Spec Pump Final

JKR 20500-0083-20
CAWANGAN KEJURUTERAAN
MEKANIKAL
KERAJAAN MALAYSIA
JABATAN KERJA RAYA MALAYSIA
Standard Technical Specification
BOOSTER PUMP
for
INTERNAL COLD WATER SYSTEM
PENGARAH KANAN
CAWANGAN KEJURUTERAAN MEKANIKAL
IBU PEJABAT JKR MALAYSIA
TINGKAT 24-28, MENARA KERJA RAYA, BLOK G
JALAN SULTAN SALAHUDDIN
50480 KUALA LUMPUR
2020
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SECTION 3
TECHNICAL SPECIFICATION
Table of Contents
3.1 GENERAL ................................................................................................ 1

3.2 PUMP TYPE AND PERFORMANCE ....................................................... 1
3.3 PUMPING SYSTEM ................................................................................. 2
3.3.1 General..................................................................................................... 2
3.3.2 Booster Pump System .............................................................................. 3
3.3.3 Pump Operation ....................................................................................... 4
3.4 MATERIALS OF CONSTRUCTION ......................................................... 6
3.4.1 Casing ...................................................................................................... 6
3.4.2 Impeller..................................................................................................... 6
3.4.3 Pump Shaft............................................................................................... 7
3.4.4 Mechanical Seal ....................................................................................... 7
3.4.5 Bearings ................................................................................................... 7
3.4.6 Flexible Coupling Unit .............................................................................. 7
3.4.7 Vibration Isolation Material ....................................................................... 7
3.4.8 Bolt and Nuts ............................................................................................ 8
3.5 VARIABLE SPEED DRIVE ....................................................................... 8
3.6 PRESSURE VESSEL/HYDROPNEUMATICS TANK ............................... 9
3.7 PIPES, VALVES AND FITTINGS ............................................................. 9
3.8 ELECTRICAL SYSTEM ......................................................................... 12
3.8.1 Electric Motors........................................................................................ 12
3.8.2 Motor Starter Panels .............................................................................. 13
3.8.3 Surge Protective Device (SPD) .............................................................. 15
3.8.4 Electrical Switchboard ............................................................................ 16
REFERENCE ........................................................................................................ 18
Cawangan Kejuruteraan Mekanikal
SECTION 3.0 TECHNICAL SPECIFICATION
3.1 GENERAL
All pumping system and installation shall be executed in accordance to the relevant
state water supply rules and to the approval of the state water authority / SPAN / JKKP
notwithstanding any approval given by the S.O.
The Contractor shall submit method statement of installation recommended by

manufacturer.
All pipes, fittings and equipment used for Pumping System and installation shall be of
the type and make approved by the relevant state water authority / SPAN / S.O.
The standards stated in this specification shall comply with their latest edition issued
or relevant standards approved by SPAN.
3.2 PUMP TYPE AND PERFORMANCE
The type of pump provided shall be End-suction/Single or Multi-stage/Horizontal Split

Casing/Vertical In-Line centrifugal type pumps as specified in the Schedule of Design
Requirements. The pumps shall operate at constant/variable speed with the pump and
motor coupled either directly (close couple type) or using flange coupling mounted on
common base, bolted/anchored to a concrete plinth.
All pumps with power ratings of 22.5 kW (or 30.0 pumping horsepower (HP)) and above
shall be of the Horizontal Split Casing Pump type, with pump speeds not more than
1500 rpm.
All pumps with power ratings below 22.5 kW (or 30.0 pumping horsepower (HP)) shall
be either of the Horizontal Split Casing Pumps type (with pump speed not more than
1500 rpm) or the End Suction Pump / Vertical Multi- Stage Pump type (with pump
speeds not more than 2900 rpm).
The minimum Factor of Safety (FS) in the sizing of motors shall 1.2 times the pumping
power to overcome mechanical lost and high flow low head condition. All pumps shall
not operate more than twelve (12) hours continuously.
All pumps, parts and accessories shall comply with relevant Malaysian Standards, or
equivalent international standards [such as ISO, British Standard (BS) or European
Standard (EN)] and shall be manufactured or supplied from SPAN registered
manufacturer or dealer or supplier.
The performance of the pump selected shall be indicated on manufacturer's supplied

performance curves for verification. The pump performance shall be in accordance to
BS EN ISO 9906: 2000.
The pump selected shall match the required duty point (head and flow) at the required
efficiency as listed in Table 3.1. Any deviation in efficiency at the required duty point
(head and flow) of particular pump curve shall not be more than 20% above or below
the required efficiency listed in Table 3.1.
Technical Specification Copyright © CKM2020 1

Minimum Pump efficiency (%) for each pump shall be as the following:
Table 3.1.: Minimum Pump Efficiency (%)

Pumping Rate Per Minimum Pump
Pump (m3/hr) Efficiency (%)
>30
60
≤100
>100
70
≤300
>300
75
≤1000
>1000 80
3.3 PUMPING SYSTEM
3.3.1 General
Booster pump for internal cold water system has been defined and categorised as
below:
(a) Constant speed booster pump system.
Constant speed booster pump system shall consist of minimum two (2)
numbers booster pumps as shown in the tender drawings. These shall comprise
of electrically driven pumpsets for duty and standby operation as per Schedule
of Design Requirements.
The system shall comprise but not limited to the following components:
- Controller and devices.

- Pipes, fittings and valves.
- Support base.
The system shall be provided with pumps as shown in the tender drawings.
(b) Variable speed booster pump system with external Variable Speed Drive
(VSD) unit.
Variable speed booster pump system with external VSD unit shall consists of
minimum two (2) numbers booster pumps and (2) numbers of external VSD unit
as shown in the tender drawings. These shall comprise of electrically driven
pumpsets for duty and standby operation as per Schedule of Design
Requirements.

- Support base.
- Pressure vessel/Expansion vessel.
- Variable Speed Drive (VSD) units.

(c) Variable speed booster pump set system.
Variable speed booster pump set system consists of two or more pumps
coupled in parallel and mounted on a common baseplate, variable speed drives,
controller electrical cabinet and all the necessary common pipe work and
fittings. These shall comprise of electrically driven pumpsets for duty and
standby operation as per Schedule of Design Requirements.

- Support base.
- Pressure vessel/Expansion vessel.
- Variable Speed Drive (VSD) units.
(d) Hydropneumatics pump set system.
Hydropneumatics pump set shall consist of minimum two (2) numbers booster
pumps with pressure vessel/hydropneumatics tank as shown in the tender
drawings. These shall comprise of electrically driven pumpsets for duty and
standby operation as per Schedule of Design Requirements.

- Support base.
- Pressure Vessel/Hydropneumatics tank.
3.3.2 Booster Pump System
The system shall comprise but not limited to the components as specified in item 3.3.1
depending on the booster pump type:
The duty and standby pumpsets shall be alternated automatically either based on run
time provided via timer control or scheduling provided by programmable controller or
latching switch controlled to obtain even wear and tear between pumps.
The pump casing shall be of adequate strength to withstand 1.5 times the maximum
operating pressure of the system or a minimum of 150 psi. The plinth shall be provided
to suit the manufacturer’s requirements and shall raise the pumps on plinth at least 6
in (150mm) above floor level. Mounting the pumpsets on the plinth shall be complete
with vibration isolators.
The pumps shall be selected to suit the intended type of service.

Each pump shall be fitted with screwed drain fitting mounted at the pump casing for air

lock release and suction/discharge pressure ports mounted at the inlet/outlet flanges
of the pump casing. The pump bearing housing shall be fitted with greasing nipple ports
of suitable size. Proper drainage shall be provided for all points around the pumpsets
mounting.
The duty point efficiency of all type of higher capacity pumps shall meet the minimum
requirement as specified in the Schedule of Design Requirements.
All pumps, parts and accessories shall comply to the relevant Malaysian Standards or
equivalent international standards such as ISO, British Standard (BS) or European
Standard (EN) and shall be manufactured or supplied from a supplier registered with
SPAN.
3.3.3 Pump Operation
All pump control system shall be capable of running in alternate mode, i.e.
automatic changeover between and/or amongst the pumps in every cycle of
operation.
Local control shall perform as follows:
(a) Constant Speed Booster Pump System.
The pump control system shall be based on water level in suction tank and
water level in elevated tank/reservoir or shall be based on pumping pipeline
pressure profile. Nevertheless, the pump control system shall be based on
both strategy of pipeline pressure profile and water level system as per
design requirement.
For water level control in tanks, non-float stainless steel 304 electrode with
float less control relay shall be utilized. Other means of level control shall
be used subjected to design requirement.
The pump shall be protected from dry running condition by means of cutting
off pump operation due to low suction tank water level detected or other
means of cut off strategy if specified further in the design requirement.
The pump system shall be able to run in either manual mode or automatic
mode as selected by the user/operator at the pump's control panel via
selector switch installed.
The pump manual operation shall be done at local panel via selecting the
manual mode at selector switch and pushing the ON start button. The
pump shall seize from operation if the fluid level in suction tank is low or no
flow condition is detected in the pipeline to prevent dry run damage. The
operator shall stop the pump by pushing the stop button when required.
The automatic control of pumps shall be selected at the selector switch and
shall be able to perform the following actions with level sensor system.
i) When the water level drops below Low Water Level (L.W.L.) in the
storage/elevated tank, the pump shall be switched on and shall
remain until the water level reaches Top Water Level (T.W.L).

ii) When the water level in the Storage/elevated tank reaches T.W.L.
the pump shall be switched off and shall be prevented from being
switched on again until the water level falls to L.W.L.
iii) When the water level is at or below the L.W.L. in the suction tank,
the pump shall be switched off and shall be prevented from being
switched on again until the water level rises to T.W.L.
iv) The L.W.L. and T.W.L. in the suction tank and Storage/elevated
tank shall be provided subjected to the S.O. approval.
v) Overflow water level of non-float electrode sensor shall be installed

to indicate the tank/reservoir is overflowing. An indication light at
pump control panel shall be available to notify the pump operator of
such condition.
Each pump shall have a pressure gauge fitted on the suction and delivery
pipe branch with shut-off ball valve. Flexible coupling shall be provided at
the suction and delivery pipes to prevent transmission of vibration.
(b) Variable Speed Booster Pump System.
The variable speed booster pump system shall be required as per designed
with multi delivery storage point system for ease of control, effective cost
and energy efficient.
The system shall be of variable speed pump system driven by frequency

inverter. The system shall be configurable to variable set points provided
by the frequency inverter controller or secondary pump controller as per
designed.
The controller shall receive analog pressure signal form pressure

transducer mounted at the pumps' header pipe. The pump on/off strategy
shall be based on the delivery pipeline pressure generated, where at every
tank feeded by the pumping system, there shall be a level control valve
installed. Should the level control valve closed accordingly due to rise of
water level in the tank, a back pressure is generated in the pumping line,
consequently sense by the pressure transducer install at the pump delivery
pipe header.
The variable pressure in the pipeline shall be trimmed to constant pipeline

