the specified performance,
construction, quality, space and structural loading requirements.
Material and equipment characteristics, other than those specifically covered by the drawings
and specifications, shall be at least equivalent to those of any stated trade name, or if no trade

name is stated, typical of the respective material or equipment kind.

Samples of material shall be taken in accordance with the appropriate association standard
where applicable.
Fibre Reinforced Plastic (FRP) products shall be manufactured from materials and by processes
complying with international standards for the appropriate industry.
Orthophthalic Polyester must not be used on any wastewater application or in aggressive
environments or for applications where frequent handling is likely.
Where dissimilar metals come into contact, the surfaces shall be kept from direct metal to metal
contact by use of PTFE gaskets, high strength phenol washers or other approved method of
isolation.
The following materials are prohibited and shall not be included in any components of the
equipment supplied:
i. Asbestos and materials containing asbestos;
ii. Polychlorinated biphenyls (PCBs) and materials containing PCBs;
iii. Ceramic fibres;
iv. Formaldehyde insulation;
v. Halon;
vi. Lead based paints;
vii. Chloro-fluoro-hydrocarbons (CFCs);
viii. Radioactive materials.
Castings
Preferred grades for cast materials are:
i. Spheroidal Graphite Iron: AS 1831, grade 450-310-10
ii. Austenitic Iron: AS 1833, grade S-Ni Cr 20 2 (spheroidal graphite)
iii. Carbon Steel: AS 2074, grades C3 or C4
iv. Stainless Steel: AS 2074, grade H6C.
Castings shall be close and uniform in grain, homogeneous and free from blowholes, porosity,
shrinkage, cracks and other injurious defects. Filling of holes with any substance shall not be
permitted. Castings shall be properly cleaned and fettled and all lumps and rough areas
smoothed. Defects in steel castings may be repaired by electric welding to the extent allowed by
recognised good practice, provided that approval is first obtained.
Stainless Steel
Stainless steel plate and bar subjected to welding during the manufacture of any component
shall be grade 316L (X2CrNiMo1712 to ISO 9328). Stainless steel plate or bar not subjected to
welding shall be grade 316 (X5CrNiMo1712 to ISO 9328). Stainless steel castings shall be a
stabilized grade in accordance with AS2074-2003 – Steel castings, grade H6C. Stainless steel
in shafts, spindles or similar shall be grade 420 (X20Cr13 to ISO 9328). All stainless steel shall
be passivated. Graphite greases, graphite packing and graphite compounds shall not be used in
contact with stainless steel.
Stainless steel sheet and components shall be kept separate from carbon steels during
fabrication, storage and assembly. Abrasive grinding and cutting wheels previously used on
carbon steels shall not subsequently be used on stainless steels. Protective coverings and space
separation of storage, fabrication and working areas shall be used to prevent contamination of
stainless steels with particles of carbon steel.
Mild Steel
Mild steel shall be to AS 3679, grade 250.
All mechanical equipment of mild steel construction shall be hot dip galvanised or shall be given

protective coatings to the appropriate system. Such equipment shall include pipe and machinery
supports, platforms, stairs, guardrails, baseplates, covers, and other items as specified.
Galvanising shall comply with AS/NZS 4680 and articles shall have a coating thickness not less
than HDG 390.
Where dissimilar metal surfaces come into contact that are not compatible, protection shall be
provided by an insulation gasket and washers between the dissimilar metals.
Galvanised surfaces shall not be repaired with zinc rich paint (Cold Gal) alone. A full painting
system shall be used where repairs to galvanised surfaces is required.
2-2.2 Painting and Coatings

All coatings applied under a single paint system shall be the product of a single manufacturer.
Manufacturer's printed instructions shall be strictly followed in the application of proprietary
coatings.
Care shall be exercised not to damage adjacent work during sandblasting operations. Any
damage shall be made good. Blasted surfaces shall not be left overnight before coating.
Paint shall not be applied in extreme heat, cold or in dust or smoke laden air, or in damp or humid
weather.
Drying times shall be not less than called for in manufacturer's printed instructions.
Stainless steel surfaces shall not be painted.
Drop cloths shall be placed where required to protect floors and equipment from splatter and
droppings.
Spray painting shall be conducted under controlled conditions.
Each coat shall be inspected prior to application of the next coat. Areas found to contain runs,
overspray, roughness, or other signs of improper application shall be recoated.
Forced air ventilation shall be provided, in accordance with applicable regulations, while work is
being accomplished inside a tank or other closed area.
Colour samples and stain samples shall be submitted as required.
Except where factory application of finish coatings is permitted, all items of equipment shall be
finish-painted after installation with the colour selected. Shop priming will be permitted in all
cases. Materials and application as specified herein shall govern regardless of whether coatings
are factory applied or field applied. After installation, any damaged areas in prime or finish
coatings shall be repaired as directed.
All painting and coating systems used shall meet health and environmental requirements of the
application. Particular notice shall be made for potable water applications.
All spills over applications and damage caused during the work are to be rectified prior to
completion.
2-2.3 Shipping and Handling Protection

All equipment shall be suitably protected in accordance with the manufacturer’s
recommendations to prevent foreign substances from entering the working parts and to prevent
damage during transport, storage at the manufacturer’s and/or supplier’s premises, loading, and
unloading and storage at the Site. The materials and equipment shall be secured rigidly in water-
proof crates suitable for open air storage. Crates shall be constructed so as to be easily handled
by forklift and by slings. Lifting points and orientation shall be clearly marked. Suitable blocking
straps and skids shall be provided to protect the equipment from damage in transit.
All crates, packages or equipment weighing in excess of one tonne shall have the gross weight
painted thereon in a conspicuous location (as an aid to the receiver in providing proper handling
facilities).
Prior to dispatch from the manufacturer’s premises, rotating equipment shall be fitted with
individual anti-Brinelling clamps to prevent both axial and radial movement of shafts during

transport. The supplier shall advise when, before or after installation, such clamps can be
removed. Nozzles on all equipment items such as tank connections, suction and discharge
nozzles and pipe ends shall be protected using timber or plastic covers and securing bolts or
tape to prevent entry of foreign bodies into the relevant equipment.
All gasket surfaces, flange faces, tube holes and tube ends shall be thoroughly cleaned and
greased and protected with suitable wood, metal or other substantial covering to ensure their full
protection. All exposed threaded parts shall be greased and protected with metallic or similar
substantial protectors. All female threaded openings shall be closed with tight fitting plastic
closures unless otherwise specified. Should special lifting frames or beams be required for
installation purposes, these and their instructions for correct use shall be supplied.
Pipes, fittings, pipeline materials and equipment shall be stored, transported and handled with
care. Adequate precautions shall be taken to maintain the circularity of the ends of all pipes to
ensure watertight joints when assembled. Slings, hooks and lifting appliances shall be of the
correct type as recommended by the manufacturer. Items shall be stacked safely, off the ground
on timber or polystyrene blocks. All gaskets shall be stored in a cool, dry place away from direct
sunlight.
At the Works and on Site, all mechanical components and structural steelwork shall be stacked
clear of the ground so that the collection of water in troughs, pockets and the like is reduced to
a minimum. Parts which can be damaged by rain shall be stored under cover. Any item of
equipment that has been incorrectly exposed to the weather, flooding, heat, impact or similar
abuse may be rejected and shall be made good by replacing any damaged materials or
equipment.
The Contractor shall arrange for detailed inspection of all Plant upon delivery to Site (or other
approved location) and ensure that any shortages or damage are identified and rectified in good
time prior to the date for commencement of installation.
2-2.4 Workmanship
General
All workmanship shall:
i. be in accordance with the best modern trade practice, relevant Standards and Codes of
Practice;;
ii. comply with the Contract Documents;
iii. be carried out by appropriately qualified and experienced tradesmen;
iv. be carried out under the supervision of a competent foreman;
v. result in a high standard of construction and leave a thoroughly efficient, robust, tidy and
fully operational and safe installation.
Machining shall be concentric, square to line and true. All sharp edges and burrs shall be
removed.
Bolt holes shall be drilled and spot faced for bolt head and nut. Mating parts shall be
matchmarked and dowelled.
Defective work shall not be repaired by welding, filling, plugging or any other process unless
written permission is granted. Repairs to castings associated with engines, compressors, pumps,
gearboxes or other items subjected to pressure or vibration will not be permitted. Only qualified
and competent personnel carry out welding work and where necessary to meet association
standards, carry out non-destructive testing. Any periodic non-destructive testing, and its
interval, deemed necessary during normal operation of the equipment shall be advised.
Welding
Prior to carrying out any welding, both welding and welder qualification procedures for each type
of weld to be used shall be available.
Site welding shall be minimised. All welding shall be of sound quality. In general, welding shall
be continuous, smooth and straight and with no inclusions. All other equipment in the vicinity of

welding work shall be adequately protected from spatter where required.

All welds shall provide a complete seal against the ingress of water to the interface of adjoining
surfaces or into hollow section members where corrosion protection cannot be completely
effective. Where intermittent welds are adequate for structural purposes, light seal welds shall
be applied to form a complete seal.
Welds shall be ground smooth where necessary to allow appropriate coating over the internal
surfaces. All weld spatter and slag shall be removed.
Stainless steel pipe welds shall be passivated as soon as practicable after welding. Welds shall
be contiguous and fully penetrating so that crevices do not occur.
Cutting of pipe may be done either by mechanical means or by flame cutting, depending on the
type of material to be cut. For carbon steel, flame (or arc) cutting and bevelling is acceptable
only if the cut is reasonably smooth and true and all oxides are removed from the flame cut
surfaces by grinding back to bright and sound metal. For stainless steel, flame cutting is not
permitted.
For stainless steel plasma cutting, if the pipe ends cannot be machined the pipe must be ground
back to bright sound metal prior to welding.
All welding areas shall be adequately protected against inclement weather conditions such as
rain, wind, dust and the like. All weld end preparations and adjacent areas 50 mm either side of
the weld shall be thoroughly cleaned and degreased prior to welding.
Repairs to welded joints, defective or damaged pipe fittings, or any other pressure part shall not
be carried out without notification.
If repairs or modifications are carried out after heat treatment has been completed, the areas
affected by the repair or modification shall be heat treated again.
Joints shall be tested using non-destructive testing (NDT) techniques, unless it is necessary to
use destructive testing to achieve adequate interpretation. When interpreting NDT findings of
welds made in castings and ductile iron, consideration shall be given to allowable defects in the
parent material.
Welded components shall be stress relieved prior to machining.
2-2.5 Fixings and Fittings

Fasteners
Bolts and screws shall be in accordance with AS 1111. Washers shall be in accordance with
AS1237. Nuts shall be in accordance with AS 1112.
Extensive use of stainless steel, especially for nuts, bolts and screws shall be adopted for
components coming in contact with influent or effluent water or exposed to a corrosive
environment.
On mechanical equipment and motors in contact with sewage, sludge or other corrosive
environments, fasteners shall be stainless steel grade 316.
All bolts and studs for gland joints, couplings joints and flanges shall be stainless steel grade
316 unless specified otherwise. Associated nuts and washers shall be stainless steel grade 316.
Where high strength is required and approval is given, high tensile bolts, nuts and washers may
be used.
On fixings and fasteners that may be subject to vibration, an approved method of locking shall
be incorporated. Anchor bolts for vibrating equipment installation shall follow approved
standards. In the absence of an appropriate standard, the bolts should have a minimum length
of 300 mm and shall be designed to be epoxy fixed into a hole drilled into the concrete. Epoxies
exposed to potable water shall comply with AS/NZS 4020. Plant hold down bolts shall have
double nuts; machinery shall have nylon lock nuts, locking tab or spring washer.
Unless otherwise noted, all pipe threads shall conform in dimension and limits of size to
AS 1722.2 taper jointing thread.
All threads of stainless fasteners shall be coated with an approved nickel based anti-seize

compound prior to assembly.

All fasteners, including chemical set, anchor bolts, threaded rods, nuts and washers that are
embedded into concrete shall be manufactured in stainless steel grade 316. Zinc plated or black
bolts and screws shall not be used.
On structural components, such as walkways and handrails, fasteners shall be stainless steel
grade 316 excepting when structural components are hot-dipped galvanised, hot-dip galvanised
fasteners shall be used.
On commercially supplied mechanical equipment, such as motors, gearboxes, pumps and
conveyors, the supplier shall replace any fasteners which are not of corrosion resistant materials
with fasteners which comply with this specification.
The anchor bolts, nuts, and washers shall be sized for the duty required. Chemical set or cast-
in fasteners are permitted. Wherever possible, chemical set fasteners shall be used. Chemical
anchors, when used, shall be installed in accordance with the manufacturer's directions.
Drill holes shall be thoroughly cleaned and filled with epoxy grout.
Where the relocation of masonry anchors necessitates alteration to steelwork base plates, the
installer shall determine all additional stiffening or strengthening of the base plate and adjacent
steelwork required.
Sockets
All socketed pipes shall be rubber ring jointed. Rubber rings shall comply with AS 1646.
In connecting pipes with rubber rings, the pipes shall be cleaned prior to connecting and care
shall be taken to ensure that the rubber ring is maintained in a plane at right angles to the axis
of the pipe. Each pipe shall be installed and connected as recommended by the manufacturer
and each joint checked with a feeler gauge to ensure that the ring is in place. For pipes with skid
type rubber ring joints, only the lubricant specified in writing by the manufacturer shall be applied
in making that joint. The installer shall make the joint such that the witness mark, at no point,
shall be more than one mm from the end of the socket.
Ductile iron pipes shall be joined using either the standard “Tyton” rubber ring spigot and socket
jointing system or the “Tyton-loc gasket” system.
Gaskets
Flange gaskets shall be in accordance with AS/NZS 4087.
Gaskets shall be manufactured from an elastomer (neoprene/fabric) complying with AS 1646
and may contain a reinforcement material. The minimum working pressure for gaskets shall be
1600 kPa at 3.0 mm thickness.
The gasket material shall be suitable for contact with the fluid being conveyed, the operating
conditions and environment.
Pipes and fittings shall be in their correct position, alignment and grade before the joints are
made and no springing of joints shall be permitted.
Pipe anchorages shall be provided to absorb static and dynamic thrusts from pipe fittings and
valves.
Flanges
Flanges shall be in accordance with AS/NZS 4087.
Raised face flanges shall be mated with raised face flanges. Flat faced flanges shall be mated
with flat face flanges.
Flanges on all steel, ductile iron, PVC, and GRP pipes shall be fully fixed flanges. Flanges on
ABS and PE pipes may be stub flanges with loose metal backing rings or full face up to 100 mm
pipe diameter. On ABS and PE pipes of 100 mm diameter and larger, stub flanges with metal
backing rings shall be used. Backing rings shall be manufactured from 316 or 316L stainless
steel.

