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UTTAR PRADESH JAL NIGAM

TENDER for

“SEWERAGE WORKS IN VINDHYACHAL ZONE OF MIRZAPUR (NPP) ”

UNDER

“AMRUT” SCHEME

VOLUME-II: CONDITION OF CONTRACT & TECHNICAL

SPECIFICATIONS

Cost of Tender Document : Rs. 20,000/- + (GST Extra) Earnest Money : Rs. 70,000,000/-

(Seventy lacs only) Date of Sale of Document : 17-07-2018 to 09-08-2018 Date of Submission Tender : 09-08-2018 up to 14:00 Hrs. Date of Opening of Tender : 10-08-2018 at 14:00 Hrs.

Project Manager, Ganga Pollution Prevention Unit,

U.P. Jal Nigam, Varanasi.

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INSTRUCTIONS TO BIDDERS

(1) To visit the site so as to ascertain the local conditions and availability of materials etc

and quote their rates accordingly. However, no claim shall be entertained even if the

site of works is changed/ modified.

(2) To study the schedule 'I' for materials to be supplied by the department and their issue

rate and other conditions.

(3) To quote the rates strictly as per language of price Schedule-„G‟ and bidders should not

quote or write any conditions which are not required in price schedule. The conditional

tender is liable to be rejected.

(4) To read carefully the specifications, terms and conditions, work out their own quantities

from the drawing before quoting the rates.

(5) To well acquaint themselves with the nature of work, the existing water mains,

incoming drainage and other utility service lines/obstacles etc. through the alignment,

they should include in their rates sufficient allowances to meet unforeseen expenses on

these grounds.

(6) The quantities are approximate and can vary up to any extent on either side and no

extra claim shall be entertained on this account. The contactors will be paid on the basis

of actual measurements of finished work, executed by him.

(7) No payment will be made for making the layout, construction of level pillars and

removal of debris from the alignment and grass etc. for the proper execution of work.

(8) Final payment shall be made after proper testing as per satisfaction of Engineer.

(9) ISS/ U.P.Jal Nigam/ PWD detailed specifications shall be followed during execution of

work/ recording measurements and payment etc.

(10) The tender shall be issued in duplicate but is to be submitted in one copy only

containing all necessary information therein as asked for.

(11) The tenderers should go through all the details carefully including annexure Form No. 2

L.S.G.E.D./ U.P. J.N. & drawings etc. mentioned here-in-under & sign each page

before submitting.

(12) The field survey, Hydraulic design and structural design for each and every individual

unit of work shall have to be done by the contractor and duly approved by the

department.

(13) The working pressure shall be as prescribed in the technical specifications and factory

test pressure shall be as per latest amendment of relevant IS code for the pipe to be

supplied by the contractor as per approved vendor list by the competent authority.

(14) The earnest money of as specified in tender notice for the various packages must be

enclosed with the tender in the shape of FDR/ NCR/ CDR of a Nationalized bank/ Post

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Office Saving Account duly pledged in the name of Project Manager, Ganga Pollution

Prevention Unit, U.P. Jal Nigam, Varanasi and shall be sealed in a separate envelope.

(15) Corrections in the bid should be noted over and initialed at the place of corrections.

(16) Specifications, conditions, schedules, regulations and safety measures and drawings of

bidding document constitute an integral part of the bid.

(17) Negligence of the bidder in preparing bid confers no right to withdraw the bid after it

has been opened and before expiry of stipulated validity period.

(18) The bid along with enclosures, drawings and technical literature should be in English

only.

(19) Bids should be kept valid for acceptance for a period of 120 days from the day

bids are opened.

(20) The bidding document shall be governed and interpreted according to the laws of the

Union of India.

(21) All bidders are urged to submit promptly, written requests, on matters where

clarifications or additional information are desired before per-bid meeting. No

extension in due date of submission of bids will be allowed on this ground.

(22) Bids should be responsive to the instructions to bidders and the conditions of contract

in the bid document.

(23) Bidder shall not be under a declaration of ineligibility for corrupt and FRAUDULENT

practices issued by any authority.

(24) All bidders shall include the following information and documents with their bids.

(a) Copies of original documents or notarized copy defining the constitution or legal

status, place of registration and principal place of business, written power of

attorney of the signatory of the bid to commit the Bidder.

(b) Total monetary value of construction work performed for each of the last five

years.

(c) Experience in works of similar nature and size for each of the last five years and

details of works under-way or contractually committed, and clients who may be

contacted for further information on those contracts.

(d) Major items of construction equipment proposed to carry out the contract.

(e) Qualification and experience of key site management and technical personnel for

the contract.

(f) Reports on the financial standing of the bidder, such as profit and loss statement

and auditors reports for the last five years.

(g) Evidence of adequacy of working capital for this contract (access to line of credit

and availability of other financial resources.

(h) Authority to seek references from the bidder‟s bankers.

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(i) Information regarding any litigation or arbitration resulting from contracts

executed by the Bidder in last five years or currently under execution. The

information shall include the names of the parties‟ concerned disputed amount,

cause of litigation and matter in dispute

(j) Proposals for subcontracting component of the works amounting to more than 20%

of the bid price for each, the qualification and experience of the identified sub-

contractors in the relevant field should be annexed.

(k) To qualify for the contract, bidder should stand qualified as per norms/ criteria

given in prequalification bid.

NOTE: THE CHIEF ENGINEER/ GENERAL MANAGER/OFFICER INVITING TENDERS

RESERVE THE RIGHT TO ACCEPT OR REJECT ANY OR ALL BIDS WITHOUT

ANY EXPLANATION TO BIDDERS OR ANNUL THE TENDERING PROCESS.

General Manager Signature of Contractor

U.P. Jal Nigam

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DEFINITIONS AND INTERPRETATIONS

1. TERMS: The important terms, which shall be used in the contract Documents are defined

herein. It shall be applicable to both the singular and plural number and masculine/ feminine in

gender.

2. ADDENDA AND CORRIGENDA: Written or graphic notices issued by the department prior

to submission of the tender to modify or interpret the Contract Documents.

3. TENDER/ BID: The offer or proposal of the bidder, submitted in the prescribed form to set-

forth the prices for the work to be carried out and the details thereof.

4. TENDERER/ BIDDER/ CONTRACTOR/ SUPPLIER: Any person, firm, corporation or

organization submitting a Tender or execute the work after signing the agreement with the

department.

5. CHAIRMAN: Chairman shall mean the Chairman, U.P. Jal Nigam, Govt. of Uttar Pradesh

here-in-after called the Chairman.

6. CHIEF ENGINEER: "The Chief Engineer" shall' mean the Chief Engineer (Varanasi Zone),

U.P. Jal Nigam, Varanasi here-in-after called the Chief Engineer.

7. SUPERINTENDING ENGINEER: The Superintending Engineer or General Manager shall

mean Superintending Engineer / General Manager, (Ganga Pollution Prevention Unit). U.P. Jal

Nigam, Varanasi.

8. EXECUTIVE ENGINEER: The Executive Engineer/ Project Manager shall mean the Project

Manager, Ganga Pollution Prevention Unit, U.P. Jal Nigam, Varanasi.

9. ENGINEER: shall mean the Engineer officer (or any other competent person appointed by the

Engineer-in-charge, to act in addition or replacement of the Engineer) who shall supervise the

execution of the works and administering the contract and be in-charge of the work on behalf of

the Engineer- in-charge i.e Project Manager shall mean the Project Manager, Ganga Pollution

Prevention Unit, U.P. Jal Nigam, Varanasi hereinafter called the Engineer.

11. ENGINEER-IN-CHARGE: It shall mean the Officer signing the contract on behalf of U.P.

Jal Nigam.

12. COMPETENT AUTHORITY: It shall mean the next higher authority signing the contract.

13. ENGINEER'S REPRESENTATIVE: The Engineer's representatives shall mean the Project

Engineer (Assistant Engineer), Assistant Project Engineer (Junior Engineer), Ganga Pollution

Prevention Unit, U.P. Jal Nigam, Varanasi. Herein after called the Engineer's representatives.

14. CONSULTANT: The firms or persons whose expertise has been sought by the Chairman for

the proper execution of work stipulated in the contract bond hereinafter called the consultant.

15. CONTRACTOR'S REPRESENTATIVES: Any competent person/ persons such as

Engineer/Sub-Engineer/ Work Agent/Supervisor /Foreman etc. as may be necessary duly

authorized by the contractor in writing & approve by the Engineer for the proper execution of

work/works.

16. DEPARTMENT/U.P JAL NIGAM: It shall mean the U.P. Jal Nigam hereinafter called the

department.

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17. SUB-CONTRACTOR: A sub-contractor is a person, firm corporation or organization who has

a direct contract with the main Contractor to perform parts of the works at the site, whose entity

is duly approved by the General Manager.

18. CONTRACT TIME: The number of consecutive calendar months for completion of the work

as stipulated in schedule "F" here in annexed.

19. STANDARDS: It refers to Indian-Standards issued by the Bureau of Indian Standards. All

materials and workmanship which form part of tender documents shall conform to the

relevant IS code or its latest amendments Items not covered under the IS code shall be executed

as per standard code of practice of U.P. Jal Nigam/P.W.D/U.P.Irrigation/CPWD.

20. CONTRACTOR'S EQUIPMENT: Contractor's equipment means all equipments and

appliances such as mixer, vibrator, pumps, chain pulley block, sieves and fabricated device

excavators; crane etc. for proper execution, completion and maintenance of works.

21. NOTICE OF AWARD: The written notice by the Chief Engineer to the successful Bidder for

signing the agreement on the format herein annexed in stipulated time.

22. NOTICE TO PROCEED: The written notice by the Engineer to the Contractor authorizing

him to proceed with the work. The date mentioned in the letter shall be the date of start of the

work.

23. VARIATION ORDER: A written order to the Contractor signed by the authorizing an

addition, deletion or revision in the quantum of work/drawings provided in the tender

documents.

General Manager Signature of Contractor

U.P. Jal Nigam

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GENERAL RULES AND GUIDE LINES

1.0 All work proposed for execution by contract will be notified in a form of invitation to tender

pasted in public places and signed by the officer inviting tender or by publication in News

papers or posted on website as the case may be. Tender, documents will be sold to only

registered contractors as defined in Tender notice.

2.0 CLASSIFICATION OF TENDERERS:

2.1 If the tender is made by an individual it shall be signed by the individual with his full

name and current address underneath. If the tender is made by a proprietary firm, it shall

be signed by the proprietor with his full name and name of his firm with its current

address underneath.

2.2 If the tender is made by a firm in partnership, it shall be signed by all partners of the firm

with their full names and current addresses, or by a partner holding the power of

attorney. A certified copy of the power of attorney, partnership, deed, address of the firm

and the full names and address of all the partners of the firm shall also accompany the

tender.

2.3 If the tender is submitted by a limited company or a limited corporation, it shall be

signed by a duly authorized person holding the power of attorney. Such limited company

or corporation may be required to furnish satisfactory evidence of its existence before the

contract is awarded. A copy of said company‟s articles of Association should be enclosed

to substantiate its claim.

2.4 All witnesses and sureties shall be of persons of status and probity and their full names,

occupations and addresses shall be stated below their signatures. All signatures in the

tender document shall be dated.

3.0 Receipts for payment made on account of work, when executed by a firm, must also be signed

by all the partners, except where contractors are described in their tender as a firm, in which

case the receipts must be signed in the name of the firm by one of the partners, or by some other

person having due authority to give effectual receipts for the firm.

4.0 Any person who submits a tender shall fill up the usual printed form, stating at what rate he is

willing to undertake each item of the work. Tenders, which propose any alteration in the work

specified in the said form of invitation to tender, or in the time allowed for carrying out the

work, or which contain any other conditions of any sort, including conditional rebates, will be

summarily rejected.

5.0 In case the lowest tendered amount (worked out on the basis of quoted rates) of two or more

contractors is same, then such lowest contractors may be asked to submit sealed revised offer

quoting rate of each item of the schedule of quantity for all sub sections/sub heads as the case

may be, but the revised quoted rate of each item of schedule of quantity for all sub sections/sub

heads should not be higher than their respective original rate quoted already at the time of

submission of tender. The lowest tender shall be decided on the basis of revised offer.

6.0 If the revised tendered amount (worked out on the basis of quoted rate of individual items) of

two or more contractors received in revised offer is again found to be equal, then tender shall be

rejected and fresh tender shall be invited.

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7.0 In case any one or all the lowest contractors refuse to submit revised offers, then tenders are to

be recalled after forfeiting 50% of EMD of such lowest contractors and contractor, whose

earnest money is forfeited because of non-submission of revised offer, or quoting higher

revised rate(s) than their respective original rate quoted already at the time of submission of his

bid shall not be allowed to participate in the retendering process of the work.

8.0 The officer inviting tender or his duly authorized assistant will open tenders in the presence of

any intending contractors who may be present at the time, and will enter the amounts of the

several tenders in a comparative statement in a suitable form. In the event of a tender being

accepted, a receipt for the earnest money shall there upon be given to the contractor.

9.0 The officer inviting tenders shall have the right of rejecting all or any of the tenders and

will not be bound to accept the lowest or any other tender.

10. The memorandum of work tendered for in case of Percentage Rate Tenders, only percentage

quoted shall be considered. Any tender containing item rates is liable to be rejected. Percentage

quoted by the contractor in percentage rate tender shall be accurately filled in figures and

words, so that there is no discrepancy. The procedure in above paragraphs for valuating and

deciding shall also apply.

11. In the case of any tender where unit rate of any item/items appear unrealistic, such tender will

be considered as unbalanced and in case the tenderer is unable to provide satisfactory

explanation, such a tender is liable to be disqualified and rejected.

12. The contractor shall comply with the provisions of the Apprentices Act 1961, and the rules and

orders issued thereunder from time to time. If he fails to do so, his failure will be a breach of

the contract and the Superintending Engineer/Executive Engineer may in his discretion, without

prejudice to any other right or remedy available in law, cancel the contract. The contractor shall

also be liable for any pecuniary liability arising on account of any violation by him of the

provisions of the said Act

13 ELIGIBILITY AND QUALIFICATION REQUIREMENTS

13.1. SALE OF TENDER DOCUMENTS IS RESTRICTED TO ELIGIBLE BIDDERS

ONLY:

To be eligible for award of contract, bidders shall provide evidence satisfactory to the

employer of their eligibility, and of their capability and adequacy of resources to carry

out the contract effectively. To this end, all intending bidders shall submit the necessary

information in proof of their eligibility before contract document are sold to them.

13.2 The bidders only who are registered in a particular category of works as per UP Jal

Nigam norms, which can be seen in the office on any working day, shall be allowed to

participate in bidding. For tenders of works more than RS. One crore the bidder must

emerge successful in pre-qualification bid.

13.3 Tenderes / bidders should produce original or notarized copies of following

documents along with their bids:

A) Copies of documents defining the constitution in or legal status, place of registration and

principal place of business of the company or firm or partnership of each party there to

constituting the bidder.

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B) Details of the experience and past performance of the bidder on works of a similar nature

within the past five years, and details of current work in hand and other contractual

commitments, on the formats prescribed here with the tender document.

C) Major items of construction plant immediately available with the tenderer for use in

carrying and the contract in the format prescribed.

D) The qualifications and experience of key personnel proposed for administration end

execution of the contract, on the format prescribed in the document.

E) Reports on the financial standing of the bidder (or of each partner) such as profit and loss

statements, balance sheets and auditor's report for the past five years, an estimated

financial projection for the next two years and an authority from the bidder seek

references from the bidder's bankers in addition to the information regarding financial

position, solvency and capability of the firm.

14. (a) SITE VISIT

The bidder is advised to visit and examine the site or works and its surroundings and obtain for

himself on his own responsibility, all information that may be necessary for preparing the bid

and entering in a contract. The cost of visiting the site shall be at bidder's own expense.

The bidder and any of his personnel or agents will be granted permission by the employer to

upon the land for the purpose of such inspection, but only upon the express condition that the

bidder, his personal or agents, will release and identify the employer and his personnel and

agents against liability in respect thereof and will be responsible for personal injury (whether

fatal or otherwise), loss of or damage to property and any other loss, damage-costs and

expenses however caused, which but for the exercise of such permission would not have arisen.

"Further, the contractor shall conduct all such tests and carry out all such investigations, at his

own cost, as may be required by him or by the engineer to ascertain bearing capacity of soils at

different points for founding structures and various other data on hydrological and subsurface

conditions relevant to the works and shall make available to the engineer the results of all such

tests and investigations conducted by him. The proposals and designs of the contractor shall be

based on results and finding of tests and investigations conducted by him as above subject

approval would not absolve the contractor in any way, from any of his responsibilities

regarding quality, safety, life and utility of works.

(b) PRE-BID MEETING:

All bidders who have purchased the bid documents are encourage to attend the pre-

bid meeting to be held at indicated place and time. Venue office of General Manager,

Ganga Pollution Prevention Unit, U.P.Jal Nigam, Varanasi on dated 23.07.2018 at

12:30 P.M. Er. Satish Kumar Rai, General Manager Phone No.09473942688, e-mail –

gmgangavns@gmail.com. If the efficacy of the existing arrangement in such areas is

found satisfactory then those relevant works from such areas would require to be

deleted from the scope of tender document such details will be discussed in the Pre-

bid meeting. This information and also decision on the suggestions that may be

received in the pre-bid meeting shall be made available on the Jal Nigam website

inform of addendum / amendment to be the bid documents. If addendum / amendment

required shall be deemed to be part of the bid documents. Therefore the bidders are

strongly advised to prepare their bids only after incorporation of the addendum /

amendment so issued.

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15. BIDDING DOCUMENTS

The e-tender document for the e-tender under reference comprises of following two parts:

PART-I: Technical & Financial Evaluation cum Technical Bid (Pre-qualification bid).

This part will comprise of:

(i) Fee details – It includes of the cost of tender document and prescribed earnest money in

prescribed form. A scanned copy of e-tender document fee and RTGS receipt for EMD in

PDF format must be uploaded along with Part-I of the e-bid.

(ii) Qualification Details – It includes copies of required documents in PDF format establishing

that the bidder is qualified to perform the contract if his/her bid is accepted and the bidder has

financial & technical capability necessary to perform the contract and meets the criteria

outlined in „requirements of pre-qualification‟ and fulfil all the conditions of the contract and

elsewhere in the tender.

PART-II: Financial bid / Price bid Language of e-bid:

The e-bid prepared by the bidder, as well as all correspondence and documents relating to the

e-bid, exchanged by the bidder and the department shall be written either in English or Hindi

language. The correspondence and documents in Hindi must be accompanied by

embedded/separate Hindi font files. Only English numerals shall be used in the e-bid. If any

other language is used, it shall be accompanied by a translation into English/Hindi language,

duly signed and certified by bidder, as the true translation, which will be used for interpreting

the information.

Amendment(s) of e-Tender Document :

At any time prior to the deadline for submission of e-bid, the department may, for any

reason, whether at its own initiative or in response to a clarification requested by a

prospective bidder, modify the e-tender document by amendment(s). For such

amendment(s) written „Addendum/Corrigendum(s)‟shall be issued copy of which shall be

simultaneously uploaded on the e-procurement website https://etender.up.nic.in and U.P.

Jal Nigam's website www.upjn.org. All such Addendum/corrigendum(s) shall become an

integral part of e-tender document. The relevant clause(s) of the e-tender document shall

be treated as amended accordingly.

It shall be the sole responsibility of the prospective bidders to check the website

http://etender.up.nic. in regularly for amendment(s), if any, in the e-tender document,

failing which the responsibility of any error arising out of such negligence shall rest with

the bidder.

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In order to allow prospective bidders a reasonable time to take the amendment(s) into

account in preparing their e-bids, U. P. Jal Nigam, at its discretion, may extend the

deadline for the submission of e-bids. Such extension(s) shall be uploaded on the e-

procurement website http://etender.up.nic.in, and department's website www.upjn.org.

Bid Validity period: e-bid shall remain valid for 120 days after the actual date of opening

of Technical & Financial Evaluation Cum Technical bid. In case, however, the day upto

which the bid is to remain valid happens to be a public holiday/is declared public holiday

for Govt. offices, the bid shall remain valid for acceptance till the next working day. In

exceptional circumstances, the department may solicit the bidder's consent to an extension

of the period of e-bid validity. The request and the response thereto shall be made in

writing. A bidder may refuse the request without forfeiting his/her e-bid security (EMD).

A bidder granting the request will not be required nor permitted to modify his/her e-bid.

Forfeiture of EMD : Earnest money deposit shall be forfeited

If the bidder (a) withdraws his/her e-bid during the period of e-bid validity as specified above

or (b) does not accept the correction of errors or (c) modifies its e-bid price during the period

of e-bid validity.

In case of a selected bidder, if the bidder fails to sign the contract with the department.

16. PREPARATION & SUBMISSION OF BID

16.01 The tender/bid submission module of e-procurement website https://etender.up.nic.in shall

enable the bidders to submit their duly filled e-bids online in response to this e-tender from

the bid submission start date and time till the bid submission end date and time stipulated in

the e-tender schedule.

16.02 Bidders may please note very carefully that till such time that a fresh agreement is drawn up

embodying the agreed conditions, the conditions given in this tender document shall govern

the contract.

16.03 Bidders are required to examine carefully site conditions, all instructions, forms, terms &

conditions and specifications in the e-tender document and prepare the tender in accordance

with requirements thereof. Failure to furnish all information as per the e-tender document or

submission of e-bid not responsive to the e-tender document in every respect will be at the

bidder's risk and shall result in rejection of the said e-bid.

16.04 A bid deviating in any respect from the condition etc. specified in this tender document or

found to be containing terms/conditions other than those in tender documents, shall be taken

as a conditional bid and shall be liable for rejection.

16.05 Format of e-bid: The bidder shall prepare one electronic copy of the Technical & Financial

evaluation cum Technical bid e-bids (comprises of Vol-I) and financial e-bid (Vol-II) each

separately.

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16.06 Any corrections in the documents/bank instruments, if required at all, shall be countersigned

by the bidder/bank official.

16.07 The documents designated to be uploaded shall be physically signed at all places indicated.

16.08 Signing of e-bid: The e-bid document shall be digitally signed, at the time of loading, by the

bidder or a person or persons duly authorized to bind the bidder to the contract. All the

pages/documents of the e-bid that are to be uploaded shall be digitally signed by the person

authorized to sign the e-bid. The individual, physically and digitally signing the tenders

and/or other documents, should be either :

The sole proprietor of the firm or constituted attorney of such sole proprietor.

Constituted attorney of the firm, if it is a company under the meaning of Company Law, a

scanned copy of the power of attorney should be attached.

Managing Director/President/Chairperson/Company Secretary in case of a Limited Co.

having authorization for committing the company from its Board of Director or as is required

under Company Law.

President or Secretary in case of registered co-operative society having such power through

Law/Bylaws or by special resolution.

Scanned copy of the sole proprietorship declaration/power of attorney/ authorization /

resolution / bylaws, as the case may be, must be submitted with Part-I of e-bid. This document

shall not be more than one year old as on date of opening of Technical & Financial evaluation

cum Technical bid. It should also contain address and mobile number of authorized person.

For participating in e-bid through the e-tendering system it is necessary for the bidders to be

the registered users of the e-procurement website https://etender.up.nic.in. The bidders must

obtain a User Login ID and Password by registering themselves with U.P. Electronics

Corporation Ltd., 10, Ashok Marg, Lucknow, if they have not done so previously for

registration.

In addition to the normal registration, the bidder has to register with his/her digital signature

certificate (DSC) in the e-tendering system and subsequently he/she will be allowed to carry

out his/her e-bid submission activities. Registering the digital signature certificate (DSC) is a

one-time activity. Before proceeding to register his/her DSC, the bidder should first log on to

the e-tendering system using the user login option on the homepage with the login ID and

Password with which he/she has registered.

For successful registration of DSC on e-procurement website https://etender.up.nic. in the

bidder must ensure that he/she should possess Class-2/Class-3 DSC issued by any certifying

authorities approved by Controller of Certifying Authorities, Government of India, as the e-

procurement website https://etender.up.nic.in is presently accepting DSC issued by these

authorities only. The bidder can obtain user login ID and perform DSC registration exercise

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above even before e-bid submission date starts. The department shall not be held responsible

if the bidder tries to submit his/her e-bid at the moment before end date of submission but

could not submit due to DSC registration problem.

The bidder can search for active tenders through "search active tenders" link, select tender in

which he/she is interested in and then move it to 'My Tenders' folder using the options

available in the e-bid submission menu. After selecting the tender, for which the bidder

intends to e-bid, from "My tenders" folder, the bidder can place his/her e-bid by clicking "pay

online" option available at the end of the view tender details form. Before this, the bidder

should download the e-tender document and price schedule/bill of quantity (BOQ) and study

them carefully. The bidder should keep all the documents ready as per the requirements of e-

tender document in the PDF format.

Next the bidder should upload the technical e-bid documents for fee details (e-tender fee and

EMD), Qualification details. Before uploading, the bidder has to select the relevant digital

signature certificate. He/she may be prompted to enter the digital signature certificate

password (PIN), if necessary. For uploading, the bidder should click "browse" button

against each document label in technical and financial schedules/packets and then

upload the relevant PDF files already prepared and stored in the bidder's computer. The

required documents for each document label of technical (fee details, qualification details, e-

bid form and technical specification details) and financial (e-bid form and price

schedule/BOQ) schedules/packets can be clubbed together to make single different files for

each label.

The bidder should click "Encrypt" next for successfully encrypting and uploading of required

documents. During the above process, the e-bid documents are digitally signed using the DSC

of the bidder and then the documents are encrypted/locked electronically with the DSC's of

the bid openers to ensure that the e-bid documents are protected, stored and opened by

concerned bid openers only.

After successful submission of e-bid document, a page giving the summary of e-bid

submission will be displayed confirming end of e-bid submission process. The bidder can

take a printout of the bid summary using the "print" option available in the window as an

acknowledgement for future reference.

The bidders are strongly advised to undergo training regarding submitting of e-tenders at U.P.

Electronics Corporation Ltd., 10, Ashok Marg, Lucknow at any working day, which is free of

cost. The training given to them regarding submitting of e-tenders is to be followed strictly

while submitting their bids. Notwithstanding the contents of relevant paragraphs regarding

bid submission / withdrawal, training given by U.P. Electronics Corporation Ltd., regarding

submission/withdrawal/ re-submission of e-tenders will be final. Responsibility of having

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adequate knowledge of the process and latest changes incorporated, if any, rests with the

bidder and the department shall not, in any manner, be responsible for any error or non-

submission/withdrawal of a bid on this account.

Deadline for submission of e-bid: e-Bid (Part-I & Part-II Financial Bid) must be

submitted/uploaded by bidders at e-procurement website https://etender.up.nic.in not later

than the time specified on the prescribed date. The server time displayed in the Bid

management window on the e-procurement website https://etender.up.nic.in will be the time

by which the e- bid submission activity will be allowed till the permissible date and time

scheduled in the e-tender. Once the e-bid submission date and time is over, the bidder cannot

submit his /her e-bid. The department may, at its discretion, extend this deadline for

submission of e-bid by amending the e-bid document, in which case all rights and obligations

of the department and bidders previously subject to the deadline will thereafter be subject to

the deadline as extended. Bidders are advised to start bid submission process well in advance

so that they can submit their bids in time. Delay in submission of bid due to any reason during

e-bid submission process, shall be responsibility of the bidder.

17. Withdrawal and Resubmission of e-bid :

At any point of time, a bidder can withdraw his/her e-bid submitted online before the bid

submission end date and time. For withdrawing the bidder should first log in using his/her

login ID and Password and subsequently by his/her digital signature certificate on the e-

procurement website https://etender.up.nic.in. The bidder should then select "My bids"

option in the bid submission menu. The page listing all the bids submitted by the bidder

will be displayed. Click "View" to see the details of the bid to be withdrawn. After

selecting the "bid withdrawal" option the bidder has to click "Yes" to the message "Do

you want to withdraw this bid?" displayed in the bid information window for the selected

bid. The bidder also has to enter the bid withdrawing reasons and upload the letter giving

the reasons for withdrawing before clicking the "Submit" button. The bidder has to

confirm again by pressing "OK" button before finally withdrawing his/her selected e-bid.

No e-bid may be withdrawn after the deadline for submission of e-bids during the period

of e-bid validity. If a bidder desires to withdraw his tender before the expiry of the

validity period, the department may agree to allow such withdrawal but in such a case the

earnest money shall be forfeited. If the department does not allow such withdrawal and

accepts the tender and the bidder fails to perform his part of the contract, the earnest

money deposited shall be forfeited besides other consequences for breach of the contract.

The bidder can re-submit his/her e-bid as when required till the e-bid submission end date

and time. The e-bid submitted earlier will be replaced by the new one. The earnest money

details submitted by the bidder earlier will be used for the revised tender and the new bid

15

summary generated after the successful submission of the revised tender will be

considered for evaluation purpose. For resubmission, the bidder should first log in using

his/her login ID and Password and subsequently by his/her digital signature certificate on

the e-procurement website https://etender.up.nic.in. The bidder should then select "My

bids" option in the bid submission menu. The page listing all the bids submitted by the

bidder will be displayed. Click "View" to see the detail of the e-bid to be resubmitted.

After selecting the "bid resubmission" option, click "Encrypt & upload" to upload the

revised e-bids documents.

The bidders can submit their revised e-bids as many times as required by uploading their

e-bid documents within the scheduled date & time for submission of e-bids.

No e-bid can be resubmitted subsequently after the deadline for submission of e-bids. No

request for consideration of any alteration in finally submitted offer shall be entertained.

In case of any change in Cash assets, Technical staff, Tools & Plants or change in

partners, or constitution of a Company, address of communication or telephone nos. etc.

after submission of documents the same shall be intimated to the Project Manager,

Ganga Pollution Prevention Unit, U.P. Jal Nigam, Bhagwanpur Varanasi (Mob. No.

9473942689) / General Manager, Ganga Pollution Prevention Unit, U.P. Jal Nigam,

Bhagwanpur Varanasi (Mob. No. 9473942688) immediately.

18. OPENING OF TECHNICAL& FINANCIAL EVALUATION

CUM TECHNICAL BIDS

Process of e-bid opening shall take place in the Office of the General Manager, Ganga

Pollution Prevention Unit, U.P. Jal Nigam, Bhagwanpur Varanasi on the date of opening

of Technical & Financial evaluation cum Technical bids (Pre-qualification bids)

stipulated in the e-tender schedule, in presence of the bidders‟ representatives who chose

to be present.

In the event of the specified date of e-bid opening being declared a holiday for the

department, the e-bids shall be opened at the appointed time and place on the next

working day.

The bidders‟ representatives who are present shall sign a register evidencing their

attendance.

The envelopes containing e-tender document fee receipt and EMD and other required

documents, received up to the prescribed date and time, shall be opened at mentioned

place

The bidders‟ names and the presence or absence of requisite e-tender document fee

receipt and EMD in the prescribed format and other required documents as detailed

above, will be announced at the opening.

16

Thereafter the department will open all Technical & Financial evaluation cum

Technical (pre-qualification) e-bids through E-Tender procurement solution (e-

procurement website https://etender.up.nic.in) in the presence of bidders‟ representatives

in the General Manager, Ganga Pollution Prevention Unit, U.P. Jal Nigam,

Bhagwanpur Varanasi. Technical & Financial evaluation cum Technical (Pre-

qualification) e-bids of only those bidders‟, whose e-tender document fee, EMD and other

required documents are found in order, shall be accepted.

The department will prepare minutes of Technical & Financial evaluation cum Technical

(pre-qualification) e-bid opening.

Clarification of e-Bid: During evaluation of e-bid, the department may, at its discretion,

ask the bidder for a clarification of his/her e-bid. The request for clarification shall be in

writing. An appropriate reply within the stipulated time shall be obligatory for the bidder.

Evaluation Criteria: The department will examine all accepted Technical &Financial

evaluation cum Technical e-bids to determine they are complete, whether they meet all

the conditions of the contract, whether all the required documents have been furnished as

detailed in tender document, whether the documents have been properly physically and

digitally signed as required, and whether the e-bids are generally in order. Any e-bid or e-

bids not fulfilling these requirements shall be rejected.

It shall be the discretion of the department to decide as to whether an e-bid fulfils the

evaluation criterion mentioned in this e-tender or not. Decision of the department on

matter of technical & financial evaluation results will be final and binding to all

participants. No enquiry/clarification shall be entertained on the evaluation results neither

the department will remain bound to provide any such clarifications on such results.

The bidders are advised not to mix financial bid documents with the PDF documents

uploaded for technical bid. The e-bids of those bidders who have uploaded financial bid

document with the pre-qualification (technical) bid or kept it in envelope of EMD will be

out rightly rejected.

19. OPENING OF FINANCIAL E-BID

After evaluation of Technical & Financial evaluation cum Technical (pre-qualification) e-

bid, through the evaluation committee, the department shall notify those bidders whose

technical e-bids were considered non responsive to the conditions of the contract and not

meeting the technical specifications and qualification requirements indicating that their

financial e-bids will not be opened. The Department will simultaneously notify the

bidders, whose technical e-bids were considered acceptable to the department. The

notification may be sent by e-mail provided by bidder.

17

The date, time and place for the opening of financial bids will be uploaded on the e-

procurement website https://etender.up.nic.in and communicated to the technically

qualified bidders through e-mail provided by the bidder.