pressure at selected set point pressure via increasing or decreasing the
pump speed resulting variable fluid flow inside pipe. As the pipeline
pressure rise to maximum at zero (0) flow condition for period of 1 minute,
the controller shall stop the pump rotation to avoid water boiling damaging
the pump. Should the pressure level inside the pipeline drop to
predetermine/programmed pressure band, the pump shall run again.
The pressure vessel /expansion tank shall be installed to dampen the water
hammer and pressure fluctuations avoiding false signal to the controller.
The controller shall be able to programmed/sense abnormally high ampere
condition of motor running due to very low head and high flow at pipeline.
During this condition the controller shall stop the pump and provide alarm

for system inspection for any pipeline breakage.
Dry-running protection shall be of no-float type using stainless steel

electrodes and very low motor running ampere alarm sets at the inverter
controller or any other control means.
For multiple tank level control, all water tanks shall be incorporated with
pilot operated valve or any other means of level control (if specify in the
drawings).
The operation of automatic variables speed pump system shall be based

on constant pressure set point programmed at the VSD controller.
Pressure transducer shall be installed for such purpose. Low motor ampere
during zero flow cut off strategy for the purpose of main cut in/out control
shall not be acceptable. The low motor amperage pump cut off strategy
shall only be use as secondary fail safe strategy.
The controller and pressure transducers sense the pressure inside pipeline
to cut in and cut out pump system during water delivery operation. Should
the pressure transducers become defective and for fail operation,
especially during pipe breakage (high water flow) or zero flow condition,
the inverter controller shall sense the running current of the motor for such
abnormal condition and cut off the pump operation accordingly. For such
condition, the pump controller shall generate alarm for notification of the
operator.
The automatic variable speed pump system shall be equipped with

pressure deferential switch/timer delay relay and contactor start if the
inverter system is defective. The system shall be able to shift to differential
pressure switch control mode to change the control form from inverter
driven to constant speed, contactor starts driven system. The pressure
deferential switch shall be set/configured to suitable cut in and cut off
pressure condition of pump operation.
(c) Manual Mode
The speed of the duty pump shall be varied by manual adjustment via
potentiometer at the local control panel. All control function such as
pressure transducer PID control loop shall be bypassed remaining the dry
run protection control and other protection functions active.
3.4 MATERIALS OF CONSTRUCTION
3.4.1 Casing
The casing shall be of Cast Iron EN-GJL-200 comply with BS EN 1561/ Stainless steel
or as per design requirement.
3.4.2 Impeller
The material of the impeller shall be of the zinc-free bronze / AISI 304 or AISI 316

stainless steel or as per design requirement, machined on the outside and hand
finished on the inside. The impeller shall be dynamically balanced and mounted on the
pump shaft with a key.
3.4.3 Pump Shaft
The pump shaft shall be heat treated bright stainless steel, accurately machined and
ground over its entire length. The shaft shall be protected from wear and erosion in the
pumps and stuffing box by removable bronze sleeves. These sleeves are to be keyed
to the shaft and held in place by separate external bronze shaft nuts. The sleeves shall
be provided with a positive means of preventing leakage between the shaft and
sleeves, such as 'O' rings or soft sleeve packing. The shaft shall be tapered at the
coupling end for easy removal of the pump half coupling.
3.4.4 Mechanical Seal
The pump seal shall be integral with the casing and shall be of the mechanical seal
type comply with EN 12756. The mechanical seal material shall be of either silicon
carbide, carbon or ceramic type and suitable for fluid media operation.
3.4.5 Bearings
The pump bearings shall be of the heavy duty anti friction ball or spherical roller type,
arranged for grease lubrication. Removable bearing housing shall be bolted and
dowelled to bearing brackets that are cast integral with the pump lower half casing.
Bearing housing shall be provided with a drain plug on the opposite side from the
grease cup to facilitate cleaning and lubrication of the bearing. The inboard and
outboard bearings of the pump shall be of the same size and type.
3.4.6 Flexible Coupling Unit
The pump shall be directly connected to its driver by means of a gear type flexible
coupling. The pump half coupling shall be mounted on the shaft by a taper feed and
held on by a coupling nut to permit easy removal. An approved protective guard shall
be provided.
3.4.7 Vibration Isolation Material
The pump set shall be provided with vibration isolation mechanisms such as a rubber
damper between pump set and pump plinth, flexible coupling for the suction pipe and
expansion joints for the delivery pipes.
The plinth shall be provided to suit the manufacturer’s requirements and shall raise the
pumps to at least 6 inch (150mm). Mounting of the pump sets to the plinth shall be
complete with vibration isolators.
The base plate shall be provided with a grout hole of adequate size.
For pumps which are supported on ground, neoprene / rubber mount and structural
steel base shall be employed for pumps with power ratings less than 4 kW; whereas
steel springs and concrete inertia base shall be provided for pumps with power ratings
larger than 4 kW. For pumps which are supported on a suspended floor slab, only steel

springs and concrete inertia base shall be used.
3.4.8 Bolt and Nuts
All exposed bolts and nuts in the installation for the pump set shall be hot dipped
galvanized.
3.5 VARIABLE SPEED DRIVE
The variable speed pumping system shall be installed with integrally or separately fitted
Variable Speed motors/frequency inverter, Starter Panel incorporation with
programmable controller, a pressure vessel, pressure transducer and manifold with
isolating and non-return valves mounted on common base frame. The system shall be
in packaged assembly from a SPAN approved manufacturer and product.
The variable speed drive automatic constant pressure pumping plant shall receive
water supply from a suction tank. The pump shall always work under positive suction
head condition.
The pumping system shall be able to maintain a constant delivery set pressure
regardless of the system demand within the agreed peak demand flow rate. This shall
be achieved by continuously varying the motor speed of the duty pump according to
the demand up to a maximum designed capacity required. A pressure transducer shall
sense the pressure at the delivery manifold and feedback to the variable speed drive
via programmed controller and electrical control circuit maintaining the set point
pressure. The secondary or other pumps within the control system shall be fixed speed,
cutting on and cutting off accordingly to maintain a constant set point pressure
consequently, varying the flow rate as per demand.
The control system and the microprocessor electronic controller shall be configured to
perform the following:
(a) Flexibility and simplicity in allowing the necessary programming of the system
pre-set delivery pressure to operate the pump within the specified maximum
and minimum delivery pressure range.
(b) Built-in programmable friction loss compensation which will automatically

increases the delivery pressure setting in collaboration with the increase in flow
demand. This shall be able to minimize the system pressure differences and
provide a more constant pressure along the supply line.
(c) Automatic changeover of the pump to be controlled by the frequency converter

after each start/stop of the system operation.
(d) Built-in clock function with possible weekly programming and able to switch on
the system to operate at variable different pre-set pressure points as required.
(e) When the system is not operated for more than 24 hours, it shall automatically
start the pumps for a few seconds/days under the test mode. This will ensure
its readiness at all times.
(f) Built-in programme to limit the maximum number of pump motor start/stop per
hour.

(g) The pumping plant shall be able to operate under 4 different modes specified
herein, namely ‘Auto mode’, ‘Manual mode’, ‘Frequency converter by-pass
mode’, and ‘Emergency mode’.
(h) In case of any faults, the control panel shall be able to provide LCD alarms for
pump, motor, pressure transducer, frequency converter failure, excessive
pressure and low water shortage.
(i) The system shall be protected against excessive abnormal high or low pressure
i.e. the programmed working pressure range is exceeded. An alarm shall
trigger, alerting the maintenance team and the alarm shall be registered in the
microprocessor alarm log for history retrieval. The system will automatically
resume operation to the set pressure when the system pressure falls within the
working pressure range.
(j) In case of low water level in the suction tank, the system will automatically cut
off to protect itself against dry running via low water level indication (dry contact)
from float less relay and resume operation automatically when the water level
is raised. The microprocessor will then be able to log the low water level fault
event for maintenance staff alert. The system shall be able to cut off the pump
operation on excessively low pressure pipeline condition or excessively long
high pressure (zero flow) pipeline condition.
(k) The booster pump, motor, starter panel and microprocessor-controlled unit
preferably from the same manufacturer. The complete booster packaged
system must come complete with Certificate of Originality and serial number
from pump manufacturer to ensure its authenticity.
3.6 PRESSURE VESSEL/HYDROPNEUMATICS TANK
The pressure vessel shall be nitrogen filled pre-charged type and shall be designed for
1.5 times of pumping system maximum working pressure or not less than 10 bar. The
nitrogen shall be contained in a removable rubber bladder and able to withstand
maximum working temperature of 82oC.
The vessel shall be constructed from mild steel plate to ASME Section VIII for unfired
vessel and shall be epoxy coated inside and painted outside. The vessel shall comply
to the requirements of the local authorities.
The vessel shall be fitted with pressure switches and gauges, lifting lugs, gauges,
safety valves and air valve, drain cock and inspection opening.
Pressure vessel capacity equal or higher than 250 liter shall be approved by JKKP.
3.7 PIPES, VALVES AND FITTINGS
Pipe work for pump installation shall include pipe headers/manifolds, bends, tees,
flanges, brackets, belts, nuts, valves, etc. as specified in the tender drawing.
All pipes and fittings shall be of schedule 40 stainless steel/class C galvanised mild
steel/high carbon mild steel with cement line/composite tubes conforming to BS
1387:1985 and BS 21:1985, Class C. Pipe flanges shall be to BS 10:1962 (Table E) or
as specified in the tender drawing.

The pipework and fittings of Pumping System are as follows:
(a) Gate valves shall conform to the requirements of BS EN 12288 (copper alloy
valves) and BS EN 1171 (cast iron valves) PN12 and above as specified and
shall be clockwise closing direction. The valve handwheel shall has the
embossed casted direction indicator for opening and closing direction.
(b) Non-return valves shall be of non-slam type check valve conform to BS EN

16767:2016.
(c) Strainers shall be installed up stream of all pumps. For 50 mm diameter and
below, the strainers shall be screwed steel or bronze body type. For strainer
size larger than 50 mm, flanged connection shall be used. All strainers shall be
fitted with permanents magnets and removable stainless steel/bronze
perforated mesh screen.
(d) Reducers shall be used when connecting pipes to the pump ports. The reducer
shall be of the eccentric type at the intake side and a concentric type at the
discharge side.
(e) Air relief valves shall be installed on the pipe at the pump discharge side to
allow the venting of air pockets that normally accumulate in the pipeline. The
air release valve shall be of single orifice type screwed to 25 mm steam socket
welded to the delivery header pipe.
(f) Pressure gauges shall be minimum 100mm dia. dial face. The maximum
pressure range of the gauge shall be 2 times the working pressure of the
pipeline. Pressure gauges shall be mounted on the pipeline of the pump
discharge side using suitable fittings together with an isolation ball valve. The
gauges shall be liquid infill industrial type, shock proof, stainless steel casing
c/w heavy duty valve, etc. The scale ranges shall be subjected to the approval
of the S.O.
(g) Pilot-operated float valves (if applicable) shall be installed at all incoming
pipes to all storage water tanks located at the various blocks. The valve shall
be a single chamber, hydraulically operated globe valve of single seated
construction with replaceable stainless steel seat and a reversible, resilient
inner valve disc. The valve shall be operated by an externally mounted,
modulating type float pilot.
It shall automatically control the level in the storage water tank. The valve shall
maintain a maximum high level and a minimum low level. The level at which
the valve opens and closes shall be adjustable. The main valve shall be either
wide open or closed tight and shall be unaffected by changes in line pressure
or surface disturbance. There shall be no ‘wire drawing’ due to the valve
throttling near its seat.
(h) Pressure differential switch (if applicable) shall be installed for sensing a
rise or fall in pressure in a pipeline for starting and stopping the pumps.
Pressure differential switch shall have an operating pressure range
depending on the line pressure of the system, and shall have stainless steel
diaphragm, a mercury switch and to be able to operate at 12A contact current
with SPDT terminal.