Flexible Connections
Flexible connections shall be bolted directly to the flanged outlets of corresponding elements.
Grade 316 stainless steel bolts and retainer plates or flanges shall be provided at each end of
flexible connections. All flexible connections shall prevent any external loads from being
transferred to the mechanical equipment. All flexible connections shall be rated for operating
pressures including full vacuum and the pipeline design rating.
Pressure gauges
Pressure gauges shall comply with the requirements of AS 1349. Pressure gauges shall be
industrial Bourdon Tube gauges with a glycerine filled diaphragm seal and shall be suitable for
the service specified. Unless noted otherwise, gauges shall have a nominal diameter of 100 mm
and shall be fitted with a 10 mm threaded shank.
Hydraulic oil type pressure gauges shall be used for process fluids that readily damage standard
pressure indicators (i.e. the process fluid is in contact with a diaphragm that has hydraulic oil on
the other side which transmits the pressure signal to the indicator).
Keys and Keyways
All keys and keyways shall comply with BS 4235.
2-2.6 Bearings and Lubrication

Bearings
All bearings shall be heavy duty, grease lubricated unless specified otherwise, and selected to
accommodate all mechanical loads imposed by the operation of the equipment including starting
and motor stall, up to its maximum operating conditions. All bearings shall be to ISO standard SI
unit dimensions where practicable. All bearings shall be sealed to prevent contamination and
fitted in machined housings and located by dowels to assist maintenance.
Ball and roller bearings shall be steel caged. All ball or roller bearings shall be rated in
accordance with AS 2729 with factors a1, a2 and a3 equal to one (1) to give a L10 life of 100,000
hours unless otherwise specified in the datasheet. Bearings on rotating machinery shall be
supported during transportation to ensure work hardening does not take place. Signage to this
effect must be prominently displayed.
Plain bearings shall have steel shafts running in bronze bushes and shall have a loading, based
on projected area, of not more than 300 kPa. Materials other than steel and bronze may be
accepted where full details are submitted.
Plain bearings shall have steel shafts running in bronze or self lubricating graphite impregnated
bushes and shall have a loading, based on projected area.
Drive shafts shall be mounted in heavy duty bearing assemblies. The bearings may be oil or
grease lubricated. Oil-bath lubricated bearings shall be fitted with a pressure venting device, oil
fill and drain tappings, and an oil-level sight glass. Where grease lubrication is provided, grease
relief provisions shall be supplied to prevent over greasing. Routine greasing points shall be
located at an accessible location, without the need for removal of guards or covers.
Lubrication
All components shall be lubricated as required prior to testing and delivery.
Prior to placing machinery into service, all reservoirs, sumps and tanks shall be filled to their
correct levels and all lubrication pipework shall be fully primed in accordance with the
manufacturer’s recommendations.
The lubricant shall be suitable for the particular duty and ambient temperature conditions. Two
or more brands or types of lubricants shall not be mixed.
All items above coping level requiring lubrication shall be capable of lubrication from one
location, if at all practical.
Where lubrication is required the bearing housings shall be fitted with seals and shall be grease
lubricated. Grease nipples shall be provided for all bearings. Where access is restricted, capillary

tubing shall be run from the bearings and grouped and labelled at a convenient accessible
location. Bearing housings shall be fitted with grease pressure relief devices to prevent
overpressure.
The bearing re-lubrication interval shall be calculated from the bearing/grease manufacturer’s
data.
Unless specified otherwise, grease lines, brackets, and fittings shall be stainless steel. High
pressure flexible lines shall be used in moving or vibrating applications. All grease lines shall be
of adequate size and strength, and permanently marked for identification. The amount of oil used
shall be adjusted in accordance with the manufacturer's instructions before and during start up,
to ensure correct performance. Brands, grades and types of lubricants shall not be mixed for the
same machine application.
A list of recommended lubricants and their equivalents shall be provided. Lubrication points shall
be labelled with “initial fill” lubricants. All mechanical equipment shall be furnished with the
correct lubricants to prevent corrosion during storage and installation and for starting and
commissioning the plant. Gearboxes and transmissions shall be flushed with approved flushing
oil in accordance with the suppliers’ recommendations. The flushing procedure shall include,
where possible, manual rotation of equipment to ensure complete penetration. On completion of
flushing the flushing oil shall be completely removed prior to filling with the running oil. Flushing
oil, once used, shall not be reused.
Lubricants and frequency of application shall be as recommended by the relevant equipment
manufacturer, and provided prior to commencement of commissioning.
All lubrication and oil fill points shall be labelled to specify the type of lubricant used and the
quantity required. A nameplate shall be provided at each remote lubrication point to indicate the
item it serves. Plates shall be engraved stainless steel grade 316, fastened with stainless steel
screws.
Where lubrication is required at a frequency higher than one application per week an automatic
lubrication system shall be provided. The automatic system, whether centralised or
decentralised, shall be easily viewed for fill status and functionality by the operator.
All items of mechanical equipment shall be provided with a lubrication schedule showing
recommended lubricants, acceptable alternative lubricants, lubrication points, lubrication
volumes and lubrication frequency. The lubrication schedule for each item of equipment must be
delivered separately and prior to the delivery of the equipment.
Recirculating oil systems shall be provided with an easily and safely accessible reservoir. The
reservoir shall be provided with a contents level indicator and a filler point complete with filter.
Lubrication systems reliant upon pumped circulation of the lubricant and where failure of the
system would result in catastrophic failure of the process plant or equipment shall incorporate
instrumentation to provide an alarm signal in the event of a blockage, loss of lubricant or other
malfunction.
Lubrication systems for plant used on potable water treatment installations shall be designed to
ensure that failure will not affect the potable water supply.
2-2.7 Seals
General
Seals shall be designed for a life of 100,000 hours except for applications where this cannot be
achieved by current seal technology. In this exception long life seals shall be used and the seal
installation shall be designed to permit quick replacement without major equipment dismantling.
The service life shall be extendable for an additional 100,000 hours with retrofitting.
Seals shall be an approved design effective for their purpose and requiring a minimum of
maintenance.
Material for seals shall be natural rubber, synthetic polyisoprene or a mixture of natural rubber
and nitrile rubber. The rubber hardness shall be as required by the seal design for the pressure
specified and, if required, shall be reinforced with Kevlar fabric.
Subject to approval, other elastomers with durability and mechanical properties at least

equivalent to the materials specified may be substituted.

O-Rings
O-rings for flanges shall comply with AS/NZS 4087.
O-rings which seal components shall comply with the relevant sections of AS 1646 and AS 2842.
Mechanical Seals
Mechanical seals shall have a minimum design life of 5 years when working 24 hours per day,
365 days per year.
Where mechanical seals are fitted, the pump shaft deflection, at the location of the seal, shall be
0.05 mm or less.
For pumping applications the seals may be single face seals or double face seals separated by
an oil bath, depending on the service conditions and the fluid being pumped. Seal faces shall be
lapped flat to within two helium light bands and the depth of interface roughness shall not exceed
0.3 microns.
Mechanical seals shall preferably be designed to operate without the need for external
cooling/flush water. If seal water is required, the seal water flow rate and pressure shall be
indicated.
Pump and seal design shall be such that interface temperatures under operating conditions
remain safely below the vaporisation temperature.
2-2.8 Noise and Vibration

Noise Levels
The overall sound pressure level (L10) for all equipment operating in combination to fulfil the
design performance requirements within its installed environment shall not exceed 80 dB(A) at
one metre radius from any equipment or sound enclosure. Appropriate measures shall be taken
to reduce noise levels where possible by the enclosure or lagging or other special treatment of
the noise source.
Under any operational loading condition, the works shall comply with the Occupational Health
and Safety Regulations 2007, the Environment Protection Act 1970 and the Environment
Protection (Residential Noise) Regulations 2008.
The sound pressure level (L10) of each equipment item shall be stated at a distance of one
metre.
Acoustic enclosures
Noise levels shall be contained by appropriate equipment design and acoustic enclosures.
Acoustic enclosures should be used only if other appropriate engineering measures are not
practical.
Where required, acoustic enclosures shall form an integral part of the equipment, and shall not
adversely affect the safety or function of the equipment.
Acoustic enclosures shall not impede the flow of cooling air when fully installed.
Acoustic enclosures shall be constructed in a way that they can be easily removed for
maintenance purposes. Where possible they shall be wheeled across the floor. The enclosure
shall have locks /latches when they are located over the equipment.
Normal operation should be possible without opening or removing the enclosure. Hinged access
doors shall be provided for easy access for routine inspection and maintenance.
The material used shall not be vulnerable to the high temperature inside the enclosure.
Noise tests
Following installation, equipment acceptance noise tests shall be conducted on site for
compliance and final acceptance. All equipment supplied that does not meet the requirements
for noise limits during site testing shall be rectified. Equipment that does not meet the

requirements for noise limits due to faulty installation shall be rectified. The rectified equipment
shall be retested until the requirements are met.
Vibration
Equipment, pipework and valves shall be designed and installed in a manner as to minimise the
transmission of vibration and noise from rotating or reciprocating equipment to other building
elements, structures or equipment. The design and selection of any absorbing or vibration
compensating devices shall suit the equipment and its installation in all operating conditions.
pick-up mountings shall be suitable for use with portable hand held transducers complying with
association standards. The pick-up mountings shall be fitted with protective caps.
The pick-up mounting shall be readily accessible when the motor is installed on its platform and
when the motor is running without having to remove guards, cowlings or other components.
The vibration level of any item of equipment or attached pipework shall not exceed Severity
Classification 2.8 in accordance with AS 2625.1 when operating over its normal range.
2-2.9 Couplings and Drives

General
Couplings shall be selected to enable separation of the driver and driven components without
the need to disturb the “other” component. Split-type couplings shall be supplied as a matched
pair and shall be marked accordingly. Couplings shall be manufactured from forgings and shall
be secured to their shafts by key and keyway. Spacer-type couplings shall be used where this
would facilitate maintenance of either the driver or driven machine in-situ.
Couplings shall be designed to take up axial shaft movement from either driver or the machine,
or both, without either the driver or the machine being affected.
Flexible shaft couplings shall be provided, where necessary, between motor shafts and the
driven shafts. Flexible couplings shall be of cone ring type or flexible element type rated to suit
the torque output of the motor or gearbox under all conditions of loading.
All nuts, bolts and studs on the couplings shall be of stainless steel grade 316. All exposed
couplings shall be furnished with a coupling guard.
Pumps and equipment shall be fitted with rigid or flexible couplings as recommended by
manufacturer to suit application.
Care shall be taken in checking alignment of driving and driven shafts. The motor and driven
equipment shall be in alignment from all aspects in accordance with manufacturer’s
requirements.
The whole assembly including pulleys and couplings should be balanced to eliminate vibration.
Motion detectors
Conveyors and other items, where installed, shall be provided with proximity sensor type motion
detectors or electronic shear pins on a driven element (e.g. conveyor screw element). The motion
detector shall detect rotation or movement of the item and a suitable metal "target" shall be
supplied and fitted to operate the motion detector. The motion detector contacts shall be wired
to the control system to give an alarm and/or machine shutdown if the equipment is running but
the motion detector indicates that the driven element is not rotating or moving.
Gearboxes
Each gearbox shall be designed to operate continuously at maximum duty with a service factor
that is based on the maximum operating torque and the most conservative load classification for
the drive in accordance with the American Gear Manufacturers Association (AGMA). In addition,
each gearbox shall be designed to withstand starting torques of up to 250% of the full load
running torque of the driving motor.
The direction of rotation of the input and the output shafts shall be permanently marked on the
housing. Removable gasketed inspection covers shall be provided to permit inspection of the
gears without disassembly of the gear reducer. Lifting lugs shall be provided on the housing to
facilitate safe lifting of the gearbox.

Gears and bearings shall be lubricated to manufacturer’s recommendation. Where grease

lubricated bearings are fitted, seals shall be installed to retain the grease in the housing. Grease
nipples and grease relief devices shall be fitted to housings containing grease-lubricated
bearings. Where pressure lubrication is provided a pressure switch with shutdown and alarm
outputs is required.
The unit shall be provided with sight glass or indicator to observe oil levels. All oil fill and drain
lines shall be of sufficient size to permit efficient functioning and shall be located on the gear unit
in a position, which is easily accessible from the floor. Oil and drain piping shall be supplied so
that a container may be placed under the drain discharge.
The gearbox when mounted in final location shall have inspection covers orientated to allow
unencumbered access for maintenance.
2-2.10 Lifting Equipment

General
All equipment shall be readily accessible for removal. Lifting gear, either fixed or portable, shall
be provided as appropriate. All lifting points and appliances shall comply with the relevant
association regulations and standards.
All items of lifting equipment supplied shall be clearly marked with the Safe Working Load in
accordance with AS/NZS 2550 and AS 4991, with lettering that can be read easily from the
nearest normal working platform or floor.
Original Certificate of Test and Examination signed by the person doing the test and examination
in accordance with AS 2550/NZS and AS 4991 shall be provided. All temporary lifting devices
such as davits shall be load tested in their location of use and certified accordingly. Supports for
such devices shall be designed such that overall deflection (including that of the support) remains
within prescribed limits.
Lifting equipment, including cranes, hoists and winches, shall be shall be supplied and installed
in accordance with AS 1418 and AS/NZS 2550.
Suitable lifting facilities by means including but not limited to monorails, davits, jib cranes and
gantry cranes shall be provided to enable maintenance and removal of equipment without
encumbrance.
All equipment shall be fitted with such permanent eyebolts, lifting lugs or jacking points as are
required to install, remove, and maintain the equipment. These attachments shall be located
such that equipment is balanced and stable during lifting placement. The lifting points shall be
clearly marked. Where equipment is fixed to a baseframe and both the equipment and baseframe
are fitted with lifting lugs, only the lifting lugs fitted to the baseframe shall be used for lifting the
baseframe and fixed equipment. The lifting lugs provided on the equipment shall not be used to
lift the fixed equipment and baseframe together.
Davits
Each lifting davit shall include a pedestal, mast, boom, hoist, associated lifting cables, sheaves,
hooks, handles and all fixings.
The reach, height and rotation of the boom shall be suitable for raising and lowering the
equipment from its installed position to a platform or floor area where it can be readily inspected,
serviced or transported to a loading bay. The rotation of davits shall not compromise the safe
working area on the platform or floor area.
Hoists
All hooks shall be drop forged steel with swivelling thrust bearings and a safety catch.
All external parts of hoist trolleys and chains shall be hot-dip galvanised.
The hoist and equipment shall be suitable for continuous exposure to the weather and direct
sunlight.
Hot-dipped galvanised steel chain buckets, or suitable robust plastic bucket, attached to the
trolleys or hoists shall be installed to collect hoist chains. The buckets shall be self-draining and

not accumulate water.

True vertical lift shall be available from the hoist.
All brakes shall be fail-safe under power failures. The brake mechanisms shall be protected
against rain and dust ingress where required.
Guards shall protect the rope block sheaves.
Steel wire rope shall be in accordance with AS 3569 and shall be hot dipped galvanised.
The hoist shall be capable of being fully lowered such that hook invert is level with the floor.
Electric hoists shall be controlled remotely by a hand held control station. The station shall house
all the required equipment and push buttons to provide the required two speed control in each
direction. Electric hoists shall be rated at IP56 or better.
Monorails
Beams shall be manufactured from structural section steel and be hot dipped galvanised after
fabrication. Each beam shall have trolley stops on both sides at its ends bolted to the beam.
Monorail trolleys shall be certified for both monorail and support structure. Existing structures
that support new monorail lifting equipment shall be re-certified. Similarly where existing
structures are modified to carry monorail beams the appropriate structural certifications for
modifications shall be gained.
Hoist hand chains and geared drive trolley chains shall be suspended below the runway beam
to 300 mm above the floor.
The monorail trolley bearings shall be designed to allow the load to be moved and positioned
with an effort of no greater than 150 N.
2-2.11 Equipment Installation and Layout

General
All equipment and plant shall be installed is in accordance with Relevant Acts, Regulations,
Australian Standards, Codes, and other requirements of Regulatory Authorities.
All inspections shall be by relevant statutory authorities where required. Modifications that may
be required resulting from the inspections shall be carried out.
Equipment shall be properly aligned to the prescribed centre lines and elevations, and set and
adjusted on packers and shims.
Bases of equipment shall be designed or filled in with grout so as not to create pockets in which
dirt and/or water could collect so that cleaning around the equipment can be easily carried out.
In the selection and placement of equipment, access and egress requirements shall be
maintained in accordance with OH&S Regulations.
Plinths for equipment shall be located with consideration to operating and maintenance access.
Manufacturer’s recommendations for minimum maintenance access shall be followed.
Clearance requirements for access and maintenance shall be as required by relevant codes and
standards. No supports, pipework, cables, ducting, or any other plant and equipment shall be
installed which will obstruct the minimum required clearances.
Packers shall be of sufficient size to sustain an effective load bearing area. They shall be of one
piece thickness.
Shims shall be of the same size as the packer. The maximum thickness of shim shall be used to
reduce the number of shims required at any one point to a maximum of three (3). If the total
thickness required is more than 6 mm, the shims shall be replaced with a single machined plate.
Shim material shall be suitable for loading conditions and prevent galvanic corrosion brass or
stainless steel. Aluminium stock is not acceptable.