The financial e-bids of technically qualified bidders shall be opened in the presence of

bidders‟/their representatives who choose attend. The name of bidders, price quoted will

be announced at the meeting.

The department will prepare the minutes of the financial e-bid opening.

A substantially responsive bid is one which conforms to all the terms conditions

and specification of the bidding documents, without material deviation or

reservation. A material deviation or reservation is one:-

a) Which effects in any substantial way of the scope, quality or performance of

the works.

b) Which limits, in any substantial way inconsistent with the bidding

documents, the employer‟s rights or the bidder‟s obligations under the

contract; or

c) Whose rectification would affect unfairly the competitive position of other

bidders presenting substantially responsive bids.

If a bid is not substantially responsive, it will be rejected by the Employer, and may

not subsequently be made responsive by correction or withdrawal of the non-

conforming deviation or reservation.

20. LIST OF DOCUMENTS TO BE SUBMITTED OFFLINE

A sealed envelope containing the original receipt of e-tender document fee and

RTGS for EMD along with original copy of the documents specified in clause 3.9(a)

to (f) above.

This envelope shall be addressed to General Manager, Ganga Pollution

Prevention Unit, U.P. Jal Nigam, Bhagwanpur, Varanasi and shall be

superscribed “E-Tender Fee & Earnest Money : ―Sewerage works in

Vindhyachal zone of Mirzapur(NPP) In Vindhyachal, District Mirzapur,

U.P. Under AMRUT On Dbot Mode.‖

This envelope must be submitted at the Office of the General Manager,

Ganga Pollution Prevention Unit, U.P. Jal Nigam, Bhagwanpur, Varanasi

on or before the date and time specified in e-tender schedule.

21. LIST OF DOCUMENTS TO BE SUBMITTED ONLINE ON E-TENDERING WEBSITE

(A) Part-I : Technical & Financial evaluation cum Technical(Pre-Qualification) Bid:

For Technical & Financial evaluation cum Technical Part-I of e-bid, on or before the

18

prescribed date specified in e-tender schedule, please upload digitally signed scanned

notary attested photocopies (in PDF format) of:

Original receipt of RTGS for e-tender document fee and EMD.

The partnership deed or sole proprietorship declaration or company‟s registration

certificate/ memorandum of association as the case may be.

The sole proprietorship declaration/power of

attorney/authorization/resolution/bylaws, as the case may be, in favour of person

authorized to sign the tender documents physically and digitally as described above.

It shall not be more than one year old on the date of opening of Technical & Financial

evaluation cum Technical bid and shall contain address and mobile number of

authorized signatory.

Letter of application (typed on letter head of bidder as per format attached).

Declaration Form-I A for Earnest Money Deposit (as per Form-1 (f) of Volume-I).

Declaration Form-I B for Affidavit of bid validity (typed on non-judicial stamp paper

of Rs. 100/- and verified by Notary Public as per Form-1(c) of Volume-I).

Declaration Form No. I C Affidavit (typed on non judicial stamp paper of Rs. 100/-

and verified by Notary Public as per Form-1d of volume-I)

Declaration Form No. II Affidavit for fulfilling the terms & conditions of the contract

(typed on non judicial stamp paper of Rs.100/-& verified by Notary Public as per

Form1(b) of Volume-I)

Application Form (1): General Information of Bidder (as Format-1).

Application Form (2): Annual Turnover (as per Format 3).

Application Form (3 a): Details of Contracts of Similar Nature and Complexity taken

up during last 10 years (as per Format 4A).

Application Form (3 b): Abstract of Contracts of Similar Nature and Complexity (as

per Format 4B).

Experience certificate Form-4 in support of bidder‟s work experience (of each work

cited in Form 3 (a)) issued by an officer not below the rank of Executive Engineer of

client organization containing Agreement No., Date of start, Date of completion and

Value of work done.

Registration Certificate issued by Materials Manager, U.P. Jal Nigam, Lucknow.

The last Trade Tax assessment order / proof of VAT registration, TIN number and

Income tax assessment order from Income Tax Dept. for last 4 yrs.

PAN card of the firm/Sole proprietor.

Application Form (5): Statement of Financial Capability (as per Format-7).

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Audited Balance Sheet counter signed by C.A. for last five financial years clearly

indicating turnover and T.D.S.

Application Form (6): Litigation History (as per Format-10).

Application Form (7): Affidavit for List of Staff with bidder (typed on non judicial

stamp paper of Rs.10/- & verified by Notary Public as per Format-5B).

Application Form (8): Affidavit for List of Tools and Plants with bidder (typed on

non judicial stamp paper of Rs.10/- & verified by Notary Public as per Format-6).

Character Certificate from District Magistrate concerned on P.W.D. T-4 Format /

proof of applying for P.W.D. T-4 certificate from District Magistrate. (Applicable

only in case of sole propriety firm or individual bidder/vendor)

Solvency Certificate issued by District Magistrate / Nationalized Bank.(Format-12)

All the schedules given in the tender document.

The bidder shall provide a separate table giving details of taxes, duties, levies and

other applicable taxes considered by him and included in the prices offered. Service

tax shall not be included in the prices and the owner if applicable against proof of

applicability and payment shall pay the same separately.

(B) Part-II : Financial bid /Price bid : For Financial Part-II of e-bid, on or before the

prescribed date specified in e-tender schedule, please upload digitally signed duly filled

Schedule of Works / BOQ in Pdf format.

Note : If any of the documents mentioned in Part-I sl. 1 to 25 above is

uploaded without attestation of notary public, original of the same shall have to be

presented by concerned bidder for verification on the date of opening of Part-I, failing

to which the bid shall be rejected.

22. VALIDITY OF TENDER:

The tender shall be valid for a period of not less than 120 days from the date of

opening of the tender.

23. CANVASSING:

Any political/administrative pressure by the bidder/vendor or canvassing directly or

indirectly in favor of his offer will render his tender liable to rejection. Such bidders

will be debarred from participating in other‟ bids of U.P.Jal Nigam in the State.

24. MISCELLANEOUS:

The contractor shall note carefully that the receipt / acknowledgement of any

employee other than authorized in respect of materials issued to him or received back

from him by the department will not be considered valid. The contractors are

therefore advised that they should obtain acknowledgement/receipts only from the

authorized official of the department who should not be below the rank of an

Assistant Project Engineer (Junior Engineer).

20

25. ADDENDUM : If the Engineer decides that the contract documents require changes,

corrections, clarifications or interpretations prior to the receipt of tenders, an

appropriate „Addendum‟ will be issued & shall form part & parcel of the tender

documents.

GM/PM Signature of bidder/vendor

21

Form-1(a)

MEMORANDUM OF WORKS

I/We hereby tender for the work specified in the underwritten memorandum within the time

specified in such memorandum at the rates given in the Schedule of rates hereto attached and in

accordance in all respect with the specifications and drawings which said specifications and drawings

have been prepared by the Project manager, Ganga Pollution Prevention Unit, U.P. Jal Nigam,

Varanasi and have been inspected and understood by me/ us and such other written instruction and as

may be given from time to time for the due carrying out of the said work and with such materials as

are provided for by and in all other respects in accordance with the conditions hereto attached.

MEMORANDUM

(a) General description of Works---------------------------------------------------------------------------- ---

-------------------------------------------------------------------------------------------------------------------

-----------------------------------------------------------------------------------------------------------------

(b) Estimate Cost. Rs.

(c) Earnest Money Rs.

(d) Security Money (including earnest money). Rs.

(e) Percentage to be deducted from bills. -------- Percent.

(f) Time allowed for the work from date of written order to commence Calendar months --------

months.

Should this tender be accepted I/We hereby agree to abide by and fulfill all the terms and provisions

of the said conditions of contract annexed hereto and within--------days from the time when called

upon to do so execute a contract embodying the conditions hereto attached and also deposit the said

security with the Project manager, Ganga Pollution Prevention Unit, U.P. Jal Nigam, Varanasi

for the due performance of the said contract.

The sum thus deposited as security money, full amount of which is to be absolutely forfeited to the

said Governor/Chairman, U.P. Jal Nigam or his successor in office should I/We not when called upon

to do so by the Project manager, Ganga Pollution Prevention Unit, U.P. Jal Nigam, Varanasi on

the day to execute the said contract and deposit full amount of security deposit specified in the above

memorandum, and in the event of the default the transaction affected this tender shall cease and

determine.

dated the ----------- day of ------------------ 20--

Witness (1) : Signature of contractor

Witness (2) :

Accompanying tender is hereby accepted by me on behalf of the Chairman of Uttar Pradesh Jal

Nigam subject to the current financial year's allotment.

Dated the ----------- day of ------------------ 2018

Signature of the officer by whom accepted

Designation

22

Form-1(b)

Note- This form is not be filled in by the bidder

U.P. Jal Nigam

FORM OF AGREEMENT (On Stamp of Rs. 100/-)

LUMP SUM-CUM-ITEM RATE CONTRACT

THIS INDENTURE made on the --------day of---------------20-- between --------------------

---------------------herein after called the contractor which expression shall where the context so admits

or implies be deemed to include his heirs, executors and administrations of the one part and Chairman

of Uttar Pradesh Jal Nigarn herein after called the Chairman which expression shall where the context

so admits or implies, be deemed to include Ins successor-in-office and assigns of the other part,

WHEREAS the said Chairman requires the execution of certain works for----------------------------------

---------------------------------------------------------------------------------------------------------------------------

----------------

herein after called the said works which said works are more particularly described in the drawings

and specifications hereto annexed AND ALSO requires the provisions of the necessary material

therefore and have caused the necessary drawings and specifications and schedules of rates to be

prepared and the contractor has delivered to the said Chairman a Tender for the execution of the said

works and the provision of the said materials AND WHEREAS the Chairman has accepted such

Tender subject to the provisions and condition here to attached : NOW THIS INDENTURE

WITNESSETH as follows : In consideration of the covenant, for the Payment by and on behalf of

the said Government here in after contained, the contractor hereby covenants with the Chairman that

he will supply all necessary materials, and execute and complete in a thoroughly sound and

workmanlike manner and afterwards maintain for the requisite period stated in the said Conditions all

the works set out said specifications and schedules of rates here to attached, signed by the contractor,

and as explained in the said drawing hereto attached, and in accordance, in every respect, with the

requirements, stipulations and conditions hereto attached

In consideration of the covenants by the contractor hereinafter contained the said Chairman

hereby covenants with the contractor to pay to him for the execution, completion and maintenance of

the work as a aforesaid according to the rates.

It is hereby agreed and declared that all the provision of the said conditions, drawings,

specifications and schedules of rates of marked.

And hereto attached shall be as binding upon the contractor and upon the said Chairman as if the same

has been repeated herein and shall be read as part of these presents.

23

In witness where of the parties hereto have affixed their signature on the --------day of ---------

- 2018

Signature of Contractor.

Witness:

Witness:

Signed on behalf of the Chairman by

Designation of the Officer

Witness:

Witness:

24

Form-1(c)

(Declaration to be filled in, signed and witnessed & to be submitted with the

Tender)

From: --------------------------------------------------

-------------------------------------------------

-------------------------------------------------

To,

The General Manager,

Ganga Pollution Prevention Unit,

S.T.P. Campus, Bhagwanpur,

U.P. Jal Nigam Varanasi (U.P.)-221005.

1. I/We ......................................................................................... (Name of Contractor/ Firm) have

read, the various conditions governing the contract attached hereto, studied the specifications,

possess the knowledge of site conditions, availability of materials and labour. I/We offer to do the

work ----------------------------------------------------------------------------------------------------------------

-----------------------------------------------------------------------------------------------------------------------

----- as per specifications/ drawings and abide by the conditions. I/We also agree to keep this offer

valid up to 120 days from date of receipt of the tenders.

2. I/We agree to complete the works within --------- months from the date of issue of letter of intent.

3. A sum of Rs. -------Lacs towards earnest money in the form of Bank

........................................................................................dated...................... pledged in the name of

Project Manager/Executive Engineer, ------------------- Unit, U.P. Jal Nigam, ------------, is

enclosed.

4. The full value of earnest money shall stand forfeited without prejudice to any other rights or

remedies if,

(a) I/We do not execute the contract documents within thirty days from the date of issue of

letter of intent.

(b) I/We do not commence the work within 10 days after the date of issue of orders to that

effect.

5. Until a formal agreement is prepared and executed, acceptance of this tender shall constitute a

binding contract between me/us and the department subject. to modifications if any as indicated in

the letter of acceptance of me/our offer for this work.

6. All tender documents/drawings duly signed are returned herewith, along with a declaration as

specified.

25

Enclosures: One tender along with all enclosures

Witness:

1. ..................................................... Signature

(Sig. of witness) Name of Contractor...............

Address..........................................

.......................................................

.......................................................

.......................................................

2. .....................................................

(Sig. of witness)

Address........................................

.....................................................

.....................................................

26

Form-1(d)

AFFIDAVIT

(On stamp of Rs. 10)

I/We hereby tender for the work specified in the tender written memorandum within the time

specified in such memorandum in accordance with noted all said specifications, regulations, safety

measures and drawings contained in this tender have been inspected and understood by me/us and

also undertake to make compliance of such other written instructions as may be given from time to

time for carrying out the said works.

1. That I/We do hereby solemnly state that I/We do not intend to migrate to any foreign country

during the period of the contract and that I/We will produce a clearance certificate from the

Income Tax Officer at the time of final payment or taking refund of the security deposit, if

demanded.

2. I/We undertake to abide by the following provision of G.O. No. G-2 1893/X-916-48 dated 7th June

1960.

“No person who has retired from Government/Jal Nigam services as an Engineer or Gazetted Officer

is employed or Engineering has employed any such retired Engineer or Gazetted Officer, is entitled to

tender for the notified work up to two years from the date of such retirement unless special permission

of the Government/Jal Nigam has been obtained and is furnished by the contractor along with his

tender”. I/We also agree that if it any time before acceptance of tender or thereafter I/We are found to

have violated the aforesaid provision, my/our tender and the contract, if entered into with me/us at

option of the Chief Engineer (------ )/ G.M/S.E (----------------------------),Ex.En./P.M(--------------------

---UNIT) U.P. Jal Nigam, ----------------, be liable to immediate cancellation in which case my/our

entire earnest money or the security deposits (as the case may be) shall stand forfeited to Jal Nigam

and I/We shall have no right to claim any compensation whatsoever, on account of the cancellation of

our tender or contract.

Witness : Contractor :

Dated : Dated :

Address : Address :

27

Form-1(e)

LETTER OF UNDERTAKING

1. I/We.....................................................................................................have read the general and

special conditions of the contract which are appended to the tender and I/We agree to the

conditions laid therein if the contract is awarded to me/us.

2. I/We have also read the specifications, studied drawings, understood the scope of works included

in the tender and to be executed by me/us.

3. I/We have visited the site of works and, am/are well acquainted with the local practices,

availability of the materials and labour and their prevailing market rate.

4. I/We agree to abide by the departmental rules regarding deductions made in the bills like income

tax, security deposits and Trade Tax etc.

5. I/We do not ask for revision of rates due to any escalations in rates of materials or labour in the

rates quoted by me in this offer throughout the period of construction and completion of the

works.

6. I/We keep the validity of our offer for 120 days from the date of opening of the tender.

7. I/We undertake to complete the works and hand over ..................... within the stipulated/allotted

time for the, completion of the works in good workman like manner.

8. I/We stand guarantee for the repair of the works to the full satisfaction of the department during

the maintenance period.

9. I/We have no doubts or un-cleared ambiguities regarding the specifications, details in

the drawings, scope of the works, and have fully understood our responsibilities in

executing and completing the works to the full satisfaction of the Engineer I/C.

10. I/We have based our tender rates having the full knowledge of the statements and facts.

Should my/our offer is accepted, I/we hereby agree to abide and fulfill the terms and conditions

annexed hereto and within 10 days of the date of receipt of an information of acceptance of

my/our offer from the General Manager, Ganga Pollution Prevention Unit, U.P. Jal Nigam,

Varanasi. I/We shall communicate in writing my/our acceptance of said offer and shall also

execute an agreement embodying the conditions hereto attached.

11. I/We also agree that the drawing, specifications, terms and conditions set-forth in the offer from

the General Manager/S.E., (-------l), Jal Nigam, ----------- together with its acceptance thereof in

writing by me/ us shall form part of the agreement.

12. I/We further agree that in the event of my/our failure to convey my acceptance of the offer

to the said General Manager within 10 days (ten days) of its receipt, ........................ the General

Manager may withdraw offer and forfeit the earnest money deposited by me/us.

13. Form No. 2 LSGED which contains form of agreement, shall be filled at the time of agreement

on a non-judicial stamp paper of Rs. 100.00 of U.P. Govt. along with a revenue stamp of Rs. 2.00

affixed on it. The validity period will be 120days from the date of opening of tender.

28

14 AND that it is hereby agreed and declared that all the provisions of the said conditions drawings

specifications and schedules of rates hereto attached or mentioned, shall be as binding upon

me/us and upon the said U.P. Jal Nigam as if the same had been repeated herein and shall be read

as part of these presents.

WITNESS : SIGN. OF CONTRACTOR

WITNESS :

29

Form-1(f)

(EARNEST MONEY)

I/We deposit herewith an Earnest Money for Rs. ------ Lacs (---------------- Lacs) in the

following form as per terms and conditions laid down in the tender notice.

I/We also agree to deposit requisite security money as per terms and conditions of the tender

document.

The details of deposit of earnest money are given below:

Sl. No. Description Amount (Rs.) Name of Issuing Bank/ P.O.

Date :

............................ Signature of Contractor

................................................... Name

........................................................ Address

30

UTTAR PRADESH JAL NIGAM

DBOT MODE CONTRACT

CONDITIONS OF CONTRACT FOR WORKS MORE THAN Rs. 100 LACS

1. INTERPRETATION

In these conditions and in the specifications which are herein attached the term “THE CHIEF

ENGINEER” shall mean the concerning “Chief Engineer (Varanasi Zone) U.P. Jal Nigam.

Varanasi. The “SUPERINTENDING ENGINEER” shall mean the S.E. / General Manager,

Ganga Pollution Prevention Unit, U.P. Jal Nigam, Bhagwanpur, Varanasi.

“ENGINEER” shall mean the Engineer officer (or any other competent person

appointed by the Engineer – in-charge, to act in addition or replacement of the Engineer) who

shall supervise the execution of the works and administering the contract and be in-charge of

the work on behalf of the Engineer- in-charge i.e. Ex. En./P.M., Ganga Pollution

Prevention Unit, U.P. Jal Nigam, Varanasi hereinafter called the Engineer.

“ENGINEER – IN - CHARGE” shall mean Officer signing the contract

“COMPETANT AUTHORITY” shall mean next higher authority than Engineer – in –

charge.

“WORK or WORKS” where used in these conditions and specifications shall unless

there be something either in the subject or context repugnant to such construction, be

construed and taken to mean “WORKS” by or by virtue of the contract contracted to be

executed whether temporary or permanent and whether original, altered, substituted or

additional.

2. TIME OF COMPLETION OF WORKS

The time allowed as set forth in Schedule-„F‟, for carrying out the works shall be 24

(Twentyfour) calendar months including 3 (three) calendar months for testing and

commissioning and Schedule of important Milestones as set forth in Schedule- „F‟ shall be

strictly observed by the contractor and shall be reckoned from the date on which the order to

commence work is given to the bidder/vendor.

3. CONTRACTOR‘S LIABILITY TO PAY COMPENSATION

The works shall throughout the stipulated period of the contract be proceeded with all

due diligence (time being deemed to be essence of the contract) and the contractor shall pay

as compensation an amount equal to 3 (three)% per month of delay of work to be computed

on per day basis or such smaller amount as the Chief Engineer (whose decision in writing

shall be final), may decide on the amount of the construction cost of the whole work, so that

the works remain un-commenced or unfinished after the proper dates and further to ensure

good progress during the execution of the works the contractor shall be bound to complete

one forth of the whole of the works before one forth of the whole time allowed under this

contract has elapsed, one half of the work before one half of such time has elapsed and the

three fourths of the work before three fourths of such time has elapsed. In the event of the

contractor failing to comply with these conditions, he shall be liable to pay as compensation

an amount equal to 3 (three) % per month of delay of work to be computed on per day basis

or such smaller amount as the Chief Engineer (whose decision in writing shall be final) may

decide on the said cost of the whole works for every day that the due quantity of works

remain incomplete PROVIDED ALWAYS that the entire amount of compensation to be paid

under the provisions of this clause shall not exceed 10% of the Tendered Value of work or of

the Tendered Value of the item or group of items of work for which a separate period of

completion is originally given.

31

The amount of compensation may be adjusted or set-off against any sum payable to the

contractor under this or any other contract with the Nigam. In case, the contractor does not

achieve a particular milestone mentioned in schedule F(schedule of time of completion), or

the re-scheduled milestone(s) submitted by him and accepted by the Engineer, the amount

shown against that milestone shall be withheld, to be adjusted against the compensation

levied at the final grant of Extension of Time. With-holding of this amount on failure to

achieve a milestone, shall be automatic, without any notice to the contractor. However, if the

contractor catches up with the progress of work on the subsequent milestone(s), the withheld

amount shall be released. In case the contractor fails to make up for the delay in subsequent

milestone(s), amount mentioned against each milestone missed subsequently also shall be

withheld. However, no interest, whatsoever, shall be payable on such withheld amount.

4. RIGHTS OF BREACH OF CONTRACT

In any case in which U.P. Jal Nigam under any clause or clauses of these conditions

the contractor shall have rendered himself liable to pay compensation amounting to the whole

of the security deposit whether deducted in one sum or deducted by installment, the Engineer

on behalf of the Chairman, U.P. Jal Nigam, shall have power to adopt any of the following

course as he may deem best suited to the interest of JAL NIGAM.

(a) To rescind the contract of which rescission notice in writing to contractor under the

hand of the Engineer shall be conclusive evidence and in which case the security

deposit of the contractor together with such sum or sums due to him under this

contract shall stand forfeited and be absolute at the disposal of the said Chairman.

(b) Or determine the contract and call in another contractor or employ daily labour to

dismantle bad work, if necessary (the bad work to be certified by the Engineer whose

decision shall be final), and to renew and complete the said work and pay the cost of

such contractor for the daily labour and price of material required for such

dismantling, renewing and completion out of the said security deposit for such sum or

sums as may be due to the contractor under this contract and if such cost be more than

the amount made up of the security money and the sum or sums due to the contractor

under this contract, the difference between it and sum made by the security money

and the balanced due to the contractor as aforesaid shall be a debt due from the said

contractor to the said Chairman. In the event of either of the above course being

adopted by the Engineer, the contractor shall have no claim to compensation for any

loss sustained by him by reasons of his having purchased or procured any materials or

entered into any agreements, or made any advances on account of or with view to the

execution of the work or the performance of the contract. And in case the contract

shall be rescinded under the provision aforesaid, the contractor shall not be entitled to

recover or be paid any sum for any work therefore actually performed under this

contract, unless and until the Engineer shall have certified in writing the performance

of such work and the value payable in respect thereof, and he shall only be entitled to

be paid the value so certified.

(c) Contract can be Determined also on following issues

Subject to other provisions contained in this clause, the Engineer-in-Charge may, without

prejudice to his any other rights or remedy against the contractor in respect of any delay,

inferior workmanship, any claims for damages and/or any other provisions of this contract or

32

otherwise, and whether the date of completion has or has not elapsed, by notice in writing

absolutely determine the contract in any of the following cases:

(i) If the contractor having been given by the Engineer-in-Charge a notice in

writing to rectify, reconstruct or replace any defective work or that the work is

being performed in an inefficient or otherwise improper or un workman like

manner shall omit to comply with the requirement of such notice for a period

of seven days thereafter.

(ii) If the contractor has, without reasonable cause, suspended the progress of the

work or has failed to proceed with the work with due diligence so that in the

opinion of the Engineer-in-Charge (which shall be final and binding) he will

be unable to secure completion of the work by the date for completion and

continues to do so after a notice in writing of seven days from the Engineer-in-

Charge.

(iii) If the contractor fails to complete the work within the stipulated date or items

of work with individual date of completion, if any stipulated, on or before

such date(s) of completion and does not complete them within the period

specified in a notice given in writing in that behalf by the Engineer-in-Charge.

(iv) If the contractor persistently neglects to carry out his obligations under the

contract and/ or commits default in complying with any of the terms and

conditions of the contract and does not remedy it or take effective steps to

remedy it within 7 days after a notice in writing is given to him in that behalf

by the Engineer-in-Charge.

(v) If the contractor had secured the contract with Government as a result of

wrong tendering or other non-bonafide methods of competitive tendering or

commits breach of Integrity Agreement.

(vi) If the contractor being a company shall pass a resolution or the court shall

make an order that the company shall be wound up or if a receiver or a

manager on behalf of a creditor shall be appointed or if circumstances shall

arise which entitle the court or the creditor to appoint a receiver or a manager

or which entitle the court to make a winding up order.

(vii) If the contractor assigns, transfers, sublets (engagement of labour on a piece-

work basis or of labour with materials not to be incorporated in the work, shall

not be deemed to be subletting) or otherwise parts with or attempts to assign,

transfer, sublet or otherwise parts with the entire works or any portion thereof

without the prior written approval of the Engineer -in-Charge/Superintending

Engineer.

5. NON-EXERCISE OF CONTRACTOR‘S LIABILITY TO PAY COMPENSATION

In any case in which any of the power conferred upon the Engineer by Clause 4 hereof, shall

have become exercisable and the same shall not be exercised, the non-exercise thereof shall

not constitute a waiver of any the conditions hereof, any such powers shall not with standing

33

be exercisable in the event of any future case of default by the contractor for which, by any

clause or clauses hereto he is declared liable to pay compensation amounting to whole of his

security deposit and the liability of the contractor for past and future compensation shall

remain unaffected. In the event of the Engineer putting in force either of the powers (a) or (b)

vested in him under the preceding clause, he may, if he so desires, take possession of all or

any tools, plant, materials, and stores in or upon the works the site thereof or belonging to the

contractor or procured by him intended to be used for the execution of the work or any part

thereof, paying or allowing for the same into account at prevailing market rates to be certified

by the Engineer, whose certificate thereof shall be final, otherwise the Engineer may give

notice in writing to the contractor or his other authorized agent require him to remove such

tools, plants, materials or stores from the premises (within a time to be specified in such

notice), the Engineer may remove them at the contractor‟s expenses or sell them by auction

or private sale on account of the contractor and at his risk in all respects, and the certificate of

the Engineer as to the expense of any such removal, and the amount of the proceeds and the

expense of any such sale be final and the conclusive against the contractor.

6. EXTENSION OF TIME:

If the contractor shall desire an extension of time or rescheduling of Mile stones for

construction of the work on the ground of his having been unavoidably hindered in its

execution or any other ground, he shall apply in writing to the Engineer within seven days

after the date of hindrance on account of which he desires such extension as aforesaid, and

the Engineer shall grant, if in his opinion (which shall be final), reasonable time, if any, as

may in his opinion be necessary or proper.

6.1 Extension of time where no compensation is levied under clause-3:

If the work(s) be delayed by:-

(i) Force majeure such as war, riots, fire, flood, hurricane, typhoon, strikes, explosion,

lightining and acts of state or governmental actions prohibiting or impedining any

party from performing its respective obligation under the contract etc, or

(ii) Abnormally bad weather, or

(iii) Serious loss or damage by fire, or

(iv) Civil commotion, local commotion of workmen, strike or lockout, affecting any of the

trades employed on the work, or

(v) Delay on the part of other contractors or tradesmen engaged by Engineer in executing

work not forming part of the Contract, or

(vi) Non-availability of stores, which are the responsibility of Nigam to supply or

(vii) Non-availability or break down of tools and Plant to be supplied or supplied by

Nigam or

(viii) Pending road cutting permission by concerned authorities i.e. Nagar Nigam ,PWD,

NH, NHAI, Forest, Defense and local administration etc

(ix) Delay in land acquisition or title dispute or pendency at Court at Law

(x) Stoppage of work by local administration due to any law and order condition or due to

any code of conduct during any municipal or assembly or parliament election.

(xi) Due to change in technology, alteration and deviation in specifications of materials

and works and change in scope of work or increase in quantum of work.

(xi) Any other cause which, in the absolute discretion of the Engineer is beyond the

contractor‟s control.

Then upon the happening of any such event causing delay, the contractor shall immediately

give notice thereof in writing to the authority as indicated in Schedule „F‟ but shall

nevertheless use constantly his best endeavors to prevent or make good the delay and shall do

all that may be reasonably required to the satisfaction of the Engineer-in-Charge to proceed

with the works. The contractor may be allowed a reasonable extension of time for delay on

34

these grounds by the Engineer but any compensation or price escalation shall not be allowed.

However lawful deviation in rates may be allowed by the Chief Engineer due to change in

technology and due to alteration and deviation in specifications of materials and works

beyond the scope of this tender as per terms set forth in clause-13 (Alternation in

specification and drawings) below.

6.2 As soon as possible after the Contract is concluded, the contractor shall submit a Time

and Progress Chart for each mile stone and get it approved by the Department. The Chart

shall be prepared in direct relation to the time stated in the Contract documents for

completion of items of the works. It shall indicate the forecast of the dates of commencement

and completion of various trades of sections of the work and may be amended as necessary

by agreement between the Engineer-in-Charge and the contractor within the limitations of

time imposed in the Contract documents, and further to ensure good progress during the

execution of the work, the contractor shall in all cases in which the time allowed for any

work, exceeds one month (save for special jobs for which a separate programme has been

agreed upon) complete the work as per mile stones given in Schedule „F‟.

The contractor shall prepare an integrated programme chart in MS Project/Primavera

software for the execution of work, showing clearly all activities from the start of work to

completion, with details of manpower, equipment and machinery required for the fulfilment

of the programme within the stipulated period or earlier and submit the same for approval to

the Engineer-in- Charge within ten days of award of the contract. The programme chart

should include the following:

a. Descriptive note explaining sequence of the various activities.

b. Network (PERT / CPM / BAR CHART).

c. Programme for procurement of materials by the contractor.

Programme of procurement of machinery / equipment having adequate capacity,

commensurate with the quantum of work to be done within the stipulated period, by the

contractor. In addition to above, to achieve the progress of Work as per programme, the

contractor must bring at site adequate shuttering material required for cement concrete and

R.C.C. works etc. for three months within one month from the date of start of work till the

completion of RCC work as per requirement of work. The contractor shall submit shuttering

schedule adequate to complete structure work within laid down physical milestone.

If at any time, it appears to the Engineer-in-Charge/Engineer that the actual progress of work

does not conform to the approved programme referred above or after rescheduling of

milestones, the contractor shall produce a revised programme within 7 (seven) days, showing

the modifications to the approved programme to ensure timely completion of the work. The

modified schedule of programme shall be approved by the Engineer in Charge/Engineer.

The submission for approval by the Engineer-in-Charge/ Engineer of such programme or

such particulars shall not relieve the contractor of any of the duties or responsibilities under

the contract. This is without prejudice to the right of Engineer-in-Charge/ Engineer to take

action against the contractor as per terms and conditions of the agreement.

Non application by the contractor for extension of time/ rescheduling of the

milestones shall not be a bar for giving a fair and reasonable extension/ rescheduling of the

milestones by the authority as indicated in Schedule „F‟ and this shall be binding on the

contractor.

6.3 In case, the work cannot be started due to reasons not within the control of the

contractor, as in 6.1 above, within 25% of the stipulated time for completion of work

or three months whichever is higher, either party may close the contract. In case

35

contractor wants to close the contract, he shall give notice to the Nigam stating the

failure on the part of Nigam. In such eventuality, the Performance Guarantee of the

contractor shall be refunded within 30 days, however no interest shall be payable to

contractor on this account and fresh tenders will be called.

6.4 All risks of loss of or damage to physical property and of personal injury and death

which arise during and in consequence of the performance of the Contract other than

the excepted risks, referred to in clause 6.1, are the responsibility of the contractor.

7. ENGINEER‘S CERTIFICATE OF COMPLETION:

On completion of the work the contractor shall be furnished with a certificate by the

Engineer of such completion, but not such certificates shall be given nor shall the work be

considered to be completed until the works shall have been measured by the Engineer, whose

measurement shall be binding and conclusive against the contractor and the contractor shall

have removed from the premises on which the work has been executed all scaffolding,

surplus materials and rubbish and cleaned off all dirt and debris in upon or about the premises

of which he may had possession for the purpose of executing the said works. If the contractor

shall fail to comply with the requirements of this clause as to removal of scaffolding, surplus

materials and rubbish and cleaning of all dirt and debris on or before the date fixed for the

completion of work/s the Engineer may at the expenses of contractor remove such

Scaffolding, surplus materials and rubbish and dispose of the same as he thinks fit and clean

off such dirt and debris of all expenses so incurred and shall have no claim in respect of any

such scaffolding or surplus materials as aforesaid except for any sum actually realized by the

sale thereof after deducting the aforesaid expenses.