(i) Pressure transducer (if applicable) shall detect the pressure at the delivery
manifold and via the controller to maintain a constant delivery set pressure
during operation by continuously varying the motor speed of the duty pump
according to the demand. The pressure transducer shall be of thick film
technology where the pressure measuring cell is fully welded without sealing
parts, no elastomer seals. compact and rugged construction. The cover shall
be of Stainless steel 1.4404 / AISI 316L (inside thread Schrader 1.4305 / AISI
303 only). The sensor shall be short circuit proof and protected against polarity
reversal. Each connection is protected against crossover up to max. supply
voltage. The respond time shall be < 2 ms, 1 ms and load cycle shall be <
100hz. The sensor shall conform to EN 61326-2-3 and enhanced EMC
protection of EN 50121-3-2. The accuracy shall meet the below requirements:
Parameter Unit
Characteristic line 1) % fs ± 0.3
Resolution % fs 0.1
Thermal characteristic 2) Max. % fs/10K ± 0.2
Long term stability acc. IEC EN 60770-1 Max. % fs 0.25
1)
typical; (incl. zero point, full scale, linearity, hysteresis and repeatability)
2)
-15 ... 85 ºC
(j) Stainless steel 304 insulated electrode and floatless relay shall install with
separator avoiding short circuit. The electrode shall be installed inside PVC pipe
to avoid cyclic on/off at relay control side due to splashing water. The electrode
shall be installed at both suction and storage tank to control pump operation as
per design requirements.
(k) Isolation valve of suitable pressure rating shall be installed at pumps outlet
and inlet, and at every distribution pipe for maintenance purpose.
(l) Air cocks and two lubricators/nipples shall be fitted at the suction and
delivery branch flange of the pumps.

3.8 ELECTRICAL SYSTEM
All designs, materials, construction works and equipment installed shall conform to the
relevant standards, regulations and by-laws imposed by authorities having jurisdiction
over the installation of an electrical system.
The following Act, Regulations and standards shall generally be applicable

to the design of electrical systems:
(a) Electricity Supply Act 1990
(b) Electricity Regulation 1994
(c) Malaysian Standards (MS IEC 60364), where applicable
(d) JKR Specification for Low Voltage Internal Electrical Installation (L-S1)
Where there is a discrepancy between standards, or differences in requirements

specified in two or more documents, or between published specifications and the
specific requirements of a local authority having jurisdiction, over electrical installations,
JKR Specification L-S1 shall be adopted.
3.8.1 Electric Motors
The pump motors shall be made from approved manufacturers, preferably the same
manufacturer of the pump or approved manufacturer recommended by the pump
manufacturer. All electric motors shall be totally enclosed fan cooled and fully
tropicalised and shall be furnished with class `F' insulation and suitable for operation
on single and three phase 50 Hz power supply.
All electric motors shall be furnished with isolator gears and starter gears which shall
be fully tropicalised and comply with BS EN 60947-4-1, BS EN 62271-102 and BS EN
62271-106.
Thermal overload protection devices in all phases, over-current protection devices, and
under-voltage releases shall be furnished and incorporated in the circuits of all electric
motors.
All motors shall be of the induction type as specified below:
(a) All motors shall be high efficiency motors and comply with MS 1525:2019. Only
motors with efficiencies higher than standard IE3 classified under MS1525:2014 as
shown in Table 3.2 should be used where operating hours exceed 750 hour per
year. Motor energy efficiencies are to be tested according to MS IEC60034-2:2005
or its latest edition.

Table 3.2: Efficiency Class Definition for 2-Pole and 4-Pole Motors (MS 1525:2014).
Motor Efficiency (%)
Motor
Capacity 2-Pole Motors 4-Pole Motors
(kW)
Motor Motor Motor Motor Motor Motor
Class IE3 Class IE2 Class IE1 Class IE3 Class IE2 Class IE1
0.75 80.7 77.4 72.1 82.5 79.6 72.1
1.1 82.7 79.6 75.0 84.1 81.4 75.0
1.5 84.2 81.3 77.2 85.1 82.8 77.2
2.2 85.9 83.2 79.7 86.7 84.3 79.7
3 87.1 84.6 81.5 87.7 85.5 81.5
4 88.1 85.8 83.1 88.6 86.6 83.1
5.5 89.2 87.0 84.7 89.6 87.7 84.7
7.5 90.1 88.1 86.0 90.4 88.7 86.0
11 91.2 89.4 87.6 91.4 89.8 87.6
15 91.9 90.3 88.7 92.1 90.6 88.7
18.5 92.4 90.9 89.3 92.6 91.2 89.3
22 92.7 91.3 89.9 93.0 91.6 89.9
30 93.3 92.0 90.7 93.6 92.3 90.7
37 93.7 92.5 91.2 93.9 92.7 91.2
45 94.0 92.9 91.7 94.2 93.1 91.7
55 94.3 93.2 92.1 94.6 93.5 92.1
75 94.7 93.8 92.7 95.0 94.0 92.7
90 95.0 94.1 93.0 95.2 94.2 93.0
110 95.2 94.3 93.3 95.4 94.5 93.3
132 95.4 94.6 93.5 95.6 94.7 93.5
160 95.6 94.8 93.8 95.8 94.9 93.8
200 to
95.8 95.0 94.0 96.0 95.1 94.0
1000

The AC Motors shall also comply to the following:
(a) Single phase AC motors shall not exceed 1 hp and if over 1/2 hp shall be fitted
with a suitable starter designed to limit the starting current and including a no-
volt release.
(b) Three phase AC motors up to and including 10 hp may be of the squirrel cage
type. Up to 3 hp Direct On Line (DOL) starting may be used, and above 3 hp a
Star-delta or Auto transformer or soft starter shall be provided and a no- volt
released provided.
All motors from 2 hp shall have a power factor of not less than 0.85 % load.
3.8.2 Motor Starter Panels
All motor starter panels shall be of the floor standing cubicle type except for motors

having loads of less than 250 A which can be of the floor standing or wall mounted
type.
The motor starters shall either be integrated with the electrical switchboard, or it shall
be a standalone module with sub-main cables being fed from the main switchboard
through circuit protective devices to its starter panel complete with earth fault relay and
over current relay IDMT.
The motor starter panel shall have the following features:
(a) ACB/MCCB shall be provided for main incoming supply to its starter panel.
(b) The kA rating of the ACB/MCCB shall comply with the fault level of the motor
starter panel.
(c) Direct On Line (DOL), Star-delta, Autotransformer, Soft starter contactors and
frequency inverter shall be rated to handle the full load current of the motor.
(d) Miniature circuit breaker (MCB) shall be provided for individual control circuits.
(e) Motor heater circuits shall be equipped with motor heater switches and indicator
lights.
(f) Panel heater circuits shall be equipped with MCB, heater switches, thermostat
controls and indicator lights.
(g) The types of motor protection relays to be provided shall be dependent on

power ratings as follows:
0 kW - 37 kW Thermal Overload Relay with ERL

Electronic microprocessor or
Above 37 kW Electromechanical type of motor
protection relay
(h) All motor starters shall be provided with phasing relays complete with MCB.
(i) The entire autotransformer and rotor resistance bank, complete with
thermistors, shall be installed at the top compartment of a switchboard; and
within the same vertical module of switchboard housing the motor circuit.
(j) The main earth chamber shall be painted in green colour, and the proposed
type to be employed shall be subject to the approval of the Certifying Agency.
(k) The motor can be operated by local manual control, automatic control or remote
control mode via a SCADA/ Telemetry system where specified.
(l) Cables for automatic operation shall be of 2.5 mm2 or above, and insulation
shall be above 10M ohm.
(m) All electrode sets shall be of 13 mm diameter, and of stainless steel make.
(n) The starter shall have a protection timer incorporated in the starting sequence
where specified.

(o) All indicator lights shall be of the LED type.
(p) Power factor shall be corrected to not less than 0.90 lagging where specified.
(q) All capacitor banks (if applicable) shall be rated at 440V and shall be protected
by fuses.
(r) All outgoing cables to motors shall be laid in trenches or concealed in G.I.
conduits placed on the floor slab
3.8.3 Surge Protective Device (SPD)
Lightning protection system shall be provided for pumping system, service reservoirs
and suction cistern.
Lightning protection system for the building shall be of the Faraday cage type
conforming to MS IEC 62305.
Lightning surge protection devices shall be provided for all power and data lines to
ensure all equipment inside computer rooms, network equipment rooms and SCADA/
Telemetry control rooms are protected against lightning surges complying with Zone 1
Protection as defined in IEC 61643-12.
Protector should also be installed at local power boards feeding electronics equipment.
The protector must not interfere with or restrict the systems normal operation. It should
not:
(a) Corrupt the normal mains power supply.
(b) Break or shutdown the power supply during operation
The SPD shall be tested in accordance to MS IEC 61643-11, MS IEC 61643-11, MS

IEC 61643-12.
The protector should have continuous indication of its protection status. Visual status
indication should clearly show:
(a) Full protection present
(b) Reduce protection-replacement required
(c) No protection- failure to protector
An advance volt free remote Warning Light should be including for remote indication
of:
(a) Pre-fail warning of protector
(b) Power failure
(c) Tripping of MCCB/ blown fuse