Installation in Hazardous Areas

Particular care needs to be taken with equipment installed in hazardous areas. Where an area
is classified as hazardous, the installation shall be appropriate for that area and comply with
AS/NZS 60079 and HB 13. This includes the equipment selection and installation.
Equipment shall be certified for use in the particular hazardous area in which it is to be installed.
Suitable documentation shall be provided with each equipment item for inclusion on the site
hazardous area equipment register.
The installation and maintenance of equipment located in hazardous areas shall only be carried
out by personnel who fulfil the hazardous area competencies as outlined in AS/NZS 4761.
Equipment alignment
All mechanical equipment shall be set, levelled, aligned and inspected with precision tools (steel
straight edge, dial indicator and graduated machinist levels).
Specifically, all direct driven equipment shall be aligned by the use of a dial test indicator or laser
alignment. Both the driver and the driven shafts shall be rotated simultaneously to each of the
four positions at 0, 90, 180 and 270 at which readings shall be taken.
The maximum allowable out-of-alignment tolerance shall be 50µm (0.050 mm) unless specified
otherwise in individual equipment installation instructions.
An alignment record sheet shall be completed for each coupling aligned. This alignment
procedure shall also conform to the equipment manufacturer’s instructions.
All alignments shall be inspected and approved by the relevant equipment supplier’s accredited
representative. Inspections by the equipment supplier shall be coordinated and documented.
Grouting
Grouting shall be provided under all mechanical equipment and supports when mounted on a
concrete base or plinth.
2-2.12 Operations and Maintenance

The works shall be designed for operation and maintenance personnel to carry out their routine
tasks without the need to shut down process units. Equipment service points shall be readily
accessible.
In particular the following shall be adhered to:
i. Equipment arrangement shall be designed to have ready accessibility for operation,
maintenance and installation work.
ii. All indicators and instrumentation shall be in easy to read locations.
iii. Pipework and supports shall be arranged to allow convenient access for operation &
maintenance of the equipment. There shall be quick and unobstructed exit for people
working around equipment.
iv. All equipment should be accessible for operation from the normal operational position.
v. Equipment shall be conveniently located in order to ensure the safe removal and
replacement. Removal of such equipment shall not inhibit the availability of other installed
equipment.
2-2.13 Labelling
Labels shall be fixed to all items of equipment for both custom build and proprietary items. Labels
shall be 316 stainless steel plates and fixed by oval head stainless steel screws.
The label (or nameplate) shall be suitably engraved to provide information of a descriptive and
technical nature relating to the item of equipment.
The information given on the label shall include but is not limited to typical data as listed below:
i. Equipment number;

ii. Equipment type, e.g. Screw conveyor, Axial Flow Fan, Torque Flow Pump;
iii. Name of manufacturer;
iv. Model Number;
v. Serial Number;
vi. Rated Speed. If two speed, state both speeds. If variable speed, state upper and lower
limits;
vii. Capacity, e.g. pumps - litres/sec, hoppers - m³;
viii. Rating in kW or as appropriate;
ix. Full Load Current;
x. Guaranteed Duty Point Head and Flow.
All data shall be in metric units.
The information to be supplied depends on the equipment item. For example, for a gearbox
provide the reduction ratio.
The labels shall be in addition to nameplates of other materials, should these be supplied as part
of the equipment.
The label dimensions should be selected to be suitable for the information contained thereon.
The label shall be affixed to the specific item of equipment so that it may be conveniently read
when in the installed position and should be attached to a principal component of the equipment
item so that it is not misplaced or inadvertently discarded on a replacement part during an
overhaul.
2-2.14 Critical Spare Parts and Tools

All special tools required to operate and maintain the equipment shall be supplied with the
equipment. Special tools shall be regarded as the tools that cannot be procured "over the
counter" at the local hardware store.
These special tools shall not be used for the erection of the Works and must be handed over in
a completely new and unused condition prior to equipment handover.
The special tools must be labelled to know what they are for and certified for the specific use
and meet relevant AS.
2-2.15 Inspection, Testing and Commissioning

General
Testing and commissioning shall include, but not be restricted to:
i. Reliability and acceptance testing to demonstrate that all equipment and systems can be
successfully and reliably operated under working conditions;
ii. Submission of final Operation and Maintenance Manuals;
iii. Submission of any outstanding ‘as constructed’ records for all the work under contract,
including re-submission of any ‘as constructed’ records that may require amendment as a
result of changes during the commissioning process;
iv. Continuous operation of the equipment for a specific period prescribed in the particular
requirements section without any faults. During this period, if any major fault occurs, the
test shall recommence for a further specified period after the fault has been rectified unless
noted otherwise.
All necessary documentation shall be produced as verification that installation testing and
commissioning has been successfully completed. An up to date copy of developing test records
shall be present on Site at all times during construction and commissioning for information and
review. Should the Plant fail any test, any actions deemed necessary shall be taken to correct
the failure and repeat the test.

Factory Inspection Tests

Factory testing shall be witnessed where applicable as nominated.
Inspection and Test Plans shall be provided for approval prior to 28 days before commencement
of factory testing.
Notification of the test date shall be 14 days prior to the test.
All major items of equipment shall be subject to factory testing prior to delivery to ensure
compliance with the specified performance criteria. A factory certification of compliance shall
accompany each item and a copy shall be included in the Operations and Maintenance Manuals.
Test certificates, Operations and Maintenance Manuals, installation manuals and all other
documents specified in the Inspection and Test Plan, as approved, shall be provided separately
from the equipment before the equipment is delivered.
Installation and Pre-Commissioning Checks
The right to inspect equipment during the installation period is reserved at all times.
After the plant and equipment has been installed the following checks shall be performed as a
minimum and recorded to confirm and certify satisfactory installation and construction
completeness:
i. Check installation conforms to the design and specifications using available data (design
drawings, manufacturer’s drawings and manuals, piping and instrument drawings,
schematic diagrams and connection diagrams);
ii. Confirm suitability of mechanical equipment operation;
iii. Checking alignment of all couplings, belts, gears, valves;
iv. Checking freedom of correct shaft rotation;
v. Checking tightness of seals and inspecting packing of glands;
vi. Checking tightness of all fixings and that mounting and bracketing is tidy and secure;
vii. Checking that lubrication of equipment is complete and correct lubricant is supplied in
correct quantities;
viii. Checking that all moving parts and hot surfaces are properly protected;
ix. Check that all safety guarding and insulation is in place and secured as designed;
x. Checking access required to carry out operations and maintenance tasks;
xi. Checking cleanliness of equipment and systems, including piping, tanks and machinery;
xii. Point to point checking of all wiring and cabling to verify continuity and connection to correct
terminals and correct identification/labelling;
xiii. Insulation resistance tests on power cabling;
xiv. Checking calibration, setting and adjustment of all instrumentation;
xv. Obtaining installation acceptance certification from all equipment suppliers;
xvi. Conducting any other checks specified or recommended by the equipment manufacturer
and supplier;
xvii. Checking that electrical installation is complete and all instrumentation is configured
correctly.
The above shall include all checks and tests which can be performed without energising the plant
or equipment.
An inspection of the completed installation and sign off of relevant documentation is required to
confirm that the installation complies with the design requirements. This is required, where
stipulated, to guarantee required performance and to meet the terms of the warranty.

Pressure Testing
During testing, all areas involved in the testing, including the full length of the pipeline shall be
cordoned off and designated a testing area.
A hydrostatic test shall be carried out in accordance with AS 4041 and AS 4037.
Hydrostatic testing shall be carried out to achieve the following:
i. Detect leakage at components and flange joints of the equipment;
ii. Assist in assessing the adequacy of the piping system design, materials, and fabrication;
iii. Partially relieve residual fabrication stresses.
Adequate precautions are to be taken before, during and after the hydrostatic test to ensure no
damage to, or disintegration of, the equipment. In particular, the following precautions shall
apply:
i. Ensure the sump pumps at the bottom of a valve chamber floor have been checked and are
fully operational prior to the commencement of the hydrostatic test;
ii. Vent all air via the manual air vent before hydraulically pressurising the equipment;
iii. Dispose of water after testing as directed;
iv. All temporary pipes, connections and blanking devices shall be designed and installed to
withstand the appropriate test pressure;
v. All dismantling joints and flange adaptors and flexible couplings etc, in the section of
pipework to be tested, shall be fully tied as required for safe testing and operation;
vi. No component undergoing pressure testing shall be subjected to any form of shock loading;
vii. All test equipment shall be removed and the pipework etc re-installed/re-assembled to the
original operational condition after successful hydrostatic testing
All instruments, testing equipment, labour and fittings necessary for the test shall be provided by
the test team. Test equipment required to carry out the hydrostatic test shall include, but not be
limited to, the hand pump, isolation valves, pressure gauge(s), pressure relief valve, pipework
and fittings for connection of the test equipment.
Unless required otherwise, plastic shall be tested in accordance with the procedures specifically
approved by the pipe manufacturer for the particular pipe. Such procedures shall be submitted
for review prior to testing.
The lengths of pipe to be individually tested shall be selected by the taking into account the
ability of valves to withstand the test pressure and the various classes of pipe. Valves shall only
be used if they are specifically suited for seat closed testing at the specified test pressure.
Alternative means of pressurising the pipeline and measuring make-up water may only be used
after submission and approval.
A visual inspection of the pipework shall be made during and after testing to identify any distortion
of pipe spools due to inadequate supports. Distorted sections shall be replaced and the pipe
supports replaced before retesting of the pipework.
Any leaks shall be recorded, corrected and a full retest carried out.
Temporary spades and blanks installed for testing purposes shall be suitable to withstand the
test pressure without distortion. Presence of spades shall be clearly visible during testing.
Spring supports shall be restrained or removed and expansion bellows removed during
hydrostatic testing.
Test Certificates
Following completion of all tests, a full set of test certificates for each item of mechanical
equipment must be submitted.

2-3 VALVES AND ACTUATORS

2-3.1 General Requirements
Valves shall comprise a complete operating unit incorporating all necessary supports and
mechanical linkages, and shall incorporate an actuator where necessary.
Valves and actuators shall be supplied such that they are ready for installation.
All valves and actuators shall be capable of meeting the performance requirements as detailed
in the relevant specifications and schedules.
The equipment shall be designed, manufactured and rated for the maximum operating conditions
and to meet the specified hydrostatic test conditions. All valves shall be works tested.
Valve gearboxes shall be provided where necessary to allow handwheel operation at maximum
differential pressure. Gearboxes shall be fully enclosed.
The size, shape, strength and rating of all parts shall be of sufficient strength to provide an
appropriate safety factor under all working conditions.
All screws, nuts and bolts used to fasten equipment shall be threaded in accordance with the
relevant standard. Where fastenings are part of a proprietary item then the supplier’s standard
shall be used subject to the Contractor’s approval.
All parts requiring grease lubrication shall be fitted with hydraulic grease nipples.
The same supplier shall be used when two or more equipment items of the same type and sized
are required.
If equipment requires mechanical methods to be moved and/or installed then lifting lugs shall be
provided.
Depending on the size, and hence weight of a valve, it shall be supported independently of the
pipes which they connect. In any event valves > 300 mm NB shall be independently supported.
Valves shall be placed, when possible, so that they can be operated and serviced from grade or
access platform.
Level control valves shall be located in sight of their level indicators. Locally mounted indicators
or controllers shall be located in sight of the control valve they control. When possible, control
valves shall be installed with the stem in the vertical position.
Swing check valves shall preferably be located in horizontal pipe runs. Prior to installing swing
check valves in vertical legs, The Contractor shall seek confirmation from the manufacturer that
the selected swing check is suitable for installation in this orientation.
Relief valves shall be installed in an upright position and in a position accessible from a platform
or grade. Relief valves discharging hazardous liquids or gases shall be piped to a point of safety
to personnel.
Control valves shall be suitable for cavitation free operation over the complete range of valve
operating conditions.
Stop valves shall be capable of opening against full unbalanced head and closing against full
flow. They shall open and close smoothly without vibration or cavitation and without damage.
If required the end of a valve operating spindle shall be designed to accommodate a standard
steel extension spindle in accordance with AS 2638. Reference shall be made to the supplier’s
recommendations when valve installation dictates that valve spindles are not installed vertically.
Valves located outside buildings shall have non-rising spindles, and shall be fitted with a locking
device where operation will be critical to the process/plant being controlled/isolated.
All valves shall be closed by a clockwise rotation of the closing mechanism. The face of each
mechanism shall show clearly the labels OPEN and SHUT and the direction of turn to open and
shut the valve.
Unless otherwise stated, flanged valves shall be to AS 4087.
Valves shall be drop tight in the closed position.

Butterfly valves shall be installed with the spindle in the horizontal plane and have the lower part
of the disc move in the same direction as the flow when the valve is opened.
Valve internal surfaces shall be free of sharp protrusions.
Valves shall be designed or installed such that fluid will not pool on the valve housing.
Valves shall be lockable in the closed or open position with a standard padlock. The valve
specific requirements will be stated on the valve data sheet and/or schedule.
2-3.2 Material Requirements

Castings shall be made in accordance with the best foundry practice and shall be free from all
defects.
All nuts, bolts, washers, studs for flange connection shall be stainless steel grade 316 to suit the
mating flanges and suitable for maximum working pressure. All shafts, spindles and appropriate
supports shall be manufactured from stainless steel grade 316. External components not
specifically detailed shall be from stainless steel grade 316 or other approved corrosion resistant
material.
2-3.3 Valve Identification

The following lettering shall be cast on the body of the valve:
i. Manufacturer’s brand;
ii. Valve size and type.
The cast lettering shall be in legible block type letters and, where practical, not less than 25 mm
high and projecting not less than 3 mm.
The following information shall be shown on an engraved stainless steel nameplate. This
nameplate shall be permanently attached to the body of the valve (using stainless steel fixings)
and be clearly visible after installation:
i. Working pressure (kPa);
ii. Year of manufacture;
iii. Tag number;
iv. An arrow denoting direction of flow if applicable;
v. Total mass (kg);
vi. Manufacturer’s identification number;
vii. One of the following applicable informations:
o NO – Normally Opened;
o NC – Normally Closed;
o NT – Normally Throttled;
o NA – Normally Automatic;
o SOC – Set on Commissioning.
2-3.4 Water Services Australia Specifications

Valves shall comply with this specification and WSAA Product Specifications where such
specifications exist. Reference is made to the following WSAA Product Specifications:
Standard Title
WSA PS – 260 Gate Valves, Resilient Seated
WSA PS – 261 Gate Valves, Metal Seated

WSA PS – 262 Extension Spindles for Gate Valves
WSA PS – 263 Butterfly Valves
WSA PS –264 Non-Return (Reflux) Valves
WSA PS – 265 Air Valves for Water Supply
WSA PS – 266 Knife Gate Valves for Water Supply and Sewerage
WSA PS – 267 Hydrants (Spring) for Water Supply
WSA PS – 268 Automatic Control Valves
WSA PS – 269 Extension Spindles for Valves, General
WSA PS – 273 Vacuum Interface Valves
WSA PS – 274 Resilient Seated Ball Valves for Sewage Pressure Mains
WSA PS – 275 Air Valves for Sewerage
WSA PS – 276 Resilient Seated Ball Valves for Property Services
The WSAA Product Specifications make reference to various options for each valve. These
options will be specified in the valve schedule.
Valve types that are not covered by the WSAA Product Specifications shall comply with this
specification and the valve schedule.
2-3.5 Sluice Valves and Gate Valves

The requirements given here for sluice valves are also applicable for gate valves.
Sluice valves shall have bodies of high quality cast iron and shall be fitted with resilient seals up
to 350 mm. Above 350 mm, the wedge shall be of cast iron with renewable wedge face rings of
gunmetal and the spindle shall be of stainless steel 316L.
Except as otherwise specified in the particular specification, sluice valves shall have rising
spindles.
Where sluice valves above 350 mm bore are mounted with the spindle in the horizontal plane,
valve bodies shall be fitted with renewable gunmetal machined gate slides and the gates with
renewable hard bronze shoes accurately machined to reduce sliding fraction.
Extension spindles shall be of grade 316L stainless steel and be compliant with the specification
for valve stems. They shall be of the muff type and shall be drilled and provided with a nut and
bolt for securing the spindle to the valve stem, which shall likewise be drilled to accept the bolt.
Spindles of length greater than 3 m shall be supplied with intermediate spindle support bearings.
Sluice valves for sewage applications shall be fitted with bronze wedge gates.
All sluice valves shall be fitted with cast iron handwheels unless otherwise specified. Stem caps
shall be provided on all valves detailed for key operation and shall be secured with socket-
headed setscrews.
Sealing shall be so arranged that replacement can be accomplished with ease and shall not
require the removal of the valve from the pipeline. Stem sealing by toroidal ‘O-ring’ shall not be
permitted. For sewage a conventional soft packed stuffing-box arrangement is required, and the
packing shall be non-asbestos.
The dimensions of a gate valve fitted with a bypass valve shall not exceed the basic dimensions
set down in ISO 5996:1984 or equivalent and ISO 5208:1993 or equivalent.
Valves of 500 mm nominal diameter (300 mm if power actuated), or larger shall be fitted with a
wedge release jacking screw and locknut.