8. PAYMENTS:

On measurements of the work done for the convenience of the contractor, interim

payments shall ordinarily be made monthly but final payments shall not be made until the

whole of the work shall have been completed and certificate of the completion of the work

given and it shall be lawful for the said Engineer to deduct a sum equal to 5% of the said

payment and such sum or sums to be held in deposit as further security for the due

performance of the conditions of this contract, provided always that the Engineer may refuse

to advance such payments if in his opinion the progress of the work or the conduct of the

contractor is not satisfactory or the contractor has in any other way done or neglected to do

anything so as to make it doubtful whether the works will be completed by him in accordance

with the contract. But all such interim payments shall be recorded as payments by way of

advance against the final payments only and as payment of work actually done and completed

and not regular the requiring of bad unsound and imperfect or unskillful works to be removed

and taking a way or reconstructed or re-erected or be recognized as on admission of the due

performance of the contract or any part thereof in any respect of the accruing of any claim,

nor shall it conclude, determine or effect in any way the powers of the Engineer under these

conditions or any of them as to the final settlement and adjustment of the account or

otherwise or in any other way vary or affect this contract. The final bill shall be submitted by

the contractor within one month of the date fixed for the completion of the work otherwise

the Engineer's certificate of the measurements (due notice having given before hand to the

contractor of the date of such measurements) and of total amount payable for the works

accordingly shall be final and binding on all parties. No interest shall be paid for delayed

payment due to paucity of funds.

8.1 The security deposit / performance security shall be 10% of the contract price.

If performance security deposit taken less than 10% of the contract price initially then the rest

security deposit shall be deducted from the running bills and the final bill of the contractor at

the rates mentioned above. The security deposit as deducted above can be released against

36

bank guarantee issued by a scheduled bank/nationalized bank, on completion of work in all

respect. Provided further that the validity of bank guarantee shall be valid up to 60 days after

work has been completed and commissioned and maintenance or defect liability period is

over and is extended from time to time depending upon extension of contract granted under

provisions of clause 6 above.

8.2 If rates quoted by selected bidder/vendor in Schedule–G are more than 15% below

SOR, one percent additional security for every 2% below rates or part thereof on prorate

basis, for performance shall be deducted from bills of contractor for satisfactory completion

of work which shall be returned only after completion of work in all respect; however no

interest or compensation shall be given on this account to contractor.

If the submitted bid is seriously unbalanced, the employer/department will get the

clarification about internal consistancy of rates and may ask the bidder/vendor to deposit

additional performance security to safeguard the interest of department.

9. BILL TO BE SUBMITTED ON PRESCRIBED FORM:

The contractor shall submit all bills on the prescribed forms to be had on application

at the office of the Engineer and the charges in the bills shall always be entered at the rates

given in the schedule of rates hereto attached, or in the case of an extra work ordered in

pursuance of these conditions and not mentioned or provided for the Tender, at the rates

hereinafter to be agreed upon.

10. STORES SUPPLIED BY U.P. JAL NIGAM:

10.1 No material shall be supplied by the department. All the construction material shall be

arranged by the bidder/contractorvendor at his cost but all such material should be ISI marked

or as specified in the contract and shall be factory tested. If required such testing will be done

at factory by the Engineer or his representative or by third party agency at the cost of

contractor. All manufactured items shall be supplied by the contractor from the list of

approved vendors ,if such list is available, or contractor will get his vendor‟s list duly

approved by the Engineer.

10.2 If any materials that may be supplied from the Engineer's stores or as may be

provided by the Engineer (such materials will be charged for at the rates specified in the

schedule “I” of rates marked hereto annexed), shall be used by the contractor for the purpose

of this contract only and the value of the full quantity of materials so supplied may be set off

or deducted from any sums then due on thereafter to become due to the contractor under this

contract or otherwise on against or form the security deposit.

As soon as the work is awarded, the contractor shall finalize the programme for the

completion of work as per clause of contract and shall give his estimates of materials required

on the basis of drawings/or schedule of quantities of the work. The contractor shall give in

writing his requirement to the Engineer which shall be issued to him keeping in view the

progress of work as assessed by the Engineer, in accordance with the agreed phased

programme of work indicating monthly requirements of various materials. The contractor

shall place his indent in writing for issue of such materials at least 15 days in advance of his

requirement.

Such materials shall be supplied for the purpose of the contract only and the value of the

materials so supplied at the rates specified in the aforesaid schedule shall be set off or

deducted, as and when materials are consumed in items of work (including normal wastage)

for which payment is being made to the contractor, from any sum then due or which may

therefore become due to the contractor under the contract or otherwise or from the security

deposit. At the time of submission of bills, the contractor shall certify that balance of

materials supplied is available at site in original good condition.

37

The contractor shall submit along with every running bill (on account or interim bill) material

wise reconciliation statements supported by complete calculations reconciling total issue,

total consumption and certified balance (diameter/section-wise in the case of steel) and

resulting variations and reasons therefore. Engineer shall (whose decision shall be final and

binding on the contractor) be within his rights to follow the procedure of recovery.

The contractor shall bear the cost of getting the material issued, loading, transporting to site,

unloading, storing under cover as required, cutting assembling and joining the several parts

together as necessary. Notwithstanding anything to the contrary contained in any other clause

of the contract and all stores/materials so supplied to the contractor or procured with the

assistance of the U.P. Jal Nigam shall remain the absolute property of U.P. Jal Nigam and the

contractor shall be the trustee of the stores/materials, and the said stores/materials shall not be

removed or disposed of from the site of the work on any account and shall be at all times

open to inspection by the Engineer-in-Charge or his authorized agent. Any such

stores/materials remaining unused shall be returned to the Engineer in as good a condition in

which they were originally supplied at a place directed by him, at a place of issue or any

other place specified by him as he shall require. In case of any loss or damage of such stores,

same shall be charged and recovered at double the issue rates from the bills or security money

of the contractor.

Provided that the contractor shall in no case be entitled to any compensation or

damages on account of any delay in supply or non-supply thereof all or any such materials

and stores provided further that the contractor shall be bound to arrange such stores at his

own and execute the entire work if the materials are supplied by U.P. Jal Nigam within the

original scheduled time for completion of the work. If a part of the materials only has been

supplied within the aforesaid period, then the contractor shall be bound to do as much of the

work as may be possible with the materials and stores supplied in the aforesaid period. For

the completion of the rest of the work, the contractor shall be entitled to such extension of

time as may be determined by the Engineer-in-Charge whose decision in this regard shall be

final and binding on the contractor.

11. MATERIAL AND PLANT OF CONTRACTOR :

All materials brought by the contractor upon the site of the works shall be deemed to

be the property of the Chairman and shall not on any account be removed from the site of the

works during the execution of the works and shall at all times be open to inspection by the

Engineer. The Engineer on the completion of the works or upon the stoppage of the works as

provided for in clause 14 of this contract shall have an option of taking over any such unused

materials at prevailing market rates, with the provision that the price allowed to the contractor

shall not exceed the amount originally paid by him for the same as he (the Engineer) shall

desire upon giving a notice in writing under his within seven days of the completion of the

works to that effect, and all materials not so taken over by the Engineer shall cease to be the

property of the Chairman and the contractor shall have no claim for compensation on account

of any such materials as aforesaid which are not so taken over by the said Engineer, unused

by him (the contractor) or for any wastage in or damage to any such materials.

12. WORKS TO BE EXECUTED IN ACCORDANCE WITH THE SPECIFICATION

The contractor shall execute the whole and every part of the work in a most

substantial and workman like manner both as regards to materials and otherwise in every

respect in strict accordance with the specifications. The contractor shall also confirm exactly

and faithfully to the drawings and instructions in writing relating to the work signed by the

Engineer.

The contractor shall comply with the provisions of the contract and with the care and

diligence execute and maintain the works and provide all labours and materials, tools and

plants including for measurements and supervision of all works, structural plans and other

38

things of temporary or permanent nature required for such execution and maintenance in so

far as the necessity for providing these, is specified or is reasonably inferred from the

contract. The contractor shall take full responsibility for adequacy, suitability and safety of all

the works and methods of construction.

13. ALTERATION IN SPECIFICATION AND DRAWINGS:

The Engineer shall have powers to make any alteration or additions to the original

specifications, drawings and instructions that may appear to him, to be necessary or advisable

during the progress of the work, and the contractor shall be bound to carry out the work in

accordance with any instruction which may be given to him in writing signed by the Engineer

and such alterations shall not invalidate this contract and any additional work which the

contractor may be directed to do in the manner above specified as part of the work shall be

carried out by the contractor on the same conditions in all respect on which he agreed to do

the main work, and at the same rates as are specified in the Schedule of Rates marked, 'G' for

the main work. And should any alteration necessitate a curtailment of the work described in

the specifications and shown on the drawings, it shall be lawful for the Engineer to deduct

from the sum of Rs. ------- value of this contract as a sum equal to the amount that the

curtailed portion of the work if carried out would have cost based upon the rates set forth in

the schedule of rates marked 'G'. The time for the completion of the work shall be extended if

applied for by contractor in writing in the proportion that the additional work bear to the

original contract work and the certificate of the Engineer shall be conclusive as to such

extension.

And if the additional work includes any class of work which no rates provided in this

contract, then such class of work shall be carried out at rates to be agreed upon between the

Engineer and contractor in writing prior to the work being taken in hand. The basis for fixing

such rates shall ordinarily be the U.P. Jal Nigam erstwhile L.S.G.E.D. schedule of rates for

the district and if not covered by it, SOR of PWD/ U.P. Irrigation Department / CPWD will

apply. Provided always that if the contractor shall commence work or incur any expenditure

in regard thereto before the rate shall have been determined as lastly therein before,

mentioned, then and in such case he shall only be entitled to be paid in respect of the work

carried out or expenditure incurred by him prior to the date of the determination of the work

carried out or expenditure incurred by him prior to the date of the determination of the rates

as aforesaid according to such rate or rates shall be fixed by the Engineer. In the event of a

dispute, the decision of the Chief engineer shall be final.

14. NO COMPENSATION FOR ALTERATION IN OR REDUCTION OF WORK

TO BE CARRIED OUT :

If at any time after the commencement of the work the Chief Engineer

/Superintending Engineer shall for any reason whatsoever not require the whole thereof as

specified in this contract to be carried out, the Engineer shall give notice in writing of the fact

to the contractor and upon the receipt of such notice in writing the works under this contract

shall cease and the conntractor shall have no claim to any payment or compensation

whatsoever on account of any profit or advantage which he might have derived from the

execution of the works in full, but which he did not derive in consequence of the full amount

of the works not having been carried out, neither shall he have any claim for compensation by

reason of any alterations having been made in the original specifications, drawings and

instructions which shall involve any curtailment of the work as originally contemplated.

15. ACTION AND COMPENSATION PAYABLE IN CASE OF BAD WORK:

If it shall appear to the Engineer or his subordinate in charge of the works that any

works has been executed with imperfect or unskilled workmanship or with materials of any

inferior description or that any materials or articles provided by the contractor, for the

execution of the works are unsound or of a quality inferior to that contracted for or otherwise

39

not in accordance with the contract, the contractor shall on demand in writing from the

Engineer specifying the work materials or articles complained of forthwith rectify remove

demolish and reconstruct the work so specified in whole or in part as the case may require or

as the case may be, remove the materials or articles so specified and provide other proper and

suitable materials or articles at his own proper charge and cost, and in the event of his failing

to do so within a period to be specified by the Engineer in his demand aforesaid, then the

contractor shall be liable to pay compensation at the rate of one percent or such smaller

amount as the Chief Engineer (whose decision in writing shall be final) may decide, on the

amount of the cost of the whole work for every day not exceeding ten days, while his failure

to do shall continue, and in case of any such failure the engineer may rectify remove,

demolish and reconstruct the work, or remove and replace with others the materials or articles

complained of, as the case may be at the risk and expense in all respect of the contractor and

such expenses may be deducted from such sum as may be due to the contractor or may

become due to him and from his security deposit. An instruction by the Engineer as to the

amount of the expenses incurred shall be final and binding upon the contractor.

16. WORKS TO BE OPEN TO INSPECTION:

All works under or in course of execution or executed in pursuance of the contract

shall at all times be open to the inspection of Engineer and his subordinate or a third party as

deemed necessary in the opinion of the Engineer and the contractor shall all times during the

usual working hours and at the all other times of which reasonable notice of the intention of

the Engineer or his subordinate to visit the works shall have been given to the contractor,

either himself be present to revive orders and instructions or have a reasonable agent duly

accredited in writing present for the purpose. Orders given to the contractor's agent shall be

considered to have the same force as if they had been given to the contractor himself. Verbal

orders shall not be considered as binding on either party until they are confirmed in writing

signed by the Engineer. The contractor shall ,without any extra charge or compensation,

make all good for such inspection including arrangement of all labours, appliance ,access,

safety etc at his own cost.

17. NOTICE TO BE GIVEN BEFORE WORK IS COVERED UP :

The contractor shall give not less than five days notice in writing to the Engineer or

his duly authorized assistant in charge of the work before covering up, for otherwise placing

by beyond the reach of measurement any work in order that the same may be measured and

correct dimensions thereof be taken before the same is so covered up or placed beyond the

reach of measurement and shall not cover up or place beyond the reach of measurement any

work without the consent in writing of the Engineer or his duly authorised assistant in charge

of the work, and if any work shall be covered, up or replaced beyond the reach of

measurement without such notice having been given or consent obtained the same shall be

uncovered at the contractor's expense, or in default thereof no payment or allowance shall be

made for such work or the materials with the same was executed.

18. CONTRACTOR LIABLE FOR DAMAGE DONE AND IMPERFECTION:

If the contractor or his work people or servants shall break, defense, injury or destroy

and part of a building, in which they be working or any building, road, fence, enclosure, land

or cultivated ground continuous to the premises on which the work any part of it is being or

executed, if any damage shall happen to the work, which in progress, from any cause

whatever or any imperfections become apparent in it within months after the final certificate

of its completion shall have been given by the Engineer as aforesaid, the contractor shall

make the same good at his own expense, or in default the Engineer may cause the same to be

made good by other workman, and deduct the expenses (of which the certificate of the

Engineer shall be final) from any sum that may be then or at any time thereafter may become,

due to the contractor or from his security deposit. All compensation, loss or damage to

40

physical property and of personal injury or death of any or more persons, which arise during

and in consequences of the performance of the contract due to his negligence or overlooking

of safety measures.

19. CONTRACTOR TO SUPPLY LABOUR, PLANT, LADDERS, SCAFFOLDINGS,

etc.:

The contractor shall supply at his own cost all labour skilled and unskilled and all

things necessary (except such special things, if any, as may, in accordance with the

specification, be supplied from the Engineer stores), such as plants, tools, appliances,

implements, ladders, cordage, tackle, scaffolding, shoring, shuttering, pumps, boilers, fuel,

oils, packing, derrick, boring tools, winches and power as well as all other apparatus and

temporary work requisite or proper for the proper execution of the works, whether original,

altered or substituted and whether included in the specifications or other documents part of

the contract or to in these considerations or not which may be necessary for the purpose of

satisfying or complying with the requirements of the Engineer as to any matter as to which

under these conditions he is entitled to be satisfied or which he is entitled to require, together

with carriage therefore to and from the work. The contractor shall also supply without charge

the requisite number of persons, with the means and things necessary for the purpose of

setting out the works, and counting, weighting and assisting the measurement and

examination at any time and from time to time of the work done or materials supplied by him.

Failing his so doing the same may be provided by the Engineer at the expense and risk of the

contractor and the expenses (of which the certificate of the Engineer shall be final) may be

deducted from any money due to the contractor under this contract or from his security

deposit. The contractor shall also provide at his own expense all necessary fencing and light

required to protect the public from accident, and shall assume all liability for and indemnity

the Chairman against all actions or suits arising out of or in connection with the carrying out

of the works whether such actions are brought by members of the public, neighboring owner

or workmen employed on works, save only actions for permanent interference with

casements to which the site may be subject at law or in equity or otherwise arising out title of

the site. The contractor shall in carrying out works confirm to the statutory and other legal

enactment applicable to them and give all notices and pay all fees payable to local authorised

and others in respect of them. The contractor shall be responsible for the adequacy, strength

and safety of all shoring, structuring, bounding, curbing, brick work, masonry concrete

permanent or temporary, appliances, matter and things furnished by him for the purpose of

this contract.

20. FEMALE LABOUR:

All Government of India, Supreme court directives regarding female employee should

be follow strictly.

21. WORKS NOT TO BE SUBLET WITHOUT SANCTION:

This contract or any part thereof shall not be assigned or sublet without the written

approval of the Chief Engineer. And if the contractor shall assign or sublet his contract or

attempt to do so or become insolvent commence any insolvency proceedings or make any

composition with his creditor or attempt to do so or if any bribe, gratuity, gift, loan perquisite,

reward or a advantage, pecuniary or otherwise shall either directly or indirectly be given,

promised or offered by the contractor or any of his servants or agent to any public in the

employ of U.P. Jal Nigam in any way relating to his office of employment of U.P. Jal Nigam,

in any way relating to his office or employment or officer or person shall become in any way

Engineer may thereupon by notice in writing rescind the contract and the security deposit.

U.P. Jal Nigam and the same consequences shall ensure as if the contract has been rescinded

under clause 4 thereof, and in addition the contractor shall not be entitled to recover or be

paid for any work that has already been performed under this contract.

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22. SUM PAYABLE BY WAY OF COMPENSATION:

All sums payable by way of compensation under any of these conditions shall be

considered as reasonable compensation to be applied to the use of the said Chairman, without

reference to the actual loss or damage sustained, and whether or not any damage shall have

been sustained.

23. WORKS TO BE UNDER DIRECTION OF ENGINEER:

All works to be executed under the contract shall be executed under the direction and

subject to the approval in all respect of the Engineer for the time being who shall be entitled

to direct at what point or points and in what manner they are to be commenced and from time

to time carried on.

24. DECISION OF CHIEF ENGINEER TO BE FINAL:

Except where otherwise specified in this contract, the decision of the Chief Engineer

for the time being shall be final, conclusive and binding on all parties to the contract upon all

question relating to the measuring of the specification, drawings and instructions herein

before mentioned and as to the quality of workmanship or materials used on the work, or as

to any other question, claim, right matter or things whatsoever, in any way arising out of

relating to, the contract, drawings, specifications, estimates, instructions under the works, or

the execution, or failure to execute the same whether arising during the progress of the work

or after the completion or the sooner determination thereof the contract.

25. ACTIONS WHERE NO SPECIFICATION:

In the case of any class of work of which there is no mention in the specification such

work shall be carried out in all respect in accordance with the Bureau of Indian standards

Specifications. In case there are no such specifications in Bureau of Indian Standards, the

work shall be carried out as per manufacturers‟ specifications or as per Jal Nigam / LSGED /

CPWD/UPPWD/UP Irrigation specifications. In case there are no such specifications, the

work shall be carried out as per instructions and requirements of the Engineer.

26. CONTRACTOR TO EMPLOY COMPETENT AGENT AND FOREMAN:

During the execution of the works and until the work is taken over by the order of the

Engineer, the contractor shall employ a competent agent and such foreman as may be

necessary for the proper execution of the "WORKS" (and then work is carried on day and

night there shall be a foreman in charge of each shift) who shall be engaged constantly on the

works to ensure proper management and efficient control.

27. EARNEST MONEY AND RECEIPT OF AND POWER AS TO SECURITY

MONEY:

27.1 The Earnest Money Deposit (EMD) amounting Rs. 70,00,000/- (Rs. 70.00 Lacs) must

be Deposited with the e-tender in form of RTGS made by any nationalized bank of

India pledged in favour of “Project Manager, Ganga Pollution Prevention Unit,

U.P. Jal Nigam, Varanasi. 27.2 The Chairman has received from the contractor the sum of 5% of tender cost i.e. Rs. -

-------------(including earnest money deposit validated up to time as given in schedule-

F),.the receipt of which is hereby acknowledged. This said sum together with the

sum made up the 5% described in clause 8 of this contract (i.e. 10% total) shall

be held as security for the performance of all the conditions and stipulation of

the contract, and the Engineer is empowered to deduct from time to time from such

security money all or any sum or any sums which may become due from the

contractor as liquidated damages for the breach of any or all the covenants or

provisions of this contract. If not confirmed under the provisions of this contract, the

security money or such balance thereof as may be left after making the deductions

aforementioned will be returned to the contractor after ------- months after the final

certificate of the completions of the works shall have been given by the Engineer and

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after the Engineer shall have satisfied himself that all the terms of the contract have

been duly and faithfully carried out by the contractor.

27.3 Fixed deposits receipts OR Bank Guarantee(on the Performa as per Annexure-3) of

the State Bank of India, Allahabad Bank and Central Bank or any other

scheduled/nationalized bank shall also be accepted as security provided that all such

fixed deposits receipts must be issued in the name of the U.P. Jal Nigam, and that they

will be accepted as security on the conditions that Nigam will hold the deposit at the

risk of depositor and will not be liable in the event of the loss of the security due to

failure of the Bank or to any other clause, and that if the security is lost the loss will

fall on the depositor who will have to deposit fresh security.

27.4 All compensations or the other sums of money payable by the contractor under

the terms of this contract may be deducted from, or paid by the sale of a sufficient part

of his security deposit or from the interest arising there from, or from any sums which

may be due to or may become due to the contractor by Government on any account

whatsoever and in the event of his Security Deposit being reduced by reason of any

such deductions or sale as aforesaid, the contractor shall within 10 days make good in

cash or fixed deposit receipt tendered by the State Bank of India or by Scheduled /

nationalized Banks (if deposited for more than 12 months) endorsed in favour of the

Engineer, any sum or sums which may have been deducted from, or raised by sale of

his security deposit or any part thereof.

27.5 The Performance Guarantee or security for the due performance shall be initially valid

up to the stipulated date of completion plus 60 days beyond that. In case the time for

completion of work gets enlarged, the contractor shall get the validity of Performance

Guarantee extended to cover such enlarged time for completion of work. After

recording of the completion certificate for the work by the competent authority, the

performance guarantee shall be returned to the contractor, without any interest.

27.6 In case of contracts involving maintenance of building and services/any other work

after construction of same building and services/other work, then 50% of Performance

Guarantee shall be retained as Security Deposit. The same shall be returned year wise

proportionately.

28. WORKMEN'S COMPENSATION ACT: In every case in which by virtue of the provision of section 12, sub-section (i) of the

Workmen‟s Compensation Act, 1923, U.P. Jal Nigam is obliged to pay compensation to a

workman employed by the contractor or by any sub-contractor from him in the execution of

the said work, Nigam will recover from the contractor the amount of the compensation so

paid; and, without prejudice to the rights of Government under section 12, sub-section (2) of

the said Act. Nigam shall be of liberty to recover such amount or any part thereof by

deducting it either from the earnest money or security deposited by the contractor or to his

credit under Clause-19 of these conditions or from any other sum due by Nigam to the

contractor under this contract or otherwise.

29. Nigam shall not be bound to contest any claim made against it under section-12, sub-

section (1) of the said Act, except on the written request of the contractor and upon

his giving to Nigam full security for all costs for which Nigam might become liable in

consequence of contesting the claim.

30. Dismantled Material Govt. Property:

The contractor shall treat all materials obtained during dismantling of a structure,

excavation of the site for a work, etc. as Government‟s/Nigam/ULB property and such

materials shall be disposed off to the best advantage of Government/Nigam/ULB according

to the instructions in writing issued by the Engineer-in-Charge.

31. Lien in respect of claims in other Contracts:

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Any sum of money due and payable to the contractor (including the security deposit

returnable to him) under the contract may be withheld or retained by way of lien by the

Engineer or any other contracting person or persons through Engineer against any claim of

the Engineer or such other person or persons in respect of payment of a sum of money arising

out of or under any other contract made by the contractor with the Engineer or with such

other person or persons.

It is an agreed term of the contract that the sum of money so withheld or retained

under this clause by the Engineer will be kept withheld or retained as such by the Engineer or

the Government or till his claim arising out of the same contract or any other contract is

either mutually settled or determined by the arbitration clause or by the competent court, as

the case may be and that the contractor shall have no claim for interest or damages

whatsoever on this account or on any other ground in respect of any sum of money withheld

or retained under this clause and duly notified as such to the contractor.

32. Unfiltered water supply:

The contractor(s) shall make his/their own arrangements for water required for the work and

nothing extra will be paid for the same. This will be subject to the following conditions.

(i) That the water used by the contractor(s) shall be fit for construction purposes to the

satisfaction of the Engineer.

(ii) The Engineer shall make alternative arrangements for supply of water at the risk and

cost of contractor(s) if the arrangements made by the contractor(s) for procurement of

water are in the opinion of the Engineer, unsatisfactory.

32.1 Departmental water supply, if available

Water if available may be supplied to the contractor by the Nigam subject to the following

conditions:-

(i) The water charges @ 1% shall be recovered on gross amount of the work done.

(ii) The contractor(s) shall make his/their own arrangement of water connection and

laying of pipelines from existing main of source of supply.

(iii) The Nigam do not guarantee to maintain uninterrupted supply of water and it will be

incumbent on the contractor(s) to make alternative arrangements for water at his/

their own cost in the event of any temporary break down in the Nigam/Municipal

water main so that the progress of his/their work is not held up for want of water. No

claim of damage or refund of water charges will be entertained on account of such

break down.

33. Alternate water arrangements

(i) Where there is no piped water supply arrangement and the water is taken by the

contractor from the wells or hand pump constructed by the Government, no charge

shall be recovered from the contractor on that account. The contractor shall, however,

draw water at such hours of the day that it does not interfere with the normal use for

which the hand pumps and wells are intended. He will also be responsible for all

damage and abnormal repairs arising out of his use, the cost of which shall be

recoverable from him. The Engineer-in-Charge shall be the final authority to

determine the cost recoverable from the contractor on this account and his decision

shall be binding on the contractor.

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(ii) The contractor shall be allowed to construct temporary wells in Government land for

taking water for construction purposes only after he has got permission of the

Engineer-in- Charge in writing. No charges shall be recovered from the contractor on

this account, but the contractor shall be required to provide necessary safety

arrangements to avoid any accidents or damage to adjacent buildings, roads and

service lines. He shall be responsible for any accidents or damage caused due to

construction and subsequent maintenance of the wells and shall restore the ground to

its original condition after the wells are dismantled on completion of the work.

34. Levy/Taxes/Royalty payable by CONTRACTOR

GST or any other Tax or Cess in respect of this contract shall be payable by the

contractor shall be deducted from the bills of the contractor at prevalent rates.

Certificate showing the details of such deductions shall be issued by the Jal Nigam. to

the contractor as and when required. However excise exemption certificate shall be

provided as applicable.

TRADE TAX CLEARANCE CERTIFICATE: If the contractor is a Trade Tax assess, he should produce a valid Trade Tax

clearance certificate, before the payment of the final bill, failing which the payment will be

with-held. In case he is not liable to Trade Tax Assessment, a certificate to this effect from

the competent Trade Tax authority shall be produced before payment of the final bill.

(i) Building and other Construction Workers Welfare Cess@1% or as applicable shall be

deducted from all the bills (advance, running or final bills) of contractor.

(iii) However, in respect of goods and service tax, excluding works under programmes

exempted from goods and service tax by a government order, same shall be paid

by the contractor to the concerned department on demand and it will be reimbursed to

him by the Engineer after satisfying that it has been actually and genuinely paid by

the contractor or suitable deduction shall be made from the bills of contractor as per

prevalent laws as in force from time to time by the Government and TDS certificate

shall be issued.

(iv) The contractor shall deposit royalty and obtain necessary permit for supply of the red

bajri, stone/grit, Kankar, sand, murrum etc. from local authorities and shall produce

form MM-11 to the engineer in its support or same shall be deducted from the bills of

the contractor.

(v) Income tax @ 2% or as applicable shall be deducted from all the bills (advance,

running or final bills) of contractor and TDS certificate shall be issued.

35. Conditions for reimbursement of levy/taxes if levied after receipt of tenders:

(i) All tendered rates shall be inclusive of all taxes and levies (except Service Tax)

payable under respective statutes. However, if any further tax or levy or cess is

imposed by Statute, after the last stipulated date for the receipt of tender including

extensions if any and the contractor thereupon necessarily and properly pays such

taxes/levies/cess, the contractor shall be reimbursed the amount so paid, provided

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such payments, if any, is not, in the opinion of the Superintending engineer (whose

decision shall be final and binding on the contractor) attributable to delay in execution

of work within the control of the contractor.

(ii) The contractor shall keep necessary books of accounts and other documents for the

purpose of this condition as may be necessary and shall allow inspection of the same

by a duly authorized representative of Engineer and shall also furnish such other

information/document as the Engineer may require from time to time.

(iii) The contractor shall, within a period of 30 days of the imposition of any such further

tax or levy or cess, give a written notice thereof to the Engineer that the same is given

pursuant to this condition, together with all necessary information relating thereto.

36. Termination of Contract on contractors death, becoming insolvent, insane or

imprisoned: In the event of the death of the contractor & his firm (where the contractor being in

partnership), becomes dissolved or a corporation goes into liquidation, the contact may be

terminated by notice in writing posted at the site of the works and advertised in one of the

issue of a newspaper and all acceptable works shall be paid, after recovering all the dues at

appropriate rates without compensation to the contractor, to the person or persons entitled to

receive such payment.

37. ADVANCE:

37.1 Secured Advance on Non-perishable Materials

The contractor, on signing an indenture in the form to be specified by the Engineer

shall be entitled to be paid during the progress of the execution of the work up to 75% of the

assessed value of any materials which are in the opinion of the Engineer non-perishable,

non-fragile and non-combustible and are in accordance with the contract and which have

been brought on the site in connection therewith and are adequately stored and/or protected

against damage by weather or other causes but which have not at the time of advance been

incorporated in the works. When materials on account of which an advance has been made

under this clause are incorporated in the work, the amount of such advance shall be recovered

/deducted from the next payment made under any of the clause or clauses of this contract. No

secured advance, shall however, be paid on high-risk materials such as ordinary glass, sand,

petrol, diesel, wood etc.

37.2 Mobilization advance Mobilization advance not exceeding 10% of the cost of contract work at “SBI base

rates ( prevailing at the date of payment +1%” interest may be given, if requested by the

contractor in writing within one month of the order to commence the work. Such advance

shall be in two installments each of 5% of contract value or to be determined by the

Engineer-in- Charge at his sole discretion. The first installment of such advance shall be

released by the Engineer-in-charge to the contractor on a request made by the contractor to

the Engineer in- Charge in this behalf after signing the contract bond and receiving the date

of start of work. The second and subsequent installments shall be released by the Engineer-

in- Charge only after the contractor furnishes a proof of the 70% of satisfactory utilization of

the earlier installment to the entire satisfaction of the Engineer-in-Charge and after start of

work at site physically. Before any installment of advance is released, the contractor shall

execute a Bank Guarantee Bond from Scheduled commercial Banks (Public Sector Bank) or

such other Bank authorize by Reserve Bank of India for the amount equal to 110% of the

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amount of advance and valid for the contract period. This Bank Guarantee (B.G) from

Scheduled commercial public sector Bank for the amount equal to 110% of the balance

amount of advance) shall be kept renewed from time to time to cover the balance amount and

likely period of complete recovery. Bank Guarantee may be given in more than One

(Maximum 5) parts but equal to 110% of mobilization advance in total and in this case, B.G.

will be released for the amount for which recovery has been made.

Recovery of Mobilization advance:

The mobilization advance as above shall bear a simple interest at the rate of “SBI base

rates ( prevailing at the date of payment +1%” and shall be calculated from the date of

payment to the date of recovery, both days inclusive, on the outstanding amount of advance.

Recovery of such sums advanced shall be made by the deduction from the contractors bills

commencing after first twenty per cent of the gross value of the work is executed and paid, on

pro-rata percentage basis to the gross value of the work billed beyond 20% in such a way that

the entire advance is recovered by the time eighty per cent of the gross value of the contract is

executed and paid, together with interest due on the entire outstanding amount up to the date

of recovery of the installment.

38. Insurance:

38.1 The contractor at his cost shall provide, in the joint names of the Employer and the

contractor, insurance cover from the Start Date to the date of completion, in the amounts and

deductibles stated in the Contract Data for the following events which are due to the

contractor's risks:

a) Loss of or damage to the Works, Plant and Materials;

b) Loss of or damage to Equipment;

c) Loss of or damage to property (except the Works, Plant, Materials, and Equipment) in

connection with the Contract; and

d) Personal injury or death.

38.2 Insurance policies and certificates for insurance shall be delivered by the contractor to

the Engineer for the Engineer's approval before the completion date which will be inclusive

of defect liability period / Start Date. All such insurance shall provide for compensation to be

payable in Indian Rupees to rectify the loss or damage incurred.

38.3 Alterations to the terms of insurance shall not be made without the approval of the

Engineer.

38.4 Both parties shall comply with any conditions of the insurance policies.

39. COMPLIANCE WITH LABOUR REGULATIONS:

During continuance of the Contract, the contractor and his sub contractors shall abide

at all times by all existing labour enactments and rules made there under, regulations,

notifications and bye laws of the State or Central Government or local authority and any

other labour law (including rules), regulations, bye laws that may be passed or notification

that may be issued under any labour law in future either by the State or the Central

Government or the local authority. The list of such regulations and bye laws is given in

Annexure-1. The contractor shall keep the Employer indemnified in case any action is taken

against the Employer by the competent authority on account of contravention of any of the

provisions of any Act or rules made there under, regulations or notifications including

amendments. If the Employer is caused to pay or reimburse, such amounts as may be

necessary to cause or observe, or for non-observance of the provisions stipulated in the

notifications/bye Laws/Acts/Rules/regulations including amendments, if any, on the part of

the contractor, the Engineer/Employer shall have the right to deduct any money due to the

contractor including his amount of performance security. The Employer/Engineer shall also

have right to recover from the contractor any sum required or estimated to be required for

making good the loss or damage suffered by the Employer. The employees of the contractor

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and the Sub-contractor in no case shall be treated as the employees of the Employer at any

point of time.