The status indication should warn of protection failure between all combinations of
conductors including neutral to earth.
The SPD shall be supplied with detailed installations. The installer must comply with
the installation practice detailed by the SPD manufacturer.
All motors and equipment shall be earthed with a minimum wire size of 2.5mm tinned
copper and shall be sized in accordance with the MS IEC 60364-5-54. These earth
wires shall be neatly run back to connect up to the copper earth busbar provided in the
main switchboard.
3.8.4 Electrical Switchboard
The contractor shall supply and install a metal clad or electro galvanised wall mounted
switchboard which shall house all circuit breakers, starters, contactors, relays, selector
switches, Hertz meter, power factor meter, voltmeter and ammeter. The switchboard
shall be fabricated from galvanised steel sheets of not less than 2.0 mm and shall be
of rigidly structural construction with all joints neatly and finished flush and all bare
edges turned over or lipped.
The doors of the metal switchboard shall be fabricated from pressed steel sheet of not
less than 16 SWG and shall be rigidly reinforced on the inside with all edges finished
round. The doors shall be fitted with a handle such that it cannot be open unless the
isolator switches of handles are turned to OFF position thereby cutting off the power
supply to the electrical mechanisms on the inside to the metal switchboard. Felt or
rubber insert gaskets shall be corporate in the frames of the metal switchboard to
ensure dust-proof locking arrangement. The doors of the metal switchboard shall be
fitted on the inside with shelves for storing spare cartridge fuses and contacts and
electrical circuit’s diagrams.
All contactors, starters, relays and controllers shall be fitted on insulated panels. All
incoming and outgoing circuits and wiring shall be brought to the contactors, starters,
relays and controllers via insulated terminal strips mounted within the cubicle and all
wiring between terminal strips and equipment inside the control panels shall be neatly
run and tapped strictly in accordance with the requirements of the Tenaga Nasional
Berhad.
Low Voltage switchboards shall comprise of the following:
(a) Cubicle
i) A floor standing cubicle shall be provided if the main incoming feeder has
a running load of 250A and above.
ii) Either a floor standing or wall mounted cubicle shall be provided if the
main incoming feeder has a running load of less than 250A.
(b) For Main Incoming of 800 A and above
Air Circuit Breakers (ACB) complete with one (1) element earth fault IDMT
relay, three (3) elements over current IDMT relay and all current transformers
for protection, shall be provided. IDMT shall be of the numerical or electro-

mechanical type. Surge Protection devices complying with Zone 1 Protection

as defined in IEC 61643-12 shall be provided.
(c) For Main Incoming of less than 800 A
Moulded Case Circuit Breaker (MCCB) complete with one (1) element earth
fault IDMT relay, three (3) elements over current IDMT relay and all current
transformers for protection, shall be provided. IDMT shall be of the numerical
or electro-mechanical type. Surge Protection devices complying with Zone 1
Protection as defined in IEC 61643-12 shall be provided.
(d) For Main Incoming of less than 60 A only
A 60 A MCCB complete with shunt trip coil in series with a Zero Current
Transformer (CT) and Earth Leakage Relay (ELR), complete with over current
used at the incomer side, shall be provided. Electric Surge Protection devices
complying with Zone 1 Protection as defined in IEC 61643-12 shall be provided.
(e) Outgoing Breakers at Main Switchboards
All outgoing breakers from main switchboards to other parts of the electrical
system (such as distribution boards and motor starter panels) shall be of the
MCCB type, complete with shunt trip coil of appropriate rating. The rating of
MCCB shall be 30% higher than the full load current.
(f) Harmonics
Automatic harmonic current suppressors, capacitors and blocking reactors of

appropriate ratings shall be installed in the main switchboards where harmonic
generating equipment such as Variable Speed Drives (VSD) is installed.
(g) Circuit Wiring
All sub-circuit and final circuit wiring shall be encapsulated by high impact uPVC
conduits when concealed in false ceiling or walls, and by galvanised iron (G.I.)
conduits when exposed or supplied to fire protection devices.
(h) Cable Supports
All cable trunkings, trays, ladders shall be hot-dipped galvanised. Identification

shall be provided for electrical trunkings and cable trays. The number of cables
installed in trunking trays, conduits, and ladders shall be such that a space
factor of 45% is not exceeded.
(i) Materials for Switchboard and Distribution Board
The construction materials for switchboards and distribution boards (DB) shall
be as follows:
i) Main Switchboard
Constructed from electro-galvanised, or galvanised steel iron sheet,

with minimum ingress protection conforming to IP42. Form 3B

segregation requirement shall be met. Panel thickness shall be at least

2 mm and painted in beige colour with a paint thickness of at least 75
microns on average.
ii) Sub-switchboard
Constructed from electro-galvanised or galvanised steel iron sheet, with

minimum ingress protection conforming to IP42. Panel thickness shall
be at least 2mm, and painted in beige colour, with a paint thickness of
at least 75 microns on average.
iii) Distribution Board
Constructed from electro-galvanised or galvanised steel iron sheet, with

minimum ingress protection conforming to IP42. Panel thickness shall
be at least 1.5 mm and painted in beige colour with paint thickness of at
least 75 microns on average.
----------------------------------------------- END OF SECTION 3.0 -----------------------------------------
REFERENCE
1. Suruhanjaya Perkhidmatan Air Negara. Uniform Technical Guidelines Water

Reticulation and Plumbing [Internet]. April 2018. Selangor, Malaysia: Suruhanjaya
Perkhidmatan Air Negara (SPAN); 2018. Available from: https://www.span.gov.my

SECTION 4
TESTING, ADJUSTING, BALANCING

AND COMMISSIONING (TABC)
Table of Contents
4.1 GENERAL ................................................................................................1

4.2 INSPECTION AND TESTING PLAN (ITP) ...............................................1
4.2.1 Pre Delivery Stage ....................................................................................3
4.2.2 Delivery Stage ..........................................................................................4
4.2.3 Installation Stage ......................................................................................4
4.2.4 Functional Performance Test ....................................................................5
4.3 COMMISSIONING ....................................................................................8
4.3.1 Handing Over Documents ........................................................................8
4.3.2 System Familiarisation Program ...............................................................9
SECTION 4.0 TESTING, ADJUSTING, BALANCING AND COMMISSIONING
4.1 GENERAL
This section specifies the requirements for all testing, adjusting, balancing and
commissioning (TABC) of the mechanical works to be carried out under the contract.
The objectives of TABC are:
i) To verify the delivered materials are as per approved specification and good
physical condition.
ii) To verify the installation works are carried out in accordance to specification
and good engineering practices.
iii) To verify the performance in terms of functionality, safety, maintainability and

operational ability of the installed equipment to ensure the system meet the
specified design intention through a series of tests and adjustments.
iv) To ensure all test result are systematically recorded and verified prior to
system commissioning.
TABC works are divided into four stages as the following:
i) Pre Delivery stage.
ii) Delivery stage.
iii) Installation stage.
iv) Functional Performance Test stage.
Contractor shall submit Inspection and Testing Plan (ITP) of TABC works to be
carried out in accordance to with this specification to Superintending Officer (S.O.) for
review and approval.
4.2 INSPECTION AND TESTING PLAN (ITP)
ITP shall consist of:
a) List of All TABC Requirement
All TABC works with specific scope and boundaries shall be clearly stated at every
stage of TABC works and comply with the design requirement. Sample of Schedule
of Inspection and Testing Plan as per Table 1.
TABC Copyright © CKM 2020 1

Table 1: Schedule of Inspection and Testing Plan
Inspection and Scope and

Stage Responsibility
Test Name Boundaries
Pump Performance
Pump Manufacturer
Test
Pre-Delivery Stage
Switchboard Test Switchboard Manufacturer
Visual Contractor
Inspection
Duty & standby Contractor
Delivery Stage
pumps
Documentation-
Contractor
(DO, QA etc.)
Pipe and
Leak Test Contractor
fittings
Cable continuity Power cable

and Insulation from incoming Contractor
Installation Test and outgoing
Stage
Duty, standby
pumps, all
Orientation of
switches and Contractor
Equipment sensors, valves &
fittings
Pump start-up Pumps,

Functional Test Switchboard,
Performance all switches and Contractor
Stage Pump Functional sensors, valves &
Performance Test fittings
b) TABC Work Program
TABC work program shall be integrated into main project schedules.
c) Method Statements
TABC method statements shall consist of TABC procedures, responsibilities,

necessary tools, measuring equipment with valid calibrated certification,
consumables items and acceptance criteria. Type of test required is listed in
Schedule of Inspection and Testing (Table 1).
Method statements and acceptance criteria for all testing equipment shall be
prepared by contractor and submit to the S.O. / S.O.’s representatives for
approval. Any ITP changes shall be resubmitted to the S.O./S.O.’s
representative for approval.
Acceptance criteria shall be stated as per Schedule of Design Requirements,

technical specifications or any applicable standards.
Prior to the commencement of the TABC works as per approved ITP, contractor shall
issue Request for Inspection and Testing (RFIT) to the S.O. During the TABC,
contractor shall have his technical team available to aid the testing and to perform
any adjustments as directed.
The TABC works shall be carried out under the direction of experienced personnel
and witnessed by S.O. or S.O.’s representatives. No subsequent installation works
shall proceed without S.O.’s approval of the test result.
Depending on the specific demands of individual installation, S.O.’s may require

additional or substitute testing works in regard to any elements in the installation
other than those indicated in this Specification.
4.2.1 Pre Delivery Stage
Pre-delivery inspection and performance test shall be conducted before site delivery.
These tests shall be witnessed by the government’s representative if deemed
necessary by the S.O. All travelling, food and accommodation cost of government
representatives related to witnessed performance test shall be included in the
contract.
A factory test shall be defining as any test of equipment required as stated in the
contract, conducted at manufacturer’s plant or at an independent and accredited test
facility approved by the S.O.
Performance test method statement, test standard and acceptance criteria shall be
submitted to S.O for record. The manufacturer shall conduct the test, pass all the
acceptance and produce a signed test report. All test report shall be submitted to
S.O.
Manufacturer shall be responsible for any reworks and adjustment of the equipment if
the test results fail to comply with the approved acceptance criteria.
Pump Performance Test and Inspection
Performance rating tests for the pumps shall be performed by the manufacturer to
verify equipment performance against design specifications and compliance with the
specification.
Performance rating test of duty and standby pumps shall comply as per Schedule Of
Design Requirement.
Switchboard Test and Inspection
Routine tests on the switchboard (category 1: l ≤ 600A by Suruhanjaya Tenaga) shall

be carried out before delivery to site. Routine tests shall include inspection and
checking of wiring, electrical continuity of the protective circuits, connections and
effectiveness of mechanical actuating elements and interlock.