2-3.6 Knife Gate Valves

Knife gate valves shall present a virtually full clear bore opening to the flow when fully openend.
The valve body shall be cast, ductile iron or SG iron, incorporating an elastomer body seal
captive between the body valves in a closed loop. The seal shall contact the slide along its edge,
being positively guided by the compressed seal. No cavity between the edge of the slide and the
body is permitted. The body shall incorporated specially contoured flush-out corners in the invert,
such that any solids in the blade guides pushed down to the invert as the slide is closed are
flushed into the flow by the increased velocity of the medium. The valve body shall have
increased clearance in the chest area to minimise the possibility of solid material causing the
valve to jam due to compaction.
The valve slide shall be grade 316L stainless steel, ground on its faces and two long edges, and
shall have a leading edge radius larger than the valve bore radius, incorporating a single chamfer
to give a cutting action through solids in the line onto the body flush invert, ensuring at all times
a complete bubble-tight, non compacting shut-off.
The body/slide sealing system shall be outside the fluid flow path through the valve so that it is
protected from abrasion and erosion damage caused by solids and grit in the flow to ensure long,
maintenance-free seal life.
Sealing to atmosphere shall be replaceable elastomer sealing elements in the chest of each side
of the body, protected by brass scrapers against damage by entrained abrasive material. In the
event of leakage, adjustment of the sealing elements shall be effected by the introduction of a
grease compound behind the elastomer section through access tapping in the valve body edge:
this operation shall be carried out without the need for special tools or packing injectors.
The valve shall be suitable for bi-directional flow and shall give tight shut-off against the full
unbalanced head acting on either side of the closed slide.
The valves shall be of bonnetless construction, and shall have operating mechanisms supported
either on a robust open cast iron hood or on a minimum of four steel pillars to give strength,
rigidity and structural integrity.
Means of locking the valve in the open/closed positions shall be provided.
2-3.7 Eccentric Plug Valves

Eccentric plug valves to be in accordance with ISO 5211:2017 and be double-flanged, and where
required by the contract, be provided with electric actuation. Gearboxes shall be used for valves
greater than 350 mm NB.
The valve body shall be cast iron with Ni-resist plug and resilient seat face. The spindle shall be
grade 316L stainless steel supported in heavy-duty corrosion resistant bearings. The closing
action shall be by the plug pressing on a raised seat and the plug shall be retained within the
valve body by a securely bolted bonnet.
In the opened position, the plug shall be out of the flow and provide a straight flow path through
the valve.
Gland replacement shall be accomplished with the minimum of dismantling. Asbestos packing is
not permitted.
Position indicators shall be provided.
2-3.8 Metallic Ball Valves

Ball valves shall be permitted on pipeline diameters of 50 mm or less (e.g. Air/Gas dosing lines).
Ball valves shall be fitted with limit stops.
The ball and body shall be arranged to provide straight through flow when the valve is fully
opened.
Valves bodies shall be grade 316L Stainless Steel. Cast iron bodies are permitted provided they
are fitted with a grade 316L stainless steel liner or are rubber lined. The ball and stem shall be
grade 316L stainless steel and seats shall be PTFE. The valve stem shall be designed such that

thrust is taken by the shaft and not via the ball and seats. Body material shall be suitable for the
chemical being handled.
Both metallic and non-metallic valves shall be three-piece pattern to facilitate replacement of the
ball, seat, backing ring etc. without dismantling of the pipework.
2-3.9 Plastic Ball Valves

All plastic valves shall be certified by the manufacturer as completely compatible with the
intended and specified service.
Compatibility shall apply to the material of the valve and internal components, including all seals,
gaskets, O-rings and washers.
Except as otherwise specified, valve ends shall be flanged or be socket-type with union ends,
designed for solvent welding. The manufacturer shall provide specific recommendations for
solvent and primer.
Plastic ball valves shall have a PN16 pressure rating at ambient temperatures, with reduced
ratings for higher temperatures.
Ball valves for sodium hypochlorite solution service shall have the ball or body drilled as per the
valve manufacturer's recommendations to permit venting of pressure and gas from the confined
ball cavity when the valve is closed. The drilling shall vent to the upstream end of the valve. The
drilling shall be 3mm opening, de-burred.
Ball valves shall be provided with an actuating handle or powered actuator as required.
All valves shall be mounted in such a position that the valve position indicator (T-handle when
used) is plainly visible.
2-3.10 Diaphragm Valves

Diaphragm valves shall have straight pattern bodies with no lining. The diaphragm assembly
shall be replaceable inline. Valves shall have non-rising handwheel spindle operation and a
position indicator protruding from the bonnet assembly. Valves shall be easily automated by the
replacement of the manual bonnet assembly with a pneumatic actuator bonnet assembly. Valves
shall be lockable with a standard pad lock.
Position indicators shall be provided.
Valve Body
Valves of size DN50 and larger shall be fully flanged. Flange size and drilling shall conform to
AS 4087. Flanges shall be truly machine faced for their full width and the faces shall be square
to the axis of the valve. The back faces shall be either machined or spot faced at bolt holes.
Each body shall be manufactured from the materials specified in the schedule and shall be
properly cleaned and finished.
Valve Diaphragm
The diaphragm shall be manufactured from materials specified in the table below. The diaphragm
shall provide a uniform seal around the throat of the valve.
Valve Operating Assembly
Valve bearings shall be self-lubricated. Bearings shall be designed for a minimum B10 operating
life of 100,000 hours and shall be readily replaceable.
The design of the spindle and bearings shall be such that they will safely sustain maximum
differential pressure rating across the closed valve. The spindle and any keys or dowels etc. for
transmitting the torque between the shaft and hand wheel shall be capable of withstanding the
maximum torque required to operate the valve.
The operating assembly shall be provided with adequate drainage of any diaphragm leakage of
water to indicate a diaphragm failure. The valve spindle shall be securely attached to the bonnet
by suitable mechanical means.
Fixings shall be of stainless steel grade 316 or materials of equal or superior strength and

corrosion resistance. The valve packing shall be asbestos-free.

Material Requirements
Body and bonnet materials: Cast Iron ASTM A-126 CL
Liner material: Cast Iron ASTM A-126 CL
Diaphragm material: Butyl Rubber
Compressor material: Cast Iron ASTM A-126 CL
Spindle material: Carbon Steel
Spindle nut material: Brass
Body bolt material: 316 Stainless Steel
Flanged joint bolting selection (fasteners): 316 Stainless Steel
Coatings: Jotacote 412 or approved equivalent
Flange gaskets, O-rings and lubricants: EPDM, Nitrile and Dow Corning O-ring Lubricant #55 or
approved equivalent
Bactericidal lubricant: BK Standard Pipe Jointing Lubricant or approved equivalent
2-3.11 Swing Check Valves

Swing check valves shall be in accordance with ISO 15761:2002. Swing check valves shall be
double flanged with cast iron bodies. In foul sewage, the valves shall be constructed to allow
solid matter to fall clear of the valve flap and shall allow 100 mm minimum passing capacity.
Swing check valves shall be suitable for operating in the horizontal plane, unless otherwise
specified.
Swing check valves shall be of the quick-acting single-door type designed to minimise slam on
closure by means of heavy gunmetal-faced doors weighted as necessary. The valves shall be
fitted with renewable gunmetal door sealing faces, which shall be positively fixed. The door hinge
pin/shaft shall extend through a sealing gland on the side of the body and be fitted with an
external lever to permit backflushing. Glands shall be of the stuffing-box type with the exception
that for valves below 450 mm bore they may be of the ‘O-ring’ type. Valves shall have a non-
slam closing characteristic in reverse flow, which shall be accomplished by use of the inertia of
the valve. Weights may have to be added to the lever arm to accommodate shorter closing times
as determined by the Surge Analysis Study.
All valves shall embody the following features:
i. Detachable cover plates of ample dimensions to facilitate and withdrawal of the flaps.
ii. Cast iron flaps fitted with gunmetal seat faces to close at an angle not more than 80° to the
axis of the pipe.
iii. The flap seating faces shall mate accurately with the gunmetal renewable seating rings in
the valve body.
iv. Ample pockets below the flap into which may fall any solid matter, which might otherwise
prevent the flap from closing.
v. Suitable stops or other means to prevent the valve opening to an angle of less than 30° with
the axis of the pipe.
vi. The flap shall be hung from, and positively secured to, a grade 316L stainless steel pin.
The hinge pin/shaft shall preferably be square in section to ensure positive location of the
door. If circular shafts are utilised the back flushing lever shall be located on a squared
section, the diagonal dimensions of which shall be equivalent to the full diameter of the
shaft. Both door and lever shall be positively and securely fixed to the hinge pin/shaft. Grub
screws, pins (parallel to taper) or clamps are not acceptable. All internal fixing devices shall
be of grade 316L stainless steel.

2-3.12 Ball Type Non-Return Valves

Where specified, ball type non-return valves and shut off valves are permitted. In each case, the
body shall be of 316L stainless steel and provide straight through flow when the valve is fully
opened.
2-3.13 Air Valves

Air valves shall be either of the “dual” large orifice type having a float operated large discharge
orifice and a lever operated small discharge orifice, or of the small orifice type having a float
operated small discharge orifice, and designed to prevent clogging of the floating mechanism.
The air valve float chamber and float chamber cover shall be of cast iron with all other parts of
non-corrodible materials. All orifices shall be located well clear of the liquid level in the float
chambers, and designed to prevent sedimentation of floating solids. Valve bases shall be as
specified.
Air valves shall be provided with separate isolating valves and drain plugs. Air valves with ‘built
in’ isolation facility are not permitted. Air release valve installation used for sewage pumping
applications shall have the chamber drain to be piped to an adjacent wet well or sewer.
The installation of air valves utilising solid cylindrical control floats is acceptable.
2-3.14 Pressure Relief Valves

Pressure relief valves shall be angle pattern relief valves with the spring assemblies physically
separated from the process medium. Relief valves shall include a lever actuator for manual
opening of the valves. The valves shall be capable of passing the maximum required flow at 10%
over the valve set pressure.
i. Body materials Cast Bronze AS 1565-C83600
ii. Cover material: Cast Bronze AS 1565-C83600
iii. Spindle material: DR Brass AS 1567-486
iv. Disc material: Cast Bronze AS 1565-C83600
v. Seat material: Cast Bronze AS 1565-C83600
vi. Spindle gland packing or O-ring: PTFE or Nitrile
vii. Spring material: Spring steel
viii. Flanged joint bolting selection (fasteners): 316 Stainless Steel
ix. Flange gaskets, O-rings and lubricants: EPDM, Nitrile and Dow Corning O-ring Lubricant
#55 or approved equivalent
x. Bactericidal lubricant: BK Standard Pipe Jointing Lubricant or approved equivalent
Pressure relief valve set points shall be factory set and tested
Pressure relief valves on chemical feed systems shall be of diaphragm type. The setting of
pressure relief shall be field adjustable. Diaphragm material shall be PTFE/EPDM or an
alternative material as required to suit the fluid application.
2-3.15 Reduced Pressure Zone Valves

RPZ installations shall be provided on all connections to potable water mains.
Reduced pressure zone (RPZ) valves shall be straight through, double check valve style units
suitable for high water contamination hazard areas. Each RPZ valve shall be supplied with a
strainer and 2 No. lockable isolation valves assembled into the 1 No. unit. RPZ valves shall be
suitable for horizontal installation. RPZ valves shall conform to AS 2845.1 and AS 2845.3.
i. Body materials: 316 stainless steel
ii. Disc/Piston material: 316 stainless steel
iii. Spring material: 316 stainless steel

iv. Seat material: EPDM

v. Flanged joint bolting selection (fasteners): 316 SS
vi. Flange gaskets, O-rings and lubricants: EPDM, Nitrile and Dow Corning O-ring
vii. Lubricant #55 or approved equivalent
viii. Bactericidal lubricant: BK Standard Pipe Jointing Lubricant or approved equivalent
All RPZ facilities shall be installed and tested in accordance with AS3500 by a licensed plumber.
2-3.16 Solenoid Valves

Solenoid valves shall be of a modular style, comprising a valve assembly and a push-over coil.
The valve diaphragm shall be attached to the armature as a single assembly. The
diaphragm/armature assembly and the armature guide tube shall be mounted on the valve body.
The coil shall push over and attach to the armature guide tube and therefore be isolated from
the process fluid. The valves shall be capable of operating from zero pressure.
Pilot operated solenoid valves will not be acceptable. The valves shall be designed to minimise
water hammer.
Electrically actuated valves shall be have an electrical protection rating commensurate with its
location and operating environment. Where actuators are located in hazardous areas, the
actuator electrical protection rating shall be commensurate with its allocated hazardous area
zone. In all other areas, the minimum IP rating shall be IP54.
i. Solenoid valves shall be suitable for a 24 V DC power supply.
ii. Body materials: 316 Stainless Steel
iii. Diaphragm material: EPDM
iv. Coatings: N/A
v. Additional testing: N/A
vi. O-rings and lubricants: Nitrile and Dow Corning O-ring Lubricant #55 or approved equivalent
vii. Bactericidal lubricant: BK Standard Pipe Jointing Lubricant or approved equivalent
2-3.17 Electrical Actuators

Valve actuators shall be directly mounted onto and supported by the valves that they control,
unless the valve is underground where the actuator shall be mounted at coping level. Actuators
shall be suitable for remote automatic control and shall incorporate means for local manual
operation using a handwheel or lever. Actuators shall have integral starters and control
equipment, unless the actuator motor is of a size that necessitates a panel-mounted starter, in
which case it will be specified in the particular specification.
The output shaft shall be hollow to accept a rising stem and incorporate thrust bearings of the
ball or roller type.
The design shall permit the gear case to be opened for inspection or disassembled without
releasing the stem thrust or taking the valve out of service.
Valves stem and threads shall be provided with grease lubrication, rising spindle valves being
protected with a totally enclosed grease packed cover tube.
The actuator shall be fitted with a drive bushing which is easily detachable for machining to suit
the valve stem or gearbox input shaft. Bushing shall be fitted in the base of the actuator to enable
standard length valve stems to be used.
Only two categories of sealing are permitted:
i. All selected equipment for use in a hazardous area shall have undergone an appropriate
conformity assessment procedure (CAP) to demonstrate compliance with the essential
health and safety requirements of European Directive 94/9/EC (ATEX 95), as enacated in
the U.K. by the Equipment and Protective Systems Intended For Use in Potentially
Explosive Atmospheres Regulations 1996 and the Equipment and Protective Systems

(Amended) Regulations 2001.

ii. Watertight, dust-tight complying with the requirements of IEC 60529 or ISO 20653:2013
IP67 or better.
Actuators shall be suitable for pedestal mounting and interchangeable without removal of the
associated valve, penstock, pedestal, etc.
Actuator mounting flanges to be to BS EN ISO 5210 for multi turn actuators and BS EN ISO 5211
for quarter turn actuators.
Sealing of static joints shall be by ‘O-ring’ on moving components to prevent leakage of lubricant
from the machine.
The actuator shall provide double sealing between the terminal compartment and the internal
electrical elements of the actuator, fully protecting the motor and all other internal electrical
elements of the actuator from ingress of moisture and dust when terminal cover is removed on
site for cabling.
For control purposes, limit switches shall be fitted to the actuator at both the closed and opened
positions of the valve. Limit switches shall also be fitted for signalling purposes. All these shall
be fitted internally. Limit switches contacts shall be volt-free. The switch contact rating shall be
5 A, 250 V a.c., 30 V d.c. Valve position shall be clearly marked externally on the actuator.
The actuators shall be sized so that they develop sufficient torque to reliably seat/unseat the
valve or penstock off its seat, and to provide adequate torque throughout its operating range.
The torque output must be at least 20% more than is required under maximum operating
conditions (i.e. maximum differential head). The drive shall incorporate a lost motion hammer
blow feature.
Adequate overload protection shall be provided to prevent actuator motor damage in the event
of seizure. This shall either be in the form of torque switches or over-temperature thermostats.
The torque switch shall latch out on operation, and to be reset by driving in the opposite
directions. A mechanical latch shall be provided to prevent the open torque switch tripping while
the initial unsealing hammer blow is applied.
Setting of the torque and limit switches shall be carried out without the requirement to remove
any electrical compartment covers.
Adjustable mechanical limit stops shall be provided for opened and closed positions of actuators.
Actuators supplies shall be 415 V, three-phase or 110 V single-phase or less for quarter-turn
and 415 V, three-phase for multi-turn.
The motor shall have class F insulation in accordance with IEC 60085:2007 and shall be rated
for a Class B (80 K) temperature rise. Temperature rise shall be measured by the resistance of
the windings during full load conditions, in accordance with IEC 60079-1:2014, IEC 60092-
1:1964 and IEC 60349-1:2010.
Actuators in hazardous areas shall be in accordance with ATEX 11 2G EEx de 11CT4 in
accordance with EN 50014, EN 50018 and EN 50019.
Certain valve actuators will require fail-safe operation in the event of an electricity mains failure.
The Contractor may achieve this either by using fail-safe actuators or by providing standby power
supplies for the affected actuators. There should be no tendency for any actuator to “creep”
either opened or closed, both in normal operation or under mains failure conditions.
Anti-condensation heaters for use on 110 V a.c. shall be provided for all actuator motors.
The actuator motor gerbox shall be of the total enclosed oil bath lubricated type suitable for
operation at any angle and provided with appropriate filling and drain plugs.
A handwheel shall be provided for manual operation of the valve. It shall not operate during
powered actuator movement by way of a positive means of disconnection from the motor driven
mechanism. The wheel shall be maintained in its engaged position once this is selected until
powered movement takes place when it shall automatically disconnect and “free wheel”. The
handwheel gearing shall be selected to allow valve operation without undue effort i.e. not
exceeding 25 kgf.