40. Drawings and Photographs of the Works:

40.1 The contractor shall do photography/video photography of the site firstly before the

start of the work, secondly mid-way in the execution of different stages of work and

lastly after the completion of the work. No separate payment will be made to the

contractor for this.

40.2 The contractor shall not disclose details of Drawings furnished to him and works on

which he is engaged without the prior approval of the Engineer in writing. No

photograph of the works or any part thereof or plant employed thereon, expect those

permitted under clause 40.1, shall be taken or permitted by the contractor to be taken

by any of his employees or any employees of his sub-contractors without the prior

approval of the Engineer in writing. No photographs/ Video photography shall be

published or otherwise circulated.

41.0 APPROVAL OF DESIGNS AND DRAWINGS The contractor shall submit, if applicable as per scope of work, detailed hydraulic and

structural designs and detailed drawings conforming to conceptual drawing including

calculations and specification in triplicate (3 sets), separately for main and all appurtenant

works to be supplied and erected by him. The design, detailed calculations and drawings shall

be got prepared by the contractor from qualified experienced and reputed designer from any

Indian Institute of Technology / National Institute of Technology / Central & State owned

technical institutions which are recognized by A.I.C.T.E. & from any University in

consultation and with the approval of the Engineer, however, the contractor will be entirely

and fully responsible for the structural stability, soundness and water tightness and safety

against earth quakes and wind pressure, of the structure or works to be carried out.

41.1 On submission, these designs and drawing will be reviewed by the Engineer or his

representative and he may suggest modification, alteration, if any, which shall be

promptly complied with by the contractor.

41.2 After satisfying himself, the Engineer will accord approval to the designs, detailed

drawings and detailed specifications. The contractor shall then submit five (5) sets of

final designs, calculations, detailed drawings and specification for all the works

along with required quantity of Cement & Steel duly bound for incorporation in

the contract which will be incorporated and form a part of the contract Such approval

shall however not relieve the contractor of his responsibilities of the correctness of the

designs, drawings and specifications and he shall be fully responsible for that.

41.3 On completion of the contract he shall provide the Engineer with fully dimensioned

built in drawing of the whole installation and construction in five (5) sets embodying

and alterations and amendments that may have been agreed upon and executed. The

contractor shall withdraw any worker or supervisor etc. only after the consent of the

Engineer.

42.0 DISCREPANCIES: If there is a discrepancy between the Drawings and the Specifications, such

discrepancies shall be promptly reported to Engineer and the contractor shall obtain the

Engineer‟s interpretation which shall be binding on the contractor.

43. Dispute Redressal System/Arbitration clause

43.1 If any dispute or difference of any kind what-so-ever shall arises in connection with or

arising out of this Contract or the execution of Works or maintenance of the Works there

under, whether before its commencement or during the progress of Works or after the

termination, abandonment or breach of the Contract, it shall, in the first instance, be referred

for settlement to the competent authority(Chief Engineer), described along with their powers

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in the Contract Data, above the rank of the Engineer, The competent authority shall, within a

period of forty-five days after being requested in writing by the contractor to do so, convey

his decision to the contractor. Such decision in respect of every matter so referred shall,

subject to review as hereinafter provided, be final and binding upon the contractor. In case

the Works is already in progress, the contractor shall proceed with the execution of the

Works, including maintenance thereof, pending receipt of the decision of the competent

authority as aforesaid, with all due diligence.

43.2 DECISION OF CHIEF ENGINEER TO BE FINAL:

Except where otherwise specified in this contract, the decision of the Chief Engineer

for the time being shall be final, conclusive and binding on all parties to the contract upon all

question relating to the measuring of the specification, drawings and instructions herein

before mentioned as mentioned in clause 24 above.

43.3 Either party will have the right of appeal, against the decision of the competent

authority, to the arbitration if the amount appealed exceeds rupees one lac.

43.4 PROCEDURE FOR ARBITRATION:- In case where the contractor is not satisfied with the decision of the Chief Engineer, the

matter shall be referred to the Managing Director. Every dispute, difference or question

which may at any time arise between the parties to the contract or arising out of or in respect

of the contract shall be referred to the arbitration of „MANAGING DIRECTOR‟ of U.P. Jal

Nigam, who will have the power to decide the same as an arbitrator if he so likes or may

nominate any working or retired Chief Engineer of Jal Nigam or any one as an arbitrator to

decide it and his AWARD shall be final and binding on the parties. In the event of the

arbitrator to whom the matter is originally referred being transferred or vacating his office or

being unable to act for any reason, he shall either enter upon the reference himself or appoint

another person to act as arbitrator. Such person shall be entitled to proceed with the reference

from the state it was left by his predecessor. The Managing Director while nominating any

one as Arbitrator will have the power to fix the FEE of the nominee. The arbitrator will have

the power to decide the COUNTER-CLAIM if lodged by the other party. The arbitrator will

also have the power to award pendent elite and further interest on the principal sum so

awarded but not in excess of 6% P.A. (Simple Interest) or as he thinks reasonable. Initially

the FEE of the Arbitrator will be paid by the claimant i.e. the party who invoked the

arbitration clause which will be one of the elements of costs of the arbitration and will finally

be borne by the parties as per award of the arbitrator. The VENUE of arbitration will be

decided by the Managing Director.

In all cases where the amount of the claim in dispute is Rs. 100000/- (Rupees one Lac) and

above, the arbitrator shall give reasons for the award. The party invoking the arbitration shall

specify the dispute to be referred to arbitration together with this amount or amounts claimed

in respect of each such dispute, subject to the provision of the arbitration Act 1940 or any rule

made there under and for the time being in force shall apply to the arbitration proceedings.

The arbitrator may from time to time with the consent of the parties enlarge the time for

marking and publishing the award. The decision taken by the arbitrator will be final and

binding on both the parties in question and matters relating to this contract.

44. Procedure for Resolution of Disputes

44.1 The Competent Authority mentioned in clause 42.2 shall give a decision in writing

within 45 days of receipt of a notification of a dispute.

44.2 Where the Initial Contract Price as mentioned in the Acceptance Letter is Rs. 25.00

Crore and below, disputes and differences in which an Adjudicator has given a

decision shall be referred to a sole Arbitrator. The sole Arbitrator would be appointed

by the agreement between the parties; failing such an agreement within 15 days of the

reference to arbitration, the appointing authority, namely the Managing Director on

49

behalf of Chairman U.P. Jal Nigam shall appoint. Arbitrator will give decision within

45 days. If any fee is to be paid to Arbitrator (not more than Rs. 1.00 Lacs), it shall be

borne equally by both the parties.

44.3 Arbitration proceedings shall be held at Lucknow or any other place as decided by the

both parties mutually in U.P. (India) but on the approval of Managing Director. The

language of the arbitration proceedings and that of all documents and communications

between the parties shall be English.

44.4 Performance under the contract shall continue even after reference to the arbitration

and payments due to the contractor by the Employer shall not be withheld, unless they

are the subject matter of the arbitration proceedings.

44.5 Either party may refer a decision of the Competent Authority to Arbitration within 28

days of the Competent Authority's written decision. Arbitration shall be under the

Arbitration and Conciliation Act 1996. If neither party refers the dispute to

Arbitration within the above 28 days, the Competent Authority's decision will be final

and binding.

44.6 The Arbitration shall be conducted in accordance with the following procedure, in

case Initial Contract Price is more than Rs. 25.00 Crore or the contractor is a Foreign

contractor, who has bid under ICB:-

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51

masonry, shall be provided. The contractor(s) shall also at his/ their own cost make

arrangements for laying pipe lines for water supply to his/ their labour camp from the

existing mains wherever available, and shall pay all fees and charges there off.

(e) The contractor(s) shall make necessary arrangements for the disposal of excreta from

the latrines in a hygienic manner.

(f) The contractor(s) shall provide efficient arrangements for draining away sullage water

so as to keep the camp neat and tidy.

(g) The contractor(s) shall make necessary arrangements for keeping the camp area

sufficiently lighted to avoid accidents to the workers.

(h) The contractor(s) shall make arrangements for conservancy and sanitation in the

labour camps according to the rules of the Local Public Health department.

46. SITE ENGINEER & FIRST-AID:

46.1 The contractor shall employ a site Engineer who is well experienced in the type of the

works he has to handle and shall have worked in similar projects earlier. He should be

well acquainted with all latest Indian Standards, codes of practice, and local practices

of construction and has good managerial qualities. He should also be capable of

handling labour force tactfully and extract good quality of workmanship and have to

plan execution of works efficiently. He shall be well acquainted with specifications,

construction equipment & its use, testing and supervising the works. He shall have

good ability to guide his subordinates, and conscious about the time limit of the

contract.

46.2 The contractor shall make all arrangements for first aid and medical facilities to the

laborers at his own expenses.

46.3 Proper protective accessories and all safety equipments like gum boots, gloves,

goggles and helmets etc. as found necessary, shall be provided to the laborers free of

cost, by the contractor.

47.0 TESTING: The material to be supplied by the contractor as per schedule-“G” shall be tested as

per relevant IS code / relevant Manual issued by MoUD, G.O.I. The contractor shall

give timely notice to the Engineer indicating place and date where & when the testing

is to be carried out. All tests are subject to the approval of the Engineer or any agency

appointed by the Engineer. The stores supplied willfully, without testing shall be

rejected. contractor will provide all testing facilities at his works and at his cost.

48.0 ORAL AGREEMENT: No oral order, objection, claim or notice by any party to the other shall effect or

modify any of the terms or obligations contained in the Contract Documents, and

none of the provision of the Contract Documents shall be held to be waived or

modified by reason of any act whatsoever, other than by a definitely agreed

waiver or modification there-of in writing, and no other evidence shall be

introduced in any proceeding of any other waiver or modification.

49.0 CLEANING UP :

49. 1 contractor shall at all times during the work keep the site and premises,

adjoining property and public property free from accumulations of waste

materials, rubbish and- other debris, resulting from the works, and at the

completion of the work, he shall remove all waste-materials, rubbish and

debris from the site and premises as well as all tools, construction

equipment‟s, machinery and surplus materials and shall leave the site and

premises clean, tidy and ready for occupation by the Engineer-in-Charge. The

contractor shall restore to its original condition those portions of the site not

52

designated for alteration in the tender documents such as paved walkways,

parking areas and road etc.

49.2 Cleaning up operations shall include the removal and disposal of earth that

renders surplus after filling as directed and approved by the Engineer. No

waste material shall be buried or disposed off unless approved in writing by

the Engineer-in-Charge.

50.0 FOSSILS: Any find made on the site such as antique relics, coins and fossils or any other

valuable articles shall be immediately made over to the care of Engineer-in-Charge on behalf

of the Government.

51 TESTS ON COMPLETION: 51.1 After the completion of work the contractor shall give minimum of twenty one (21)

days notice in writing to the Engineer to carry out the required test to ascertain the

soundness of the work executed by him.

51.2 If in the opinion of Engineer the tests are being unduly delayed, he may by notice in

writing, call upon the contractor to make such tests within 21 days, from the date of

issue of letter. In the event of the contractors failure to carry out such tests within the

stipulated time, the Engineer may himself proceed to get the work done at the risk and

cost of the contractor.

53 COMMUNICATIONS: Communications between parties which are referred to in the conditions are effective

only when it is received. However, in case a registered letter sent to the contractor on

the address given by him, is not received by him or his representative the notice will

be considered as delivered and will be effective from the date of dispatch of letter.

54 PERSONNEL: The contractor is to employ either the key personnel named in the Schedule of key

personnel to carry out the functions stated in the Schedule or other personnel

approved by the Engineer. The Engineer will approve proposed replacement of key

personnel only if their qualifications, abilities, and relevant experience are equal or

better than those of the personal listed in the Schedule.

55 MANAGEMENT MEETINGS 55.1 Either the G.M./S.E. or the contractor may require the other to attend a

management meeting. The business of a management meeting is to review the

plans for remaining work and to deal with matters raised in accordance with

the terms and conditions of the contract bond.

55.2 The Engineer is to record the business of management meetings and is to

provide copies of his record to those attending the meeting. The responsibility

of the parties for actions to be taken is to be decided by the Engineer either at

the management meeting or after the management meeting and stated in

writing to all who attended to meeting.

56. CURRENCIES:

All payments shall be made in Indian Rupees.

57. RETENTION:

On the completion of the whole of the works, the total amount retained is repaid to the

contractor when the Defects liability Period has passed and the Engineer has certified that all

defects notified by him to the contractor have been removed.

58. SAFETY MEASURES

The contractor shall be responsible for fencing in a good sufficient manner, all open

excavations, works and materials at site so as to prevent accidents by day and by night. He

shall also be responsible for lighting up in proper and sufficient manner at night the portion of

53

the work which is open or under construction & he shall always maintain a sufficient number

of watchmen on duty when his staff is not actually working. He shall also be responsible for

the safety of his materials as well as any other materials, issued to him for use on the work

from the beginning of the works' up to the time of its completion and handing over. He shall

make his rates sufficiently comprehensive to cover all such charges. In the event of any

accidents, mishaps due to his failure to observe these and other precautions, he shall be

responsible for the payment of all damages, compensations, and losses that may arise. The

rates in schedule "G" shall be deemed included all charges on this account. A List of safety

measures which is mandatory is attached as Annexure-2

59. DISPOSAL FOR SURPLUS EARTH AND CARRIAGE CHARGES

The contractor shall provide disposal for surplus earth within 8 km. as per direction

of Engineer and shall remove from the works, spoils and rubbish and shall include in his rates

quoted for the excavation in Schedule 'G' a sufficient amount to cover the cost of this and all

carriage charges in this connection. He shall also include in his rates all other carriage and

transport charges that may be necessary for the proper carrying out and completion of the

entire contract work. The surplus earth spoils and rubbish so disposed shall be neatly dressed

by the contractor. Engineer may specify the location for the disposal of earth which shall be

binding on contractor. All excavated surplus earth is the property of owner or local body so

disposal of such earth shall be on specified location as directed by Engineer or local body

otherwise contractor shall be liable to pay the cost of earth and royalty as applicable.

60. PUMPING DURING CONSTRUCTION The contractor shall provide all appliances such as pumps engines, machinery suction

and delivery pipes, foundation fastenings, fuel lubrication, cotton, waste and labour necessary

for dealing with sub-soil water, flood water, drainage problem and discharge from

pipelines/sewers broken during construction or any other causes which are encountered

during the construction of the works and the contractor shall make his rates sufficiently

comprehensive to cover the cost of such work until and unless specified in Schedule-G under

a separate item of work of specific nature.

61. WORKMANSHIP

All works, in general, shall be carried out in a most workmanship like manner, true to

level and plumb. The entire work shall be given a neat appearance and appealing look. No

patch or mark of form and shuttering shall be visible in any other parts of the work and the

same shall be made even and smooth. The R.C.C. work shall be rendered even and smooth by

means of cement and coarse sand mortar 1:3 or so and by rubbing it with carborandum stone.

62. EMPLOYMENT AND REMOVING OF CONTRACTOR PERSONS During the execution of work and until the work is taken over by the Engineer, the

contractor shall employ for the execution of the work persons who are careful, skilled and

experienced in their trades and calls. The engineer shall have full power to ask the contractor

to remove immediately from the site of works, who in the opinion of the Engineer,

misconducts or misbehaves or are incompetent in the proper performance of their duties or

are otherwise undesirable.

63. EMPLOYMENT OF MAINTENANCE GANG

The contractor's attention is also drawn to the necessity for employing proper

maintenance gang during the period of maintenance for immediate repairs of any defects that

may be noticed or brought to the notice during the period of maintenance. The Engineer shall

get any such defects rectified if the contractor fails to do so and the cost in this connection

shall be recoverable from contractor.

64. RECORDS TO BE MAINTAINED BY CONTRACTOR

The contractor shall maintain following records at site of work in the desired form.

These records shall be open for inspection by the Engineer/his representative during

54

execution of work. These shall be submitted to the U.P. Jal Nigam on the completion of the

work.

(i) Cement & steel consumption register.

(ii) Log books of Mixer, Vibrator and other such equipment.

(iii)Date wise record showing results of different tests got conducted by the contractor.

(iv) Daily progress report.

(v) Concrete register.

65. SITE OFFICE ,COMPUTOR ,OPERATOR AND VEHICLE

If the tendered cost is more than Rs. Five crores, contractor will have to provide for his use

site office with one attendant on the site with furniture and toilet along with a computer with

operator, two vehicles till the completion of work including testing and trial run and

performance period for which bidder/vendor shall make sufficient provision in his rates as

below.

Signed by Bidder/vendor

Signed on behalf of the Chairman,

Uttar Pradesh Jal Nigam,

Designation of Officer

Contract Value Site office Computer

More than 5.00 crore

to Rs. 25.00 crore

One (20 sq/m) One Desktop with

operator

More than 25.00

crore to Rs. 100.00

crore

One (30 sq/m) + One

additional (20 sq/m)

One Desktop computer

with Operator + one

laptop

More than 100.00

crore

One (30 sq/m) + One

additional (20 sq/m) with

attendant

One Desktop computer

with Operator + two

Laptop

55

CONDITIONS OF PARTICULAR REFERENCE/SPECIAL

CONDITIONS

1. It shall be the sole responsibility of the contractor to obtain the ward wise list of beneficiaries

from Nagar Nigam for making the house connection in his scope/area of work and no additional

payment shall be made on this account.

2. The Contractor shall submit the list of such beneficiaries in the office of Engineer before

execution of the work.

3. The contractor shall get the list approved from the Engineer before commencement of the work.

4. The Contractor shall present the details of the house connection made in the attached

CONNECTION RECIEPT (ANNEXURE 5) which shall be duly filled and counter signed by the

consumer, which will include Identity proof of the house owner.

5. The Contractor shall deposit the above mentioned CONNECTION RECIEPT at the time of

presentation of bill along with a list of connections done by him

6. The identity and list of connections shall be open to inspection and verification by the Engineer

or his representative or by the concern official of Nagar Nigam.

7. The objective of giving house connection under this scheme is universal coverage of each house

hold in the project area, Hence it will also be the responsibly of the contractor that no house is

provided a second connection otherwise his payment shall be withheld which will be released

only after due sanction of Nagar Nigam authorities, Who are the owner of house connection and

sewer system as a whole

8. It will be mandatory for the contractor to get the prior sanction of Nagar Nigam for any second

house connection if so desired on the basis of de facto ownership of more than one family/set of

owners.

General Manager/Executive Engineer Sign of Contractor

56

ANNEXURE-4

Equipments and materials of makes as per the list annexed shall be offered. Any other

make which is approved by competent authority/Chief Engineer(E&M) may also be offered

subject to the sole discretion of the UPJN.

Sl. Description of Item Offered Make.

Non Clog Submersible/ VNC Pump

Motors

M.C.C.B.

Power Cable

PVC copper wires(FRLS)

Lighting Fixtures & Luminaries

Rotary/selector switches

Relays

Volt Meter/Instruments

Ammeter/Instruments

Reflux and Sluice Valve

Chain Pulley Block/Lifting tackles

C.Ts. &PTs.

Push button

Nuts & Bolts

Electro magnetic flow meter

Starter

Cable Termination glands and lugs

Capacitor.

C.I. Pipes and Fitting and Dismantling Joint

CVT

PVC/ HDPE conduits/pipes

11 kV VCB breaker and panel

11 kV end termination & straight through joint

Cable jointing kit

Alternators for DG set

Diesel Engines for DG set

Transformer

Level switch/Indicator

Steel tubular poles

GI pipes/poles

57

SEAL &SIGNATURE OF BIDDER/VENDOR

58

59

60

S

C

H

E

D

U

L

E

–

A

(

C

i

v

i

l

W

o

r

LOCATION OF SITE : Object of this tender is to “SEWERAGE WORKS IN

VINDHYACHAL ZONE OF MIRZAPUR(NPP),VINDHYACHAL,DISTRICT

MIRZAPUR,U.P.The site location and layout plan of STPs (For Tender Purpose Only) is

attached herewith

61

.

ARIAL VIEW AND INDEX PLAN OF VINDHYACHAL, MIRZAPUR

62

Index Plan of Vindhyachal

63

SCHEDULE – B (Civil Works)

==================================================================

===

DRAWINGS: The bidders may inspect the index plan or any other requisite document such

as type designs, unit estimates, structural/architectural drawings etc. for the work under the

scope of this tender in the office of the Project Manager, Ganga Pollution Prevention Unit,

U.P. Jal Nigam, Varanasi on any working day between 10.00 A.M. to 5.00 P.M. before the

due date for submission of tender.

List of drawings to be supplied to the bidder/vendor

Index Map showing plan of STP, MPS and IPS.

Type design and drawing of Building works.

64

SCHEDULE – C (Civil Works)

================================================================

contractor has to furnish a list of vendors of DI K-9 pipes which shall be got approved

by E/I prior to supply and start of work.

I/We have read, under stood and accept for compliance, the above mentioned (Schedule-A to

C) instructions and conditions of this schedule and have taken these factors into account

while quoting rates in schedule-G

Sign of Bidder/vendor

65

SCHEDULE – D

==================================================================

======

LIST OF SAMPLES TO BE SUBMITTED: Tenderer whose offer is accepted has to

submit the following samples in seven days before starting up the work.

1. Sample of construction material, raw material as well as concrete cubes for testing.

2. Samples of DI K-9 Pipe and rubber ring/collar.

In addition to the above the contractor may be required to submit any other sample that may

be required by the engineer before the commencement or during the progress of the work. As

regard specials the contractor shall submit list of manufacturers to be finalized by the

engineer in charge. The materials of only approved manufacturers shall be brought at site for

use in work.

TESTS : All the necessary and required tests before commencement of the work, during the

construction and after the construction regarding material and work shall be conducted as per

latest IS code/Manual on sewerage and sewage Treatment-2013 specifications or as desired

by the Engineer as per terms and conditions of the contract documents. contractor will also

arrange for third party inspection and test certificate from the Manufacturer. All testing

charges shall be borne by the contractor. Following test reports shall have to be submitted by

the contractor.

1. Test of dimensions of DI K-9 Pipe.

2. Three edge bearing test.

3. Absorption test.

4. Hydrostatic test.

5. 7 days and 21 days Cube strength test of concrete.

6. Sieve analysis of sand, core sand and grit.

7. Compressive strength and absorption test of Bricks.

8. In addition to the above the contractor may be required to submit the test report any other

sample that may be required by the engineer before the commencement or during the

progress of the work.

I/We have read, under stood and accept for compliance, the above mentioned (Schedule-D to

E) instructions and conditions of this schedule and have taken these factors into account

while quoting rates in schedule-G

Sign of Bidder/vendor

66

SCHEDULE – E (Civil Works)

==================================================================

===

TIME OF COMPLETION : The complete work as specified herein THIS BID

DOCUMENT shall be completed in all respects, passes to the satisfaction of Engineer-in-

charge and tested as per latest relevant U.P. Jal Nigam/U.P. P.W.D. or I.S.

specifications/codes and provisions of latest CPHEEO Manual, on the subject within

24 (TWENTY FOUR) including 3 months of trail run calendar months from the date

of written order to the contractor for commencement of the work

Note :- As applicable.

The contractor‟s responsibility shall, however, not end till 3 months trial testing form

the actual date of completion and 15 years of O&M. All the defects or damages, if any, found

during the trial and testing period shall be rectified by the contractor at his own cost for

which no claim whatsoever shall be entertained by the department. However responsibility of

the contractor shall not end till the taking over of connection by the local body/Nagar Nigam.

I/We have read, under stood and accept for compliance, the above mentioned

instructions and conditions of this schedule and have taken these factors into account while

quoting rates in schedule-G

Sign of Bidder/vendor

67

SCHEDULE – F (Civil Works)

==================================================================

===

INSTRUCTIONS & CONDITIONS BEFORE QUOTING RATES

1 Tenderers are advised to visit the site and acquaint themselves with the work and their

nature. Tenderers must read and understand the relevant specifications and standards

mentioned in this tender.

2 Tenderers must quote rates for executing these works against items of schedule „G‟ in

figure and as well as words in English or Hindi only.

3 Tenderers must quote the rates taking the account of the liabilities and arrangement to

be done during execution such as Trade tax, probable price escalation and stamp duty.

The rates quoted by the bidder/vendor in schedule „G‟must also include arrangement

of water at site for labour and for testing of pipe lines, arrangement of all labours,

materials and T&P , laying jointing and testing and of pipe lines, arrangement to be

made for safety at site during day and night including diversion of traffic, making bye

pass passages for traffic pedestrians. It should also inclusive cost of 3 months

successful trial run and stabilization period thereafter 15 years operation and

maintenance.

4 In general, the quantities mentioned against items are on the basis of the estimate but

these may vary to any extent on either side for which no extra claim shall be

entertained.

5 Tenderers must also taken into account all the conditions and instructions as detailed

in this tender elsewhere.

6 No claim whatsoever due to any increase in labour rates, railway/highway transport

freight, octroi, market rates, duties of all type, taxes shall be entertained after the

tender has been received. Tenderers are advised to account for these while quoting

the rates.

7 Any conditions, alteration, correction or imposing of conditions other than those

called for shall make the tender liable to rejection.

8 No overwriting shall be accepted and if it is unavoidable, written matter shall be cut

by one line and signed and written in fresh.

I/We have read, under stood and accept for compliance, the above mentioned

instructions and conditions of this schedule and have taken these factors into account

while quoting rates in schedule-G.

Sign of Bidder/vendor

68

SCHEDULE ‗A‘ (E & M WORKS)

PURPOSE:

Provision for all E&M equipments in this tender

document have been made for the construction of 1 Nos. Sewage Pumping

Stations (Ward No 3 Shiv Pur) so as to pump the sewage to Sewage

Treatment Plant and to reduce the pollution load of river Ganga.

WITNESS BIDDER/VENDOR

DATED DATED

69

SCHEDULE ‗B‘ (E & M WORKS)

CONTRACT DRAWING ACCOMPANYING THE

SPECIFICATION:

Plan and elevation of all the e quipment along with detail

showing modification suggested for complete work. Literature, Detailed

Renovation/ Rehabilitation methodology including Schedule for various

activities, characteristic curves, Data Sheets, layout drawing etc. should

also be furnished with the other.

WITNESS BIDDER/VENDOR

DATED DATED

70

SCHEDULE ‗C‘ (E & M WORKS)

LIST OF DRAWING IN DUPLICATE TO BE SUBMITTED BY

THE CONTRACTOR TO THE ENGINEER FOR APPROVAL

DURING THE COURSE OF CONSTRUCTION OF WORKS

1- Completed and final to the scale general arrangement drawing

showing all the electrical and mechanical equipments.

2- Quality assurance plan for all E/M equipments and field quality plan

for execution of the work.

3- Completed and final to the scale foundation plans.

4- Completed and final to the scale other detailed dimensioned and

sectional working drawings required by the Engineer from time to

time.

71

COMPLETION PLAN

03-03 binded set of above drawing/documents together

with the printed instructions, characteristic curves and bulletins of the

various equipment installed at the site of work.

WITNESS BIDDER/VENDOR

DATED DATED

72

SCHEDULE ‗D‘ (E & M WORKS)

TEST CERTIFICATES TO BE SUPPLIED:

Copies of test certificate of all the Electrical &

Mechanical equipments tested at manufacture‟s works shall be sent to the

Engineer by the Contrctor.

WITNESS BIDDER/VENDOR

DATED DATED

73

SCHEDULE ‗E‘ (E & M WORKS)

Testing and performance of Pumping Plants, D.G. Sets

and 11/0.4 KV Sub-Stations and connected works shall be carried out at

manufacturer‟s works as detailed in the scope of work under testing of

equipment. Working and performance of all the equipments shall also be

conducted at site of work as per relevant IS/IER.

WITNESS BIDDER/VENDOR

DATED DATED

74

SCHEDULE ‗F‘ (E & M WORKS)

The complete Dismantling of existing infra-structure, supply,

installation of all the equipment and other appurtenant works will be

completed, tested and commissioned to the satisfaction of Engineer with

21 months from the date of start of work. Thereafter, 03 months trial run

for stabilization of system will be carried out. The completion schedule is

as below:-

1- Construction Work:- 21 Months

2- Trial run, testing, commissioning 03 Months

and stabilization period

3- Defect Liability Period 12 Months

WITNESS BIDDER/VENDOR

DATED DATED

75

SCHEDULE G

(Attached Separately)

76

SCHEDULE – „H‟

ADDITIONAL ITEM RATES

All extra or additional work done or substituted work in place of work

omitted by order of Engineer shall be valued at the rates and price set out

in the contract, if in the opinion of the Engineer same shall be applicable.

If the contract does not contain any rates or prices applicable to the extra

or additional work, then the rates shall be minimum of the following:

(a) Derived from the tendered/contract rates of the contract of

similar class of work.

(b) Derived from the UP. Jal Nigam schedule of rates of the year

in which the work actually done.

If the rates cannot be decided as above for

additional/extra work, then such class of work shall be agreed upon

between the Engineer and contractor in writing prior to the work

being taken up in hand but it shall be based on U.P Jal Nigam/U.P

PWD/U.P Irrigation/CPWD schedule of rate.

WITNESS BIDDER/VENDOR

DATED DATED

77

SCHEDULE – I

==================================================================

=====

DEPARTMENTAL ISSUE RATES OF MATERIALS:No material shall be issued by the

department and the contractor shall arrange and procure all the materials required for proper

completion of work.

Note- Any material if available in U.P. Jal Nigam &demanded by the contractor may be

issued to the contractor but for such material, the contractor shall not claim delay in

work. Such material shall be issued at the rates greater of the following:

I. Current market rate of that time.

II. Book value plus store handling charges.

I/We have read, under stood and accept for compliance, the above mentioned instructions and

conditions of this schedule and have taken these factors into account while quoting rates in

schedule-G

Sign of Bidder/vendor

78

SCHEDULE – ‗J‘ (CIVIL WORKS Excluding STP)

1 Survey, Investigation, Preparation of drawing, design, submission

of approved drawing & design from competent authority

1%

2 During construction period as per measurement 84%

3 After testing and commissioning and stabilization 10%

4 After completion of trial run period of 6 months 5%

100%

79

SCHEDULE – ‗J‘ (CIVIL WORKS FOR STP)

1. Survey, Investigation, Preparation of drawing, design, submission

of approved drawing & design from competent authority

2.00%

2. Construction of 1 no. Inlet System (Screen & Grit Chamber) as per

approved drawing & design.

4.00%

3. Repairing/Rehabilitation of anaerobic pond including leveling,

dressing, repair of embankments, RCC Intake & Outlet Structures,

Membrane Liner 500 micron including all material, labour, T&P

etc. complete as per direction Engineer-in-charge.

1.00%

4. Construction of 1 no. sump cum pump house including inlet

system, E&M Works (such as motors, pumps, DG Set, wiring,

valves etc.) etc. as per the approved design & drawing.

8.00%

5. Construction of 10 nos. vertical flow constructed wetlands beds as

per approved design & drawing.

45.00%

6. Construction of 10 nos. horizontal flow constructed wetlands beds

as per approved design & drawing.

18.00%

7. Construction of 1 no. Chlorine contact tank as per approved design

& drawing.

4.00%

8. Construction of 1 no. Alum dosing system as per approved design

& drawing.

0.50%

9. Construction of C.C. road with M-20 grade mix over PCC 1:4:8

including necessary excavation, cartage upto site and disposal of

surplus earth, all labour, T&P, all taxes etc. complete as per

approved design & drawing.

1.00%

10. Construction/Repairing/Rehabilitation of boundary wall as per

approved design & drawing.

1.00%

11. Internal wiring/other necessary electrical and mechanical works as

per approved design & drawing.

0.50%

12. After testing and commissioning and stabilization 10.00%

13. After completion of trial run period of 6 months 5.00%

100%

80

SCHEDULE – ‗J‘

TERMS AND METHOD OF PAYMENT (E&M WORKS)

1.

(a)

SUPPLY

Procurement of Pumping Plants, Generators, Transformer, Piping

and Valves, Starters, Main LT Panel, HT Panel, Control panel spares

for Pumping plants, specials, Metering Apparatus, H.O.T. Crane,

Power wiring and earthing materials etc required for complete

installation.

70 %

(b) Along with progressive payment of related Installation / erection 15 %

(c) Along with progressive payment for testing in field condition and

commissioning

5%

(d) After completion of six calendar months of trial run period and

issuance of taking over certificate

10%

TOTAL 100 %

2.

(a) INSTALLATION

Installation / Erection of related items

70 %

(b) After satisfactory testing in field condition and commissioning 20 %

(c) After completion of six calendar months of trial run period and

issuance of taking over certificate

10%

TOTAL 100 %

NOTE:

1. All the payments as mentioned above shall be advance payment and in no case it shall

be treated as acceptance of work for which such payment has been made

2. All the rates in schedule G are inclusive of all government levies, GST, F.O.R. site.

3. contractor will be fully responsible for proper storage of material after the supply and during

the erection till the commissioning.