Test Results or Certificate duly certified by Competent Person as in Electricity

Regulations 1994 shall be issued for every switchboard supplied and installed.
Rejection of Equipment
The Government shall reserve the rights to reject any item of the equipment that fail
to comply with the Specification of this contract.
4.2.2 Delivery Stage
All incoming material and equipment to site shall be verified by visual inspection,
documentation and measurement that delivered items are comply with technical
specification, as per approved materials and good physical conditions. Materials
delivered to site shall be free from defects and adequately protected against site
conditions.
List of verify and inspection during delivery stage as per Table 2:
Table 2: Verify and Inspection
Inspection / Test Name Description

- Good physical conditions
Visual Inspection - Free from defects
- Adequately protected
- Delivery Order
Documentation - Quality Assurance
- Technical Data
- Size, dimension and capacity

- Orientation of equipment and
Measurement
plant layout
Rejection of Material
The Government shall reserve the rights to reject any item of the material that fail to
comply with the Specification of this contract.
4.2.3 Installation Stage
Visual Inspection.
List of visual inspection and testing during installation as per Table 3:

Table 3: Visual Inspection of Pumping System
Inspection / System/
Objectives
Test Name Component
Verify that all pumps house/room components are

Pumps installed as per approved shop drawings,
House/Room approved material list installation, method
statement and free from installation effects.
Visual Verify the alignment of shaft, mounting, inertia

inspection Pump Set block & spring isolator.
Verify types of pipe, condition, protection and

Piping colour coding and inhibitors.
Switches, Verify that all switches and sensors, valves &

sensors, valves fittings are installed are installed as per approved
& fittings shop drawings.
Rejection of Installation Work
The Government shall reserve the rights to reject any installation work that fail to
comply with the Specification of this contract.
4.2.4 Functional Performance Test
All Functional Performance Test shall commence after all inspection and testing
during installation stage has been completed. List of functional performance test are
as the following:

Table 4: Pump Inspection and Test List
Inspection / Test Name Objectives
Verify the pump functionality and performance as

per published performance data included pump cut
Pump Operating Test
in/cut off flow rate, RPM, current and voltage,
efficiency pump and vibration pump.
Pipe Flushing and Leak Verify integrity of all pipe joints and fittings, pipe
Test internally clean and water quality are acceptable.
Vibration and Noise Level Verify the vibration and noise level is within
Test permissible range.
Testing of Electrical
Verify the continuity of power supply.
Wiring
Automatic Operation of
Pumps (Duty and Verify the operation of the system as per design.
Standby)
Verify the minimum rated pressure and maximum
rated pressure of the vessel.
Pressure Vessel
Demonstrate (simulation) the operation of the vessel
under actual operating condition.
Switchboard and Power Supply
List of Switchboard and power supply inspection and test name are listed in Table 5.
Detail method statement for testing shall be submitted conforming to the test
requirements in this specification. Only competent person as in Electricity regulations
1994 shall conduct the Switchboard testing.
Pipe Flushing and Leak Test
All pipes within scope of works shall be flushed before test. Flushing will be done by
a fresh potable water or dry compressed air wherever water flushing is not desirable
to clean the pipe of all dirt, debris or loose foreign materials. No leakage of any kind
will be permissible during testing. Flushing will be continued till the inside of the pipe
is fully cleaned to the satisfaction of the S.O.
Cable Continuity Test
Cable continuity test shall be performed on each power cable Perform an acceptance
test on cables, including terminations and joints, after cable system installation and
before the cable system is placed into service in accordance with ANSI/IEEE 400 by
means of direct current (DC) and recorded in the relevant testing form.

Table 5: Switchboard and Power Supply Inspection and Test Requirements
Inspection / Test
Description
Name
 Verify physical switchboard components are as per

specification.
 Check for tripping setting and system trip
 Check for wiring, motor insulation and record data.
 Check for cable terminal tightness.
Switchboard General  Check for equipment and panel grounding connection.
Inspection  Check for any sign for cable heating. Cable
temperature shall be measured and verify against IEEE
standards for temperature rise during full load.
 Check for voltmeter and ammeter function and
accuracy record running voltage and ampere.
 Check for control circuit function as intended.
 Verify that power supply parameters are within

permissible range, safety protections are in place and
physical condition of switch board and cabling works
are acceptable as per specification and approved shop
Power Supply Test drawings.
 Verify the rotation of equipment / phase sequencing is
according to manufacturer recommendation.
 Verify phase protection relay installation and function.
 Switching from normal electrical to essential supply.
 Circuit breaker and Earth Fault Protection calibration

and discrimination shall be conducted and
coordinated between electrical contractors.
Overcurrent and
 Circuit breaker and Earth Fault Protection shall be
Earth Fault
tested against simulated leakage current.
Protection
 Inverse definite minimum time (IDMT) tripping delay
shall be selected/programmed for equipment overload
starting to prevent nuisance tripping during starting.
Testing Instrument and Accessories
All permanent sensors and gauges use for measurement of temperature, pressure
and flow shall be factory calibrated and all calibration certificates shall be submitted
to S.O prior to testing works.
The contractor shall provide all necessary testing, calibrating instruments and labour
required for the testing, adjusting, balancing and commissioning of the complete
pumping system installed under the contract.

The contractor shall also allow for any necessary replacement of parts in order to
achieve the conditions specified in the drawings and specification.
Table 6: Testing Instruments
Measurement Type Accuracy
Clamp meter
Ampere 2.0% ± 5 digits (45-65 Hz)
(instantaneous)
Clamp meter
Voltage 1.5% ± 5 digits
(instantaneous)
Active Power:
± (1.2% of reading + 0.005% of
range)
Combined power, -> (For PF ≥ 0.99);
ampere, voltage, power Power/Energy logger
factor and (continuous)
± (1.2% of reading + 7 x (1-PF)
energy
+ 0.005% of range)
-> (from 0.6 PF to 0.98PF)
Sound Level Meter Class 1 as per

Noise (Average)
Class 2 IEC 61672-:2002
± 5% of reading (from 0.01 g to

Vibration Vibration Analyses 50g); where “g” in meter per
second square.
RPM Motor tester Tachometer 0.05% ± 1 digits
4.3 COMMISSIONING
Commissioning includes achieving, verifying, and documenting that the performance

of facilities, systems, and assemblies meets defined objectives and criteria.
All completed test forms and test summary shall be submitted to S.O./S.O.’s
representative for final review and approval. Having satisfied that all appropriate tests
have been conducted and the performance of the installation meet the design
objectives; S.O.’s representative will issue or recommends to the S.O. for the
issuance of Certificate of Practical Completion (CPC).
4.3.1 Handing Over Documents
After the issuance of Certificate of Practical Completion, contractor shall submit all
related project handing over documents as the following:

a) Test Report complete with fully verified Inspection Checklist and Test Forms.
b) Defects List.
c) Operation and Maintenance Manual which includes.
 Manual/Standard Operating Procedures

 Preventive Maintenance Schedule and Manual
 Equipment/Product Engineering Data.
 Operation set point (cut in/ cut off pressure, flow rate etc)
 Switchboard overload setting and set points
 Contractor and manufacturer contact details
 Circuit Diagrams
 Inventory List
d) As-built drawings (Softcopy and Hardcopy) in the form of:
 Hard Copies sets of As-built drawings in as actually constructed

pertaining to the Works including all services and facilities systems
and all supporting documents such as Operation and Maintenance
Manual, Testing and Commissioning Certificates.
 Digital Copies in AutoCAD (.dwg) or any other compatible format to be
stored in compact discs or removable storage.
 Digital Copies in Acrobat (.pdf) or any other compatible format to be
stored in compact discs or removable storage.
e) Schedule of System Familiarization Program to end users.
4.3.2 System Familiarisation Program
In-class and practical familiarisation program shall be conducted to the personnel

nominated by S.O. within one (1) month of issuance of Certificate of Practical
Completion. Program shall focus on:
 Overview of design concept and objectives

 Operation instruction & competency requirement
 Maintenance procedures
 Critical operating parameters monitoring and
 Emergency response & safety procedures
Contractor shall submit program modules and materials to S.O for approval prior to
commencement of training. Particulars of trainee shall be recorded and send to S.O.
for records.
----------------------------------------------- END OF SECTION 4.0 -------------------------------------------

SECTION 5
SPECIFICATION FOR COMPREHENSIVE

SERVICE & MAINTENANCE
Table of Contents
5.1 GENERAL .................................................................................................. 1

5.2 WORKMANSHIP AND MATERIALS .......................................................... 1
5.3 SUPERVISION ........................................................................................... 1
5.4 SCOPE OF WORK ..................................................................................... 1
5.5 CONSUMABLE MATERIALS ..................................................................... 2
5.6 REPAIRS .................................................................................................... 2
5.7 SERVICE AND MAINTENANCE RECORDS ............................................. 2
5.8 RATES FOR SERVICE AND MAINTENANCE AFTER DEFECT LIABILITY
PERIOD (DLP) ........................................................................................... 3
5.9 PAYMENTS ................................................................................................ 3
5.10 SCHEDULE OF THE COMPREHENSIVE SERVICE & MAINTENANCE .. 3
5.11 SCHEDULE OF RATES FOR THE COMPREHENSIVE SERVICE AND
MAINTENANCE ......................................................................................... 7
SECTION 5.0 SPECIFICATION FOR COMPREHENSIVE SERVICE & MAINTENANCE
5.1 GENERAL
The work covered by this section is for the supply of all materials, appliances, labour
and necessary incidentals for the service and maintenance of the Pumping System and
Ancillary Equipment.
All work to be performed under this Specification shall be in accordance with the
commercial practice and must be in strict accordance with this Specification.
5.2 WORKMANSHIP AND MATERIALS
The work described in this Specification shall be performed by workmen skilled in the
service, maintenance and repair of Pumping System and Ancillary Equipment of all
types and shall be executed in accordance with the best commercial practice.
All materials to be supplied in connection with work under this Specification shall be
new and unused and shall generally be of the best quality as regard manufacture and
performance.
5.3 SUPERVISION
The Contractor shall have an electrical competent person in charge of the service,
maintenance and repair work to be carried out under this Specification. This competent
person shall be in the direct employ of the Contractor and accepted by the
Superintending Officer (S.O.).
5.4 SCOPE OF WORK
All machinery and equipment comprising the complete Pumping System and Ancillary
Equipment shall be serviced and maintained.
The Contractor is to provide and execute service and maintenance program for a
period of one (1) year and provide emergency repair service at any time if required to
do so by the S.O.
The service and maintenance of the complete Pumping System and Ancillary
Equipment shall be in strict accordance with the Servicing and Maintenance Schedule
as set out in clause 5.10 below.
The Contractor shall advise the S.O. of any defects in any part or parts of the complete
Pumping System and Ancillary Equipment observed during routine inspection and
service and shall repair such defects if required to do so by the S.O.
The Contractor shall advise the S.O. of any defects in any part or parts of the complete
Pumping System and Ancillary Equipment observed during routine inspection and
service, and shall repair or replace parts of such defects if required to do so by the S.O.
Specification for Comprehensive Service & Maintenance Copyright © CKM2020 1