The handwheel shall be provided for manual operation of the valve in accordance with ISO
5208:2015 and ISO 5211:2017. Handwheel gearing shall enable one person to manually
open/close the valve without undue effort and in a reasonable time period, in accordance with
ISO 5208:2015 and ISO 5211:2017.
It shall be possible to secure hand or powered operation by means of padlocking in the selected
mode.
Where necessary to present the actuator handwheel at a convenient operating height, flange-
mounted pillars shall be provided which fully enclose the necessary valve stem extension
spindles. Supplementary support of the extension spindle within its pillar shall be provided for
long shafts.
The open/close direction of rotation shall be clearly indicated on the handwheel.
A visual position indicator shall be provided within the actuator, complete with a pointer showing
opened/closed and in travel positions, and a sealed potentiometer to transmit continuous remote
position, where necessary. Where specified in the particular specification, this indicator shall be
illuminated.
Electrical and mechanical disconnection of the motor should be possible without draining the
lubricant from the actuator gearcase.
Modulating duty actuators shall be capable of 3000 operations per hour as a minimum.
Standards
IEC 60085:2007 Electrical Insulation – Thermal evaluation and designation
ISO 5208:2015 Industrial Valves – Pressure testing of metallic valves
BS EN ISO 5210:2017 Industrial Valves. Multi-turn valve actuator attachments
BS EN ISO 5211:2017 Industrial Valves. Part-turn actuator attachments
IEC 60079-1:2014 Explosive atmospheres – Part 1: Equipment protection by
flameproof enclosures “d”
IEC 60092-1:1964 Electrical installations in ships – Part 1: General Requirements
IEC 60349-1:2010 Electric traction – Rotating electrical machines for rail and road
vehicles – Part 1: Machines other than electronic converter-fed alternating current motors
IEC 60947-7-1:2009 Low-voltage switchgear and controlgear – Part 7-1: Ancillary
equipment – Terminal blocks for copper conductors
2-4 PENSTOCKS
2-4.1 General
Penstocks shall be of robust design, suitable for their application, and their construction shall be
capable of resisting deflection under the worst operating head conditions. Each penstock shall
be provided with a suitable handwheel adequate for the duty required.
Penstocks shall carry identification marks and/or brass plates to identify the penstock number
and function.
All penstocks shall be clockwise closing.
Gearing shall be supplied where necessary to ensure that the required operating force applied
by hand to the rim of the wheel does not exceed 25 kgf. If the handwheel cannot be readily
accessed, extension spindles, headstocks and foot brackets shall be provided where specified.
The penstocks shall be supplied complete with all accessories, fittings, fixing bolts, nuts and
washers ready for installation. Fixing nuts and bolts shall be supplied by the manufacturer and
shall be of stainless steel 316L.
The doors shall be designed for ON or OFF seating pressures, suitable for an off-seating head
of 8.5 m. The seals shall be watertight under these conditions for head and direction of flow.
For apertures where the width exceeds twice the height, a dual spindle actuation system shall

be used.
The frame and door shall be designed such that under the specified design head pressure the
horizontal and vertical deflection should be less than 1/500th of the critical span for stainless
steel and 1/300th for aluminium. However it should have no influence on the function of the
penstock.
The frame seal shall be mounted and sealed to the wall with a suitable approved elastomeric or
grout sealing system. The manufacturer shall specify in general arrangement drawings what
system is to be utilised. The method of sealing shall be suitable for the environment it will be
exposed to.
There shall be a means of fixing the frame to the structure whilst maintaining free movement of
the door for the full length of travel and support a minimum of 50% of the door height when in
the fully raised position.
The manufacturer shall specify the location, size and quantity of chemical anchors for installation
to prevent deflection of the frame under the maximum specified design head pressure.
The design shall allow for the replacement of all the seals without removing the frame from the
structure.
Lifting points shall be included for handling and installation.
The door shall be designed for easy removal for maintenance.
The door shall provide flow isolation within the specified leakage rates when fully closed and
when under the maximum specified head conditions.
The headstock/pedestal shall be designed for 270N rim pull force applied to the handwheel.
The headstock/pedestal shall be designed to allow removal of the door from the frame without
causing structural damage.
Where required, gearing shall be provided so that the handwheel to operate the penstock is
located at a height no greater than 1.5m above the walkway floor level.
Sealing shall be provided at the sides, bottom and if required, the top of the door. Seals shall be
mounted on the door or frame and be replaceable without causing structural damage to the
frame. Resilient seals shall not have guiled joints. The seal material type and durometer
hardness shall be specified by the manufacturer.
Seals shall be manufactured from a material that is not injuriously affected by the fluid,
temperature or environmental conditions to which the seals will be subjected to in service.
Spindle design shall be checked using Euler’s Buckling Formula. Spindles shall be designed so
that they are of sufficient section to prevent buckling or deformation when subjected to axial
forces generated from 270N rim pull force applied to the handwheel.
Intermediate spindle supports shall be provided as required
Adjustable limit nuts shall be provided on all rising spindles to limit door travel and to prevent
buckling of the spindle due to application of excessive load.
Spindles shall have suitable thread finishes that will avoid excessive wear of components.
2-4.2 Materials
Where non-metallic materials are used, they shall be fit for the intended purpose. They shall
exhibit dimensional stability when exposed to weather, sunlight and where relevant after
extended periods of immersion. Any such material exposed to direct sunlight shall be UV
stabilised.
The materials of construction for penstocks shall be at least equal in quality to the following:
Component Material Standard Grade
Frame Stainless Steel ASTM A240M 316L & Duplex 2205,

2507

Aluminium Marine AS/NZ 1734 5083-H321/H116, 6061-

Grade T6, 6351-T5, 6005A-T5
Door Stainless Steel ASTM A240M 316L & Duplex 2205,

2507
Aluminium Marine AS/NZ 1734 5083-H321/H116, 6061-

Grade T6, 6351-T5, 6005A-T5
Fasteners Stainless Steel ASTM A276 316 & Duplex 2205, 2507
Spindle Stainless Steel ASTM A276 316 & Duplex 2205, 2507
Drive Nut Aluminium Bronze

Manganese Bronze
Ertacetal
Anchor Bolts Stainless Steel ASTM A276 316 & Duplex 2205, 2507
(Chemical)
Spindle Stainless Steel ASTM A276 316

Extension
Door Guides Ultra High Molecular -

Weight Polyethylene
(UHMWPE)
Seals EPDM, Neoprene, AS1646/AS2369.2 -

Plasticised PVC and
UHMWPE
2-5 CENTRIFUGAL PUMPS

2-5.1 Performance Requirements
General Performance Requirements
The pump shall be selected to meet the full range of duty conditions stated in the pump data
sheet. Pumps shall be capable of delivering the specified performance across the full range of
site climatic conditions specified. The advantages of lower impeller speeds shall always be
considered.
Contractors shall select the most economic pumps given the constraints of the operating
parameters, as operating costs will be considered in association with the capital costs in the
evaluation.
The pump duty pressures shall be adjusted to include losses due to all components included in
the scope of supply. Allowance shall be made for maximum and minimum pressure drop across
components when calculating the maximum and minimum pressures.
The pump shall have a stable H-Q characteristic curve and shall be non-overloading.
For slurry/sludge pumps, the capacity shall be 105% to 120% of the design flow rate (to be
reviewed on a case by case basis). The design flow rate is the maximum flow rate shown on the
data sheet.
The guaranteed duty flow rate shall be in the range from 80 to 105% of best efficiency flow for
the selected impeller. However, the run-out conditions shall be considered such that the run-out
flow for any pump shall not exceed 120% of the best efficiency flow rate for the selected impeller
diameter.
Pump speeds shall not exceed 1500 rpm for pumps delivering less than 30 l/s and shall not
exceed 1000 rpm for pumps delivering greater than 300 l/s.
The velocity through the eye of the impeller shall not exceed 3 metres per second. Although this

does not apply for pumps with “free-flow” vortex type impellers, it shall be used as a guide to
prevent pump selection with excessive velocities through the pump.
Contractors shall provide technical brochures, for the plant proposed and this shall include full
technical details of thrust bearings, lubrication, sealing and protection devices.
Minimum or maximum size impellers for the casing are not permitted. At least one increase and
one decrease in size shall be allowed. The Contractor must confirm duty diameters as well as
maximum and minimum diameters in the pump technical schedule.
The pump shall be selected to maximise operating efficiencies without modification, polishing or
coating of the impeller and without cavitation or damaging vibration over the entire range of flow
conditions.
The net positive suction head (NPSH) required shall be compatible with that available to enable
the pump to operate without cavitation, over the full range of flows at all sump liquid levels.
The Net Positive Suction Head Required (NPSHr) of the pump shall be based on actual 3% head
drop method test results. The pump shall have an NPSHr at least 2 m less than Net Positive
Suction Head available or, the NPSHa shall be at least 133% greater than the NPSHr, whichever
is the greater, at any point between zero flow and the maximum operating range flow attainable
against the characteristic curve.
For a variable speed driven pump the drive speed shall be capable of being increased by at least
3% from rated speed without overloading the drive system.
The pump head versus flow characteristic shall be stable and rise continually to close valve head
and be non-over loading.
Pump testing to be in accordance with BS EN ISO 9906:2012.
Efficiency and Power Consumption
Power consumption of the pump shall not exceed 90% of the motor rated power output at any
point on its curve.
2-5.2 Technical requirements

General Requirements
The layout of the pumps shall provide adequate clearance and safe access for operation and
maintenance.
The pumps shall be provided with clearly identified, permanent lifting points to give a safe and
balanced lift.
The equipment shall be the manufacturer’s standard design with the additional requirements
called for by this specification. Preference will be given to equipment for which local spare parts
are available.
The pump sets and the associated equipment shall be suitable for installation in an open,
unprotected outdoor environment and shall be suitable for unattended operation and have
minimal maintenance requirements.
Unless otherwise nominated, the equipment shall have a minimum design life of 15 years.
Materials of Construction
Materials of Construction shall be in accordance with Section 2-2 in addition;
i. Where not specified, materials shall be selected with proper reference to the specified
operating environment, pumped medium, guaranteed/expected service life and availability.
ii. Phenolic insulating sets or dielectric unions shall be used for cathodic protection when
dissimilar metals are joined.
Mounting Arrangement
Mounting arrangements shall be designed to facilitate accurate alignment and prevent excessive
distortion under all operating conditions.

Motor drives for vertical pumps shall be mounted either:

i. Directly onto the pump casing using an adaptor stool; or
ii. Onto a free standing stool fixed rigidly to the floor and connected to the pump using a flexible
spacer coupling; or
iii. Remotely and connected to the pump by line shafting.
Motor drives for horizontal pumps shall be mounted on a baseplate.
Baseplate or Support Frame
The support structure shall be stiffened to prevent the pumpset exceeding maximum vibration
levels specified.
The support structure shall be locally reinforced around foundation bolt holes.
The support structure shall be crevice free to prevent the collection of water and debris during
operation. Baseplates shall be designed to prevent the formation of trapped air pockets during
grouting.
The ends of all sections shall be sealed to prevent the ingress of water; after all corrosion
resistant coatings have been applied.
Unless otherwise nominated on the datasheet, the support structure shall be manufactured from
mild steel and hot dip galvanised in accordance with the relevant standard. The base frame shall
be stress relieved after welding prior to galvanising.
A common base plate shall accommodate pump and drive unit with the necessary adjusting
devices to allow accurate alignment of the pump/motor coupling. The pump/drive unit base plate
shall be designed with sufficient rigidity to maintain alignment in accordance with the
requirements of the coupling manufacturer without requiring additional rigidity to be supplied
from the foundations. The mounting pads for the pump and drive shall be milled/machined flat
and level. Any shims used shall be from stainless steel. The motor and coupling shall be
positively located so that they can be readily removed and replaced into position without requiring
extensive coupling alignment checks.
Couplings
Couplings shall be in accordance with section 2-2.9.
Reverse Rotation
All pump motor and coupling components shall withstand without damage, the effects of reverse
rotation due to temporary reverse flow through the pump up to 120% of normal direction rated
speed.
Casing
The pump casing shall be high grade cast iron and be abrasive resistant, capable of taking shock
loads and incorporate lifting eyes located for removal of the pump. However, for some
applications stainless steel will be specified in the technical schedules.
Pump casings and discharge pipework, up to and including the isolation valves and non-return
valves, shall be rated for the maximum closed valve head developed; inclusive of the maximum
suction pressure or 16 Bar, whichever is the greater. Pump casings shall be tested to twice the
working pressure, or the maximum surge pressure, whichever is the greater.
Pipework including inline equipment downstream of the isolating shall also be rated for the closed
valve head developed unless it is open to atmospheric conditions.
The casing shall be designed to resist abrasion and mechanical shock imposed by solids in the
pumped flow.
The casing casting shall be dressed to a good commercial standard to expose any surface
imperfections.
Components in the pump casing that may be subject to wear shall be easily removable for
refurbishment or replacement.

All mating surfaces shall be accurately machined and provided with deep registers, dowels and
spigots where necessary, to ensure alignment.
If specified on the data sheet, connections shall be provided on the pump flanges or casing for
connection of pressure gauges and venting, drain and seal flushing pipework. Instrument
tappings shall be DN20 half couplings screwed BSP female tapered to AS 1722.1. Instrument
tappings shall be fitted with a screwed reducing nipple and DN15 ball valve of stainless steel
construction. Venting connections shall be positioned on the highest practicable point on the
casing. All unused, tapped holes shall be fitted with solid, corrosion resistant, metal plugs.
A separate removable suction casing shall be provided, to gain access to the impeller without
dismantling the discharge pipework.
Shafts
The shaft shall:
i. Be machined from solid one-piece bar stock of stainless steel grade 316 or better;
ii. Have a ground finish over its entire length;
iii. Be equipped with replaceable shaft sleeves in areas subjected to wear.
The shaft shall be designed such that the first lateral critical speed is not less than 150% higher
than the maximum operating speed of the pump.
The first lateral critical speed shall be calculated for the maximum diameter impeller able to be
fitted to the pump, without any support from wearing ring(s) or neck ring(s).
The maximum lateral deflection of the shaft shall be determined to establish permissible internal
clearances, taking into account all lateral hydraulic reactions on the impeller and any external
loads.
Impeller
The pump impeller shall be a one-piece casting specifically designed/profiled for the duty and
conditions detailed in the project-specific specification/data sheet.
The impeller shall be fixed to the shaft such that shaft rotation in either direction shall not cause
it to loosen.
The impeller shall be dynamically balanced prior to assembly in accordance with ISO 1940-1.
The direction of rotation of the impeller shall be clearly and indelibly marked on the pump casing
with an arrow.
Impeller tip speeds shall not exceed the values indicated in the table below:
Fluid type Max allowable tip speed m/s
Water/wastewater 40
Medium Slurries 35
Heavy Slurries 30
Elastomer Impellers 26
Wear Rings
Casing wear rings shall be locked to prevent rotation by dowel or similar approved method. Ease
of replacement shall be a major design criterion. The wear rings shall be of bronze for potable
water or cast iron for sewage and designed such that hydraulic pressure aids the sealing of the
ring into the pump casing. Stainless steel may be used. Casing wear rings shall be incorporated
on all rotating / stationary interfaces, except for low head sewage pumps such as Vortex types.
Renewable wear rings shall be supplied on the suction side of fully shrouded impellers and there
shall be renewable wear rings fitted to the matching parts of the casing.