Signature ………………… Signature …………….

Name of Tenderer …………… Name ……………..

Company / Firm Seal UPJN Office Seal

Note: The percentage payment mentioned herewith against each item is percentage of

cost of equipment / Plants

81

Technical Specifications

82

(A) SCOPE OF WORKS

1.1 General

Scope of work consists of “Survey, Investigation, collection of all type of field data, soil characteristics, underground utilities and accordingly preparation of Engineering design & drawing for Laying 25.804 Km sewer line (200 mm- 700 mm), construction of Patengra SPS (3 mld), Laying of rising mains Patengra SPS( 200 mm diameter, 335 m length), construction of 7 mld capacity STP based on SBR technology with disinfection system with all appurtenant works including testing and commissioning on Turn Key basis. STP will be constructed in the campus of existing STP. Total duration of the construction of work is 24 months including three (3) month for testing and commissioning. After three month of testing and commissioning a period of 12 months for defect liability period.The contractor shall carry out all the items of work required for the successful completion of the work, mentioned in the price schedule as a turnkey contract including replacement & repair of underground utilities such as for power cable and other obstacles. All tools, tackles, machinery, manpower and all consumables, materials, equipment, machineries, instruments, accessories, Electricity, Water skilled and unskilled manpower and all safety indication devices etc. are to be arranged by the contractor for full completion of work. Although Contractor shall be actively involved in getting the permissions for road cutting and power connection at Sewage Pumping Stations and Sewage Treatment Plant but power connection charges shall be paid by the owner to the concerned departments directly.

Scope of work shall include but not limited to the following: -

1. Detailed survey, Investigation & concise collection of all type of field data, soil

characteristics, underground utilities etc around site of work ie. In sewerage District D of Allahabad.

2. Preparation and submission of detailed engineering design and drawings of all the works

given in price schedule of the tender. 3. Execution of the following works:

A. Gravity Sewers

(i) Supply of RCC NP2/ NP3/ NP4 non pressure pipes and Laying of gravity sewers of the following sizes and length in different parts of sewerage district D.

Material of Pipe Size/ Diameter of Sewers

Total Length

DI K7 200 mm 21297 m DI K7 250 mm 1652 m

Sub Total 22949 m RCC NP3 300 mm 442 m RCC NP3 350 mm 514 m RCC NP3 400 mm 413 m RCC NP3 450 mm 648 m RCC NP3 500 mm 562 m RCC NP3 700 mm 86 m

Sub Total 2665 m G. Total 25614 m

83

(ii) Construction of manholes in accordance with the provisions laid down in the latest version of IS 4111(Part 1).

(iii) Laying of sewer of following sizes by micro tunneling method.

Size/ Diameter of Sewers

Total Length

200 mm 110 m 300 mm 25 m 400 mm 30 m 450 mm 25 m

Total 190 m

(iv) Permanent reinstatement of roads after sewer laying works as per PWD

specifications including sand filling in the trenches where depth of excavation is more than 3.0 m.

B.

C. Rising Mains:

(i) Laying & Jointing of Patengra IPS of 200 mm Dia folowing sizes DI/ CI/ PSC pipes rising mains with specials including fixing of sluice valves, scour valves, air valves at proper locations etc complete.The work also incluses dismentling of roads, excavation, timbering & shoring, dewatering, refilling of trenches and temporary reinstatement of roads.

E. Construction of New Sewage Pumping Stations

(i) Construction of Patengra SPS (3 mld)

(a) Civil Works:

Screen channel, for installation of two mechanical and three manual screens.

Construction of wet well and Valve Chamber.

Construction of platform for Diesel Generator

Construction of MEP Building

Construction of transformer yard

3.60 m wide Campus road, Boundary wall, fencing with 2 gates

Fire fighting arrangements, land scaping, site development etc.

(b) Electrical & Mechanical works:

Pumps of capacity 145 cum/hr at 15 m Head - 3 Nos.

Pumps of capacity 60 cum/hr at 15 m Head - 2 Nos. conveyor system Suction, Delivery lines, rising main with necessary valves and other

accessories 3 ton capacity HOT crane – 1 No. Panels HT vacuum circuit breakers One DG set of 250 kVA HT / LT cabling, bus trunk system, cable tray arrangement

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LT panel with proper protection and metering arrangement Automatic power factor control (APFC) panel for power factor improvement

F. Construction of 7 mld STP based on SBR technique: Supply, erection,

installation, construction, testing & commissioning of 7 mld capacity Sewage Treatment Plant based on SBR technique. The STP will have following units and effluent of STP shall meet the standards given in this tender document

1. INLET CHAMBER 2. MANUAL SCREEN CHANNEL 3. MECHANICAL FINE SCREEN CHANNEL 4. GRIT CHAMBER DISTRIBUTION CHANNEL 5. MECHANICAL GRIT CHAMBER 6. GRIT CHAMBER OUTLET CHANNEL 7. PARSHALL FLUME 8. SPLITTER BOX 9. SEQUENTIAL BATCH REACTOR 9a. SELECTOR ZONE

10. SLUDGE SUMP 11. BLOWER BUILDING 12. UV DISINFECTION CHANNEL 13. RIO FOR SLUDGE TREATMENT AREA 14. SLUDGE THICKENER 15. THICKENED SLUDGE SUMP 16. CENTRIFUGE FEED PUMP HOUSE 17. CENTRIFUGE BUILDING (FIRST FLOOR) 18a. POLYMER DOSING TANK 18b. PAC/ FeCI3 DOSING TANK 18c. DOSING, CHEMICAL STORAGE AREA 19. FILTRATE SUMP 20. WORKSHOP/ STORE HOUSE 21. GRIT/ SCREEN STORAGE SPACE 22. ADMIN & LABORATORY (G+1) 23. SLUDGE DUYING STORAGE AREA 24. MCC ROOM-1 (GROUND FLOOR) 25. MEP ROOM (PMCC ROOM) 26. OPERATOR ROOM (FIRST FLOOR) 27. IIT PANELROOM 28. STP DG SET AREA

29. CONTROL ROOM

1.2 Design & Drawings The detailed design / working drawings shall be submitted in four copies by the successful contractor within 30 days from issue of Letter of Indent (LOI) to UPJN which will be approved by Engineer-in-Charge before the start of execution of work. Contractor is liable to provide 6 (six) sets of approved design and drawing sets to Engineer along with soft copies and tracings. If changes in the submitted design / drawings are required, Engineer may either himself do so prior to approval or may request the contractor to submit the design / drawings after making the required amendments. (i) On submission these designs and drawing will be reviewed by the Department/

85

Engineer or his representative and he may suggest modification, alteration, if any, which shall be promptly complied with by the contractor.

(ii) After satisfying himself the Engineer will accord approval to the designs, detailed drawings and detailed specifications. The contractor shall then submit three CD sets of final designs, calculations, detailed drawings and specification for all the works duly bound for incorporation in the contract which will be incorporated and form a part of the contract. Such approval shall however not relieve the contractor of his responsibilities of the connectness of the designs, drawings and specifications and he shall be fully responsible for that.

(iii) On completion of the contract he shall provide the Engineer with fully dimensioned drawing of the whole installation and construction in triplicate (3 sets) along with soft copy embodying and alterations and amendments that may have been agreed upon and executed. The contractor shall withdraw any worker or supervisor etc, only after the consent of the Engineer.

(A) General Requirements:

1.1.1. Design and Engineering

a. The Contractor shall execute the basic and detailed Design of STP, SPSs and

allied structures and its execution in compliance with the technical

specifications and requirements contained in the contract, codes of practices as

published by the Bureau of Indian Standard (BIS) or its equivalent standard as

well as the latest version of “Manual on Sewerage and Sewage Treatment” as

published by the Central Public Health Engineering Organization (CPHEEO)

of the Ministry of Urban Development, Government of India, New Delhi.

Wherever, the codes, standards and manual do not provide for the Design and

execution of some component i.e. required to be Designed and executed, the

contractor shall follow the standard engineering practices as approved by

Design-Build-Operations Engineer.

1.1.2. Proposed treatment scheme

The treatment scheme shall include facilities (complete in all respects)for

receiving sewage, screening, degritting, any proven treatment unit, flow

measurement, disinfection and sludge management. Provision of exact

components shall depend on the proposed technology. In addition the following

units shall be provided as applicable to the proposed technology:

i. Electrical substation

ii. Adequate lighting to all the units.

iii. Fire-fighting equipment as per state Government department of Fire services

iv. Health, Safety and Emergency (HSE) plan must be incorporated for the

management of all staff and activities undertaken in construction and O&M

of the STP. .

v. Provisions for power generation units (if found feasible), engine rooms with

gas engines and accessories.

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1.1.3. The following general rules shall be followed in arranging the Plant:

i. Minimum clear distance of 6 m shall be allowed between adjacent units of

treatment or fixed structures to permit safe and convenient access for

operation and maintenance;

ii. Open area with necessary pavement, adjacent to all mechanical Plant shall

be provided as a maintenance lay down area;

iii. Fixed runways, lifting eyes or other means shall be provided to permit the

removal of Plant equipment that may logically be required to be removed

during the course of its normal operational life for maintenance or any other

purpose;

iv. Areas where leakage is likely to occur whether in normal use or during

maintenance, shall be provided with covered drainage channels which shall

direct the spillage either to a suitable drain or to a sump from where it can

be pumped;

v. Provided acoustic coverings where necessary to limit the noise produced

during normal operation to the limits detailed in these documents;

vi. Plant shall be arranged and the building designed to permit convenient

maintenance and removal of equipment;

vii. Environmental impacts during construction and installation/erection

works and O&M shall be identified and evaluated for geology,

seismology, soils, water resources and hydrology, physical environment

such as air quality, sound levels and noise, transportation; anticipated health

effects under normal conditions, health effects under accident conditions etc,

and relevant mitigation measures shall be implemented.

viii. Provide adequate supports and restraints for process piping, valves and

appurtenances.

ix. Connect pipework to equipment with flexible connections or make

other provisions to avoid transfer of pipe loads to devices.

x. All electro mechanical equipment, electronic instrumentation and Air

conditioning facilities shall be designed to withstand the corrosive

environment that will be prevailing in the STP.

xi. All sluice gates, valves, piping, Screens, degritting equipment, aerators and

air piping, sludge handling equipment, which will be submerged in or in

contact with sewage or sludge and stairs or ladders and hand railings for

access and platforms and walkways shall be designed with Corrosive

resistant material.

xii. Chemical piping for supply and feed of chlorine and polymer shall be of

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corrosion resistant material and shall be secured to racks or trays to be fixed

to duct walls or walls of tanks and buildings as necessary. The method of

securing the pipes to the racks and / or trays shall be by clips or similar

devices and shall be of corrosion – resistant material facilitating ease of

xiii. removal in such a way that individual runs can be changed without

dismantling adjacent pipes.

xiv. All chemical piping shall be colour banded and suitably labeled to enable

individual lines to be identified throughout their run.

xv. Particular attention shall be paid to the layout of the chemical piping, which

shall be functional and neat in appearance. Generally, where pipework is

installed in ducts, it shall be supported not less than 150 mm clear of the

floor.

xvi. Where materials subject to UV degradation are employed, they shall

be shielded from direct sunlight.

xvii. Provide necessary platforms and walkways with proper flooring works at all

levels for operation of valves, gates and mechanical equipment with stairs or

ladders and hand railings for access.

xviii. Human contact with the sewage or sludge during O&M of STP shall be

strictly avoided

1.1.4. Provision of Modular Construction for Sewage Treatment Plants

All the treatment units shall be designed and constructed for their respective flows

/ capacities mentioned in these technical specifications and shall be constructed in

suitable modular or treatment train capacities. The minimum number of modules

or treatment trains and the minimum number of each unit process component

required shall be provided to facilitate O&M. Wherever no modular approach and stand by equipment is being proposed, the bidder will provide proper justification and certify that the proposed system will fulfill effluent design standards and other safeguards in all possible flow fluctuations.

1.1.5. Receiving of Sewage

Raw Sewage will be delivered through sewer network into a Receiving Chamber to be

constructed in this contract and from where it will be taken into downstream screens.

Receiving Chamber shall be of adequate size to meet the working space requirements.

The flow from the receiving chamber will lead to

further units such as screening/ grit chamber/ secondary treatment unit etc.

based on the technology and process flow being proposed by the bidder..

1.1.6. Flow Measurement:

All pumps shall be provided with flow meters and an ultrasonic flow transmitter shall also

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be provided in the common header of the raw sewage Pumps.

1.1.7. Disinfection:

The Treated Sewage from the Secondary treatment units will be disinfected uing suitable

cost effective process/ technology. The treated and disinfected sewage shall be discharged

at near by nala (about 100 m from the plant) which ultimately falls in river Ganga.

1.1.8. Sludge Handling System – meet the relevant disposal standards:

Safe disposal of sludge meeting the required standards shallbe proposed by any required

processes namely thickening, digestion, aeration and de watering or their combination.

Efforts shall be made to reduce the sludge volume to the extent possible in a cost-

effective manner. Sludge should be stabilised before disposal. Human contact with sludge

shall be avoided.

1.1.9. Design criteria:

a. The Bidders are to adopt the same nomenclature as mentioned in the bid

document (to the extent possible) used for various treatment units in their

design report . Wherever new/ proprietary terms are being used, they shall be

explained in sufficient detail.

b. The STP shall be designed for 7 MLD capacity. The land provided is for

augmenting the capacity to the ultimate flow of 9 mld. The General

Arrangement Drawing (GAD) supported by hydraulic sizing calculation for

ultimate flow of 9 mld shall be provided. However the detailed design shall be

furnished for only 7 MLD.

c. To the extent possible, the plant must be designed in modules so as to augment

the capacity as and when the plant reaches its designed capacity. It is also

informed that the expected sewage flows cannot be generated immediately after

construction and that the sewage flows are likely to increase gradually and that

the STP should be able to perform at the designed levels even with these low

flows.

d. The process design of various units shall be done as per the norms prescribed in

the CPHEEO Sewerage Manual (Latest Edition) . If no guidelines are

mandated by CPHEEO for a certain component, the bidder shall demonstrate

that the guidelines being adopted are based on past successful experiences in

similar situtations and conform to best engineering practices.

e. The Designs and drawings as formulated by the contractor shall be subject to

approval by the owner or its authorized representative.

f. The Contractor shall be responsible for any discrepancies, errors or omissions

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in the specifications, drawings and other technical documents, desired output /

performance of the STP, whether specifications, drawings and other

documents have been approved by the Owner or its representative or not,

provided that such discrepancies, errors or omissions are not because of

inaccurate information furnished in writing to the Contractor by or on behalf

of the Owner.

1.1.10. Codes and Standards

Wherever references are made in the Contract to codes and standards, in

accordance with which the Contract shall be executed, the edition or the revised

version of such codes and standards 30 days prior to the Submission Deadline

shall apply unless otherwise specified. During Contract execution, any changes in

such codes and standards shall be applied after approval by the Owner/Owner‟s

Representative and shall be treated in accordance with GC Section 10.1.

1.1.11. Design Responsibilities

a. The Contractor ‟s Design and Design-related services shall include, but not

limited to the following:

1. Site investigation and data collection including geotechnical assessment

and soil analysis for the Design and construction of the structures required

for the STP, SPSs and allied works;

2. Selection, adoption and detailed engineering Designs for the most

appropriate techno economically feasible cost effective treatment process

technology for the treatment of the sewage ensuring that the treated

sewage meets with the stringent of the disposal standards prescribed by the

MOEF / CPCB and in the contract as may be applicable. These standards

are prescribed below:

Sr. No.

Parameter

Effluent standards for discharge into Water bodies As per MoEF

Guidelines

i. PH value 5.5 – 9.0

ii. Temperature Shall not exceed 5degree

Celcius above the

receiving water

temperature

iii. BOD ( 3 days at 27°C), mg/L

≤ 10

iv. COD, mg/L ≤ 100

v. Total suspended solids, mg/L

≤ 10

vi. Residual Chlorine, mg/L ≤ 1

vii. Oil and grease, mg/L ≤ 10

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viii. Total Nitrogen, mg/L ≤ 10

ix. Tot l Phosphate as P, mg/l ≤ 5

x. Fecal Coliforms MPN/100 ml

Desirable -100

Permissible – 230

xi. Bio-assay test 90% survival of fish after

96 hours in 100% Effluent

3. the acquisition of all data and information necessary to prepare the Design

and that are required to demonstrate that the 7 MLD STP meets or

exceeds the Technical Standards;

4. Preparation of Design development documents, based on the approved

HFD /schematic Design documents accepted by the Owner, consisting of

drawings and other documents appropriate to the size of the 7 MLD STP,

SPSs to describe the units and character of the entire proposed plant

including architectural, mechanical, civil works, and electrical systems,

materials, operations, landscaping, and such other elements as may be

appropriate; design shall be done to accommodate peak flow also.

5. the preparation of Design-Build Documents setting forth in detail the

requirements for construction based on the Design development

documents accepted by the Owner;

6. obtaining all approvals, permits, including building permits, and licenses

for the Design-Build Services, necessary compliances with occupational

health and safety requirements, environmental management plan as

specified in Appendix 1 of SCC, except for those approvals, permits or

licenses that the Owner is explicitly required to obtain itself under the

Applicable Law in which case the Contractor shall prepare all

documentation and provide assistance to the Owner in obtaining such

approval, permits or licenses;

7. the conducting of general reviews of the progress of the Design process, to

the extent necessary, in order to determine to the Contractor ‟s satisfaction

that the Design services are performed in compliance with the

requirements of the Contract and Applicable Laws.

1.1.12. Design-Build Documents

a. The Contractor shall prepare all the Design-Build Documents. The Design

Build Documents shall include the plans, Designs, drawings, as-built

documents, operations manuals, specifications, schematic Design documents,

Design development documents, and all modifications thereto required in

order to properly and fully test for, analyses for, plan, Design and build the

STP and all allied works as contemplated in the Technical Standards and the

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remaining provisions of the Contract.

b. The Contractor shall prepare any other document, as may be requested by the

Design-Build-Operations Engineer, that the Owner considers necessary to

monitor the progress of the Design-Build Services and assess the Contractor ‟s

compliance with the Contract.

c. The Contractor shall provide the Owner with three sets of all of the Design-

Build Documents in reproducible form and shall modify them to keep them

up-to-date as requested by the Owner acting in a professionally reasonable

manner. The Design-Build Documents, with the exception of the as-built

documents, shall be subject to the review and approval of the Owner prior to

performing any of the services set out in DBSS in respect of any Design-Build

Document.

d. When the Contractor notifies the Owner in accordance with DBSS, the

Contractor shall provide to the Owner one copy of the “as built Designs,

Drawings/Documents” in reproducible form showing the exact as built

locations, sizes and details of the STP. The STP shall not be considered to

have reached Completion for the purposes of DBSS until such Design-Build

Documents have been provided. The Contractor shall update the as built

Designs, Build Drawings/Documents as necessary for the correction of defects

or deficiencies contemplated by DBSS.

1.1.13. Design Considerations

In preparing the Design for the STP and allied works and the Design-Build

Documents, the Contractor shall,

a. Protect public health and safety, including by the means set out in DBSS

b. maximize the protection of the environment and minimize any

adverse environmental impacts caused by the construction of STP throughout

the Service Area and Country, including as may be required,

recommended or advisable pursuant to any technical standard or

environmental assessments conducted on, at or near the STP site and by the

means set out in DBSS;

c. Consider the existing infrastructure and the Sewage Treatment Plant to be

connected with the Trunk infrastructure.

d. Ensure the STP and allied works has the capacity to accommodate the

anticipated sewage based upon the verifications prepared by the Contractor

pursuant to DBSS;

1.2. Design Responsibilities – On Site Issues

In preparing the Design for the STP and the Design-Build Documents, the

Contractor shall ensure that the Design,

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a. makes adequate preparation and plans to ensure traffic movement and safety

during the laying of the network.

b. makes adequate preparation and plans and takes adequate measures for

controlling access to the STP site by animals and humans and vehicular traffic

at the perimeter of the site, including plans for plantings and vegetation,

fencing, lockable gates at vehicular access points, and the creation of an

internal (perimeter access corridor inside or, with appropriate local and other

approvals, surrounding the Site;

c. provides for allied works like control valves chambers, anchor /thrust /pedestal

blocks, internal access roads within the site and proposed units within the STP

site;

d. provides for ancillary works like new approach road that lead to or will be

used to access the Plant, culverts, compound wall with gates, fencing etc.;

e. provides for all utility services required for all of the Services

f. provides utilities services at the STP site such as electricity, telephone, potable

water, non- potable water and sewage collection and disposal.

1.2.1. Sewage Treatment Plant and SPS Layout and operation sequence

a. The Contractor shall be responsible for the planning and Designing of the

area of the Site for 7 MLD STP and SPSs, including,

b. Design and Construction of 7 MLD STP and SPSs and all allied /ancillary

works with an approach road to enter the facility and then carry out STP

Operation & Maintenance for 10 years by way of other services. Contractor

shall verify these details as per site condition.

c. The STP shall comprise treatment process, as may be techno economically

feasible and cost effective.

d. The Contractor shall have responsibility to dispose the treated sewage at the

designated location under the Contract. The Contractor shall have no right

over the use of treated wastewater and sludge except for generation of power

from sludge (if found feasible) for use in the STP.

e. On completion of the 10 years O & M period, the contractor shall have to

handover the STP to the Owner in full working condition, with necessary

replacements of the components towards the end of their economic life as

suggested by the manufacturers / operations manuals etc.

f. Also includes landscaping of plant area, internal roads with access to all units,

illumination of the entire STP site, pathways, storm water drainage, compound

wall all around & gates, administrative building including store house for tools

and spares, laboratory with water supply and waste water disposal

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arrangements, access road of 7 m carriageway, O&M manual and as-built

drawings for all civil, electrical & mechanical works. All units shall be

provided with draining arrangements with suitable valves/gates with

chambers.

g. Supply and providing safety equipment namely gas mask, breathing apparatus,

Air hose respirator, portable lighting equipment, non-sparking lighting

equipment, portable air blowers, safety belts, inhalators and diver suit at the

commencement of O & M.

h. The contractor shall train the Owner‟s selected staff for on job training during

the specified 6 months of O & M period. A Maximum of Fifteen (15) staff of

Owner will be trained for a total period of 45 days during the last year of the

Operations Period.

i. Handing over of the Plant in good working condition with all relevant

documents such as as-built drawings, physical & operational condition of the

assets, rights on proprietary technologies, software, systems, O&M manual,

periodical reports along with soft copy to Owner.

j. Design shall be such that the plant requires minimum land foot print within the

total land made available under this contract and also lesser energy and less

manpower requirement with full automation for its sustainable and efficient

operation & maintenance.

i. For the disposal of Grit and screening materials, solid waste etc., the same

shall be disposed of by the contractor at his own cost at the site

Designated by the Owner

1.3. Design of 7 MLD STP, SPS (3.00 MLD) on Site Areas for Other Uses

a. In preparing the Design and layout for the STP, SPSs and allied structures, the

Contractor shall Designate areas of the site for use in,

i. SPSs

ii. Sewage Treatment Units including receiving well/ equalisation

chamber, pumping arrangement and other elctro-mechanical units/

equipment;;

iii. Sludge handling facilities;

iv. Ancillary works;

v. Site administration and Lab building;

vi. Perimeter buffer zones;

vii. Staff quarters etc.

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1.4. Surface and Ground Water Management

In preparing the Design for the STP and all allied works and the Design-Build

Documents, the Contractor shall,

a. plan and Design the surface drainage at the Site of STP and SPSs with

adequate water drainage channels, pipes, sewers, structures and appurtenances,

including for higher, adequate to manage the highest seasonal levels and

volumes of storm water; and

b. plan and Design the STP and SPSssite with adequate protection from flooding

whether from rain, groundwater, high rivers, storms or any other source.

1.5. Site Administrative Facility

a. The Contractor shall be responsible for the administration of the STP, SPSs

and all allied works during the Design-Build Period and the Contractor shall

Design,

b. temporary office facilities for use by the Contractor and its Sub Contractor s

in the administration and execution of the Design-Build Services;

c. Project Facility for use in the administration of the Operations Services to

accommodate personnel, furniture, utility services, a lunch room, washrooms

and public toilets adequate or the Operations staff;

d. appropriate signage for the Site and the STP and SPSs , including signs that,

i. identify the STP, SPSs and its units;

ii. provide warning and hazard notification in Designated areas where

warranted; and

iii. identify areas of the STP and SPSs that are restricted to visitors and are

accessible to only Designated employees of the Contractor ;

e. the landscaping for the Facility as per the Design-Build Documents;

1.6. Other Design Responsibilities

The Contractor shall carry out the following Design or Design-related

responsibilities:

a. the Contractor shall prepare plans and Designs for all temporary works as

required by the Contractor ‟s Design and as required by the Contract

b. the Contractor s shall prepare plans and Designs for landscaping of the site;

c. the Contractor shall prepare plans and Designs for the acquisition of all data

and information necessary to prepare the Design, including, but not limited to,

any intrusive site investigations, off-site surveys and environmental baseline

monitoring required or contemplated under the Contract; and

d. the Contractor shall prepare detailed plans and methodologies for the testing

and inspection of the Plant and Equipment.

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(B) GENERAL SPECIFICATIONS

Technical Specifications:

A. Sewage Treatment Plant of 7 MLD Capacity

1.0 Primary Treatment Units

Primary Treatment Units comprising Inlet Chamber, Fine Screen Channels and Grit

Chambers shall be designed for Peak Flow.

1.1 Inlet Chamber

Inlet Chamber of STP shall receive the flow from Raw Sewage Pumping Station, located in

STP area. Inlet Chamber shall be designed for Peak Flow. The entire construction shall be in

M30 grade reinforced cement concrete and as per IS 3370. RCC Platform/Walkway,

minimum 1.20 m wide with Hand Railing as per specifications shall be provided. RCC

Staircase, minimum 1.20 m wide with Hand Railing as per specifications shall be provided

for access from Finished Ground Level to the top of the Unit & to the Operating

Platform/Walkway.

Average Flow : 7 MLD

Peak Factor : 2.25

Peak Flow : 15.75 MLD

Number of Units : 1 No.

Hydraulic Retention

Time : 30 Sec at Peak Flow

Free Board : 0.50 m min.

All other accessories, whether specified or not, but required for completion of Contract

shall form the part of Bidder‟s Scope.

1.2 Mechanical & Manual Fine Screen Channels

Two Mechanical Fine Screens (Working) and one Manual Fine Screen (Standby) shall be

provided in Fine Screen Channels. Each Fine Screen Channel shall be designed for 50% of

Peak Flow. Mechanical screen shall be of Mat/perforated plate type.

The entire construction shall be in M30 grade reinforced cement concrete and as per IS

3370. RCC Platform/Walkway, minimum 1.20 m wide with Hand Railing as per

specifications shall be provided. RCC Staircase, minimum 1.20 m wide with Hand Railing

as per specifications shall be provided for access from Finished Ground Level to the top of

the Unit & to the Operating Platform/Walkway.

The clear opening shall be 6 mm for Mechanical Fine Screen and 10 mm for Manual Fine

Screen. The Mechanical and Manual Screens shall be made of SS 304 flats (3 mm for

Mechanical and 8 mm for Manual Screen). Bin and Chute arrangement shall be provided to

take the screenings. Screenings dropped from Chute shall be collected in a wheel Burrow.

Manually operated CI Sluice Gates shall be provided at the upstream and downstream ends

to regulate the flow.

Average Flow : 7 MLD

Peak Factor : 2.25

Peak Flow : 15.75 MLD

Number of Units : 1 Mechanical (Working) + 1 Manual

(Stand by) each of 50% of Peak Flow capacity.

Approach Velocity at Average Flow : 0.30 m/s

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Velocity through Screen at Average Flow : 0.60 m/s max.

Velocity through Screen at Peak Flow : 1.20 m/s max.

Free Board : 0.30 m min.

Wheel Barrow : 1 No. min.

All other accessories, whether specified or not, but required for completion of Contract

shall form the part of Bidder‟s Scope.

1.3 Grit Chambers

Two Mechanical Grit Chamber (Working) along with one Manual Bypass Channel

(Standby) shall be provided after Fine Screen Channels. The Grit Chamber shall be designed

for 50% of Peak Flow and the Bypass Channel shall be designed for 50% of Peak Flow.

The entire construction shall be in M30 grade reinforced cement concrete and as per IS

3370. RCC Platform/Walkway, minimum 1.20 m wide with Hand Railing as per

specifications shall be provided. RCC Staircase, minimum 1.20 m wide with Hand Railing

as per specifications shall be provided for access from Finished Ground Level to the top of

the Unit & to the Operating Platform/Walkway.

Each Grit Chamber shall have the following features:

One tapered Inlet Channel running along one side with adjustable Influent Deflectors for

entry of sewage into the Grit Chamber.

One tapered Outlet Channel for collecting the de-gritted sewage, which overflow over a

adjustable Weir into the Outlet Channel. It shall be designed in such a way that no settling

takes place in it.

One sloping Grit Classifying Channel in to which the collected grit shall be classified.

The grit from Classifier shall be collected in a Wheeled Trolley.

A Grit Scraping Mechanism.

Screw Classifier or Reciprocating Rake Mechanism to remove the grit.

One Organic Matter Return Pump

Manually operated CI Sluice Gates shall be provided at entrance of the Inlet Channel of the

Grit Chambers as well as Byp ass Channel to regulate the flow.

Average Flow : 7 MLD

Peak Factor : 2.25

Peak Flow : 15.75 MLD

No. of Units : 1 Mechanical (Working) of 50% of Peak Flow capacity

Type : Mechanical

Size of grit particle : 0.15 mm

Specific gravity of grit : 2.65

Maximum Surface Overflow Rate : 960 m3/m2/day

Free Board : 0.30 m min.

Side Water Depth : 0.90 m min.

Wheel Barrow : 1 No. minimum

All other accessories, whether specified or not, but required for completion of Contract

shall form the part of Bidder‟s Scope.

Flow Measurement

Flow measurement shall be done online using an ultrasonic flow meter on the rising main.

2.0 Sequential Batch Reactor (SBR) Units

2.1 General

The Sequential Batch Reactor (SBR) Process shall be an advanced activated sludge process

with in-built nitrification, de-nitrification and biological phosphorous removal. The process

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shall utilize a Fill-and-Draw Reactor with complete-mix regime and operating in true-batch

mode. The complete process shall be divided into Cycles with each Cycle is of duration of

2.5 – 4 hours. All the subsequent treatment Steps – Fill/Aeration, Settling and Decanting

must take place sequentially and independently without overlapping. During Fill/Aeration

phase, the sewage shall be filled into SBR Basins and part of the treated sewage along with

activated sludge shall be recycled with the help of Recycle Pumps. Air shall be supplied for

aeration with the help of Air Blowers. During settling phase, the Filling/Aeration shall be

stopped and the mixed content shall be allowed to settle under perfect settling conditions.

During Decanting phase, the supernatant shall be removed form top with the help of

Decanters and excess sludge shall be wasted with the help of Waste Pumps.

It shall be mandatory for the bidders to tie up with a SBR technology provider and submit a

tie up agreement duly signed and notarized on a Rs. 100 non judicial stamp paper. The

technology provider should have experience of providing SBR technology in India for at

least 3 numbers of STPs each of 7 MLD capacity and achieving the treated sewage quality

as BOD ≤ 10 mg/l, TSS ≤ 10 mg/l, NH4-N ≤ 2 mg/l, TN ≤ 10 mg/l and TP ≤ 2 mg/l and

each should be working satisfactorily for at least five years as on date.

2.2 Process Design

Sequential Batch Reactor (SBR) Units shall be installed and equipped for average flow of 7

MLD.

The SBR Process shall have following independent steps without overlapping each other:

Fill & Aeration

Settling (Sedimentation/Clarification)

Decanting (Draw)

Filling, during Settling or Decanting will not be acceptable.

The complete biological system shall be designed for handling peak flow.

Suitable Nos. of SBR Basins with adequate volume shall be provided. In addition, 0.50 m

Free Board shall be provided to each Basin.

The entire construction shall be in M30 grade reinforced cement concrete and as per IS

3370. RCC Platform/Walkway, minimum 1.20 m wide with Hand Railing as per

specifications shall be provided. RCC Staircase, minimum 1.20 m wide with Hand Railing

as per specifications shall be provided for access from Finished Ground Level to the top of

the Unit & to the Operating Platform/Walkway. Plinth protection along periphery shall be

provided as per technical specifications.

The system should work on a gravity influent condition. No influent / sewage Equalization

Tanks or flash filling is accepted.

The system should be designed for maximum F/M ratio of 0.18 Kg BOD/Kg MLSS day.

MLSS maintained in the Basin should range from 3500 to 5000 mg/l.

Cycle times shall be selected adequately by the Bidder considering min. 12 hrs/day Basin of

aeration and not exceeding decanting of 2.40 m liquid depth at any time with preferred

cycle times containing max. 50% not aerated portion.

The excess sludge produced shall be fully digested. Sludge production (including

percipients) rate shall be about 0.60 – 1.20 Kg / Kg of BOD removed.

A minimum total SRT of 10 days shall be maintained to ensure digested sludge.