5.5 CONSUMABLE MATERIALS
The Contractor shall supply the following consumable materials as and when required:
(a) All pump mechanical seal and bearings.
(b) All carbon brushes required to replace worn brushes in electric motors.
(c) All electric contact points required to replace worn electric contact points in
switch gears, motor starter gears, electric control gears and electric relays.
(d) All cotton waste, soap detergent and other cleaning materials required for
cleaning purposes.
(e) All coupling bolts and rubber bush for pump coupling, pump /motor coupling
flanges.
(f) To provide pump and motor alignment service with complete alignment tools
such as alignment base plates, dial gauge or laser alignment tools and vibration
meter.
The costs of these consumable materials shall not be charged separately by the
Contractor but shall be included in the fixed monthly rate quoted by the Contractor for
the Service and Maintenance of the complete Pumping System and Ancillary
Equipment.
5.6 REPAIRS
The Contractor shall repair defects in the complete Pumping System and Ancillary
Equipment on the instructions of the S.O. The costs of such repair shall be included in
the fixed monthly rate quoted by the Contractor for the Service and Maintenance of the
complete Pumping System and Ancillary Equipment.
All repairs on the complete Pumping System and Ancillary Equipment shall be
guaranteed by the Contractor against defects in workmanship and materials for a
period of one year to take effect from date of completion of repairs. During the
guarantee period, the Contractor shall rectify defects in repairs carried out by him with
no additional charge to the Government.
5.7 SERVICE AND MAINTENANCE RECORDS
The Contractor shall provide a service and maintenance record book for the complete
Pumping System and Ancillary Equipment being serviced and maintained.
This record book shall be kept in the pump room. Details of all service, maintenance
and repairs carried out on the complete Pumping System and Ancillary Equipment shall
be recorded by the Contractor into this book for checking purposes.
The address and telephone number of the Contractor's service station shall also be
included in this record book to facilitate emergency service calls.
The Contractor shall also keep an accurate detailed record in duplicate of all service,
maintenance and repair work carried out on the complete system. This record shall be

in the form of a Maintenance / Repair Sheet and shall be countersigned by the S.O./end
user / building owner each time the system is serviced, maintained and repaired by the
Contractor.
5.8 RATES FOR SERVICE AND MAINTENANCE AFTER DEFECT LIABILITY PERIOD
(DLP)
The Contractor shall quote the rates and prices for the service and maintenance of the
complete Pumping System and Ancillary Equipment for this contract. These rates
quoted by the Contractor at the time of tenders, shall hold good for the period of three
(3) years commencing from the expiry of the defect liability period.
The Contractor maybe required to enter into a contract for the above periods with the
Government on the Standard Form of Contract for service and maintenance of
Pumping System and Ancillary Equipment, a copy of which may be inspected at the
office of the Pengarah Kanan, Cawangan Kejuruteraan Mekanikal, Ibu Pejabat JKR,
Kuala Lumpur.
5.9 PAYMENTS
Payments shall be made in accordance with Clause 24 of the Conditions Of Contract,

but bills presented for payments must be accompanied by a full statement and
substantiated by one copy of the individual maintenance/repair records required under
paragraph 7(2) of this Specification.
5.10 SCHEDULE OF THE COMPREHENSIVE SERVICE & MAINTENANCE
The Contractor shall inspect and service the machinery and equipment comprising the
complete Pumping System and Ancillary Equipment at the above premises periodically
as scheduled in the check list except where otherwise directed by the S.O.
The check list is in no way exhaustive and shall not in any way relieve the Contractor
from executing any other work necessary to ensure the efficient functioning of the
Pumping System and Ancillary Equipment.
The Contractor shall report in writing to the S.O. any defect/s observed in any part or
parts of the complete Pumping System and Ancillary Equipment. The report shall state
the cause/s of the defect/s observed and shall include an estimate of the cost of repairs
required.

FREQUENCY
NO ITEM
Monthly Quarterly Yearly
1. WATER PUMPS
Check all seals, seals and pipelines for
a. √
leaks & rectify as necessary
b. Check pump rotation manually √
Check and adjust pump glands as
c. √
necessary
Check all pump bearings and lubricate with
d. √
oil or grease as necessary
Check for motor and pump alignment and

check for rubber coupling condition, the
alignment and condition of all rubber
e. √
couplings between pumps and driving
motors, check for vibration level and rectify
as necessary
Check the tension of all belt drives, and

f. √
adjust as necessary
Check all bolts and nuts for tightness, and

g. √
tighten as necessary
2. ELECTRIC MOTOR
Check all motor bearings, lubricate with
a. √
grease as necessary
Check carbon brushes and slip rings of all
b. motors, and clean as necessary. Renew √
carbon brushes as necessary
Check safety devices fitted to all motors,
c. and clean, adjust and lubricate as √
necessary
Check for motor terminal tightness and any

d. sign of burned connection replace as √
necessary
Check and record for motor running

ampere, running voltage, vibration value
e. √
and motor body temperature. Cleaned,
adjust and rectify as necessary

FREQUENCY
NO ITEM
3. SWITCHBOARD
Inspect and check the routine operation of

all electrical starters, electrical control
gears, automatic switchover control gears,
a. √
battery charging, relays, inverter/controller
programming and set points, alarm fault
register and ancillary electrical apparatus
Clean or renew electric contactors if

b. √
necessary
Renew electric fuses, LED, push button,

c. √
ammeter, voltmeter and etc. if necessary.
Inspect and check all cable and wiring

d. √
connections
Recalibrate incoming power protection
e. √
device (OC/ELR-RELAY)
Inspect switchboard ventilation fan, heater
f. and other safety protection device, √
cleaned, repair and replace as necessary
4. PIPING AND FITTINGS
Check all water piping, valve, fitting, etc. for

leaks and sign of reverse flow in pipeline
a. √
during pump off condition. Replace
defective valve and parts as necessary.
b. Flush out system of all dirt √
Check for air lock in the system & rectify

c. √
accordingly

d. √
tighten as necessary
Check for pipeline vibration and movement
especially during pump start and pump
e. √
stop, rigidly anchor the pipe to avoid pipe
breakage.
5. BASEPLATE
a. √
tighten if necessary

FREQUENCY
NO ITEM
6. SUPPORT AND HANGER
a. Check all support and hanger if necessary √
7. PRESSURE TANK
Check, test and record pressure vessel
a. bladder, refill nitrogen as necessary to √
design pressure.
b. Check and inspect for leakage √
c. Check and test all the valves √
8. FLOWMETER
a. Physical Inspection for dust and dirt √
Physical inspection for loose/poor

b. connection and check for earthing √
connection, secure as necessary.
Physical inspection for overheated,

c. √
damaged wiring and hardware.
Inspect for abnormal reading at the flow

meter record and check for flowmeter
output current and compare the reading to
d. √
preprogrammed output value supplied by
the manufacturer. Rectify any damage as
necessary.

5.11 SCHEDULE OF RATES FOR THE COMPREHENSIVE SERVICE AND

MAINTENANCE
FOR SERVICE AND MAINTENANCE OF THE COMPLETE PUMPING SYSTEM AND

ANCILLARY EQUIPMENT
The tenderer is to note that the prices quoted will be binding in the event that the
Government decides to accept them immediately after the end of DLP. These prices
should not be subjected to variation for the period of three years after the end of DLP.
RATES BASED ON CONTRACT PERIOD OF THREE YEARS ONLY (After the end of
DLP)
For Service and Maintenance of the Pumping System Charge Per Year (RM)
and Ancillary Equipment at the above premises in strict
accordance with the Tender Specifications and for supply
of all consumable materials listed in Section 5 of the
service and maintenance as and whenever required and
to provide emergency repair service at any time as
required.
Tandatangan Petender : __________________________________
Nama Petender : __________________________________
Nama Dan Alamat Syarikat : __________________________________

(Dengan Cop)
__________________________________
Tarikh : __________________________________
Tandatangan Saksi : __________________________________
Nama Dan Alamat Syarikat : __________________________________

(Dengan Cop)
__________________________________
Tarikh : __________________________________
------------------------------------- END OF SECTION 5.0 -------------------------------------

SECTION 6.0
SCHEDULE OF DESIGN REQUIREMENTS

Table of Contents
6.1 SCOPE OF WORKS ................................................................................ 1

6.2 SYSTEM DESIGN REQUIREMENTS ...................................................... 1
6.2.1 Constant speed booster pump system ..................................................... 2
6.2.2 Constant speed booster pump system with external Variable Speed
Drive (VSD) unit. ...................................................................................... 3
6.2.3 Variable speed booster pump set system ................................................ 4
6.2.4 Hyropneumatic pump set system. ............................................................ 5
SECTION 6.0 SCHEDULE OF DESIGN REQUIREMENTS
6.1 SCOPE OF WORKS
The Sub-Contractor shall supply labor, materials, equipment and services for the
complete Pumping System and Ancillary Equipment.
The works to be performed under this contract are listed hereunder but not
necessarily be limited to the following scope of work:
(a) Supply, deliver, install, test, adjust, balance and commission of the following
system and ancillary equipment for this contract that include:
(b) Complete Pumping System c/w piping, accessories, switchboard, controls,

wiring, trunking, conduit, valve, etc.
(c) Service and maintain the above-mentioned Pumping System for a period of
one year from the date of its handing over to the Jabatan Kerja Raya in good
operating condition.
(d) Submit working drawings, as-built drawings, all test results, operation and
maintenance manuals of the services and the installed equipment.
(e) Guarantee and monthly service of the complete installed system for a period
of twelve (12) months after handing over to the Jabatan Kerja Raya, in good
operating condition.
(f) Familiarization Program as per clause 4.3.2.
(g) Deviation
Any deviation from the specifications shall not be made without prior consent
of the Superintending Officer (S.O.).
6.2 SYSTEM DESIGN REQUIREMENTS
The works to be carried out under Pump System and Ancillary equipment shall
comprise but not limited to the supply, delivery to site, installation, testing, adjusting,
balancing and commissioning and maintenance of the following equipment and
principal services, including all associated minor works and items:
Schedule of Design Requirements Copyright © CKM2020 1

6.2.1 Constant speed booster pump system.
Item Description of Equipment Unit Quantity
1. Pump c/w starter, mountings, base plates, set

pump concrete plinths, neoprene pads
etc, as per drawing and specification.
Type:
Capacity:
Speed:
Type of Driven:
2. Pump switchboard c/w cablings, conduits, lot

control wiring between switchboard and
various equipment, relays contactors,
timers protection relays, floatless relays,
automatic controls, alarms, single line
schematic circuit diagram, overvoltage
protector, earthling, voltmeter, ammeter
lightning surge protector etc as per
drawing and specification.
3. Piping works c/w valves, fittings, supports lot

and hangers, pressure gauges, pressure
differential switches, flow switches,
strainers, flexible couplings, pressure
switches, etc. as per drawing and
specification.

6.2.2 Constant speed booster pump system with external Variable Speed
Drive (VSD) unit.

Pump Type:
Capacity (Design head and flow @ 3
specified motor speed of 50 Hz, 45 Hz
and 30 Hz):
Motor Pole and pump max speed
Motor rating: Class and IE rating
Type of motor control:

various equipment, automatic controls,
alarms, single line schematic circuit
diagram, overvoltage protector, earthling,
voltmeter, ammeter lightning surge
protector etc as per drawing and
specification.

and hangers, pressure gauges, flow
switches, strainers, flexible couplings,
pressure switches, etc. as per drawing
and specification.
4. Pressure Vessel / Hydropneumatics tank / unit

Expansion vessel comes with related
accessories
5. Variable Speed Drive external unit unit

with related accessories (inverters,
controller, pressure transducers, relays
and timers).
Inverter capacity:
Programmable controller model and type:

6.2.3 Variable speed booster pump set system.

Pump Type:
and 30 Hz):

specification.

and specification.

accessories
5. Variable Speed Drive external unit unit

with related accessories (inverters,
controller, pressure transducers, relays
and timers).
Inverter capacity:
Programmable controller model and type:

6.2.4 Hyropneumatics pump set system.

Pump Type:
and 30 Hz):

specification.

and specification.

accessories
----------------------------------------------- END OF SECTION 6 ----------------------------------------------

SECTION 7.0
SCHEDULE OF TECHNICAL DATA OFFERED

Table of Contents
7.1 GENERAL ................................................................................................ 1