Renewable wear rings shall be supplied on the back side of all impellers that have balancing
holes and there shall be renewable wear rings fitted to the matching parts of the casing.
Renewable wear rings shall be of one piece and shall be securely locked in position to prevent
rotation.
Replaceable wear rings shall be provided on clean water pumps between the impeller and casing
at the front and back of the impeller.
Bearings
Bearings shall be in accordance with section 2-2.6.
Seals
Seals shall be in accordance with section 2-2.7.
The pump motor shall be protected by a tandem mechanical seal arrangement. Lip seals are not
permitted. The Contractor shall provide complete data on the seal materials, seats, faces, etc.,
and ensure suitability for the medium being sealed.
On pumps greater than 5 kW the mechanical seal performance shall be by monitoring equipment
to detect the following:
i. Moisture within the oil chamber.
ii. Moisture/water or oil within the motor casing.
iii. Temperature rise of the hydraulic driven end bearing.
iv. Loss of oil from the oil chamber.
Cooling
Cooling of the motors shall be provided by one of the following methods with the Contractor
supplying and installing all of the necessary equipment:
i. On units of less than 7 kW cooling may be provided by the casing provided that the
application meets the manufacturer’s requirements for heat dissipation. Cooling must be
sufficient when pumping at sump levels at top of pump volute.
ii. Oil cooled motor with a heat exchanger in the base plate to the pump bowl.
iii. Water jacket utilising sewage as the cooling medium. A filtering gap shall be provided to
prevent large solids blocking the cooling passages. This cooling method is not permitted for
sludge pumps.
iv. Air cooled for immersible pumpsets installed in dry well conditions. Motors shall be suitable
de-rated for the maximum ambient air temperature.
v. Motors provided with variable speed drives shall not be operated at a speed below which
heat dissipation is reduced below the menufacturer’s recommendations.
Pedestal
The pedestal shall be manufactured from cast iron of fabricated steel and shall incorporate a
boltless automatic connection between the pump and the discharge pipework and provision for
locating and retaining the lower ends of the pump guide system.
The outlet flange of the pump shall seat firmly on the outlet flange of pump stool with the weight
of the pump, and shall not leak when the pump is operating at maximum pressure.
Where submersible pumpsets are utilised in a drywell situation, the pump inlet bend/duckfoot
support shall include a quick release hand access to facilitate impeller eye clearance.
Guide Rails
A guiderail system of stainless steel Grade 316L tubing shall be provided to ensure simple and
effective removal and reinstallation of the pumpset. The system shall be vertical over its entire
length, be retained at the bottom by fixings forming part of the discharge connection and at the
top by a bracket/access frame arrangement. The guide system shall be retained at the lower end
by the pump pedestal and at the upper end by mounting brackets. Guide wires are not permitted.

Guides
The pump body shall be provided with either detachable or integral guides. The guides shall be
accurately manufactured to permit the lowering of the pump without swing or seizure until
connection is made with the pump discharge connections.
Connections
Pump connections shall be in accordance with section 2-2.5, in addition:
i. Connections shall be standard nominal bores sizes.
ii. Flange pressure ratings shall be not less than the pressure rating of the pump casing.
iii. Flexible connections shall be provided on all equipment where vibration, expansion or
loading may be a problem.
iv. Flanges shall be arranged so that bolt holes symmetrically straddle the north/south,
east/west and horizontal/vertical centre lines.
Nameplates
Labelling and Nameplates shall be in accordance with section 2-2.13.
Fastenings
Fastenings shall be in accordance with section 2-2.5.1.
Vibration
Acceptable vibration levels shall be in accordance with section 2-2.8.4.
2-5.3 Submersible Pumps

Submersible pumps shall comply with WSA 101 - 2008 Industry Standard for Submersible pumps
for sewerage pumping stations. In addition to this specification, the following shall apply to
submersible pumps:
i. Submersible pumps shall be supplied complete with guide rails to the specified length,
mounting brackets, delivery/mounting foot and the specified length of electrical cable.
ii. All components shall be of materials suitable for submergence in the specified fluid.
iii. The impeller and casing shall be designed to suit the specified amount of fluid contaminants
including solid particles. This may include wear resistant materials and open impeller
design.
iv. The motor shall be hermetically sealed and be capable of operation in air.
v. The pump shall incorporate a pressure compensated oil filled seal chamber.
vi. Sensors shall detect any water leakage into the oil chamber.
vii. Thermal switches shall detect any over temperature in the motor.
viii. Motor leads shall be sealed to the motor by a compression gland. The cable sheath shall
be suitable for continuous submergence and oil and grease resistant. The cable shall be
long enough to allow for one re-termination and in any case shall be a minimum of 6 metres
long.
ix. Hand hole cleanouts shall be provided on the casing to facilitate clearing out of accumulated
debris for larger pumps.
x. Sump pumps shall be equipped with a suction screen of aperture less than maximum
sphere size, which can be pumped.
xi. A heavy-duty Grade 316 stainless steel lifting chain shall be provided for each pump unit.
Grade 316s Stainless steel ‘D’ shackles shall be provided at 1500mm centers and on chain
end for connection to the pump unit. The chain shall be supplied with a proof load certificate
and shall be sized appropriately.
xii. A Grade 316 stainless steel hook arrangement shall be provided to fix the chain to an easily

reached access point.

For dry well mounted submersible pumps, the pump shall include a water jacket to keep the
motor cool should the manufacturer deem it necessary. The supply path to the cooling jacket
shall be such as to prevent fluid contaminants from blocking the jacket passages. The cooling
jacket where provided shall be capable of being sealed from the fluid and connected to an
external cooling supply.
Dry well units shall be supplied with a suitably sized baseplate, stool or fabricated structural steel
supporting frame depending on the installation orientation. The supporting structure shall be
designed to suit the pump suction arrangement and shall ensure that no work below the
stool/baseplate is needed when installing or removing the unit.
The pump suction or suction bend on a dry well unit shall be a flanged connection. Access to the
pump suction or suction bend shall be as close to the bend as practical.
Submersible pumps shall be capable of running partially or totally submerged in a wet well
configuration without overheating. They shall also be capable of withdrawal from the wet sump
without the requirement for entry to the wet sump for disconnection by maintenance personnel.
Pump and motor units shall be designed for a working life of 100,000 hours with overhauls at not
greater than 20,000 hour intervals. All components shall be capable of renovation during
overhaul making maximum use of readily replaceable parts.
Impeller
The impeller shall be selected by the manufacturer for its ability to handle sewage. The impeller
shall be of the screw, torque flow or semi-open mixed flow types and made from high grade cast
iron, or duplex stainless steel. Ni-hard cast iron shall be used where high grit content is likely.
Provision shall be made to prevent the build up of solids behind the impeller. Hydraulic balance
holes are not permitted.
Each pump shall be capable of passing a 100 mm minimum diameter spherical solid through the
impeller and associated passages without choking, and be designed for the sewage and
conditions of Palembang city.
The leading edges of the impeller shall be capable of shearing any rags or plastics within the
pumped media without chipping or splitting.
The impeller shall be positively secured to the high tensile steel or stainless steel pump shaft
and dynamically balanced as a whole.
Pump Inlet and Outlet
The inlet of the pump must be positioned so that the circulation of fluid to the intake is not
impaired by benching in the sump.
2-5.4 End Suction

In addition to the general technical requirements:
i. End suction pumps shall include a spacer coupling to enable the withdrawal of the impeller
and shaft assembly without disturbing the drive or casing.
ii. Unless specified otherwise, the delivery flange on end suction pumps shall be vertically
upwards.
iii. Construction of the pumps shall be such that the complete rotating element can be
withdrawn from the casing as a unit without removal of the motor.
iv. Pump flanges shall be fitted with pressure tappings.
v. Pump casings shall be fitted with a drain plug.
vi. Packed glands shall be fitted with gland drains.

2-5.5 Propeller Pumps/Mixers

General
The unit shall be free of vortices and vibration and shall not permit air entrainment into the liquid.
Surface splashing shall not be acceptable.
The unit shall be capable of delivering the specified performance across the full range of site
climatic conditions.
Pump sizes and models shall be standardised as much as possible in order to limit size ranges
and spare parts.
Pumps shall be high-speed, horizontal, submersible direct driven motor units and close-coupled
design.
Pumps shall be complete operational units including all necessary accessories. Pumps shall be
factory coupled and supplied as one fully assembled unit complete with motor, shaft, propeller
and accessories.
Units shall be entirely suitable for continuous operation.
Units shall be supported from and located by guide rails.
Each unit and the associated equipment shall be suitable for installation in a submerged open,
The unit shall be provided with clearly identified lifting points to give a safe balanced lift.
The unit shall be selected to maximise operating efficiencies without modification of the propeller
and to maximise the hydraulic power transmitted to the fluid.
Power consumption of the unit at operating speed shall not exceed 95% of the available motor
rated power output at that speed.
Minimum Submergence
The unit shall be guaranteed to operate continuously at the minimum water level without:
i. Formation of vortices;
ii. Voiding of inflow to the propeller;
iii. Overheating of the motor; or
iv. Vibration or mechanical damage.
Propellers
Propeller blades shall be high efficiency, self-cleaning blades, from 316 stainless steel, balanced
with taper fit to motor shaft.
Propellers shall be secured to the motor shaft and shall be retained against circumferential and
axial movement. Positive mechanical locking is required in both directions of rotation.
Propellers shall be statically and dynamically balanced on their shafts. Balancing holes in the
propeller shall not be permitted.
The propeller shall provide uniform velocity across its full diameter and shall operate without
cavitation.
Locking of propeller to shaft shall tighten with normal operation.
Propeller speeds shall not exceed 1500 rpm.
Shafts and Shafts Seals
Shafts shall be single piece 431 stainless steel, be of ample size to transmit the full driven output
and shall be accurately machined on all surfaces.

The total deflection of shafts, at maximum operating thrust with full size propellers, shall be less
than 1 in 800.
Mechanical seals shall be used. Mechanical seals shall be an all stainless steel single acting
mechanical seal with silicone-carbide sealing faces. A minimum of two (2) mechanical seals are
required per unit with an intermediate pressure compensated oil chamber.
The propeller shall be mounted directly on an extension to the motor shaft.
Ancillary Equipment
Each unit shall be supplied complete with a placement/removal system incorporating:
i. Guide rail and rail support brackets;
ii. Lifting wire and cable capture clips. The lifting wire shall be shackled to the unit and it shall
not be permitted to enter the tank to attach the wire to the unit;
iii. Load test certificates
The guide rail arrangement shall:
i. Be designed such that the unit can be placed and removed without bolting of joints, or use
of tools;
ii. Comprise a single continuous rail extending from the base of the tank to the level of the
maintenance access platform and which has an end stop to prevent the propeller coming
into contact with the tank floor;
iii. Be capable of withstanding the loads imposed during operation, placement or removal of
the unit, to ensure that the unit can be raised and lowered without lateral deviation;
iv. Permit accurate location of the unit;
v. Ensure that there is no interference of the guide arrangement on other static structures
vi. Be manufactured in stainless steel grade 316
The stainless steel grade 316 lifting wire shall:
i. Be a continuous length of suitably rated stainless steel twisted wire cable;
ii. Include stainless steel grade 316 shackles, connection(s), clips etc. to the unit;
iii. Include break-type clips for attachment of the motor cable(s).
Surfaces of components subject to rubbing or sliding action shall be provided with elastomeric
bushes, pads, designed to prevent surface damage to the stainless steels and corrosion.
Dynamically loaded components shall be one piece castings.
2-5.6 Spare Parts and Special Tools

All special tools required to operate and maintain the equipment shall be supplied with the
equipment. Special tools shall be regarded as the tools that cannot be procured "over the
counter" at the local hardware store.
These special tools shall not be used for the erection of the Works and must be handed over in
a completely new and unused condition prior to equipment handover.
The special tools must be labelled to know what they are for and certified for the specific use
and meet relevant AS.
2-5.7 Testing
Testing shall be in accordance with section 2-2.15. In addition Contractor shall arrange for the
Engineer to be present at Factory Acceptance Testing of all pumps with a pump power exceeding
25 kW.
Pump testing shall be in accordance with AS 2417 Grade 2 or agreed equivalent International
Standard.
The performance of each pump shall be tested using the motor to be supplied.

Flow, head, power, vibration and other required parameter measurements shall be taken at
several flow rates to provide a definable smooth curve for head, efficiency, absorbed power and
motor electrical power (all versus flow rate) extending from zero flow to the maximum flow the
pump will achieve against the system curve. Where pumps are operated at variable speed the
test shall be repeated at the lowest speed and any other speed required to achieve the various
duty points indicated on the pump data sheet.
The test flow rates shall include:
i. zero flow; (centrifugal pump only)
ii. the guaranteed duty point;
iii. all secondary duty points;
iv. maximum achievable flow.
2-6 POSITIVE DISPLACEMENT PUMPS

2-6.1 Performance Requirements
General Performance Requirements
The pump shall be selected to meet the full range of duty conditions stated in the pump data
sheet. Pumps shall be capable of delivering the specified performance across the full range of
site climatic conditions specified.
If a multi-stage progressive cavity pump is requiredprovided, the number of stages shall be
stated on the pump data sheet.
The maximum rotor speed and the maximum statorrotor rubbing velocity (progressive cavity
pumps only) shall be stated on the data sheet.
The maximum speed of the pump shall be de-rated and the pressure per stage limited according
to the level of abrasive solids present in the pumped medium as specified in the table below:
Level of Abrasive Solids Maximum Pressure per % Speed De-rating
Stage (bar)
None 6 0
Light 5 25
Medium 4 50
Heavy 3 75
This clause applies to progressive cavity and rotary lobe pumps only.
The maximum diameter of solid sphere required/able to be passed by the pump shall be stated
on the data sheet.
The pump shall be selected to maximise operating efficiencies without modification, polishing or
coating of the impellerrotor.
Power consumption of the pump shall not exceed 90% of the motor rated power output at any
point on its curve.
2-6.2 Technical requirements

General Requirements
The layout of the pumps shall provide adequate clearance and safe access for operation and
maintenance.
The pumps shall be provided with clearly identified, permanent lifting points to give a safe and
balanced lift.