2.3 Decanting Device

The Decanting Device shall be Moving Weir Arm Device of SS 304 with top mounted

Gear Box, Electric Drive, Scum Guard, Down comers, Collection Pipe, Bearings. The

maximum design travel rate shall be 60 mm/min with proven hydraulic discharge capacity

of the decanter proportional to the selected Basin area.

There should be maximum one (1) Decanter per Basin.

The hydraulic design based on design flow rate as given above shall not exceed flow speed

of 1.30 m/s.

Flexible rubber hose kind of decanter Sealing is not acceptable.

One or more decanters shall be provided in each basin which functions under a controlled

lowering rate to withdraw treated water out of SBR Basins.

98

The decanting mechanism shall be designed for a variable speed mode of operation.

Decanter shall be capable to travel at varying speeds. The rate of travel of the decanter shall

be adjustable during its travel in air and into the liquid surface, at which point the rate of

travel of the decanter shall be automatically adjusted to a calculated rate of operation. The

maximum design travel rate shall be restricted to 60 mm/min. Rope driven or Fixed

subsurface arrangements will not be acceptable.

The rate of operation shall be calculated for each cycle and shall be determined by

the volume of treated effluent to be discharged per cycle. The calculation of decanter travel

shall ensure that the volume of treated effluent shall be discharged throughout the

designated decant phase of the process cycle. The travel of the decanter shall be limited and

controlled by limit switches which shall communicate with the PLC. Upon reaching the

designated BWL, the decanter shall return to its parked position.

During non-decanting cycles, the decanter collection weir shall be parked above the top

water level of the basin during aeration and settling phases, thereby eliminating any

possibility of solids carryover during these phases. Therefore weirs or entry ports of the

Decanters shall not be submerged below the top water level of the basin during non-decant

phase. Each decanter shall be fitted with a scum retention mechanism to prevent surface

scums and floatables from exiting with the treated effluent.

In addition, at park position, the decanter shall also provide fail safe overflow protection in

the event of a power failure by allowing clear supernatant to flow via gravity, under the

scum guard, over the weir, and into the decanters and out of the basins.

If more than one decanter is provided per basin, operation of all decanters shall be

synchronized precisely using synchronization panel to achieve even distribution of flow

through each decanter.

Weir loading for each decanter shall not exceed 140 m3/hr/m of the inlet weir. During

Decanting Phase, decanter weir shall always be visible from the basin walkway to provide

the operator with a visual check of the effluent quality. Maximum velocity down comer

shall not exceed 1.0m/sec. at the designed decant flow.

All components of the decanter except seals and bearings shall be constructed of stainless

steel 304. The decanter seals and bearings shall be constructed of maintenance free,

synthetic materials for longest possible service life. All seals and bearings shall be shipped

factory assembled, simplifying installation. All fasteners shall be constructed of 304

stainless. Site fabrication of decanters shall not be allowed.

Drive mechanism or actuator shall be equipped with variable frequency drive connected to

PLC to facilitate its operation at varying flow rates to ensure controlled and seamless

operation at varying flow rates. Complete Drive Mechanism shall be mounted on the

walkway to provide easy access for maintenance and service purposes.

All critical decanter components that may require routine inspection or maintenance

shall be easily accessible from an access platform at basin coping level without

taking a basin out of service or draining or partially draining the basin. It shall be possible

to carry out decanter maintenance activities without interrupting normal operation of

the basin while the decanter is at its parked position during non-decant phases of the

process cycle.

The SBR blowers, Automatic Air supply Valves, RAS Pumps/Mixers, switching

mechanism shall be interlocked with the decanter controls so that aeration/mixing is

prevented in a basin which is settling or decanting.

2.4 Aeration System

The aeration facility shall be installed for 7 MLD average flow.

Only Fine Bubble Type, EPDM / PU Membrane Diffusers shall be acceptable with

minimum Membrane Diffusers to Floor Coverage Area of 5%. Combination of aeration

techniques using Aerators/Submersible Mixers etc. is not acceptable. Diffusers shall be

submerged, fine bubble / fine pore, high transfer efficiency, low maintenance and non-

buoyant type. Diffusers shall be panel / tubular type. In case tubular type Diffusers are used,

only top half surface area of the Diffuser shall be considered for supply of air. Material of

99

construction for entire under water system including accessories shall be of non-corrosive.

Complete Diffuser as a unit shall be assembled at the manufacturing factory level. The grid

supports shall of adjustable type made of SS 304.

The Air Blower Arrangement shall be capable of handling Total Water Level and Bottom

Water Level operation conditions controlled by process sensors such as DO, Temperature

and Level.

Each set of blower shall have at least one dedicated standby. Minimum One working air

blower in each set shall operate via VFD while others may be operating at a fixed constant

speed on soft starter configuration.

The blowers for air diffuser system shall be positive displacement (roots) type, and head for

blowers shall be decided on the basis of efficiency of diffusers and maximum liquid depth

in tank duly considering the losses governing point of delivery (diffusers) and the blowers.

Blowers shall be complete with motor and accessories like base frame, anti vibratory pad,

silencer, non return valve, air filter etc. as per requirements. Vibration due to operation of

blowers shall be to avoid damage to structures. Further, blowers shall have acoustics to

ensure that the noise level at 1.86 m from blowers is below 80-db. The blower room shall

have sufficient ventilation, lighting and working space. The room will be equipped with

sufficient capacity EOT (Min 2 T or 1.5 times the weight of blower, whichever is more) to

facilitate removal of blower/ motor etc. for repairs. The room will also have rolling shutter.

The blower and air diffuser system shall include PLC based control for diffuser operation.

The operation and speed of blowers shall be automatically adjusted using parameters like

Oxygen Uptake Rate, Dissolved Oxygen and Temperature, Incoming flow and liquid level

in the basin such that the DO is supplied as per demand and power utilisation for operation

of blowers is optimised. The main air header/ring main shall be in MS as per relevant IS

painted both outside and inside with corrosion resistant paint as per manufacture's

recommendations. The header / ring main shall be supported on saddles at suitable intervals

or will be protected against external corrosion in case they are laid below ground. The

header shall have auto valves to facilitate switch over aeration cycle from one basin to other

by PLC operation. The header shall supply air to fixed type diffuser grids at various

locations through air supply pipes. Air supply pipe above water level shall be in GI and

below water level it shall be in Imported PVC as per relevant standards. All under water

lateral pipes shall be of Imported PVC. Junction between air header and air supply pipe

shall be suitably protected against corrosion due to dissimilar materials. All other

accessories, whether specified or not, but required for completeness shall form part of

contractors scope. An Air cooler shall be provided, if required at the common discharge

blowers to ensure that the air temperature at the inlet of diffusers is less than 80 deg. C

All other accessories, whether specified or not, but required for completeness shall form

part of Contractors scope.

2.5 Return Sludge and Excess Sludge Pumps

Dedicated Return Sludge and Excess Sludge Pumps shall be provided in each SBR Basin.

The Pumps shall be of submersible / horizontal centrifugal type suitable for handling

biological sludge of 0.8 – 1% solids consistency. Capacity and Heads shall be decided

based on process requirements. Each Basin shall be provided with suitable lifting

arrangements to facilitate lifting of these Pumps if required for maintenance.

a. Return Sludge Pumps

Capacity and Head : As per requirements

Type : Submersible / Horizontal Centrifugal

Liquid : Biological Sludge of 0.8 – 1% solids consistency

Specific gravity : 1.05

Solid size : 40 mm (Maximum)

Temperature : Min. 25 C

Efficiency : more than 50%

Quantity : 1 No. per Basin + 1 No. Store Standby

100

b. Excess Sludge Pumps

Capacity and Head : As per requirements

Type : Submersible / Horizontal Centrifugal

Liquid : Biological Sludge of 0.8 – 1% solids consistency

Specific gravity : 1.05

Solid size : 40 mm (Maximum)

Temperature : Min. 25 C

Efficiency : more than 50%

Quantity : 1 No. per Basin + 1 No. Store Standby

2.6 Automation and Control

PLC based Automation System with application software based on Rockwell or equivalent

to control SBR System including all Gates, Air Blowers, Pumps, Valves and Decanters as

per Bidder‟s/Technology Provider‟s own design including I/Os with 20 % Spares and UPS.

HMI Panel shall comprise latest Personal Computer with 22” LCD Monitor, Multi Media

Kit, Printer, Internet Connection, RS-View, RS-Links (Gateway Version), Process and

Operator Software with dynamic Flow Charts, Pictures, Screens, Alarms, Historical Trends,

Reports etc. SCADA based Automation System to monitor the following parameters

continuously in each SBR Basins:

Fill Volume

Discharge Volume

Temperature

DO Level

Oxygen Uptake Rate

Air Blower Speed

Decanter Speed

3.0 Disinfection (Chlorination) Units

Disinfection (Chlorination) Units including Chlorination Tank and Chlorinator cum

Chlorine Tonner House shall be designed for Average Flow or Decant Flow whichever is

higher.

3.1 Chlorination Tank and Chlorinator cum Chlorine Tonner House

Treated sewage from SBR unit shall be taken to Chlorination Tank by RCC Channel/RCC

Pipe of Class NP3. Gas Chlorine shall be added for disinfection at suitable dosing rate.

Baffle walls shall be provided in the Tank to facilitate hydraulic mixing of treated sewage.

The entire construction shall be in M30 grade reinforced cement concrete and as per IS

3370.

Design Flow : Average Flow or Decant Flow whichever is more

Number of Units : 1 No.

Hydraulic Retention Time : 30 Minutes (excluding Outlet Channel after Weir)

Free Board : 0.50 m min.

A Chlorinator cum Chlorine Tonner House shall be provided above/near Chlorination Tank

to house Chlorination Systems. It shall be RCC (M25) Frame cum Brick Masonry Structure

with Rolling Shutter, Windows & Ventilators, Electrical Hoist with Electrical Travelling

Trolley of minimum 3 Ton capacity or 1.5 times the weight of the single Unit whichever is

more to lift the Pumps/Chlorine Tonners and Safety Equipment including Sand Buckets,

Fire Extinguishers and Fire Alarms etc. Also it shall be provided with IPS Flooring, Internal

& External Plaster and Internal & External Painting. Plinth Protection shall be provided

along the periphery as per specifications.

101

All other accessories, whether specified or not, but required for completion of Contract shall

form the part of Bidder‟s Scope.

3.2 Chlorination System

Gas Chlorination System comprising Vacuum Chlorinators (2 Nos.), Water Feed Pumps (2

Nos.), Interconnecting Piping and Appurtenances, Chlorine Gas Detector, Empty Chlorine

Tonners (Suitable for 30 days‟ Storage) with Trunions, Lifting Device and Suspended

Weighing Scale, Residual Chlorine Test Kit, Safety Equipment (e.g. Exhaust Fan, Canisters,

Gasmasks etc.), Mandatory Spares, Chlorine Leak Detection and Chlorine Leak Absorption

System including FRP Half Hoods, Caustic Solution Tank, Caustic Recirculation Pump,

Centrifugal Fan, Interconnecting Piping and Ducts complete and other required ancillary

shall be provided.

Design Flow : Average Flow or Decant Flow whichever is more

Type : Vacuum Type

Chlorine Dosing : 5 ppm min.

Quantity of Chlorinator : 2 Nos. (1Working + 1Standby)

All other accessories, whether specified or not, but required for completion of Contract

shall form the part of Bidder‟s Scope.

4.0 Sludge Dewatering Units

Sludge Dewatering Units comprising Sludge Sump and Pump House, Centrifuge House and

Dewatering Polymer Dosing System shall be designed for Average Flow.

4.1 Sludge Sump & Pump House

A Sludge Sump shall be provided to hold excess sludge from SBR Basins. It shall be

equipped with a submersible mixer to facilitate mixing of its contents on continuous basis. It

shall be constructed in M30 grade reinforced cement concrete and as per IS 3370.

Design Capacity : As required for 7 MLD Average Flow

Number of Units : 1 No.

Hydraulic Retention Time : 6 hrs. min. of Average Daily Sludge Production

Free Board : 0.50 m min.

A Pump House shall be provided near Sludge Sump to house Sludge Transfer Pumps

(Centrifuge Feed Pumps). It shall be RCC (M25) Frame cum Brick Masonry Structure with

Rolling Shutter, Windows & Ventilators and Electrical Hoist with Electrical Travelling

Trolley of minimum 1 Ton capacity or 1.5 times the weight of the single Unit whichever is

more to lift the Pump and Safety Equipment including Sand Buckets, Fire Extinguishers

etc. Also it shall be provided with IPS Flooring, Internal & External Plaster and Internal &

External Painting. Plinth Protection shall be provided along the periphery as per

specifications.

All other accessories, whether specified or not, but required for completion of Contract

shall form the part of Bidder‟s Scope.

4.2 Sludge Sump Mixers & Sludge Transfer (Centrifuge Feed) Pumps

Submersible mixer (<500 rpm) shall be provided inside the sludge sump to keep the sludge

in suspension. The material of construction of the mixer shall be SS304 along with lifting

device with SS 304 square tube.

All other accessories, whether specified or not, but required for completion of Contract

shall form the part of Bidder‟s Scope.

102

Sludge Transfer (Centrifuge Feed) Pumps shall be of positive displacement type Screw

Pumps suitable for handling biological sludge of 0.8 – 1% solids consistency.

Capacity and Head : As required for 7 MLD Average Flow

Type : Positive Displacement Type Screw Pump

Liquid : Biological Sludge of 0.8 – 1% Solids Consistency

Specific gravity : 1.05

Solid size : 40 mm (Maximum)

Temperature : Min. 25 C

Efficiency : more than 30%

Quantity : As per requirement + 1 Standby Min.

All other accessories, whether specified or not, but required for complete shall form part of

contractors scope.

4.3 Mechanical Sludge Dewatering Device (Centrifuge) and Centrifuge Platform

The Mechanical Sludge Dewatering Device shall be solid bowl type Centrifuges designed

for 100% trouble free operation at all times and provided as per the following guidelines.

The device shall be so located that the dewatered sludge can be loaded into Trucks/ Trolleys

/ Containers directly. Preferably the device shall be so located that the dewatered sludge

falls into the Trucks/ Trolleys / Containers without requirement of another Material

Handling Unit.

The dewatered sludge shall have a minimum solids concentration of 20% or more

(measured as dry solids w/w basis) so that it can disposed by open body Trucks/Trolleys.

The Centrifuge shall be solid bowl type of co-current/counter current design, as decided by

the Bidder. It shall have sufficient clarifying length so that separation of solids is effective.

The Centrifuge and its accessories shall be mounted on a common Base Frame so that the

entire assembly can be installed on an elevated structure. Suitable Drive with V-Belt

arrangement and Turbo Coupling shall be provided along with Overload Protection Device.

Differential speed and Bowl speed shall be adjusted by changing the Pulleys. Differential

speed may be adjustable by use of epicyclical gears. The Bowl shall be protected with

flexible connections so that vibrations are not transmitted to other Equipments. The Base

Frame shall be provided with anti-vibration Pads. The Drive Motor shall be of 1,450 RPM.

The noise level shall be 85 dB (A) measured at 2.00 m distance under dry run. The

vibration level shall be below 50 micron measured at Pillow Blocks under dry run

condition.

Capacity : As required for 7 MLD Average Flow

Operating Hours : 18 hrs per day maximum

Type : Solid Bowl Type

Liquid : Biological Sludge of 0.8 – 1% Solids Consistency

Specific gravity : 1.05

Quantity : As per requirement + 1 Standby Min.

All other accessories, whether specified or not, but required for complete shall form part of

contractors scope.

A Centrifuge Platform shall be provided near Centrifuge Feed Pump House to house

Centrifuges. It shall be a G(Stilt) + 1 type RCC (M25) Frame Structure. Centrifuges shall be

installed at First Floor whereas Trucks/Trolleys/Containers shall be parked at Ground Floor.

An Electrical Hoist with Electrical Travelling Trolley of minimum 3 Ton capacity or 1.5

times the weight of the single Unit whichever is more and Safety Equipment including Sand

Buckets, Fire Extinguishers etc. shall be provided. Also it shall be provided with Anti-Skid

103

Tile Flooring, Internal & External Plaster and Internal & External Painting. Plinth

Protection shall be provided along the periphery as per specifications.

4.4 Polyelectrolyte Dosing System

Polyelectrolyte shall be dosed online at the inlet of Centrifuge. Minimum dosage of

polyelectrolyte shall be 1.50 – 2.50 Kg/Ton of dry solids in sludge at 0.1% solution

strength. There shall one Solution Preparation Tank and one Solution Dosing Tank, each

suitable for minimum 8 hrs. of operation and quipped with slow speed Mixer (100 RPM).

The entire construction shall be in M30 grade reinforced cement concrete and as per IS

3370. RCC Platform/Walkway, minimum 1.00 m wide with Hand Railing as per

specifications shall be provided. RCC Staircase, minimum 1.00 m wide with Hand Railing

as per specifications shall be provided for access from Finished Ground Level to the top of

the Unit & to the Operating Platform/Walkway.

Design Capacity : As required for 7 MLD Average Flow

Number of Units : 2 Nos.

Hydraulic Retention Time : Suitable for min. 8 hours of Operation

Free Board : 0.50 m min.

The solution will be dosed using mechanically actuated diaphragm type Metering Pumps.

Dedicated Dosing Pumps shall be provided and shall be interlocked with Centrifuge in such

a way that they Start/Stop along with Centrifuge.

Capacity and Head : As required for 7 MLD Average Flow

Type : Mechanically Actuated Diaphragm Type Metering Pump

Liquid : Polyelectrolyte Solution of 0.1% Strength

Quantity : As per requirement + 1 Standby Min.

5.0 Plant Utilities

5.1 SBR Air Blower cum Administrative cum MCC & PLC/Control Building

The SBR Air Blower cum Administrative cum PLC/Control Building shall be G+1 type

RCC (M25) Frame and Brick Masonry Structure. SBR Air Blower House, Workshop &

Tool Room shall be constructed at ground floor whereas Administration Block (comprising

Office, Conference Hall and Laboratory), PLC/Control Room shall be placed at first floor.

PMCC, HT Substation shall be placed in separate Structure.

SBR Air Blower House shall house Air Blowers for SBR Basins. It shall be equipped with

Rolling Shutters, UPVC Windows/Ventilators, Exhaust Fans and a Manual forklift of

minimum 3 Ton capacity or 1.5 times the weight of Air Blower whichever is more.

Similarly, PLC/Control Room shall be designed.

Laboratory shall be fully equipped with all necessary Equipments, Instruments, Chemicals,

Reagents, Glassware and Furniture.

Adequate number of Toilets and Washbasins shall be provided separately for Men &

Women at each floor. A covered Overhead Tank of capacity 5 m3 shall be provided along

with an Underground Water Tank of capacity 10 m3 to cater to the water requirements of

the Building.

In addition, the Building shall be provided with Porch, Staircase, Passages,

Wooden/Aluminium/Glass Doors / Windows / Ventilators and Safety Equipments including

Sand Buckets, Fire Extinguishers and Fire Alarms etc. Adequate Flooring shall be provided

in various Rooms/Areas as per requirement or as per instructions of the Engineer-in-charge.

Internal & External Plaster with Painting shall be done as per instructions of the Engineer-

in-charge. Plinth Protection shall be provided along the periphery as per specifications.

104

The Building shall be provided with the following:

Sr.

No.

Item of work Work

1

Personal Computer

in PLC/Control

Room

2 Nos. of latest version & configuration

complete.

2

Printer in

PLC/Control Room

1 No. of A3 Size Laser Printer of latest

version & configuration complete.

3

Telecommunication

Facility

Min. 1 No Telephone Line with a Broad

Band facility. The chargers will be born by

the Contractor up to the O & M Period.

4

Plant Model

1 No. Wall Mounted Process Model

(Electronic Plant Display Model) with

Flow Diagram (Minimum size 3 m x 1.5

m)

1 No. 3D Model with display of flow

direction and lighting.

5 Air Conditioner Adequate nos. of Air conditioners shall be

provided as directed by Executive

Engineer.

5.2 Electrical HT Substation

The Electrical HT Substation shall be provided to house HT Components comprising

Metering Kiosk, HT Panel, Indoor Transformers and Power Control Centres. It shall be

RCC (M25) Frame and Brick Masonry Structure equipped with Rolling Shutters,

Windows/Ventilators, Exhaust Fans and Safety Equipments including Sand Buckets, Fire

Extinguishers and Fire Alarms etc. complete.

Also, it shall be provided with IPS Flooring, Internal and External Plaster with Painting and

Plinth Protection along the periphery as per specifications.

5.3 DG House

The DG house shall be provided to house DG Set of adequate rating capable of running the

entire STP and pumping station located in STP area at Peak Flow including AMF Panel,

Fuel Tank and other Accessories. It shall be RCC (M25) Frame and Brick Masonry

Structure equipped with Rolling Shutters, Windows/Ventilators, Exhaust Fans and Safety

Equipment including Sand Buckets, Fire Extinguishers and Fire Alarms etc. complete. Also

it shall be provided with IPS Flooring, Internal and External Plaster with Painting and

Plinth Protection along the periphery as per specifications.

5.4 Security Cabins

Security Cabin of size 3.00 m x 3.00 m shall be provided at each entry Gate of the Plant. It

shall be RCC (M25) Frame and Brick Masonry Structure equipped with Doors,

Windows/Ventilators, etc. complete. Also, it shall be provided with Flooring, Internal and

External Plaster with Painting and Plinth Protection along the periphery as per

specifications.

5.5 Schedule of Finishes

Sr.

N

o

.

Unit Flooring Doors Windows /

Ventilators

1 Administrative

Block, Laboratory,

Marbonite flooring

of approved make.

Solid Core Flush

Door with heavy

Aluminium of

approved make

105

MCC Room, PLC

& Control Room,

Security Cabins

The size of

Marbonite tiles

shall be min 600

mm x 600 mm &

thickness min 10 –

12 mm

duty Brass

Fittings of

approved make

2 SBR Air Blower

House, Workshop

& Tool Room,

Chlorinator cum

Chlorine Tonner

House, Sludge

Pump Houses,

Electrical HT

Substation, DG

House

IPS Flooring with

Abrasion Resistant

Additives of

approved make

MS Rolling Shutter

(See Through Type)

of approved make

Aluminium of

approved make

3 Centrifuge

Platform

Anti Skid Tile

Flooring of

approved make

--- ---

4 Vehicle Parking

Area

Coloured Pre-cast

Heavy Duty Paving

Blocks with

Lacquer Finish

--- ---

5 Toilet Blocks Coloured Glazed

Tiles

UPVC of approved

make

UPVC of

approved make

6 Staircase: Inside

Building

Grey Granite

Flooring of

approved make

--- ---

5.6 Roads, Pathways & Vehicular Parking Area

All internal Roads shall be provided with Drainage and constructed to prevent standing

water. All Roads shall be minimum 5.0 m wide of WBM with asphalting BM+AC. WBM

shall be constructed with 80 mm metal (150 mm thick), 40 mm gravel (100 mm thick) with

hard murum casing. BM shall be 75 mm thick (4% bitumen content) and AC shall be 40

mm thick with (6.25% bitumen content).

Pathways shall be constructed interconnect the entire Plant with Roads. Minimum width of

pathways shall be 2.00 m. Pathways shall be in coloured Pre-cast Heavy Duty Paving

Blocks with Lacquer Finish.

Vehicle Parking Area shall be shall be provided to permit the parking of Vehicles in

coloured Pre-cast Heavy Duty Paving Blocks with Lacquer Finish.

The entire system of Roads, Pathways and Vehicle Parking Area shall be designed such that

Vehicles involved in the delivery of Materials, Chemicals, Consumables and Residual

Disposal can continuous route through the Works and get out again.

5.7 Storm Water Drainage

Adequate Storm Water Drainage shall be provided adjacent to the Internal Roads

considering local rainfall intensity with 100% runoff. It shall be in RCC Class NP 3 pipe of

min 600 mm dia. with necessary Chambers at appropriate locations. These Chambers shall

be covered with CI Gratings. This Storm Water Drainage shall be connected to the nearby

Storm Water Drain or Channel of City Network.

106

5.8 Boundary Wall with Gate

Boundary Wall shall be constructed all around the STP plot. Boundary Wall having

architectural and elegant view shall be provided along entire periphery of the Plot. Height

of boundary wall should not be less than 2.0 m from finished ground level. It should be able

to bear wind pressure up to 80 Km/hr. At least two Entry Gates, 3.60 m wide each shall be

provided. Each Entry Gate shall be provided with a Wicket Gate.

5.9 Internal Water Supply and Water Supply for Gardening

Proper water facility shall be provided at STP. Rate of water supply may be kept as 150 liter

per capita per day for a population of 20 people. Storage should not be less than 1000 litres.

Water supply for gardening purpose may be from treated final sewage in sufficient quantity.

5.10 Disposal of Plant Residuals & Treated Sewage

Plant Residuals (Screenings, Grit and Dewatered Sludge) and treated sewage shall be the

property of the Employer. However, the Contractor shall be responsible for disposal of

Plant Residuals within 12 Km from Site. Treated Sewage shall be discharged into nearby

Nallah. The Contractor may sell off the Dewatered Sludge but at the discretion of the

Employer.

5.11 Landscaping

Landscaping involves beautification of Sewage Treatment Plant site by cultivating lands,

plants and trees of environmental value and suitably modifying the appearance of STP site.

It shall add scenic value to the STP site to obtain maximum visual impact. Contractor has to

develop proper landscaping in the STP site from professional landscaper approved by

OWNER. Area for future expansion shall also be considered for landscaping.

6.0 Interconnecting Piping and Valves

All interconnecting Piping, Gates, Valves, Specials and other appurtenances, auxiliaries and

accessories required as per Process Design and Scope of Work. In case of Rising Mains,

thrust blocks shall be provided wherever required. In case of buried Pipes, warning tapes

shall be provided of the appropriate colours. The material of construction for major

interconnecting Piping shall be as follows:

Piping: Guide Line for Velocity

S

r

.

N

o

.

Service

Design

Velocity

m/s

Limitations

1 Gravity Lines for Sewage

& Water

0.60 – 1.2

Designed as pipe line

flowing full.

Min. Velocity shall not be

less than 0.6 m/sec. Max.

Velocity up to 1.2 m/sec is

allowable at Peak Flow.

2 Pressure Lines for

Sewage & Water

0.6 – 2.5 Min. Velocity shall not be

less than 0.6 m/sec. Max.

Velocity up to 2.5 m/sec is

allowable at Peak Flow.

3 Air (Pressurized Lines) 18 – 22 Max. Velocity shall not be

more than 25 m/sec in any

section.

4 Scum & Sludge Lines 0.6 – 1.5 Irrespective of flow,

107

S

r

.

N

o

.

Service

Design

Velocity

m/s

Limitations

Diameter shall not be less

than 150 mm for Gravity

Lines.

5 Chemical Feed Lines 0.6 – 1.5 Irrespective of flow,

Diameter shall not less than

20 mm.

Notwithstanding the above, the Bidder shall submit a Pipe Line Schedule with Tag No.,

Flow, Size, Type, Material of Construction etc. with detailed P & ID for approval of the

Engineer-in-charge prior to any further engineering or procurement/fabrication and

installation.

Generally, the Material of Construction shall be selected based on the following guide lines.

The Bidder can make suitable selection depending on Service, Type of Flow (i.e. Gravity or

Pressurized) and Diameter of Pipe.

Piping: Guide Lines for MOC

S

r

.

N

o

.

Service Type of

Flow MOC

1 Waste Water /

Sludge Gravity RCC NP-3 Class

2 Waste Water /

Sludge Pressurized

CI Class “LA” / DI

K-9

3 Service Water Gravity /

Pressurized GI “C” Class

4

Air Lines:

Headers, Vertical

Down-comers

Pressurized

Above Water: MS

Sand/Shot Blasted,

Epoxy Painted

Under Water: SS 304

5

a

Air Grid Piping:

Aeration Zone Pressurized UPVC Schedule 40

5

b

Air Grid Piping:

Selector Zone Pressurized SS 304

6 Chemicals Gravity /

Pressurized

SS 304 except

Chlorine & FeCl3

7 Chlorine &

FeCl3

Gravity /

Pressurized Schedule 40 UPVC

Valve: Guide Line

108

S

r

.

N

o

.

Service Type MOC

End

Conne

ction

A Sewage / Sludge

1

Gravity /

Pressurize

d

Knife

Gate

CI Body & SS

304 Gate &

SS 410

Spindle

Flange

d/Waf

er

2 Delivery of

Pump

Swing

Check

CS Body &

SS 304

Internals

Wafer

3

Suction &

Delivery of

Pump

Knife

Gate

CI Body & SS

304 Gate &

SS 410

Spindle

Flange

d/Waf

er

B Service Water

1

Gravity /

Pressurize

d

Ball

CS Body &

SS 304

Internals

Flange

d/

Screw

ed

2 Delivery of

Pump

Swing

Check

CS Body &

SS 304

Internals

Wafer

3

Suction &

Delivery of

Pump

Butter

fly

CI Body & SS

304 Internals Wafer

C Air

1 Pressurize

d Ball

CS Body &

SS 304

Internals

Flange

d/

Screw

ed

2 Delivery of

Blower

Swing

Check

CS Body &

SS 304

Internals

Wafer

3

Suction &

Delivery of

Blower

Butter

fly

CI Body & SS

304 Internals

Flange

d

D Chemicals

1

a

Gravity /

Pressurize

d

Ball

As per

Chemical

Compatibility

Chart

Flange

d

1

b

Gravity /

Pressurize

d

Diaph

ragm

As per

Chemical

Compatibility

Chart

Flange

d

1

c

Gravity /

Pressurize

d

Plug

As per

Chemical

Compatibility

Flange

d

109

Chart

Notwithstanding the above, the Bidder shall submit a Valve Schedule with Tag No., Flow,

Size, Type, and Material of Construction, End Connection etc. with detailed P & ID for

approval of the Engineer-in-charge prior to any further engineering or

procurement/fabrication and installation.

7.0 Electrical & Instrumentation Works

It shall be the Contractor‟s responsibility to obtain adequate incoming HT power from State

Electricity Authority based on the maximum demand load. The Employer will pay the

charges for obtaining the above connection whereas necessary liasoning for the same shall

be done by the Contractor in consultation with Engineer-in-charge.

Two nos. of Transformers (1W + 1SB) for full load of the plant with 10% overload shall be

provided. These shall be step down Transformers suitable for indoor installation

manufactured in accordance with IS 2062/1962 and as modified from time to time. They

shall be supplied with all accessories and mounting as per IS 2062 and shall also have Dial

Thermometer, Bucholz Relay, Rollers and Explosion Vent. Each Transformer shall be

provided with off load tap changer for ± 2.5%. The windings shall be of connections as per

vector group DY II. The efficiency of the Transformer at 100%, 75% and 50% loading

should also be indicated separately. The Transformer should be tested as per I.E. Rules &

Regulations. Suitable cable boxes for H.T. and bus ducting for L.T. side be provided.

The entire Plant shall be operated on 415 V, 3-Phase, 50 Hz, 4-Wire system. The

Contractor‟s Scope of Work shall include the following:

Obtaining incoming HT Power from State Electricity Authority including necessary

liasonoing, documentation etc. complete.

HT Cable with Termination Kit from “Source” to the Electrical HT Substation located at

the Sewage Treatment Plant.

HT Substation including 4-Pole Structure, Metering Kiosk, HT Panel, Transformers, Power

Control Centre etc. complete.

Motor Control Centres.

Cabling including Power, Control and Instrumentation Cables.

Earthling for Electrical equipments as well as Instruments.

Internal Lighting in Buildings.

External Lighting.

Local Push Button Stations near respective Drives.

Any other item / accessories required for successful completion of the Project.

The Contractor shall design/execute the System as per standard specifications, I.E. Rules

and Regulations, requirements of State Electricity Board and other local Authorities and

actual site conditions.

Also, the Contractor shall provide adequate automation for fully automatic operation of the

entire Sewage Treatment Plant including Primary Treatment Units, Biological Treatment

Units based on SBR technology, Chlorination Tank, Sludge Dewatering Units through a

one Programmable Logic Centre (PLC) and Supervisory Control and Data Acquisition

(SCADA) with Man-Machine Interface (MMI). Provision shall also be made to operate

each Unit of the Plant manually, if required.

8.0 PLC/PC/SCADA BASED AUTOMATION SYSTEM FOR ENTIRE STP

The complete Plant shall be designed for automatic operation through Programmable Logic

Control (PLC) and Supervisory Control and Data Acquisition (SCADA). This shall be

achieved by either individual equipment PLCs with SCADA/HMI or single PLC and

SCADA for entire Sewage Treatment. These shall be located at control room of the STP.

The plant shall have provision for operations in following modes –

110

Automatic – Auto operation through PLC/digital controller.

Manual – Operator intervention through SCADA/HMI.

Local – Local operation through local control panel located near equipment.

Audio Visual Alarms –

Audio visual alarms shall be initiated under emergency or equipment trip conditions, other

than usual service alarms. Salient features of the proposed control system shall be as

follows:

Dynamic display of all Units, equipment and drives shall be available on SCADA screen.

It shall Acquire, process and manage the processed data.

It shall safeguard the process by means of interlocks and alarms.

Auto/Manual operation of each drive shall be made by selecting a soft switch on

SCADA/HMI screen.