7.2 PUMP SET ............................................................................................... 1
7.3 PIPING AND ACCESSORIES .................................................................. 7
7.4 LIST OF CATALOGUES SUPPLIED ...................................................... 10
SECTION 7.0 SCHEDULE OF TECHNICAL DATA OFFERED
7.1 GENERAL
The tenderer shall complete this Schedule of Technical Data of Equipment Offered
as set out below. All information for, shall be given correctly and supported by copies
of manufacturer’s published technical data for the equipment being offered.
The tenderer is required to supply all the information as stipulated below and must be
specific with regards to the make or manufacturer of the equipment offered. The
words "or approved equivalent" wherever stated by the tenderer shall be deem void.
The tenderers are compulsory to submit pump performance curve. Failure to

submit of pump curve will be disqualified for tender evaluation.
7.2 PUMP SET
JKR CONTRACTOR’S
NO. ITEMS
REQUIREMENT OFFER
1.0 Pump
No. of pump offered To state by designer
Manufacturer To state by tenderer
Country of origin To state by tenderer
Country of manufacturer To state by tenderer
Model To state by tenderer
Type To state by designer
Flow rate of pump (igpm) To state by designer
Total head of pump (m) To state by designer
Efficiency of pump (%) To state by designer
Weight of pumpset (kg) To state by tenderer
Type of Impeller To state by tenderer
Material of impeller To state by designer
Material of casing To state by designer
Material of shaft To state by designer
Types of bearing To state by tenderer
Method of lubrication of shaft
Grease
bearing
Diameter of suction inlet (mm) To state by tenderer
Diameter of discharge outlet
To state by tenderer
(mm)
Material of mechanical seal To state by designer
Type of Driven To state by designer
Attached Catalogue Yes
Attached Pump Curve Yes
Schedule of Technical Data Offered Copyright © CKM2020 1

JKR CONTRACTOR’S
NO. ITEMS
REQUIREMENT OFFER
2.0 Motor
Type To state by tenderer
Rated motor power To state by tenderer
Rated motor voltage 415 V
Rated motor frequency 50 Hz
Rated motor speed (rpm) To state by designer
Number of pole To state by tenderer
Full load current To state by tenderer
Locked rotor current To state by tenderer
Efficiency
- At 100% load To state by tenderer
Power Factor
Degree of protection IP55
Class of insulation Class F
Type of bearing To state by tenderer
Type of lubrication To state by tenderer
Attached Catalogue Yes
Energy efficiency rating IE3

JKR CONTRACTOR’S
NO. ITEMS
REQUIREMENT OFFER
3.0 Electrical Requirement

*Note: The tenderers shall
check online the latest
Electrical Material Approval
List (EMAL)
3.1 Pump Switchboard
Type To state by designer
Make and manufacturer To state by tenderer
Material of Switchboard To state by tenderer
Dimension of switchboard To state by tenderer
Operating Voltage 3 phase/50Hz/415 V
Total rated current consumption To state by tenderer
suggestion IP42
Class of Protection IP55 refer table SPAN
page 92
Attached registered
YES
manufactured certification
3.2 Inverter and Controller

Make
Model
Inverter rated Voltage Rated
Current Capacity
Build in RFI filter and integrated
(YES/NO)
DC link chokes
Potentiometer provided for
(YES/NO)
manual regulation of frequency
Protection rating IP 66
Pump cascade control capability (YES/NO)
(Master and slave mode):
Dry run/end of curve detection: (YES/NO)
Pipe fill mode provided (YES/NO)
Pipe leak - high flow detection (YES/NO)
Physical pressure display (YES/NO)
privided
3.3 Circuit Breaker

Make To state by tenderer
Range Capacity (Volt/Amp/Hp) To state by tenderer

JKR CONTRACTOR’S
NO. ITEMS
REQUIREMENT OFFER
Starter (Autotransformer Starter
3.4
/Soft Starter)
3.5 Contactor
3.6 Relay
3.7 Timer
3.8 Current Transformer

3.9 Selector switch


JKR CONTRACTOR’S
NO. ITEMS
REQUIREMENT OFFER
3.10 Start/Stop push button

3.12 Power factor meter

3.13 Surge Protection Device (SPD)

3.14 Ammeter
3.15 Voltmeter

3.16 Control wire fuses



JKR CONTRACTOR’S
NO. ITEMS
REQUIREMENT OFFER
3.17 Motor incoming power
3.18 Wire Type/Size

3.19 Motor power rating

3.20 Earth fault relay and over current

3.21 Hour Counter

3.22 Fuses

7.3 PIPING AND ACCESSORIES
JKR CONTRACTOR’S
NO. ITEMS
REQUIREMENT OFFER
1.0 Piping
Material
Pressure rating To state by tenderer
2.0 Gate Valves

Brand To state by tenderer
Material To state by tenderer
Attachment catalogue Yes
3.0 Motorized Gate Valves (If

Applicable)
Type
Size (mm) To state by tenderer
Pressure rating
Actuated by Electric Motor
Actuator To state by tenderer
Supply (Ph/V/Hz) To state by tenderer
Actuating time from fully open to To state by tenderer
fully closed (sec)
4.0 Check Valves


NO. ITEMS JKR CONTRACTOR’S

REQUIREMENT OFFER
5.0 Y-Strainer
6.0 Pressure Gauge

Range To state by tenderer
7.0 Pressure Transmitter

8.0 Flow Switch


NO. ITEMS JKR CONTRACTOR’S

REQUIREMENT OFFER
9.0 Pressure Vessel
Capacity
Working Pressure
Dimension To state by tenderer
10.0 Flowmeter
Size To state by tenderer
Accuracy To state by tenderer
Certificate of Std To state by tenderer
11.0 Stainless Steel Electrode

(non-float) c/w holder and
spacer
No unit of offered To state by tenderer
Manufacturer's name To state by tenderer
Brand/model To state by tenderer
County of origin To state by tenderer
Supply voltage(V) To state by tenderer
Power consumption (A) To state by tenderer
Type of cable To state by tenderer
Size of cable (mm) To state by tenderer
Type cable use outdoor Armoured Cable
application

7.4 LIST OF CATALOGUES SUPPLIED
Tenderer shall list down and attached the relevant catalogues related to the
equipment/system offered in this tender.
No. Catalogues
----------------------------------------------- END OF SECTION 7 ----------------------------------------------

SECTION 8
SCHEDULE OF PRICE
Table of Contents
8.1 GENERAL ITEMS.....................................................................................2

8.2 DOMESTIC COLD WATER PUMPING SYSTEM.....................................3
8.2.1 Constant speed booster pump system. ....................................................3
8.2.2 Variable speed booster pump system with external Variable Speed Drive
(VSD) unit. ................................................................................................4
8.2.3 Variable speed booster pump set system. ................................................5
8.2.4 Hyropneumatic pump set system..............................................................6
8.3 SUMMARY OF PRICES ...........................................................................7
8.4 SCHEDULE OF DELIVERY, INSTALLATIONS & COMMISSIONING......8
SECTION 8.0 SCHEDULE OF PRICE
The tenderer shall complete this Schedule of Prices at the time of tender. The Government
is under no obligation to accept the lowest tender and reserves the right to accept any
tenders in part or full and to vary the quantities stated with no variation to the rates.
The prices entered in this schedule shall be for the supply, installation, testing and
commissioning of the complete system and ancillary equipment/works in accordance with
the requirements of the specification and drawing together with one (1) year maintenance
and guarantee as specified.
The tenderer shall give an accurate breakdown of the tender price sum for the whole works
in the price schedule below. The tender price breakdown shall be inclusive of the cost of
material, labour charges and all other incidentals necessary for the completion of the said
works.
Where works are specified in the specifications or tender drawings or incidental to the
contract and no corresponding price breakdown item are provided for, the cost of such work
shall be deemed to be included under the relevant items of works in the tender price
breakdown below.
For cases where there are discrepancies in quantities in the tender document, the higher
quantity shall take precedent and applicable for the purpose tender pricing and the
contractor shall clearly indicate in his tender submission.
The tender price breakdown may be used as a basis of making progress payment. However,
the Superintending Officer or his representative reserves the rights to vary the price
breakdown by making the necessary adjustment if in his opinion the breakdown given by the
tenderer is unreasonable, when making such payment. Being a lump sum contract the full
tender sum, after making adjustments for any variation to the works, shall be paid upon
completion of all works specified.
The price of any variation to the works shall not necessarily be based on the corresponding
price breakdown, if deemed reasonable it may be used, otherwise it shall be on agreed
rates.
Where work is specified or incident to the contract and no corresponding payment item has
been allowed for, the cost of such work shall be deemed to be included under the relevant
items of work listed in the summary below.
The breakdown of prices are for major components in the schedule of prices and it is
not exhaustive. It is the contractor's responsibility to price out for all scope of works
as per tender drawings & specification even though is not specifically indicated in the
schedule of prices.
Schedule of Price Copyright © CKM 2020 1

8.1 GENERAL ITEMS
Unit Price
Item Description of Equipment/Works Qty. Unit
Price (RM)
1 Preliminaries:
a. Insurances LS
b. Performances bond LS
2 Documents:
a. Contract Document c/w hard cover binding and
Set
stamping.
b. Working Drawing Set
c. As-built Drawings
 Hard copies sets
Set
 Digital Copies in AutoCAD (.dwg)
 Digital Copies in Acrobat (.pdf)
d. Operation And Maintenance Manual Set
e. Contract document in CD format Nos.
3 Monthly Progress Report Inclusive of Digital Image
Lot
or Photos.
4 Cost for Industrialized Building System (IBS) related
Lot
works and coordination.
5 Painting of the complete system, Identification,
Lot
Names Plates, etc. as per drawing and specification
6 All Civil Works necessary for complete installation
of the above systems include coring, cutting,
Lot
digging, drilling, cart away debris, etc. and making
good to S.O satisfaction.
7 Testing and Commissioning as per specification
a. Post Occupancy Testing and Commissioning as
per specification Lot
b. Adjustments to the system controls such (Re-
balancing, re-tuning, re-checking and re-
adjustment etc.)
8 One Year Maintenance During Maintenance and
Lot
Defect Liability Period
9 Management Cost (inclusive of attending site,
coordination & technical meeting)
a. Accommodation Lot
b. Transportation
c. Miscellaneous
10 Other Necessary Work Not Included Above But
Necessary to Complete The Pumping System.
(Please Give Detail ):
a.
b.
Total to be carried to SUMMARY OF PRICES of
Section 8.3

8.2 DOMESTIC COLD WATER PUMPING SYSTEM
Unit Price
Price (RM)
1 Electric motor pump set c/w starter, couplings, base
plate, neoprene pads, concrete plinth etc. as per No.
drawing and specification
2 Standby electric motor pump set c/w starter,
couplings, base plate, neoprene pads, concrete No.
plinth etc. as per drawing and specification
3 Pump switchboard c/w cablings, conduits, control
wiring between switchboard and various
equipment, automatic controls, alarms, single line
schematic circuit diagram, undervoltage & Lot
overvoltage protector, earthing, voltmeter,
ammeter, lightning surge protector etc. as per
4 piping works c/w valves, fittings, accessories etc as
per drawing and specification. Lot
5 Stainless steel electrode c/w holder and other
accessories as per drawing and specification Lot
6 Sample Board, sample of workmanship (mock up)
for approval of S.O. Lot
7 Item not included above, but shown in the
drawings, described in the specifications, required
by the legislation or obviously necessary for the
successful completion and efficient operation of the
entire installation :-
a.
b.
A. Total to be carried to SUMMARY OF PRICES
of Section 8.3