The equipment shall be the manufacturer’s standard design with the additional requirements
called for by this specification. Preference will be given to equipment for which local spare parts
are available.
The pump sets and the associated equipment shall be suitable for installation in an open,
Unless otherwise nominated, the equipment shall have a minimum design life of 15 years.
Lubrication points shall be accessible without removing guards.
Materials of Construction
Materials of Construction shall be in accordance with section 2-2, in addition;
Where not specified, materials shall be selected with proper reference to the specified operating
environment, pumped medium, guaranteed/expected service life and availability.
Phenolic insulating sets or dielectric unions shall be used for cathodic protection when dissimilar
metals are joined.
Mounting Arrangement
Mounting arrangements shall be designed to facilitate accurate alignment and prevent excessive
Motor drives for vertical pumps shall be mounted either:
i. Directly onto the pump casing using and adaptor stool; or
ii. onto a free standing stool fixed rigidly to the floor and connected to the pump using a flexible
spacer coupling; or
iii. remotely and connected to the pump by line shafting.
Motor drives for horizontal pumps shall be mounted on a baseplate.
Baseplate or Support Frame
The support structure shall be stiffened to prevent the pumpset exceeding maximum vibration
levels specified.
The support structure shall be locally reinforced around foundation bolt holes.
The support structure shall be crevice free to prevent the collection of water and debris during
operation. Baseplates shall be designed to prevent the formation of trapped air pockets during
grouting.
The ends of all sections shall be sealed to prevent the ingress of water; after all corrosion
resistant coatings have been applied.
Unless otherwise nominated on the datasheet, the support structure shall be manufactured from
mild steel and hot dip galvanised in accordance with the relevant standard. The base frame shall
be stress relieved after welding prior to galvanising.
A common base plate shall accommodate pump and drive unit with the necessary adjusting
devices to allow accurate alignment of the pumpmotor coupling. The pumpdrive unit base plate
shall be designed with sufficient rigidity to maintain alignment in accordance with the
requirements of the coupling manufacturer without requiring additional rigidity to be supplied
from the foundations. The mounting pads for the pump and drive shall be milled/machined flat
and level. Any shims used shall be from stainless steel. The motor and gearbox shall be
positively located so that they can be readily removed and replaced into position without requiring
extensive coupling alignment checks.
Couplings
Couplings shall be in accordance with section 2-2.9.
Casing
The casing shall be designed to resist abrasion and mechanical shock imposed by solids in the

pumped flow.
The casing casting shall be dressed to a good commercial standard to expose any surface
imperfections.
Components in the pump casing that may be subject to wear shall be easily removable for
refurbishment or replacement.
All mating surfaces shall be accurately machined and provided with deep registers, dowels and
spigots where necessary, to ensure alignment.
If specified in the project pump data sheet, connections shall be provided on the pump flanges
or casing for connection of pressure gauges and venting, drain and seal flushing pipework.
Instrument tappings shall be DN 20 half couplings screwed BSP female tapered to AS 1722.1.
Instrument tappings shall be fitted with a screwed reducing nipple and DN 15 ball valve of
stainless steel construction. Venting connections shall be positioned on the highest practicable
point on the casing. All unused, tapped holes shall be fitted with solid, corrosion resistant, metal
plugs.
Stator
With the exception of free-moulded stators, the stator shall be designed to prevent the pumped
medium penetrating between the stator and the casing.
Rotor
Unless otherwise specified on the data sheet, the rotor shall be electrolytically chromium plated
in accordance with AS1192 and have a minimum coating thickness of 200µm in the area of the
rotor major diameter.
Shafts
The shaft shall:
i. Be machined from solid one-piece bar stock of stainless steel grade 316 or better;
ii. Have a ground finish over its entire length;
iii. Be equipped with replaceable shaft sleeves in areas subjected to wear.
The shaft shall be designed such that the first lateral critical speed is not less than 150% higher
than the maximum operating speed of the pump.
The first lateral critical speed shall be calculated for the maximum diameter impeller able to be
fitted to the pump, without any support from wearing ring(s) or neck ring(s).
The maximum lateral deflection of the shaft shall be determined to establish permissible internal
clearances, taking into account all lateral hydraulic reactions on the impeller and any external
loads.
Bearings
Bearings shall be in accordance with section 2-2.6.
Seals
Seals shall be in accordance with section 2-2.7.
Connections
Pump connections shall be in accordance with section 2-2.5, in addition,
Connections shall be standard nominal bores sizes.
Flange pressure ratings shall be not less than the pressure rating of the pump casing.
Flexible connections shall be provided at all equipment where vibration, expansion or loading
may be a problem.
Flanges shall be arranged so that bolt holes symmetrically straddle the north/south, east/west
and horizontal/vertical centre lines.

Drive Assembly
Drive assemblies shall be in accordance with section 2-2.9, in addition,
The pump shall be either of ‘block’ type construction or provided with a separate bearing housing.
If a coupling rod and joints are used, they shall be sealed for life.
The profile of the coupling rod and joints shall be designed to avoid entanglement of fibrous
material.
The drive system shall enable easy dismantling of the pump. The drive shaft and mechanical
seal, where fitted, shall be replaceable without the need to dismantle the bearing housing.
Gearbox
Gearboxes shall be in accordance with section 2-2.9.3, in addition, for all sludge pumping duties,
the gearbox shall be capable of transmitting the maximum motor output torque and shall have a
minimum American Gear Manufacturers Association (or equivalent) service factor of 1.5.
Nameplates
Labelling and Nameplates shall be in accordance with section 2-2.13.
Dry Running
If necessary for the protection of the pump in dry running conditions, protective devices and
systems shall be provided to prevent damage to the pump. These may include methods to detect
no flow and provide a signal to the PLC for pump shut down.
Fastenings
Fastenings shall be in accordance with section 2-2.5.1.
Vibration
Acceptable vibration levels shall be in accordance with section 2-2.8.4.
2-6.3 Progressive Cavity

Progressive cavity pumps shall be heavy duty, industrial, low speed units that comprise a helical
rotor which rotates within an elastomeric stator.
The pump casing shall be able to be rotated in 90° steps.
Progressive cavity pumps shall be of a single pitch helical rotor and double pitch stator, high
efficiency design. The materials selected shall provide good abrasion resistant, low NPSH
characteristics and positive non-pulsating flow, over the full range of operating conditions.
The drive assembly shall enable easy dismantling of the pump. The drive shaft and mechanical
seal, where fitted, shall be replaceable without the need to dismantle the bearing housing. If a
coupling rod and joints are used, they shall be sealed for life.
The pumps shall be supplied with a mechanical seal. The gland packed stuffing box type will not
be accepted.
The materials of construction for progressive cavity pumps shall be at least equal in quality to
the following:
Component Material Standard and Grade
Baseplates Galvanised Mild Steel AS 3678 Gr. 250
Casings Cast Iron AS 1830 Gr. T200
Rotors Stainless Steel AISI Gr. 316 – Chrome Plated
Stators Elastomer
Shafts Stainless Steel AISI Gr. 416
Nuts and Bolts:
Wetted Parts Stainless Steel AISI Gr. 316
Non-wetted Parts Stainless Steel AISI Gr. 316
Studs Steel AS 2528
Anchor Bolts Stainless Steel AISI Gr. 316
Guards Galvanised Mild Steel AS 3678 Gr. 250
Elastomer to be selected to suit fluid being pumped, e.g. natural rubber for sludge, nitrile rubber
for Polyelectrolyte.
2-6.4 Peristaltic
The pumpset shall be self-priming and permit pumping in either direction without reverse flow of
liquids, slurries or suspensions.
The pumpset shall be designed so that liquids, slurries or suspensions are retained within the
casing in the event of a hose/tube burst.
Peristaltic pumps shall be provided with air vessels or pulsation dampers of ample size to effect
smooth rates of discharge.
The casing shall be provided with a bolted, removable front cover to enable the rotor, hose and
bearing assemblies to be removed without disturbing the inlet/outlet pipework.
Front covers weighing over 25 kg shall be hinged or provided with suitable lifting points. Front
covers weighing less than 25 kg shall be provided with handles to facilitate removal/replacement.
The casing shall incorporate the bearing housing, which shall be accessible via a removable
cover plate.
Connections shall be provided on the rear of the casing to prevent accidental damage/facilitate
the removal of the front cover, for the following:
i. A means of relieving the pressure in the casing in the event of a hose/tube burst;
ii. Breather tubes to accommodate expansion/contraction of the hose lubricant;
iii. High and low lubricant level probes; and/or
iv. Lubricant fill/drain points. These shall consist of bosses appropriately drilled and tapped.
All unused tapped holes shall be fitted with solid, corrosion resistant, metal plugs.
The hose/tube material shall be suitable for the fluid to be pumped.
The hose/tube shall be easily replaceable.
A burst hose monitoring facility shall be provided.
The hose/tube shall be connected to the inlet and outlet pipework using secure connectors
capable of providing reliable, leak free operation for the specified design life, as well as ease of
removal and replacement when required.
The sliding interface between the hose/tube and shoe/roller shall be lubricated by partial
immersion in a lubricant bath.
Compression of the hose/tube shall be effected by shoes/rollers. The number of shoes/rollers
shall be a minimum of three unless specified.
Shimming facilities shall be provided for the shoes/rollers to enable pumping performance to be
optimised.
The shoe/rollers shall be easily accessed and replaceable.
The rotor shall be securely keyed to the drive shaft. Shaft rotation shall not be relied upon to
ensure the rotor is locked in position.

Shaft seals shall be provided to prevent leakage of hose/tube lubricant from the casing and
bearing lubricant from the bearing housing.
Where used for a chemical dosing application, manual adjustment of the flow rate of the dosing
chemical shall be achieved by variation of the speed of rotation of the pump. Automatic
adjustment of the flow rate of the dosing chemical shall be in response to an external analogue
0/4-20mA control signal
Rotary adjusters (knobs, hand wheels etc.) provided for manual speed adjustment shall be
provided with a locking facility. The scale on rotary adjusters shall be graduated in divisions of
no more than 5% of the maximum speed.
2-6.5 Diaphragm
The pumpset shall be self-priming and capable of dry running without damage.
A means of detecting diaphragm failure shall be provided unless specified otherwise.
Pumpsets shall be fitted with ball or ‘duckbill’ valves.
Bias flow conditions shall be created within the valves during operation which rotate the balls
and spread wear evenly over the sealing areas.
Balls shall be coated with a polyurethane elastomer to improve seating performance, unless
specified otherwise.
A variable stroke connecting rod shall be provided. If specialist tools are required for adjustment
of stroke, these shall be provided with the pumpset unless specified otherwise.
The connecting rod shall be spring loaded to prevent hydraulic lock and/or cushion forces acting
on the diaphragm due to solids trapped beneath it. Solid connecting rods shall not be used.
The drive end of the connecting rod shall incorporate a rolling element bearing. Plain bearings
shall not be used. The bearing shall be provided with an accessible lubrication point (remote if
required).
If, at the rated operating conditions, pulsation dampers are required on the pumpset inlet and/or
outlet to achieve the diaphragm life and/or reduce pressure peaks to acceptable levels these
shall be included.
A means of detecting diaphragm/trunnion failure shall be provided unless specified otherwise.
The driveshaft shall possess adequate torsional and axial stiffness to prevent excessive
All bearings shall be adequately lubricated to prevent excessive wear/seizure under all operating
conditions.
2-6.6 Rotary Lobe

The pumpset shall be of twin rotor design with lobed rotors mounted on separate parallel shafts,
counter rotating within the pump casing.
Shaft rotation shall be synchronised to ensure that no contact occurs between the rotors and/or
the rotors and the pump casing.
The pumpset shall be designed to permit pumping in either direction with minimal reverse flow.
The casing shall incorporate a front cover plate that can be easily removed to allow access to
the rotors. Sacrificial inserts shall be fitted in the front cover plate to allow for wear. Alternatively,
reversible front cover plates may be provided.
Front covers weighing over 25 kg shall be hinged or provided with suitable lifting points, as
specified on the data sheet. Front covers weighing less than 25 kg shall be provided with handles
to facilitate removal/replacement.
The casing shall be fitted with positively located wear plates at the back of the rotors to enable
rotor-to-casing tolerances to be adjusted to their optimum value. If specified on the projects pump
specific datasheet, positively located radial wear plates shall also be fitted. All wear plates shall
be easily replaceable without disturbing the inlet/outlet pipework.
Pump casings shall be of substantial construction to give long life under abrasive conditions and
to enable them to withstand shock loads caused by solids in suspension.
The rotors shall be replaceable in-situ.
The rotors shall be retained in position by torque locking assemblies and splines. Any special
tools required for the removal, adjustment and installation of rotors shall be supplied with the
pumpset.
The rotors and shaft shall be marked to ensure correct alignment/synchronisation on re-
installation.
Timing gears shall be precision manufactured, involute form spur or helical gears. The gearbox
shall be designed to accommodate any thrust forces generated by the timing gears.
The timing gearbox casing shall have integrally cast mounting feet with machined faces.
The casing shall incorporate accessible oil filling and drain plugs that allow in situ oil
removal/replenishment without excessive spillage. An oil level window/sight glass shall be
provided.
The casing shall include machined spigots and/or dowels to ensure accurate alignment with the
reduction gearbox casing.
The casing shall be supplied with shims for correct assembly with the pump casing.
The timing gearbox shafts shall be of one-piece construction, machined all over. Both shafts
shall incorporate integral timing gears to enable synchronous rotation. Shafts shall be sized to
accommodate all possible loads over the specified operating range of the pump, including direct-
on-line (DOL) starting. The first critical shaft speed shall be in excess of the maximum shaft
speed.
Shafts shall be individually withdrawable for maintenance.
The maximum shaft deflection should not exceed 0.05 mm at the location of the mechanical seal
faces when operating at duty flowrate and 0.1 mm at minimum continuous flowrate.
Pumps shall be supplied with large bore seal chambers suitable for modern mechanical seal
design. Gland packing shall not be used.
The timing gears shall be provided with a common oil chamber to the bearings.
Compound gauges shall be fitted to the suctions of pumps installed in dry wells, and pressure
gauges to the deliveries of all pumps unless specified otherwise.
2-6.7 Dosing Pumps

The pumps shall be capable of the flows, heads and turndowns stated in the data sheet.
Very small diaphragm type dosing pumpsets, i.e. solenoid driven type, incorporating automatic
speed adjustment only, (i.e. no stroke adjustment), shall be acceptable subject to their being
able to meet the dosing range specified and the specified pump accuracy.
Dosing pump systems shall be provided with facilities for manual ventingpriming
Where the specified duty cannot be achieved via a pump with a single head, pumps with multiple
dosing heads, i.e. duplex or triplex pump heads can be provided subject to prior approval.
Hydraulic driven diaphragm dosing pumps for very large or high-pressure applications shall be
fitted with double diaphragms and diaphragm rupture detection systems.
Refer to sections earlier in this document for requirements of specific dosing pump types (i.e.
peristaltic, diaphragm etc.)
The pumps shall be of sufficient rated capacity, number and with adequate turn down to achieve
the complete range of dosing flow rate requirements for each of the required dosing points.
The dosing pumps shall be provided with automatic adjustable feed rate by means of speed and
stroke length adjustment. Minimum and maximum operating speeds shall be limited to those
approved by the supplier and/or manufacturer to prevent overheating, excessive wear or
damage. The stroke length shall be manually adjustable with 0 to 100 percent capacity control
while the pump is in operation. Controls shall provide positive repeatable settings within plus or
minus 2 percent over the entire range. Pump delivery shall be repeatable within plus or minus 1
percent accuracy.
Each pump shall be provided with the supplier’s standard manual vernier, or digital indicating
stroke positioner, readable to within ¼ of 1% of full stroke. A locking device shall be incorporated
on the stroke positioner to prevent accidental adjustment of stroke.
The usable stroke adjustment turndown used when sizing variable stroke length diaphragm
dosing pumpsets shall be limited to 5:1 or 20-100% for mechanically actuated pumps and to 10:1
or 10-100% for hydraulically actuated dosing pumps.
On AC motor driven dosing pumps the usable speed turndown shall be limited to 5:1 or 15 SPM.
Solenoid type fixed stroke lengthvariable stroke frequency dosing pumps shall be limited to a
minimum of 30 SPM.
Dosing pump steady state accuracy shall be within ±2% over the full dosing range. The steady
state accuracy is the variation between the measured flow at any one point compared to
measurements taken again with all parameters remaining unchanged and constant, e.g. speed,
stroke, chemical, temperature, pressure etc.
Dosing pump repeatability shall be within ±3% over the full dosing range. The repeatability is the
variation between the measured flow at a given pump setting compared to the measured flow
when returned to the same setting.
Dosing pump linearity shall be within ±3% over the full dosing range. The pump characteristics
shall be such that the change in pumped flow rate for different pump settings, e.g. speed, stroke
is linear, i.e. the change in pump flow shall be directly proportional to the change in the relevant
pump setting.
The main body of the pumps, containing gears, reciprocating and variable stroke mechanism
etc., shall be contained in a substantial metal/plastic casting pump body to ensure correct
alignment and rigidity. The casing material shall be suitable for use with the chemical.
An anti-siphon device, such as a back pressure valve, shall be fitted on each pump discharge
that shall prevent the tank contents from flowing through the pump when the pump is not in
operation.
Pumpsets shall be provided with a protective coating of chemical resistant paint, appropriate to
the chemicals being dosed, applied in the factory.
All components subject to pressure shall be hydraulically tested to 150% of rated pressure.
Inlet pipework to chemical dosing pumps shall be connected to draw from a suitable calibration
vessel with a capacity between maximum and minimum graduations equivalent to approximately
30 seconds pumping at maximum pumping rate.
2-6.8 Spare Parts and Special Tools