In Auto mode, each drive shall operate based on pre-set sequence and interlock. Also

automatic change over from working to standby drive shall happen after a drive reaches

pre-set hours of operation.

In Manual mode, each drive shall be operated in Local/Remote mode by selecting a soft

switch on SCADA/HMI screen. In Local mode, each drive shall be operated from the Local

Push Button Station (LPBS) located nearby. In Remote mode, operation from LPBS shall

be disabled and each drive shall be operated manually from PLC. Also provision for

working/standby selection of drives by selecting a soft switch on SCADA screen shall be

provided.

Run/Trip indication of all drives shall be displayed on SCADA/HMI screen.

Open/Close indication of all Auto Sluice Gates and Auto Valves shall be displayed on

SCADA/HMI screen.

Annunciation & Alarm facility shall be available in PLC/HMI/SCADA. In the event of a

Fault, the symbol representing the equipment/drive shall continue flashing on SCADA/HMI

screen with equipment/drive description appearing at bottom of the SCADA/HMI screen

and electric Hooter shall continue blowing until the Fault Alarm is acknowledged.

Data logging of Running Hours of each drive, Alarms, Historical Trends of monitored

Parameters, etc. shall be envisaged in SCADA.

Report generation for plant performance.

The process system must have pre-configured software packages which can be adapted to

the process by parameterization.

The monitor images must be designed to be user-friendly by hierarchical breakdown with

the possibility of selective display and optimum selection possibilities.

Changing of parameters and other software units must be possible "online", i.e. with the

system running.

Different alarms colors provide information on their priorities.

For the system engineering offered, the Contractor must take measures, e.g. by the

installation of surge voltage arresters or surge voltage filters, to ensure that internal and

external surge voltages do not impair the function of his parts of the system.

The programs and data entered must be backed up in a non-volatile read-only memory.

A limit value and plausibility check must be provided in the software of the process station

for the measured values and messages. Exceeding of limit values or deviations detected by

the above checks must trigger an event and cause a message to be sent.

Further demanded features of the process system:

Integrated, detailed error message and fault detection concept with display on the

HMI/SCADA for quick localization of faults. The system operator must be able to identify

the fault from the error.

Essentially maintenance-free

Robust against external interferences of all kinds

Proven design and solder-free connection technique

Protection of the equipment against surge voltages

111

Automatic fault detection and quick troubleshooting in the PLC system by integrated,

hierarchically structured diagnostic devices

Power supply in wide admissible voltage range

Simple function-oriented operation

The process system (PLC, HMI/SCADA) shall be protected against power failure by an

uninterruptible power supply (UPS). When the critical charge state of the UPS is reached,

the process system is automatically shut down.

Mode selector switch

A mode selector switch is to be installed on the MCC or distribution board. It serves for

pre-selection between Automatic mode and Manual/Local mode.

The following switching functions must be provided:

Automatic – Manual/Local

Automatic: In this position, only automatic operation is possible; the local switches have no

function (Except emergency stop).

Local: Automatic mode cannot be started. The drives can be operated individually without

interlock with the local switches.

Local switches (LPBS)

Each drive must be equipped with a local switch positioned in such a location that the

corresponding machine or conveyor can be switched on in Manual/Local mode and can be

monitored visually at all times.

The local switch must have the following switching functions:

START – STOP (for drives with one direction of rotation) or

FORWARD – STOP - REVERSE (for reversible drives)

If a unit has several drives (e.g. conveyor belt drive and travel drive), the local switches

should be installed if possible in one switch box or at least installed next to one another.

Each local switch must be adequately labeled in plain text so that no operator errors can

occur.

PLC

The automatic start-up of the whole system, sequential operations and the automatic

shutdown, allowing for external control influences, e.g. EMERGENCY STOP, etc., is

performed by programmable logic controller (PLC).

This performs not only the control of the system, but also the display of the operating state

in the HMI/SCADA.

The interlocks of the individual process groups and their signaling must be performed by

the PLC.

A system must be selected which is sufficiently protected against external interference in

the supply, control and signaling lines. The aim is that the program can continue to run

without fault signals in the event of transient earth faults in the supply grid. In the event of

prolonged power failures, on the other hand, a controlled restart must be triggered (under-

voltage trip of the non-automatic circuit breaker).

PLC Specifications: Technical

The PLC shall be non-redundant.

PLC of individual equipment shall be selected to carry out necessary operations without

overloading the PLC memory.

The PLC shall have adequate I/O per card.

There shall be 15% spare I/O of each type.

The CPU shall not be loaded more than 60% of its capacity.

112

Retentively shall be 100% to save the recorded data and saving the programmed logic, other

attributes connected with system for power & system failure.

Change in programme / modifications to programme shall be possible by a portable laptop.

It is preferred to have all PLC‟s in the plant from same manufacturer.

HMI/SCADA system

The HMI system shall be designed as a minimum 6”, color, touch-screen on the panel.

Whereas SCADA system must be computer based.

All displays must be designed by the Contractor with graphic sophistication and all texts in

the visualization system must be displayed in English.

A sub-menu for each operating mode and further menus for editing the system parameters,

fault archive, etc., must be developed. It must be as simple as possible to switch between

the various menus and to edit the system parameters.

When designing the user interface or the assignment of the function keys, attention must be

paid that the function key assignment remains the same in all sub-menus so that it is

possible to jump to another menu without first having to jump back to the main menu.

It must be possible to edit the following parameters at the touch-panel and SCADA:

Operating mode

Changes in the speeds of frequency converter-controlled equipment

Start-up times

Shutdown times

Duration of the operation of warning devices

Limit values for sensors, etc.

Faults, level messages, pressed EMERGENCY STOP buttons, etc., must also be clearly

displayed at the bottom of the screen, irrespective of the selected screen page or sub-menu.

It must be possible to output all important menu items to the printer. The corresponding

interfaces must be provided.

The display of the function plans, images, etc. is affected in direct dialog with the system by

means of the mouse and keyboard.

The central SCADA shall generate various reports to analyze plant performance. The

process is documented via the laser printer.

Computer hardware and software

All programs required for operation of the system must be correspondingly compatible. The

corresponding licenses must be supplied for the standard programs. The operating systems

must be agreed upon with the Client. Minimum requirements shall meet:

CPU

Processo

r

Intel i5 or higher

Processo

r speed

2 GHz or higher

Configur

ation

Tower

Architect

ure

32 bit

System

memory

(RAM)

8 GB

Hard

disk

320 GB or higher

DVD

Drive

Combo (Read/Write)

Operatin

g system

Microsoft Windows 7 professional

113

Commun

ication

ports

USB – 4Nos., Ethernet – 1Nos.

Graphic

accelerat

or

1 GB

Power

supply

240V, 50Hz, 1Phase

Keyboar

d

Internet Keyboard (with USB interface)

Mouse Optical, 3 buttons (with USB interface)

Monitor

Type Full HD LED color monitor

Screen

size

22” or higher

Resolutio

n

1920 x 1080

Power

supply

240V, 50Hz, 1Phase

Complete Project shall operate in auto mode. As a minimum, following controls must be

considered in Bidder‟s Control Philosophy:

Inlet chamber

A clamp on type Ultrasonic or Electromagnetic flow transmitter shall be provided on inlet

pipe of inlet chamber for measurement of flow coming to Sewage Treatment Plant. PLC

shall calculate instantaneous flow as well as cumulative flow, both shall be displayed on

SCADA.

Fine screens

Each mechanical fine screen shall be installed with ultrasonic differential level transmitter /

level switch, across it; the same shall be operated on the basis of set level in SCADA. Also

if level is not reached for certain time period, the screen shall be operated on the basis set

time in SCADA.

The selection of Auto/Manual and Working/Stand-by shall be made available in SCADA.

In manual mode the screen operation will be done from SCADA screen. Physical switch

over of screens in plant will be done by operator using manual gates.

Necessary interlocks, controls, alarms, report generation, etc. shall be considered in PLC for

auto operation of fine screen.

Grit Chambers

Each grit chamber will consist of Detroiter (1No.), Organic Return Pump (1No.) and Screw

Conveyor for grit removal (1No.). As such Detroiter, Organic Return Pump and Screw

Conveyor will not have auto operation; these will be started and stopped from SCADA

screen as required.

Necessary interlocks, alarms, report generation, etc. shall be considered in PLC for

operation of Grit chamber equipment.

SBR Basin

Complete operation and control of SBR plant will be done through a separate PLC and

SCADA. However it shall have necessary inputs and generate required outputs to operate in

co-ordination upstream and downstream units of balance plant.

Alternatively contractor may provide single PLC and SCADA for entire Sewage Treatment

Plant.

Necessary interlocks, controls, alarms, report generation, etc. shall be considered in SBR

PLC for auto operation SBR basin.

114

Each SBR basins shall be equipped with Level Transmitter, DO Transmitter for monitoring

and recording of critical operation parameters through SCADA.

Sludge sump and pump

An ultrasonic type level transmitter shall be used for measurement of level in sludge sump.

Screw pumps will be used to feed sludge to Centrifuge. These will operate as per level in

sludge sump.

The selection of Auto/Manual and Working/Stand-by shall be made available in SCADA

for sludge pumps. In manual mode the Start/Stop of pump will be done from SCADA

screen.

Necessary interlocks, alarms, report generation, etc. shall be considered in PLC for

operation of chlorination system.

Chlorination tank

The selection of Auto/Manual and Working/Stand-by shall be made available in SCADA

for booster pumps. In manual mode the Start/Stop of pump will be done from SCADA

screen. Though chlorinator will have standalone operation, feedback for the equipment shall

be taken to PLC and displayed SCADA for monitoring purpose.

Necessary interlocks, alarms, report generation, etc. shall be considered in PLC for

operation of chlorination system.

Centrifuge

The drives and instruments of centrifuge shall be connected to PLC for its auto operation.

Starting of dewatering system will be a manual process.

Necessary interlocks, alarms, report generation, etc. shall be considered in PLC for auto

operation of centrifuges.

2.4 Technical Specifications – Civil Works

a) Survey Work

The Contractor shall carry out detailed survey work and submit both soft and hard copies of

contour drawings with spot levels with 10 m x 10 m grid to the Employer. Necessary

information such as reference to the location as proposed for the treatment plant by him

with respect to site boundary.

b) Geotechnical Investigation

The Contractor shall carry our Geotechnical Investigation work at the proposed location of

treatment plant. The no. of bore holes to be taken, depth of boring etc. shall be decided in

consultation with the Engineer In-charge. The Contractor has to provide the hard and soft

copies of the test reports. If the bearing capacity of the soil found lower than that is

mentioned in the soil report provided with the Tender document, the lower of the two

values shall be considered for design.

c) Process / Hydraulics Design

The Contractor shall provide his own design system and equipments based on Sequential

Batch Reaction process to treat the raw sewage up to the sewage quality as said in Clause

2.3.3 or even better.

Bidder shall design the plant in such a way that in case of non-availability of sufficient

sewage at the time of commissioning, plant can be commissioned with a minimum quantity

of sewage equal to 30% of the average capacity.

115

d) Treatment Objective

Considering the raw sewage quality and the required treated sewage quality, the Contractor

shall furnish a process train to achieve the following objectives –

To achieve guaranteed treated sewage quality or even better.

To ensure that the offered treatment process is the most appropriate and state of the

art in terms of both efficacy of treatment and cost (the Contractor shall have to produce the

performance records with the same treatment systems applied elsewhere.)

To ensure that the process is cost effective from both capital and running costs

consideration.

To ensure that the sludge produced is dewatered to a “spreadable” or “open body

transportable” consistency – so that it can be easily disposed off.

The process preferably should be free from utilization of chemical/any organic

chemicals except for sludge removal process. No toxic chemical shall be used by the

Contractor. He will submit the toxicity test report from any govt. recognized laboratory at

his own cost before using such chemical.

Oils/lubes/fuels/media/chemicals etc. to be used will be defined by Bidder.

The final treated sewage is to be disinfected through chlorination before its disposal.

e) Structural Design

The Contractor shall have to do the structural design considering the survey details and

geotechnical investigation details like safe bearing capacity, seismic forces, depth of water

table and hydraulic flow diagram. Rock anchoring shall be carried if required wherever

uplift is considered. The design of plant units and Buildings – if any, shall be submitted by

the Contractor in soft and hard copies, with General Arrangements and detail RCC

drawings. The design of units shall be finalized in consultation with the Engineer – in –

Charge. The design of units shall be as per relevant BIS or other Indian/international

standards in absence of BIS or sound engineering practice. The requirements to be fulfilled

by the Contractor are described in detail in the general civil specifications and particular

specifications for civil work for sewage treatment plant. Pressure releasing valve to release

sub soil water pressure shall be allowed at appropriate locations.

f) Construction Works

The Contractor shall construct the civil units of the plant (including intermediate process

pumping stations wherever required) to accommodate the mechanical units to fulfill the

requirement of process design. There shall be adequate working space, accessibility

considerations like RCC staircase or ladders, walkway with proper width, hand railing, etc

wherever needed. For Buildings, there shall be additional items like ventilation and lighting

requirements, flooring and finishing (hard flooring like granite for machine bearing floors)

etc. The civil units shall be constructed such that there is proper accessibility for repair or

replacement of mechanical equipments. Any concreting shall be done only after approval of

Engineer – in – charge. All construction work shall be carried out as per the provision of

CPWD specifications unless otherwise mentioned in the document.

g) Equivalency of Standards and Codes

Wherever reference is made in the Contract to specific standards and codes to be met by the

goods and materials to be furnished, and work performed or tested, the provisions of the

latest current edition or revision of the relevant standards and codes in effect shall apply,

unless otherwise stated in the Contract. Where such standards and codes are national or

related to a particular country or region, other authoritative standards which ensure an equal

or higher quality than the standards and codes specified will be acceptable subject to the

Engineer's prior review and written approval. Differences between standards specified and

the proposed alternative standards must be fully described in writing by the Contractor and

submitted to the Engineer at least 28 days prior to the date when the Contractor desires the

Engineer's approval. In fee event the Engineer determines that such proposed deviations do

116

not ensure equal or higher quality, the Contractor shall comply with the standards specified

in the Bid Documents.

h) Board

The Contractor at his own cost, shall provide sign boards at approved locations, in English

and Hindi at the site of the Works of approved size and design which provides

The name of the Project,

The name and addresses of the Employer, the Contractor and the Consultant;

The name and short description of the Project and

The starting and completion dates. Contractor shall take care of signboard and re-do it in

case of loss, damage, theft etc., as desired by the Engineer In-charge.

i) Assurance Programme/Sample Tests

Contractor shall be responsible to develop a quality control program and to all necessary

materials, apparatus, instruments, equipment, facilities and qualified staff for sampling,

testing and quality control of the materials and the under the Contractor. Without limiting

the generality of the foregoing, the actor shall either (i) establish a testing laboratory at the

site of Works which be adequately equipped and staffed to carry out all sampling and

testing in accordance with the requirement set out in the Tender document specifications

provide all field equipment and apparatus as necessary to conduct all in-situ tests and/or any

Tests on Completion, or (ii) arrange for routine sampling, testing and reporting, as required,

through a certified independent laboratory acceptable to the Engineer In-charge. The

Contractor shall obtain the approval of the Engineer In-charge for the quality control

programme developed by him and incorporate any modifications suggested by the Engineer

In-charge at no extra cost.

All costs of such sampling, testing and reporting of test results will be borne the Contractor,

and the Contractor shall include sufficient provisions in his; tendered rates to allow for

independent sampling and laboratory testing under the direction of the Engineer In-charge.

The Contractor shall furnish certified copies of all test reports to the Engineer In-charge

within 3 days of completion of the specified tests.

The Contractor shall, within 14 days after the date of the issue of Letter of Acceptance,

submit to the Engineer In-charge for his consent a detailed description of the arrangements

for conducting the quality control programme during execution of the Work, including

details of his testing laboratory, equipment, staff and general procedures. If following

submission, or at any time during the progress of Works, it appears to the Engineer In-

charge that the Contractor's quality control programme is not adequate to ensure the quality

of the Works, the Contractor shall produce a revised programme, as desired by the!

Engineer In-charge, which will be adequate to ensure satisfactory quality control, in case of

the Contractor will fail to ensure quality control program the action deem fit will be taken

against the Contractor. The Employer shall carry out supervision and quality control and

monitoring the progress of works.

j) Protection of Utilities

The Contractor is required to carefully examine the location of the Works and their

alignments and to make special enquiries with all authorities concerning utility lines such as

water supply, sewers, gas pipe, telephone (underground and/or overhead) lines, electric

cable (underground and/or overhead) etc., and determine and verify to his own satisfaction

the character, sizes, position and lengths of such utilities from authentic records. The

Contractor shall be wholly responsible for the protection and/or facilitating relocation of

such utilities as may be required and shall not make any claim for extra work or extra time

that may be required to protect or facilitate relocating such utilities. If any major shifting

realignment of water supply, sewers, gas pipes, electric and telephone lines is necessary due

117

to their interference with the proposed Works, the same may done by the Contractor. The

cost of such relocations will be borne by the Contractor.

k) Erection

Bidders have to note that various major items shall be procured / executed under this

Contract subject to inspection by the Employer or their authorized representatives at

manufacturer‟s premises. Cost of inspection shall be borne by Contractor

l) Testing of Concrete

Testing of Concrete shall be carried out as per IS4926: 1976. The contractors shall send

three flexural beams to the laboratory for every ten slabs, or part thereof, for testing flexural

strength. The admixture used shall conform to IS 9103-1979 reaffirmed on 1990 or AS1 C-

494 of 92.

All taxes/duties etc. will be borne by the contractors and not by the Employer. No extra

payment will be made for the use of admixtures.

2.5 Mechanical Equipments for STP

The Contractor shall have to design, supply, erect and commission the mechanical

equipments as proposed by him in the treatment train to achieve the required parameters.

The design, material of construction and type of various mechanical equipments shall

confirm to the standards laid in various sections of Tender document.

2.6 Electrical and Instrumentation / Automation System

The Contractor shall design, shop test, supply, transport, storing at site, erecting, testing and

commissioning all electrical equipments and instruments required for the plant as per

general specifications, specific specifications for electrical works, typical power distribution

scheme and typical control system architecture.

2.7 Disposal of Sludge/Screenings/Debris

The screenings/debris/dried sludge from the Sludge Handling Unit shall be disposed off by

the Contractor to a suitable location, which is away from the residential area. The place of

sludge disposal shall be as per the decision of the Engineer In-charge, within a radius of 12

kms from the plant. The responsibility of sludge withdrawal and disposing off lies with the

Contractor within the operation and maintenance period. The Contractor should explore the

possibility promoting it as manure.

2.8 Disposal of Excavated Stuff

It will be the responsibility of Contractor to dispose all the excavated stuff within the

Employer limits as directed by Engineer In-charge.

2.9 General Utilities

For the proper functioning of the proposed works of sewage treatment plant, connection for

rising mains, sewage channel, the other general utilities necessary for the proper functioning

of the proposed works which shall be included under this Contract are :

Internal & outdoor lighting, plant water supply and sanitation, waste disposal, etc.

Electric substations and distribution of power supply to all necessary points

Street and yard lighting and fire hydrant system for the STP.

2.10 Safety Equipment:

Safety Equipments should be provided at STP as per the recommendation of Inspector of

Industries. Contractor shall also take care of safety compliance as applicable from time to

time as per safety rules/Factory act/Indian Electricity regulations/manuals/manufacturer's

special instructions.

118

2.11 Model of the Project:

A 3D Model of the Plant shall also be submitted by the Contractor. The size of the Model

shall not be less than 1.5 m x 2.5 m. The Model shall be within a wooden Box having glass

on its top and kept over a Table fir display.

2.12 Scope of Work for Operation & Maintenance

The Bidder shall operate and maintain the Raw Sewage Pumping Stations, Sewage

Treatment Plant and all other allied works under this Contract for a period of 60 months,

including defect liability period of 12 months. For this period, the scope of work shall

include, but not be limited to the Operation and Maintenance of the following:

Raw Sewage Pumping Station and Sewage Treatment Plant for Raebareli Sewerage Scheme

including all the Civil Units and Electro-Mechanical Equipments as per the Bidder's

Proposal to ensure that all the output guarantees are met.

General Facilities and Utility Services.

PLC/SCADA based Automation system.

All other in-plant facilities listed in the detailed Scope of Work

The Bidder shall also dispose-off the sludge, screenings, grit and any other material, as per

specifications and to the satisfaction of the Engineer In-charge. It is to be noted that all

costs during the O&M period excluding cost of power and diesel for DG is to be borne by

the Contractor. Within his quoted cost, the Bidder is to ensure that the following guarantees

are maintained:

Guarantee for Quality of Treated Sewage.

Guarantee for Power Consumption.

Guarantee for Automation System.

The Bidder shall provide on job training to the Employer staff as per specifications.

The Bidder shall, at no extra cost to the Employer, repair and re-condition all the required

mechanical equipments in the concluding year of the O & M period and Hand over the

facility to the Employer in proper & fully working condition.

2.13 Operation and Maintenance Cost

All the cost for Operation and Maintenance of the Plant such as Chemicals and

Consumables, Disposal of Screenings, Grit and Dewatered Sludge, Manpower, Spares,

Repair and Maintenance of Civil, Mechanical, Electrical, Instrumentation Items including

all other major/minor repairs, breakdowns, replacements etc. excluding Cost of Electricity

and Diesel for DG shall be in the scope of the Bidder. No extra payment other than whatever

has been quoted in Price Schedule will be entertained by the Employer.

The Bidders are to quote O&M Cost and provide Functional Guarantee based on the

following data which shall be used for technical evaluation of qualifying Bids:

BOD : 250 mg/l

TSS : 375 mg/l

119

B. SPECIFICATION FOR MATERIALS:

1.1 IST

CLASS BRICKS: (M-100)

Bricks shall have a uniform deep cherry red or copper colour, shall be thoroughly burnt but not

over burnt, and regular in shape. Their edges must be Straight Square and the two bricks must

emit a clear ringing sound on being struck with each other. They must be free from cracks,

chips, flows and stones or lumps of any kind. The bricks shall comply with the I.S. – 1077.

1.2 STONE BALLAST

Stone ballast shall consist of crushed stone and shall be hard, strong, dense, durable, clean, of

proper gradation and free from weather effect. It shall be generally cubical in shape. As far as

possible, soft, thin, flaky or elongated or laminated pieces shall be avoided. For RCC work it

should not contain any materials which might affect the reinforcement. The grading and test

requirements should comply with the I.S. – 383.

1.3 TIMBER

Timber to be used in shuttering works shall be from the heart of a sound tree of natural growth,

the sapwood being entirely removed. It shall be uniform in substance, straight in fiber, free

from large, loose and dead knots, flaws, shakes, decay, rot, fungi and insect attacks and from

any other damages of harmful nature which will affect the strength, durability, appearance or its

usefulness for the purpose for which it is required. The color should be uniform as far as

possible. The other requirements of timber shall comply with the PWD specification No. 1.5

(material) part-I.

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1.4 STEEL

The steel for RCC shall be high yield strength deformed bars of Grade Fe 500 conforming to IS

-1786 -1985 the placement of reinforcement shall be as per IS 456-2000.

1.5 PORTLAND CEMENT

The cement shall be Ordinary Portland shall be 43 grade cement conforming to I.S:8112 with

its latest amendments.

1.6 SAND

The sand shall consist of natural sand, crushed stone or crushed gravel or a combination of any

of these. it should be hard, durable, clean and free from adherent coating and organic matter and

shall not contain any clay. The fine sand which shall be used for plaster and brick work shall

have F.M. as 1.25 and the coarse sand for cement plaster/ brick work shall have F.M. as 2.0 and

for cement concrete 2.9 to 3.2. All materials which shall be brought and used at site shall

confirm to I.S. - 383.

1.7 SUNDRY MATERIALS

Certain other materials not particularly mentioned or described herein may be required for the

works and these if not specifically mentioned shall comply with the description set out in

standard specifications of PWD, LSGED (now U.P. Jal Nigam) or IS for the respective

materials and these specifications in so far as they are applicable shall be deemed to be

incorporated in this contact.

1.8 BRICKS

Bricks used for the construction of brick masonry shall be hard, rectangular in shape and size

and well burnt of uniform deep red, cherry or copper colour and shall confirm to IS: 1077-1986.

The bricks shall be brought from approved brick kilns. The bricks shall be free from cracks,

chippings, flaws, stones or lumps of any kind. The bricks shall not show any signs of

efflorescence and shall be homogeneous in texture.

They shall emit a clear metallic ringing sound on being struck and shall have a minimum

compressive strength of 10.5 N/mm2 equivalent to 105 kg/cm².

They shall not absorb more than 20% of its dry weight when soaked in cold water for 24 hours

or otherwise specified in the Indian Standard Specification.

1.9 MORTAR

The proportion of the cement mortar used for the masonry work shall be as specified on the

various drawings for different places/types of construction, specifications for each part of the

work.

For cement mortar fresh Portland cement of standard specifications shall be used. Sand shall be

sharp, clean and free from organic and foreign matters. For rich mortar coarse or medium sand

shall be used and for weak mortar local fine sand may be used. Materials of mortar shall be

measured to have the required proportion with measuring box and first mixed dry to have a

uniform colour in a clean masonry platform and then mixed by adding clean water slowly and

gradually to have workable consistency and mixed thoroughly by turning at least three times.

Fresh mixed mortar shall be used, old and stale mortar shall not be used and mortar for an hour

work only shall be mixed with water so that the mortar may be used before setting starts.

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Coarse sand is mixed with the required quantity of cement for the preparation of the mortar.

Mortar shall be prepared in accordance with IS: 2250-1981. The sand used for the masonry

mortar shall meet the requirements as specified in IS: 2116-1980. For masonry mortars, sand

and cement of required proportions are mixed in small quantities in a dry state first and then

water is added to make the mortar of required consistency suitable for the type of work for

which it is required as directed by the Engineer-in-Charge. No left over mortar shall be used

and therefore only that much quantity of mortar that can be consumed within 30 minutes shall

be mixed in batches.

1.9.1 Sand for Brick Masonry

Table 1.9.1: Grading of sand for use in Masonry Mortar

IS Sieve Designation Percentage passing by mass

4.75 mm 100

2.36 mm 90 to 100

1.18 mm 70 to 100

600 micron 40 to 100

300 micron 5 to 70

150 micron 0 to 15

2.0 WATER SUPPLY FOR WORK AND DRINKING PURPOSE AND FACILITIES TO

LABOUR:

The contractor shall make his own arrangement in regard to water required for the execution

and tests of the works and shall also arrange for a supply of drinking water to his employees

and labour.

He shall bear all charges in this connection and include in his rates a sufficient amount to cover

such charges. All such facilities as are required to be provided for the labourers under the

labour welfare rules in force shall also be made available by the contractor at his own cost.

Minimum reasonable sanitary conditions are to be maintained in and around the labour camps

and at the site or work. As soon as one or more labour in trenches or at site get wounded or hurt

due to accident or carelessness immediate proper medical-aid shall be provided by the

contractor to them. However, if it is felt by the engineer that proper medical aid has not been

provided to them, it shall be incumbent upon the contractor to follow the instruction of the

engineer for proper medical-aid. A first-aid box should be maintained by the contractor during

execution period of the work. If proper medical facility is not provided by the contractor, same

shall be done by the department & cost shall be debited to the contractor‟s account.

3.0 NOTICE BOARD TO BE DISPLAYED:

Notice boards shall be supplied and fixed in suitable positions by the contractor where the roads

have been opened out for the construction of the culverts or sewers and the traffic has to be

diverted. Such boards shall display in big letter in BLACK AND WHITE or in RED AND

WHITE colours such warnings as ROAD CLOSED DRIVE SLOW, - WORK AHEAD MEN

ON WORK etc. Such caution boards be fixed at suitable points in the neighbor-hood of the

work or well before diversion where other roads join or cross the road opened out, so that

traffic may have sufficient warning to avoid the blocked road by taking any alternative routes or

by using the diversion provided by the contractor. No extra payment shall be made to the

contractor on this account. The caution boards shall be painted such that the warning or notices

glow in the night also to avoid accident or jamming of traffic.

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4.0 BARRICADING:

The contractor shall provide necessary barricading in portion the excavation is done for laying

of sewer lines. The barricading shall consist of ballies and G.I. sheet duly painted red and white

in colour as per direction and approval of E/I. The contractor shall also make arrangement in

proper warnings like providing fencing, danger flags, night warning light and watch and ward

etc.. Safety code for excavation work I.S. 3764-1966 shall be rigidly followed.

5.0 SPECIFICATION FOR HDPE PIPES:

1. The HDPE Pipe must be as per specifications confirming to IS 14333 : 1996 suitable for

following maximum permissible working pressure.

Nominal Diameter (DN) Pressure Rating of Pipe Maximum Permissible

Working Pressure, MPa

110 PN 10 1.00

160 PN 10 1.00

2. Colour

The Colour of the pipe shall be black.

3. Material

High Density Polyethylene (HDPE) used for the manufacture of pipe shall confirm to

designation PEEWA-45-T-006 OF IS 7328:1992.

3.1 The M.R.S. (Minimum Required Strength) of material used shall not be lower than

6.3 MPa at 20°C at 50 years.

3.2 The specified base density between 940.00 kg/m3 and 958.40 kg/m

3 (both inclusive)

shall be determined at 27°C according to procedure prescribed in Annexure A of IS

7328: 1992. The value of density shall also not differ from the nominal value by more

than 3 kg/m3 as per 5.2.1.1 of IS 7328: 1992.

3.3 The MFR of the material shall be between 0.20g/10min and 1.10g/10min (both

inclusive) when tested at 190°C with nominal load of 5 kgf as determined by method

prescribed in 7 of IS 2530:1963. The MFR of the material shall also be within ±20

percent of the value declared by the manufacturer.

3.4 The resin shall be compounded with carbon black. The carbon black content in the

material shall be within 2.5 ± 0.5 percent and the dispersion of carbon black shall be

satisfactory when tested according to the procedure described in IS 2500 : 1963.

4. The percentage of anti-oxidant used shall not be more than 0.3 percent by mass of finished

resin.

5. Dimensions of pipes

The outside diameter of pipes, tolerance on the same and ovality of pipe shall be a given in

table below-

Nominal Diameter (DN) Tolerance (mm) Ovality (mm)

110 1.0 2.2

160 1.5 3.2

6. Wall thickness

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The minimum and maximum wall thickness of pipes shall be as given in table below.

Nominal

Diameter (DN)

Pressure

Rating of Pipe

Minimum Permissible

Working Pressure, MPa

Maximum Permissible

Working Pressure, MPa

110 PN 10 10.0 11.2

160 PN 10 14.6 16.3

7. Visual appearance

The internal and external surface of the pipes shall be smooth clean and free from grooving

and other defects. The ends shall be cleanly out and shall be square with axis of the pipes.

Slight shallow longitudinal grooves or irregularities in the wall thickness shall be

permissible provided that the wall thickness remains within the permissible limits.

8. Performance requirements

8.1 Hydraulic Characteristics

When subjected to internal pressure creep rupture test in accordance with procedure

given in Annex-B, the pipes under test shall show no and shall not burst during the

prescribed test duration. The temperatures, duration of test and induced stresses or the

test shall conform to those specified in Table 3.

8.2 Reversion Test

When tested according to the procedure given at Annex C, the value of the

longitudinal reversion shall not be greater than 3 percent.

8.3 Density

When tested from a composite sample of minimum three pipes as per Annex A of IS

7328: 1992, it shall meet the requirement as given in 5.1.2.

9. Sampling, frequency of tests and criteria for conformity

9.1 Three samples of the same size and same pressure rating selected at random shall be

tested for compliance with the requirements of the type test, given in Table 3.

9.2 If all the samples pass the requirements of the type test, the type of the pipe under

consideration shall be considered eligible for type approval.

9.3 In case any of the samples fails in the type test, the testing authority, at its discretion,

may call for fresh samples not exceeding the original number and subject them to the

type test again. If in repeat test, no single failure occurs, the type of pipe under

consideration shall be considered eligible for type approval. If any of the samples fails

in the repeat tests, the type of pipe shall not be approved. The manufacturer or the

supplier may be asked to improve the design and resubmit the product for type

approval.

(C). DETAILED SPECIFICATIONS FOR CIVIL WORKS

1. EARTH WORK

1.1 GENERAL

The conditions/specifications laid down hereunder will hold good whether the excavation is to

be carried out over areas for leveling foundations of structures, trenches for pipes or cables or

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any other type of work which involves earth work like the leveling of forming/embankments

etc. as per UP Jal Nigam / UP PWD specifications.

a. Earthwork in excavation includes site-cleaning activities like removal of shrubs, loose

stones, rubbish of all kinds, interfering with the works and with complete removal of

roots.

b. The products of the above clearing operations shall be removed from the site, dumped,

stacked at a place or places, burnt or otherwise disposed of as directed by the Engineer-

in-Charge within the compound.

c. A permanent base line and cross lines shall be established to serve as reference grid

using MS plates, pegs, pins set in concrete or brick masonry pillars where they will be

free from disturbances.

d. A permanent bench marks or marks as required necessary for the works connected to the

nearest GTS benchmark shall be established for reference.

e. Excavation shall be carried out in all types of soil like top soil, silt, sand, gravel, soft

moorrum, clay, kankar, hard materials like disintegrated rock shale which can be

removed by picks, crowbars and shovels. Soil/earth may contain boulders. Loosening of

rocks include the other methods of excavation other than blasting such as chiseling,

wedging line drilling to avoid shattering of rocks. The Engineer-in-Charge shall decide

what method shall be adopted for removal of the hard rock.

f. Excavation, whose sides are required to be maintained at a steeper slope than the stable

slopes, will be required to be properly shored and strutted failing which the contractor

will be required to execute the work by open cutting by the approval of Engineer-in-

Charge.

g. Negligence on account of this leading to any mishap will be entirely the responsibility of

the contractor.