8.2.2 Variable speed booster pump system with external Variable Speed Drive
(VSD) unit.
Unit Price
Price (RM)
plate, neoprene pads, conrete plinth etc. as per No.
3 Pump switchboard c/w frequency converter,
cablings, conduits, control wiring between
switchboard and various equipment, automatic
controls, alarms, single line schematic circuit Lot
diagram, undervoltage & overvoltage protector,
earthling, voltmeter, ammeter, lightning surge
protector etc. as per drawing and specification
4 Pressure Vessel / Hydropneumatics tank /
Expansion vessel comes with related accessories Lot
5 Variable Speed Drive external unit c/w related

accessories Lot



entire installation. If none is required please write
‘NIL’ otherwise full details of items are to be given. (
Please Give Detail ):-
a.
b.
B. Total to be carried to SUMMARY OF PRICES
of Section 8.3

Unit Price
Price (RM)
1 VSD electric motor pump set c/w VSD unit,
diaphragm tank, starter, couplings, base plate,
No.
neoprene pads, conrete plinth etc. as per drawing
and specification
2 Pump switchboard c/w frequency converter,
cablings, conduits, control wiring between
switchboard and various equipment, automatic
controls, alarms, single line schematic circuit Lot
diagram, undervoltage & overvoltage protector,
earthling, voltmeter, ammeter, lightning surge
protector etc. as per drawing and specification


entire installation. If none is required please write
‘NIL’ otherwise full details of items are to be given. (
Please Give Detail ):-
a.
b.
B. Total to be carried to SUMMARY OF PRICES
of Section 8.3

8.2.4 Hyropneumatic pump set system
Unit Price
Price (RM)
plate, neoprene pads, concrete plinth etc. as per No.
3 Pump switchboard c/w cablings, conduits, control
wiring between switchboard and various
equipment, automatic controls, alarms, single line
schematic circuit diagram, undervoltage & Lot
overvoltage protector, earthing, voltmeter,
ammeter, lightning surge protector etc. as per

entire installation :-
a.
b.
A. Total to be carried to SUMMARY OF PRICES
of Section 8.3

8.3 SUMMARY OF PRICES
The total tender sum for the Supply, Delivery, Installation, Testing, Adjusting,
Balancing and Commissioning inclusive of one year (1 year) servicing and
maintenance for the Pumpung System and ancillary work is as follows :
Item Description / Item Price (RM)

8.1 General Items
8.2 Domestic Cold Water Pump System
8.2.2 Constant speed booster pump system with external
Variable Speed Drive (VSD) unit.
8.2.4 Hyropneumatic pump set system
TOTAL TO BE CARRIED IN THE FORM OF TENDER
TOTAL (to be carried to Form Tender)
(RINGGIT MALAYSIA _________________________________________________

(________________________________________________)
Tandatangan Petender : _________________________________________________
Nama Petender : _________________________________________________
Nama Dan Alamat Syarikat : _________________________________________________

(Dengan Cop)
_________________________________________________
_________________________________________________
Tarikh : _________________________________________________
Tandatangan Saksi : _________________________________________________
Nama Dan Alamat : _________________________________________________

(Dengan Cop)
_________________________________________________
_________________________________________________
Tarikh : _________________________________________________

8.4 SCHEDULE OF DELIVERY, INSTALLATIONS & COMMISSIONING
Item Description Of Equipment/Work Weeks
1 Delivery period of equipment from award of tender
2 Installation period required
3 Testing, Adjusting, Balancing and Commissioning (TABC)
TOTAL (WEEKS INDICATED IN FORM OF TENDER)
Notes: The whole work shall be completed before ( -Date- ), which is the date of
completion of the Main Contractor
Nama Petender : _________________________________________________

(Dengan Cop)
_________________________________________________
_________________________________________________
Tarikh : _________________________________________________
Nama Dan Alamat : _________________________________________________

(Dengan Cop)
_________________________________________________
_________________________________________________
Tarikh : _________________________________________________
----------------------------------------------- END OF SECTION 8.0 -------------------------------------------

SECTION 9.0
SCHEDULE OF RATES
Table of Contents
9.1 ELECTRIC CABLES .................................................................................1

9.2 PIPES .......................................................................................................2
9.3 FITTINGS .................................................................................................2
9.4 VALVES ....................................................................................................4
9.5 OTHERS ...................................................................................................5
SECTION 9.0 SCHEDULE OF RATES
The following rates for the various items of the work shall be used in the event of any
variation, addition or deduction in the quantities installed.
The rates shall include costs of supply, installation, incidentals, accessories, overheads and
profit. Such rates are subjected to the agreement of the Pengarah Kanan Cawangan
Kejuruteraan Mekanikal as to their reasonableness.
General description of work and materials shall be as stated in the appropriate section of the
Conditions of Contract and the Specification.
9.1 ELECTRIC CABLES
Size Price Per Meter Run ( RM )

(mm2) PVC Cable PVC Cable In Conduit
2.5
4.0

(mm2) Twisted Pair PVC Cable Twisted Pair PVC Cable In Conduit
2C x 2.5
4C x 2.5
2C x 4.0
4C x 4.0

(mm2) Amoured Cable Amoured Cable in Conduit
2.5
4.0
Schedule of Rates Copyright © CKM 2020 1

9.2 PIPES
Price Per Meter Run ( RM )

Size
dia. (mm) ABS Pipe
Stainless Steel HDPE PPR
Class 15
25
40
50
65
80
100
150
9.3 FITTINGS
Price Per Number ( RM )

Size
Stainless Steel
dia. (mm)
Elbows Tees Cross Tees
20
25
32
40
50
65


Size HDPE
dia.
(mm) Elbows Tees Cross Tees
20
25
32
40
50
65

Size
dia. PPR
(mm)
20
25
32
40
50
65

Size
dia. ABS Pipe Class 15
(mm)
20
25
32
40
50
65

Size dia. Reducing Tees

(mm) Schedule 80
Schedule 40 Seamless
Galvanised Steel Seamless
Galvanised Steel
Galvanised Steel
50 X 25
65 X 25
65 X 50
9.4 VALVES
Size Price Per Number ( RM )

(mm) Gate Valve Check Valve
25
40
50
65
150
Size Price Per Number ( RM )

(mm) Strainer Flexible Coupling
25
40
50
65
150

9.5 OTHERS
No. Supply and Install Size/ Type Unit Rate (RM)
1 Pressure Gauge a) 100 mm dia. per no.

b) 150 mm dia.
2 Pressure Switches per no.
3 Stainless Steel Non-Float per set

Electrodes c/w holder and
spacer
4 Flowswitch per no.
5 Stop Valve a) 25mm dia. per no.

b) 50mm dia. per no.
6 Float valve a) 25mm dia. per no.

c) 100mm dia. per no.
d) 150mm dia. per no.
7 Mechanical Joint Coupling a) 65mm dia. per no.

c) 150mm dia. per no.
8 Grease per kg
9 Neoprene Pad Per m2
10 Spring isolator (vibration) per no.
11 Pilot operated valve per no.
12 Manual key switch per no.
13 Lightning surge arrestor per no.

Nama Petender : _________________________________________________

(Dengan Cop)
_________________________________________________
_________________________________________________
Tarikh : _________________________________________________
Nama Dan Alamat : _________________________________________________

(Dengan Cop)
_________________________________________________
_________________________________________________
Tarikh : _________________________________________________
----------------------------------------------- END OF SECTION 9.0 -------------------------------------------


JABATAN KERJA RAYA MALAYSIA
CAWANGAN KEJURUTERAAN MEKANIKAL
IBU PEJABAT JKR MALAYSIA
TINGKAT 24-28, MENARA KERJA RAYA, BLOK G
JALAN SULTAN SALAHUDDIN
50480 KUALA LUMPUR
Telefon : (03) – 2610 8888

Faks : (03) – 2618 9510

Spec Pump Final

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JKR 20500-0083-20

Standard Technical Specification

3.1 GENERAL ................................................................................................ 1

SECTION 3.0 TECHNICAL SPECIFICATION

The Contractor shall submit method statement of installation recommended by

3.2 PUMP TYPE AND PERFORMANCE

The type of pump provided shall be End-suction/Single or Multi-stage/Horizontal Split

The performance of the pump selected shall be indicated on manufacturer's supplied

Technical Specification Copyright © CKM2020 1

Table 3.1.: Minimum Pump Efficiency (%)

3.3 PUMPING SYSTEM

(a) Constant speed booster pump system.

- Controller and devices.

- Controller and devices.

Technical Specification Copyright © CKM2020 2

(c) Variable speed booster pump set system.

- Controller and devices.

(d) Hydropneumatics pump set system.

- Controller and devices.

3.3.2 Booster Pump System

The pumps shall be selected to suit the intended type of service.

Technical Specification Copyright © CKM2020 3

3.3.3 Pump Operation

Local control shall perform as follows:

(a) Constant Speed Booster Pump System.

Technical Specification Copyright © CKM2020 4

v) Overflow water level of non-float electrode sensor shall be installed

(b) Variable Speed Booster Pump System.

The system shall be of variable speed pump system driven by frequency

The controller shall receive analog pressure signal form pressure

The variable pressure in the pipeline shall be trimmed to constant pipeline

Technical Specification Copyright © CKM2020 5

for system inspection for any pipeline breakage.

Dry-running protection shall be of no-float type using stainless steel

The operation of automatic variables speed pump system shall be based

The automatic variable speed pump system shall be equipped with

(c) Manual Mode

3.4 MATERIALS OF CONSTRUCTION

Technical Specification Copyright © CKM2020 6

3.4.3 Pump Shaft

3.4.4 Mechanical Seal

3.4.6 Flexible Coupling Unit

3.4.7 Vibration Isolation Material

Technical Specification Copyright © CKM2020 7

springs and concrete inertia base shall be used.

3.4.8 Bolt and Nuts

3.5 VARIABLE SPEED DRIVE

(b) Built-in programmable friction loss compensation which will automatically

(c) Automatic changeover of the pump to be controlled by the frequency converter

Technical Specification Copyright © CKM2020 8

3.6 PRESSURE VESSEL/HYDROPNEUMATICS TANK

3.7 PIPES, VALVES AND FITTINGS

Technical Specification Copyright © CKM2020 9

The pipework and fittings of Pumping System are as follows:

(b) Non-return valves shall be of non-slam type check valve conform to BS EN

Technical Specification Copyright © CKM2020 10

Technical Specification Copyright © CKM2020 11

3.8 ELECTRICAL SYSTEM

The following Act, Regulations and standards shall generally be applicable

(a) Electricity Supply Act 1990

(b) Electricity Regulation 1994

(c) Malaysian Standards (MS IEC 60364), where applicable

Where there is a discrepancy between standards, or differences in requirements