Spare Parts and Special Tools shall be in accordance with section 2-2.14.
2-6.9 Testing
Testing shall be in accordance with section 2-5.7
2-7 FOUL AIR FANS

2-7.1 General
Materials of construction for the Foul Air Fans shall be suitable for use in a corrosive and humid
environment and shall be Grade 316 stainless steel or other compatible materials to prevent
electrolytic corrosion, unless otherwise stated.
Centrifugal fans shall be of Grade 316 stainless steel construction, single inlet single width
(SISW), of the backward inclined impeller type. The casing and impeller shall be fully welded
construction with all welds passivated after construction. Welds shall be full seam type. All air
stream components including the inlet and outlet flanges shall be of Grade 316 stainless steel.
All fasteners and threaded items shall be from Grade 316 stainless steel throughout the
installation.
The fan motor shall be directly coupled to the fan using a flexible type coupling of Flexibox
elastomeric type or similar and approved. Suitable guarding complying with Australian Standards
shall be provided. The guards shall be fully enclosed type with easy access toggles to allow
routine inspections and maintenance functions to be carried out.
The fans shall be selected to achieve the lowest practicable absorbed power at the nominated
operating conditions. The nominal fan duty shall be achieved at 50 Hz.
2-7.2 Casing
The fan casing shall be fabricated of not less than 6 mm Stainless Steel Grade 316. The casing
shall be of the split type to allow easy access to the rotating element. The casing joint shall be
fully bolted to effect an airtight seal. The casing shall be suitably stiffened with Grade 316
stainless steel gussets and strengthening sections to prevent drumming and flexing under
operating conditions. The welds shall be full-seam and passivated after fabrication. The casing
shall be provided with inlet and outlet flanges suitable for connection to flexible couplings to
isolate the fan from the ductwork. The outlet flange shall be sized to provide an exit velocity from
the fan of less than 10 m/s.
A condensate drain of not less than 50 mm diameter shall be provided for the removal of carry
over and condensate liquors that may accumulate in the fan casing. The drain line shall be
equipped with an isolating valve upstream of the mechanism to allow regular maintenance to be
carried out.
An inspection port of not less than 450 mm square shall be provided to allow routine inspections
of the rotating assembly and casing internals to be carried out. The inspection port shall be fully
gasketted using neoprene or EPDM gaskets fully bolted to the casing.
2-7.3 Impeller
The fan impeller shall be of the backward-inclined type and manufactured from Grade 316
stainless steel. The back-plate shall be constructed from not less than 10 mm plate and shall
incorporate radial vanes attached to the rear of the back-plate to generate a slight negative
pressure in the seal area. The blades shall be constructed of plate of not less than 6 mm
thickness and where an impeller shroud is provided this shall be of not less than 4 mm.
2-7.4 Shaft and Bearings

The impeller shall be mounted on a stainless steel Grade 316 shaft and overhung from the
bearing housing. Bearings shall be all radial and axial loads shall be taken up by two sets of
spherical roller-type bearings. The bearings shall be housed in a robust housing incorporating
labyrinth-type seals and be grease-lubricated with auto lubricators.
The shaft shall be sealed against the casing using a single-split carbon seal which shall be self-
lubricating and readily accessible for easy replacement.
Bearings shall be rated for an L10B life of not less than 100,000 hours. The first shaft critical
speed shall be at least 30% higher than the maximum operating speed of the fan.
The impeller tip speed shall be in the region of 80 m/s.
The rotating assembly shall be balanced in accordance with ISO 1940-1:2003 G2.5.
2-7.5 Pedestal and Baseplate

The fan shall be mounted on a heavy section galvanised steel pedestal and baseplate assembly.
The channel sections and plate used for the construction of the pedestal shall be from not less
than 10 mm thickness. The baseplate materials shall be not less than 8 mm thickness. Welds
shall be full seam weld. All sections shall be Grade 316 stainless steel or Hot Dipped Galvanised
steel and then protected with a 2-pack epoxy base coat followed by a 2-pack polyurethane finish
coat. All necessary etch primers and undercoats shall be applied to prevent the protective
coatings from delaminating from the galvanising. All mating surfaces shall be fully machined flat
and true.
The fan pedestal and base frame shall be bolted to a concrete plinth.
2-7.6 Discharge Silencer

Each fan shall be provided with an in-line discharge silencer manufactured from Grade 316
stainless steel. All internal and external metal components shall be stainless steel and, where
welded, all welds shall be fully passivated. The sound attenuating material shall be constructed
from a material that is resistant to contamination from carry-over products and condensate.
2-7.7 Fan Drive Motors

The fan motors shall be of the high efficiency, high torque output, low noise type. The motor shall
be rated EXn for a hazardous environment.
Fans and motors shall be mounted with clear access so as to be readily accessible for all
necessary inspection, operation and maintenance activities.
Full details of the fan and motor performance shall be provided and detailed on the
manufacturer’s standard pressure, volume and power curve.
2-7.8 Pressure Loss

Each Foul Air Fan shall be designed to overcome the total pressure loss across all field ductwork,
fittings, and Odour Control Facility, post-balancing of all extraction rates from the covered
process units. The total pressure loss shall be calculated at the Detailed Design stage and
documented for approval.
2-8 FIBRE REINFORCED PLASTIC STORAGE TANKS

2-8.1 Design
All storage tanks shall be designed, fabricated and tested in full accordance with BS EN13121.
The resin and fillers selected for the tank fabrication shall be UV resistance and suitable for the
fluid/chemical stored.
For tanks having a capacity greater than 4,500 litres, a 600 mm diameter (minimum) access
opening with gasket hinged cover shall be provided with its centreline at 1.0 m above the tank
floor and on the tank top. Flanges are to be projected 150 mm (minimum) from the tank face and
reinforced with at least four well-bonded gusset plates.
Tanks shall be suitably reinforced to withstand all forces without deforming when they are filled.
Areas where additional stress and strains may be imposed on the tank walls, such as outlet/inlet,
anchor points and access openings shall be designed to cope with these additional stresses and
strains and have the same anticipated longevity as the main body of the tank.
The tops of tanks shall be capable of supporting the weight of one maintainer, with a total weight
of 120 kg.
The roof and wall thicknesses shall be designed to prevent buckling or collapse under the
specified loadings and conditions. The Supplier shall submit calculations for the wall and roof
thicknesses for checking by a third party.
Tanks shall be hydrostatically tested to 2m head in excess of normal static pressure when full.
Normal static pressure will be based on the highest chemical S.G.
The tanks nozzles shall be furnished with the specified type of nuts, bolts and gaskets. All spare
connections to be supplied with suitable blind flanges.
All branches on the tank shall finish 150 mm from the tank wall or roof with AS4087 flanges.
316 SS Stainless steel backing rings shall be provided on all flanged tank nozzles.
Gaskets with full face such as Viton or hypalon, of 50 to 60 Shore "A" Durometer shall be
provided. Type 316 stainless steel nuts and bolts are to be used. Gasket material shall be
compatible for the chemical/fluids contained.
A vent shall be provided on the apex of each storage tank roof. The vent shall penetrate the roof
and finish in a 180-degree bend with the open end facing downward. The end of the vent pipe
shall be covered with a 12 mm mesh to prevent vermin ingress.
The tank floor and drain connection shall be designed and constructed to provide complete
draining of the tank contents.
Tanks shall have provision for overflow of contents. The overflow pipe shall be installed on the
tank sidewall remote from the inlet connection. The pipe shall run down the tank side to discharge
into the bund. The overflow pipe shall terminate approximately 100 mm from the bund floor.
The tanks shall be flat bottomed.
A label on side of tank detailing material of construction, tank dimensions and volume, name of
manufacturer, date of manufacture.
Tanks shall be shop fabricated for delivery to site in one piece. Field assembly shall not be
permitted. Construction shall be such that no glass fibres are in contact with chemical solution.
All reinforcing shapes and members shall be laminated as primary bond. Secondary bonding will
not be accepted.
All flanges shall be laminated into shell by heavy layup inside to insure against leakage. Similarly,
heavy outer layup tying nozzle into shell shall be carried out.
Tanks should be equipped with suitable lifting lugs and anchor pads for handling.
Tanks located externally shall be fitted with suitable bolt down lugs.
Tanks shall be provided with fixing points for lightning conductors.
The external surface of the tank shall be tinted to the colour as directed by the Engineer.
A minimum disengagement space of 350 mm shall be provided between the base of the overflow
level and the vent connection. For blown deliveries the vent shall rise vertically for a minimum
distance of 460 mm above the tank top to the outlet point.
A cowl or cover plate, which shall not reduce the venting capability, shall be installed above the
open end of the vent pipe. Vents to tanks located indoors shall be routed to outdoors.
The fill pipe shall protrude through the top of the tank for a minimum of 150 mm and point
downwards towards the centre of the tank. Fill connections shall be designed to prevent backflow
and/or syphoning.
Tank level indicator shall be the non-contact mechanical type and level indication to be visible
at loading point.
A suitable contents indicator calibrated in cubic meters (m³) or litres, as appropriate, shall be
provided. The indicator shall be graduated in sub-units no greater than 5% of tank capacity.
2-8.2 Factory Tests

Tanks shall be hydrostatically tested at the manufacturer’s works prior to delivery. Tanks shall
be filled with water to the underside of the highest side mounted connection and allowed to stand
for a minimum period of 12 hours. There shall be no apparent deformation of the tank or leakage
from the tank during the test period.
It will not be necessary to undertake the ‘stand pipe’ test at the manufacturer’s works to simulate
hydrostatic head conditions for tanks where the relative density of the fluid to be stored is greater
than 1.0.
Testing and quality assurance certificates shall be submitted upon delivery of the tanks.
2-8.3 Installation
Tanks shall be thoroughly cleaned inside and outside and all openings, flange faces etc., shall
be blanked off with heavy-duty tape to prevent the ingress of water and dirt etc. during
transportation. One flange shall be left open to allow venting.
Suitable `mats' such as a bituminous base shall be supplied, for installation between the tank
and the plinth to prevent abrasion of the tank.
2-8.4 Site Tests

Following installation at site on the prepared foundations, the overflow shall be blanked off and
the tank shall be filled with water to the level of the tank/roof joint and held for a period of seven
days. There shall be no apparent deformation of the tank or leakage from the tank during the
test period.
For chemicals with a specific gravity greater than 1.0 a further hydrostatic test shall be carried
out on site upon the tank receiving its first fill of chemical, where the tank shall be completely
filled to the overflow and allowed to stand for seven days. There shall be no apparent deformation
of the tank or leakage from the tank during the test period. For the duration of this test the area
surrounding the tank shall be screened/cordoned off with access permitted only to personnel
wearing suitable protective apparel, for the purposes of inspecting tank nozzles and welds for
evidence of leakage or deformation.
2-8.5 Site Testing Procedures

Prior to running water into the tank, a period of at least twenty-one days shall be allowed for any
completed internal protective coating to properly cure and harden or as specified in the Quality
Assurance documentation.
The tank shall be filled with water in two approximately equal batches with a standing period of
at least twenty-four hours between completion of inflow for a batch and commencement of inflow
for the next batch.
Should any leaks or evidence of unsatisfactory performance develop, the water level shall be
drawn down and repairs carried out to the satisfaction of the Owner. The water level shall then
be raised again to ensure that the repairs are satisfactory.
The tank shall be deemed to have passed the test if, after a period of seven consecutive days,
no leakage or other defect is evident.
The Supplier shall produce all necessary documentation records as verification that installation
testing and commissioning has been successfully completed. An up to date copy of developing
test records shall be present on site at all times during construction and commissioning for
information and review.
Should the tank fail any test, the Supplier shall take any actions deemed necessary by himself
or the Purchaser to correct the failure and repeat the test.

RFQ - 005c - Specification of MEP Work

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Palembang City Sewerage Project Employer’s Requirements: Specification

Part 3: General Technical Specifications

SECTION 2: GENERAL MECHANICAL

2-1.2 Operating Conditions

2-1.3 Design Life

2-1.4 Design Loads

Status: Issued for Bidding 58 Invitation for Bids No.: 01/PT.IPAL/08/2019

Equipment shall be designed in accordance with AS/NZS 1170.

2-1.6 Equipment Safety

Status: Issued for Bidding 59 Invitation for Bids No.: 01/PT.IPAL/08/2019

Status: Issued for Bidding 60 Invitation for Bids No.: 01/PT.IPAL/08/2019

2-2 TECHNICAL REQUIREMENTS

Status: Issued for Bidding 61 Invitation for Bids No.: 01/PT.IPAL/08/2019

name is stated, typical of the respective material or equipment kind.

Status: Issued for Bidding 62 Invitation for Bids No.: 01/PT.IPAL/08/2019

2-2.2 Painting and Coatings

2-2.3 Shipping and Handling Protection

Status: Issued for Bidding 63 Invitation for Bids No.: 01/PT.IPAL/08/2019

Status: Issued for Bidding 64 Invitation for Bids No.: 01/PT.IPAL/08/2019

welding work shall be adequately protected from spatter where required.

2-2.5 Fixings and Fittings

Status: Issued for Bidding 65 Invitation for Bids No.: 01/PT.IPAL/08/2019

compound prior to assembly.

Status: Issued for Bidding 66 Invitation for Bids No.: 01/PT.IPAL/08/2019

2-2.6 Bearings and Lubrication

Status: Issued for Bidding 67 Invitation for Bids No.: 01/PT.IPAL/08/2019

Status: Issued for Bidding 68 Invitation for Bids No.: 01/PT.IPAL/08/2019

equivalent to the materials specified may be substituted.

2-2.8 Noise and Vibration

Status: Issued for Bidding 69 Invitation for Bids No.: 01/PT.IPAL/08/2019

2-2.9 Couplings and Drives

Status: Issued for Bidding 70 Invitation for Bids No.: 01/PT.IPAL/08/2019

Gears and bearings shall be lubricated to manufacturer’s recommendation. Where grease

2-2.10 Lifting Equipment

Status: Issued for Bidding 71 Invitation for Bids No.: 01/PT.IPAL/08/2019

not accumulate water.

2-2.11 Equipment Installation and Layout

Status: Issued for Bidding 72 Invitation for Bids No.: 01/PT.IPAL/08/2019

Installation in Hazardous Areas

2-2.12 Operations and Maintenance

Status: Issued for Bidding 73 Invitation for Bids No.: 01/PT.IPAL/08/2019

2-2.14 Critical Spare Parts and Tools

2-2.15 Inspection, Testing and Commissioning

Status: Issued for Bidding 74 Invitation for Bids No.: 01/PT.IPAL/08/2019

Factory Inspection Tests

Status: Issued for Bidding 75 Invitation for Bids No.: 01/PT.IPAL/08/2019

Status: Issued for Bidding 76 Invitation for Bids No.: 01/PT.IPAL/08/2019

2-3 VALVES AND ACTUATORS

Status: Issued for Bidding 77 Invitation for Bids No.: 01/PT.IPAL/08/2019

2-3.2 Material Requirements

2-3.3 Valve Identification

2-3.4 Water Services Australia Specifications

WSA PS – 260 Gate Valves, Resilient Seated

WSA PS – 261 Gate Valves, Metal Seated

Status: Issued for Bidding 78 Invitation for Bids No.: 01/PT.IPAL/08/2019

WSA PS – 262 Extension Spindles for Gate Valves

WSA PS – 263 Butterfly Valves

WSA PS –264 Non-Return (Reflux) Valves

WSA PS – 265 Air Valves for Water Supply

WSA PS – 267 Hydrants (Spring) for Water Supply

WSA PS – 268 Automatic Control Valves

WSA PS – 269 Extension Spindles for Valves, General

WSA PS – 273 Vacuum Interface Valves