1.2 DRAINAGE IN THE VICINITY OF EXCAVATION

i. The contractor shall control the drainage in the vicinity of the Excavation so that the

surface of the ground will be properly sloped to prevent surface water running into

excavated areas during construction. Arrangements shall be made for preventing rain and

other extraneous liquids entering the excavated parts. Seepage water shall be directed to

flow away from the trenches by gravity. If any pumping is required to keep the trench

and the exposed areas dry for further work the same shall be done by the contractor at his

own expenses.

ii. The rates quoted by the contractor shall be deemed to be inclusive of all the above costs

or charges for stipulations stated above.

iii. Excavated material shall not be deposited within 1.5 meters from the top edge of the

excavation.

iv. The contractor shall remove the excavated material to spoil heaps on the site or transport

the same to a place as directed by the Engineer-in-Charge.

v. If the bottom of the excavation is left exposed by the contractor and in the opinion of the

Engineer-in-Charge it has become deleteriously affected by atmospheric changes or

affected by water then the contractor shall remove at his own cost such portions of the

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affected foundations and shall make good by filling with lean concrete or with

compacted sand as directed by the Engineer-in-Charge.

vi. Where Excavation is made in excess of the depths required as shown in the drawings or

as directed by the Engineer-in-Charge the contractor shall at his own expense fill up to

the required level with lean concrete or well compacted sand as decided by the Engineer-

in-Charge.

vii. Loose, soft or bad soil encountered in Excavation at the -required depth on Engineer-in-

Charge‟s directions shall be excavated to the firm bed and the difference of levels

between the required level and the firm bed shall be filled up or dealt with as directed by

the Engineer-in-Charge.

viii. Any obstacle encountered during excavation shall be reported immediately to the

Engineer-in-Charge and shall be dealt with as instructed by him. Same shall be

applicable for any antiques/treasure found during excavation.

ix. Any public utility services/facilities like water supply lines, gas supply line, sewers,

telephone/electric cables poles etc. met with during Excavation shall not be damaged and

no disruption is caused to the utility service on account of damages caused by the

contractor. Such facilities shall be properly supported in their original positions by giving

signs, suspension beams etc. as contractors own expenses.

x. The contractor shall not undertake any concreting or constructing work of any nature on

the excavated surfaces until approved for the same is given by the Engineer-in-Charge.

xi. The contractor shall be solely responsible for the protection of adjoining properties from

damages that may be on account of excavation close to the properties whether the

property belongs to government or to a private party.

xii. The contractor shall make all arrangements for proper warnings like providing. fences,

danger flags, barricading, night warning lights, watch and ward etc, to caution the public

as well as the labourers engaged by him about the dangers that may be involved by

excavation of trenches, pits, foundations etc. Safety code for excavation work IS: 3764-

1966 shall be rigidly followed unless instructed otherwise by the Engineer-in-Charge.

xiii. Any useful material obtained during Excavation shall be stacked as directed by the

Engineer-in-Charge and will be the property of the department. The decision of the

Engineer-in-Charge in this regard shall be final and binding on the contractor.

xiv. Any material used by the contractor out of the Excavated stuff in lieu of his own

materials shall be charged to the contractor at the market rates.

xv. The rates quoted shall include back filling of excavated material and disposal of surplus

earth as directed by the Engineer-In-Charge.

1.3 EXCAVATION IN TRENCHES AND CABLE DUCTS

i. Excavation as required in trenches, cable ducts, for manholes, other overflow structures,

cross drainage works, extra depths for joints of pipes shall be carried out as shown in the

drawings/directed by the Engineer-in-Charge.

ii. For deep foundations necessary shoring and strutting shall be executed as directed by the

Engineer-in-charge. If additional slopes are to be provided where vertical cuts „are not

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possible the same shall be executed without any additional cost. The rates quoted shall be

deemed to be inclusive of all such extra work.

iii. The trench shall be kept perfectly dry by preventing the extraneous water entering the

pits and also wherever necessary by pumping at the cost of the contractor. No additional

cost of dewatering shall be payable.

iv. The trenches after laying, jointing and testing of pipes/cables are to be back filled. The

trenches shall be filled with the excavated material if found suitable as directed by the

Engineer-in-Charge.

v. All surplus soil/earth shall be transported and disposed of as directed by the Engineer-in-

Charge Boulders, sharp objects, brickbats, roots of trees, rubbish, rubble etc. shall not be

used for back filling. The back filling shall be done very carefully so as not to damage

the pipes/cables or disturb the alignment levels of the pipes/cables. The back filling shall

be done in layers on both sides of the pipes watered, consolidated by ramming to a dense

layer. The thickness of each layer shall not be more than 15 cms. Special care shall be

taken to avoid unequal pressures and not to disturb the pipe.

vi. In case the excavated material falls short of requirement the back fill soil/earth shall be

taken from borrow pits approved by the Engineer-in-Charge. The rates quoted by the

contractor shall be deemed to be inclusive of all such works.

vii. Sight rails and boning rods are to be used at regular intervals as directed by the Engineer-

in-Charge to excavate the trenches true to line and grade.

1.4 BACK FILLING /EARTH FILLING

a. Back filling of earth around liquid retaining structures and pipes shall be done only after

the water-tightness test is done to the satisfaction of the Engineer-in-Charge. Selected earth

from the excavated earth shall be used for back filling / embankment.

b. Care shall be taken to see that unsuitable soil/earth does not get mixed up with the material

proposed to be used for filling.

c. Regarding the soil/earth to be used for back filling the contractor shall have the prior

approval of the Engineer-in-Charge.

d. Backfill shall be placed in successive horizontal layers of loose material not more than 15

cm thick. The material shall be brought to within + or - 2% of the optimum moisture

content as described in IS:2720 (Part VIII) after adjusting the moisture content, the layers

shall be thoroughly compacted with such equipment . as may be required to obtain a

density equal to or greater than 95% of maximum laboratory dry density of the soil.

e. Successive layers of filling shall not be placed until the layer under construction has been

thoroughly compacted to satisfy the requirements laid down in the requirements.

1.5 FILLING AND EMBANKMENT

i. The area where filling or embankment is to be carried out shall be cleared from loose

material and the virgin soil shall be exposed. All shrubs and vegetation with roots are

cleared. All soft patches shall be removed and filled with selected soil/earth and

consolidated. Exposed soil/earth shall be consolidated properly to obtain 95% of maximum

laboratory dry density of the soil.

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ii. Approved filling material shall be uniformly spread in layers not exceeding 20 cms in

loose depth. All clods, lumps, etc shall be broken before consolidation.

iii. Successive layers of filling shall not be placed until the layer under construction has been

thoroughly compacted to satisfy the requirements laid down in these specifications.

iv. The contractor shall give the samples of the earth he proposes to use for back filling for

testing, if required or directed by the Engineer-in-Charge along with the following

characteristics of the soil/earth.

v. Only earth having plasticity index less than 20 shall be used.

vi. Soil/earth having laboratory maximum dry density of less than 1500 kg per cubic meter

shall not be used.

vii. If the layer fails to meet the required density it shall be reworked or the materials shall be

replaced and method of compaction altered as directed by the Engineer-in-Charge to

obtain the required density.

viii. If any test indicates less than the specified degree of compaction the Engineer-in-Charge

may require all the fill placed; subsequent to the latest successfully tests to be removed and

compacted and compaction procedure to be done once again to obtain satisfactory density.

ix. The contractor shall perform all necessary tests to determine optimum moisture content

and the degree of compaction. He shall furnish the results to the Engineer-in-Charge.

x. Prior to rolling, the moisture content of the material shall be brought to within +2% of the

optimum moisture content as described in IS-2720 (part VIII). The moisture content shall

preferably be on the wet side for potentially expansive soil/earth. After adjusting the

moisture content as described in this clause, the layers shall be thoroughly compacted by

means of rollers till 95% of maximum laboratory dry density is obtained.

xiii. If the layer fails to meet the required density it shall be reworked or the materials shall be

replaced and method of compaction altered as directed by the Engineer-in-Charge to

obtain the required density.

xiv. The embankment shall be finished to the alignment levels and grades, cross sections,

dimensions shown in the drawings or as directed.

xv. If sand filling is specified in the tender for filling the trenches, plinth or foundations the

sand used shall be hard, free from inorganic materials and deleterious materials and

approved by the Engineer-in-Charge. Filling shall be carried out in layers not exceeding 15

cms in loose depth and flooded and tamped till it meets the approval of the Engineer-in-

Charge.

x. The contractor shall perform all necessary tests to determine optimum moisture content

and the degree of compaction. He shall furnish the results to the Engineer-in-Charge.

1.6 SHORING/STRUTTING/TIMBERING

i. When the depth of foundation or pipe trench is great and the soil/earth is soft and generally

for depths more than 1.5 m. Stepping, sloping and or paneling and strutting of sides shall

be done as directed by the Engineer-in-Charge. The decisions regarding the positions and

depths at which and what type of precautions are to be provided shall be decided by the

Engineer-in-Charge.

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ii. It shall be the responsibility of the contractor to take all necessary precautions or steps to

prevent the sides of trenches from collapse. The contractor shall be responsible to make

good any losses or damages caused to execute works, life and property due to his

negligence.

iii. Deep excavation shall be inspected after every rain, storm, or other hazards and if

necessary the precautions required shall be augmented.

iv. Planking and strutting shall be either “Close” or “Open” type depending upon the nature of

the soil/earth and depth of excavation etc.

v. The timbering shall be of sufficient strength to resist earth pressure and ensure safety to the

adjoining property and to persons. Where the excavation is subjected to vibrations due to

machinery, vehicles, rail traffic, blasting and other sources, additional bracings shall be

provided.

vi. Generally the specifications and sizes and spacing of sheeting, wallers and struts used for

timbering of different depths shall be as given in the IS: 3764-1965 Safety code for

excavation work unless otherwise specified in the tender elsewhere. Shoring shall extend

30 cms, above the vertical sides.

vii. Withdrawal of timbering shall be done very carefully to prevent collapse of the sides of

excavation and any damage to the work executed.

viii. Open timbering shall be provided wherever the Engineer-in-Charge directs, where the

trenches are not close to any buildings/property/structures. In open timbering the trench

shall be protected by covering 1/3 the surface area by planks.

Important Note

1. The bottom of Excavation shall be trimmed to the required levels and when carried below such

levels, by error, shall be brought to level by filling with lean concrete of grade 1:4:8 or as

specified at the contractor‟s cost and nothing extra shall be paid to the contractor on this account.

2. The contractor shall be responsible for assumptions and conclusions that he may make regarding

the nature of materials to be excavated and the difficulty in making and maintaining the required

Excavation and performing the work required as shown on the drawing and in accordance with

these specifications. Cofferdams, sheeting, shoring, braking, draining, dewatering, etc. shall be

furnished and installed as required and the cost thereof shall be included in the rate quoted for the

item of excavation. The contractor shall be held responsible for any damage to any part of the

work and property caused by collapse of sides of Excavation. Materials may be salvaged if it can

be done with safety for the work and structures, as approved by the Engineer-in-Charge.

However, no extra claim shall be entertained for material not salvaged or any other damage to

contractor‟s property as a result of the collapse. He shall not be entitled to any claim for re-doing

the excavation as a result of the same.

3. The excavation for foundations shall be carried out carefully, creating least disturbance to the

founding stratum. The founding stratum should be blended by the concrete layer immediately

after exposure so that it does not loose its strength on exposure to air and water.

4. Where excavation requires bracing, sheeting, or shoring etc, the contractor shall submit to the

Engineer-in-Charge, drawings showing arrangement and details of proposed installation, and

shall not proceed until he has received approval from the Engineer-in-Charge.

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5. The contractor shall have to constantly pump out the water collected in pits due to rainwater,

springs etc. and maintain dry working conditions.

6. For the purpose of excavation in earthwork, all types of soil including kankar, moorrum, single

and boulders without binding matrix are included.

7. All excavated material obtained as a result of over excavation for which payment shall not be

made, and that shall also be transported and disposed off as directed and at places shown by the

Engineer-in-Charge, at no extra cost to the department within plot boundary.

8. All excavated materials obtained from excavation shall remain in the department‟s property. The

useful portion as decided by the Engineer-in-Charge, shall be separated from the useless ones and

deposited in regular stacks at places indicated and as directed by the Engineer-in-Charge.

9. In no case the excavated soil shall be stacked upto a distance of 1.5 m from the edge of

excavation or one-half the depth of excavation whichever is more.

10. IS Codes

Some of the important relevant applicable codes for this section are

IS: 1200 (Part-I)-Method of measurement of building and civil engineering works and earthwork

IS: 3764 - Safety -code for excavation work

IS: 4701 - Code of practice for earthwork on canals

11. Cradle and Manholes for collection sewer line shall be as per CPHEEO Manual.

2. PLAIN CEMENT CONCRETE

General

Aggregate shall be of inert materials and shall be clean, dense, hard, sound durable, non-absorbent

and capable of developing good bond with mortar. Coarse aggregate shall be of hard broken stone or

granite or similar stone free from dust dirt and other foreign matters. The stone ballast shall conform

to UP Jal Nigam, UP PWD specifications.

Fine aggregate shall be of coarse sand consisting of hard, sharp and angular grains and shall‟ pass

through screen of 4.75 mm IS Sieve. Sand shall be of standard specifications, clean and free from

dust, dirt and organic matters. Fine aggregate may also be crushed stone.

Ordinary Portland cement of 43 grade as per IS: 8112 shall be used. It shall have the required tensile

and compressive stresses and fineness. Water shall be clean and free from alkaline and acid matters

and suitable for drinking purposes.

The proportion of concrete shall be 1:3:6 (Cement: Fine Aggregate: Coarse Aggregate) by unless

otherwise specified. Minimum compressive strength of concrete of 1:3:6 proportion shall be as per IS:

456 2000 or its latest revision.

Stone aggregate sand and cement shall be mixed as per UP Jal Nigam, UP PWD specifications. All

materials shall be dry. If damp sand is used, compensation shall be made by adding additional sand to

the extent required for the bulking of damp sand.

Appropriate quantity of water required for cement may be taken as spacified in IS 456-2000 or its

latest amendment. For concrete compacted by mechanical vibrations the quantity of water shall be

reduced by 20%.

Mixing shall be of machine mixing type. Hand mixing shall not be permitted.

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Machinery Mixing: Stone ballast, sand and cement shall be put into the cement concrete mixer to

have the required proportion. For concrete of 1:2:4 proportion, first four boxes of stone ballast, then

two boxes of sand and then one bag of cement shall be put into the C.C. Mixer, the machine shall then

be revolved to mix materials dry and then water shall be added gradually to the required quantity, 25

to 30litres per bag of cement to have the required water cement ratio. The mixing shall be thorough to

have a plastic mix of uniform colour. It requires 1.5 to 2 minutes rotation for thorough mixing. Mixed

concrete shall be unloaded on a masonry platform or on a sheet iron. Output of concrete mixer is 15 to

20 mix per hour.

Regular slump test shall be carried out to control the addition of water and to maintain the required

consistency.

Formwork centering and shuttering shall be provided as required, as per standard specifications before

laying concrete to continue to support or to keep the concrete in position.

Concrete shall be laid gently (not thrown) in layers not exceeding 15 cm and with mechanical

vibrating machine until a dense concrete is obtained. (For important work mechanical vibrating shall

be used for thick or mass concrete immersion type vibrators and for thin concrete surface vibrators

shall be used for compacting concrete). Over vibration will separate coarse aggregate from concrete

and shall be avoided. After removal of the formwork in due time the concrete surface shall be free

from honey combing, air holes or any other defect.

Concrete shall be laid continuously, if laying is suspended for rest or for the following day the end

shall be shuttered and vibrated to achieve dense concrete and made rough after de-shuttering for

further jointing. When the work is resumed, the previous portion shall be roughened, cleaned and

watered and a grout of neat cement shall be applied and the fresh concrete shall be laid. For

successive layer the upper layer shall be laid before the lower has set.

After about 2 hours laying when concrete has begun to harden, it shall be kept damp by covering with

wet gunny bags or wet sand for 24 hours, and then cured by flooding with water, making mud walls

7.5 cm high or by covering with wet sand or earth and kept damp continuously for 15 days. If

specified, curing may be done by covering concrete with special type of waterproof paper as to

prevent water escaping or evaporating.

Plain cement concrete shall be provided for leveling courses, foundations, pipe bedding or at other

places wherever indicated in the drawings/directed by the Engineer-in-Charge. Grade and thickness of

all PCC works shall be as mentioned in the drawings.

The proportion of the concrete, size of the aggregate shall be as specified in the drawings and

technical specifications approved by Engineer-in-Charge.

While placing concrete directly on the soil for foundations etc. all the loose material shall be removed.

The surfaces shall be trimmed and well consolidated.

The material specifications, mixing, placing of concrete compaction, curing, removal of the form

work shall all be done as specified for reinforced cement concrete in the section of this tender

document. The clauses provided therein shall also equally apply for this item of work to the extent

relevant.

The rates quoted shall include supply of material, labour, tools and plant, water, mixing platforms,

curing, supplying, erecting and dismantling of all form works as required.

Testing and Acceptance Criteria of Concrete

131

The sampling of concrete making the test specimens, curing and testing procedures etc. shall be in

accordance with IS: 1199, IS: 3085 and IS: 516, the size of specimen being 15 cm cubes. Normally

only compression tests shall be performed in accordance with IS: 516.

For each grade of concrete and for each 8 hours of work or portion thereof the following samples shall

be taken.

At least six specimens shall be taken from the first 15.0 m3 or part thereof and three of these shall be

tested at 7 days and the remaining at 28 days. Four additional specimens shall be taken from each

additional 15.0 m of concrete or portion thereof of which 2 specimens shall be tested at 7 days and the

remaining at 28 days.

To control the consistency of concrete from every mixing plant slump tests, and/or compacting factor

tests in accordance with IS: 1199 shall be carried out by the contractor every two hours or as directed

by the Engineer-in-Charge. Slumps corresponding to the test specimens shall be recorded for

reference. The acceptance criteria of concrete shall be in accordance with IS: 456-2000.

Concrete work found unsuitable for acceptance shall have to be dismantled and replacement is to be

done as per specifications by the contractor. No payment for the dismantled concrete, the relevant

formwork and reinforcement embedded fixtures etc. shall be paid.

In the course of dismantling if any damage is done to, the embedded items or adjacent structures the

same shall be made good free of charge by the contractor to the satisfaction of the Engineer-in-

Charge.

3. BRICK MASONRY AND PLASTERING

3.1 Brick Masonry

General

All bricks shall be of class designation 10 or best locally available approved by Engineer-in-Charge

made of good brick earth thoroughly burnt, and shall be of deep cherry red or copper colour. Bricks

shall be regular in shape and their edges shall be sharp and shall emit clear ringing sound on being

struck and shall be free from cracks, chips, flaws and lumps of any kind. Bricks shall not absorb water

more than one sixth .of their weight after one hour of soaking by immersing the water. Bricks shall

have a minimum crushing strength of 105 kg/cm² (10.5 N/mm2).

Bricks shall be fully soaked in clean water by submerging in a tank for a period of 12 hours

immediately before use. Soaking shall be continued till air bubbling is ceased.

Bricks shall be well bonded and laid in English bond unless otherwise specified. Every course shall be

truly horizontal and wall shall be truly in plumb. Vertical joints of consecutive course shall not come

directly over one another, vertical joints in alternate course shall come directly over one another. No

damaged or broken bricks shall be used. Closers shall be of clean-cut bricks and shall be placed near

the ends of walls but not at the other edge. Selected best-shaped bricks shall be used for face work.

Mortar joints shall not exceed 6 mm in thickness and joints shall be fully filled with mortar. Bricks

shall be laid with frogs upwards except in the top course where frogs shall be placed downward.

Brickwork shall be carried out not more than 1.2m height at a time. When one part of the wall has to

be delayed, stepping shall be left at an angle of 45º. Corbelling or projections where made shall not be

more, than X brick projections in one course. All joints shall be raked and faces of wall cleaned at the

end of each day‟s work.

These specifications deal with all types of brickwork required for buildings, manholes, drains,

retaining walls or any construction made out of bricks.

132

3.1.1. Construction

The brick masonry shall be constructed as per the Indian Standard Code of Practice for Brick Work

IS: 2212-1962. The thickness of the joints shall not be thicker than those specified in para 5.4 of the

above Code of Practice.

The bricks shall be thoroughly soaked in water before using them on the work for at least twelve

hours and all the air bubbles shall come out during soaking process. The soaked bricks shall be

stacked on wooden planks/platforms so as to avoid sticking of the earth and other materials on to the

surfaces of bricks. Bricks required for construction in mud mortar or lime mortar shall not be soaked.

Brickwork shall be laid in English Bond unless otherwise specified. Half bricks shall not be used

except when needed to complete the bond. Each course shall be perfectly straight and horizontal. The

masonry shall be true to plumb in case of vertical walls and in case of battered construction the batter

or slope shall be truly maintained. The level of the courses completed shall be checked at every one

meter interval or less as required.

The bricks shall be laid frogs upwards. While laying the bricks they shall be thoroughly bedded and

flushed in mortar and well tapped into position with wooden mallets and superfluous mortar shall be

removed.

No part of the structure shall be raised more than one meter above than the rest of the work. In case it

is unavoidable the brickwork shall be raked back at an angle of not more than 45 degrees so as to

maintain a uniform and effectual bond, but raking shall not start within 60 cms from a corner.

In case of construction of buttresses, counter-forts, returns they are built course by course carefully

bound into the main walls.

At all junctions of walls the bricks at alternate courses, shall be carried into each of the respective

walls so as to thoroughly unite both the walls together. The brickwork shall not be raised more than

14 courses per day.

All the beds and joints shall be normal to the pressures applied upon them Le horizontal in vertical

walls, radial In arches and at right angles to the face in battered retaining walls.

Vertical joints in alternate courses shall come directly one over the other and shall be truly vertical.

Care shall be taken to ensure that all the joints are fully fitted up with mortar, well flushed up where

no pointing is proposed, nearly struck as the work proceeds. The joints in faces which are plastered or

painted shall be squarely raked out to a depth not less than 12 mm while the mortar is still green. The

raked joints shall be well brushed to remove the loose particles and the surfaces shall be cleaned with

a wire brush so as to remove any splashes of mortar sticking to the surfaces during the construction.

All iron fixtures, pipes, bolts, conduits, sleeves, holdfasts etc. which are required to built into the

walls shall be embedded in cement mortar or cement concrete as shown in the drawings/indicated in

the specifications/directed during the execution by the Engineer in-Charge as the work proceeds and

no holes be left for fixing them at a later date unless authorized by the Engineer-in-Charge.

3.1.2 Curing

Green work shall be protected from rain by covering the work suitably. Masonry work as it progresses

shall be thoroughly kept wet by watering on all the faces for at least 10 (Ten) days after completion of

the parts of the work. Proper watering cans, flexible pipes, nozzles shall be used for the purpose in

case of fat lime mortar curing shall start two days after construction of masonry and shall continue for

133

seven days. No additional payment is admissible for curing and the rates quoted are deemed to be

inclusive of the cost of curing.

3.1.3 Scaffolding

Double scaffolding sufficiently strong so as to withstand all loads that are likely to come upon it and

having two sets of vertical supports shall be provided. Where two sets of vertical supports are not

possible the inner end of the horizontal supporting pole shall rest in a hole provided in a header course

only. Only one header for each pole shall be left out. Such holes however shall not be permitted in

pillars less one meter in width or immediately near the skew backs of arches. Such holes shall be

filled up immediately after removal of the scaffoldings. Safety Code for Scaffolds and Ladders, IS:

3696-1987 (Parts I and II) shall be followed.

3.2 Plastering

Cement mortar used for plastering shall be of the mix proportions and thickness as specified on the

drawings or bill of quantities or particular specifications for the various different parts of the works.

The materials used i.e. cement, sand and water shall be of the same quality and of the same

specifications as indicated for plain and reinforced cement concrete works according to the

specifications and approved by the Engineer-in-Charge. Sand further shall meet the specifications as

laid down in IS: 1542-1977 Specification for sand for plaster.

The sand for preparation of mortar for plastering shall confirm to the following gradation, shown in

Table 3.2

TABLE 3.2: GRADING OF FINE AGGREGATES

Percentage by weight passing IS Sieve

IS Sieve Designation Class -A Class-B

4.75 mm 100 100

2.36 mm 90 to 100 90 to 100

1.18 mm 70 to 100 70 to 100

600 Microns 40 to 85 40 to 95

300 Microns 50 to 50 10 to 65

150 Microns 0 to 10 0 to 15

For the purpose of indicating the suitability for use, the sand is classified as Class A and Class B in

accordance with the limits of grading. Class A sand shall be used generally for plastering and when

they are not available, Class B sand may be used with the approval of Engineer-in-Charge.

The procurement of sand for Mortar for plastering and pointing shall confirm to be specifications

given in Table 3.2.

Surface that are to be applied with plaster shall be thoroughly cleaned to remove dust, dirt, loose

particle, oil, soil, salts etc, that may be sticking to the surfaces. The surfaces shall be washed, clean

and watered properly for 4 hours before applying plaster. Plaster shall not, in any case, be thinner than

specified. It shall have uniform specified thickness. When smooth finishing is required the cement

plastering shall be floated over with neat cement within 15 minutes after application of the last coat of

plastering. The plaster shall be protected from the sun and rain by such means as the Engineer-in-

Charge may approve.

134

The plastered surface shall be cured for 10 (ten) days. Construction joints in plastering shall be kept at

places approved by the Engineer-in-charge. When the thickness of the plaster specified is to be made

up in more than one layer the second layer shall be applied only when the lower coat is still green.

Wherever specified approved brands of additives like water proofing compounds shall be added in

specified quantities as recommended by the manufacturer of the compound or as directed by the

Engineer-in-Charge.

Wherever scaffolds are necessary for plastering they shall be provided as specified for scaffolds under

clause 3.2.2. Stage scaffolding shall be provided for ceiling plaster.

To ensure even thickness and true surface, patches of plaster about 15 cm x 15 cm shall be first

applied both horizontally and vertically 2.0 m apart. Plastering shall be done. from top of bottom and

care shall be taken to avoid joints on continuous surface.

In case any other finish like rough cast finish or dry dash finish is specified in the drawings the small

shall be provided as directed by the Engineer-in-Charge.

Surface which is to be plastered shall be roughened while they are still green or raked so as to give

proper bond between the surface and plaster.

All corners junctions shall be truly vertical or horizontal as the case may be and carefully finished.

Rounding or chamfering of corners shall be carried out with proper templates to the required size and

shapes.

The work shall be tested frequently with a straight edge and plumb bob. At the end of the day the

plaster shall be left cut clean to line. When the next days plastering is started the. day the plaster shall

be left cut clean to line. When the next days plastering is started the edge of the old work shall be

scrapped, cleaned and wetted with cement slurry. At the end of the day the plastering shall be closed

on the body of the wall and not nearer than 15 cm to any corner.

Curing shall be started as soon as the plaster has hardened sufficiently not to be damaged when

watered. The plaster shall be kept wet for at least 10 days. Any defective plaster shall be cut in

rectangular shape and replaced.

4. REINFORCED CEMENT CONCRETE AND ALLIED WORKS

GENERAL

In general RCC work is to be executed as per IS : 456-2000 or its latest revision. The water storage

tanks/reservoirs shall be followed by IS : 3370 Part I to IV & latest revision. Steel reinforcement bars

shall be of High Yield Strength Deformed (HYSD) steel bars as per IS: 1786 and shall be free from

corrosion, loose rust scales, oil, grease, paint, etc. Wire mesh or fabric shall be in accordance with IS:

1566. The steel bar shall be capable‟ of being bent without fracture. Bars shall be bent accurately and

placed in position as per design and drawing and bound together tight with 20 SWG annealed steel

wire @ 10 kg/ton of reinforcement at their point of intersection.

Formwork and shuttering shall be made with steel plate close and tight to prevent leakage of mortar,

with necessary props, bracings and wedges, sufficiently strong and stable and should not yield on

laying concrete and made in such a way that they can be slackened and removed gradually without

disturbing the concrete. For slab and beam small chamber should be given in centering, 1 cm per 2.5

m with a maximum of 4 cm. Centering should not be removed before 14 days in general (4 days for

RCC columns, 10 days for roof slab, and 14 days for beams).

135

The grade of concrete to be used shall be as mentioned in specifications/shown on drawings.

Table - 4.1 Minimum compressive strength of 15 cm cubes at 7 and 28 days after mixing,

conducted in accordance with IS: 516

Class Preliminary Test

N/mm2

Work Test

N/mm2

Maximum size of

Aggregate mm

Locations for Use

At 7

days

At 28

days

At 7

days

At 28

days

M40 33.50 50.00 27.00 40.00 20 As indicated in the

specifications or as

required

M35 30.00 44.00 23.50 35.00 20 -do-

M30 25.00 38.00 20.00 30.00 20 --do-

M25 22.00 32.00 17.00 25.00 20 --do-

M20 17.50 26.00 13.50 20.00 20 --do-

M15 13.50 20.00 10.00 15.00 20 --do-

The coarse aggregate shall usually be 20 mm to 6mm gauge unless otherwise specified. For heavily

reinforced concrete members as in the case of ribs of main beams the maximum size of aggregate

should usually be restricted to 5 mm less than the minimum clear distance between the main bars or 5

mm less than the minimum cover to the reinforcement whichever is smaller.

Mixing is done in the same manner as in PCC.

Before laying the concrete, the shuttering shall be clean, free from dust, dirt and other foreign matters.

The concrete shall be deposited (not dropped) in its final position. In case of columns and wall, it is

desirable to place concrete in full height if practical so as to avoid construction joints but the progress

of concreting in the vertical direction shall be restricted to 1.2 metre. Care should be taken that the

time between mixing and placing of concrete shall not exceed 20 minutes so that the initial setting

process is not interfered with. During the winters concreting shall not be done if the temperature falls

below 4ºC.

Concrete shall be compacted by mechanical vibrating machine until a dense concrete is obtained. The

vibration shall continue during the entire period of placing concrete. Compaction shall be completed

before the initial setting starts i.e. within 30 minutes of addition of water to the dry mixture. Over-

vibration which will separate coarse aggregate from concrete shall be avoided. After removal of the

form work in due time, the concrete surface shall be free from honey combing, air holes or any other

defect.

Concrete shall be laid continuously, if laying is suspended for rest or for the following day the end

shall be shuttered and vibrated to achieve dense concrete and made rough after de-shuttering for

further jointing. When the work is resumed, the pervious portion shall be roughened, cleaned and

watered and a grout of neat cement shall be applied and the fresh concrete shall be laid. For

successive layer the upper layer shall be laid before the lower has set.

Pre-cast concrete shall be provided with lifting device.

4.1.1 Standards

Following Indian Standards as revised most recently along with amendments will be followed for the

works included in the contract.

IS:8112 Ordinary, Portland cement

IS:383 Coarse and fine aggregates from natural sources for concrete

136

IS:445 Portland slag cement

IS:456-1978 Code of practice for plaint and reinforced concrete

IS:516 Method of test for strength of concrete

Methods of sampling and analysis of concrete

IS:2386 Methods of test for aggregates for concrete (Part I to VI)

IS:3414 Code of practice design and installation of expansion and contraction joints in

building.

IS:3713 Part- I to IV Code of practice for water storage Tanks

Standards on special subjects have been mentioned elsewhere in this para and also shall be followed.

4.2 Forms, false work or centering

4.2.1 Definitions

“Forms, formwork or shuttering” shall include all temporary moulds for forming the concrete to the

required shape, together with any special lining that may be required to produce the concrete finish

specified.

“False work or centering” shall consist of furnishing, placing and removal of all temporary

construction such as forming, props and struts required for the support of forms.

4.2.2 Materials

Steel shuttering shall be provided as directed by the Engineer-in-Charge.

4.2.3 Forms

All forms shall be of mild steel approved by the Engineer-in-Charge and shall be fabricated and

prepared water tight and of sufficient rigidly to prevent distortion due to the pressure of the concrete

and other incidental loads incident to the construction operations.

All form shall be set and maintained true to the line designated until the concrete is sufficiently

hardened. Forms shall remain in place for periods which shall be specified hereinafter. When forms

appear to be unsatisfactory in any way, either before or during the placing of concrete, the Engineer-

in-Charge shall order to stop the work until the defects have been corrected.

All formwork shall be approved by the engineer-in-charge before concrete is placed within it. The

contractor shall be required to submit copies of his calculations of the strength and stability of the

formwork or false work but not withstanding the Engineer-in-Charge‟s approval of these calculations,

nothing shall relieve the contractor of his responsibility for the safely or adequacy of the formwork.

Formwork shall be true to line and braced and strutted 10 prevent deformation under the weight and

pressure of the unset concrete, constructional load, wind and other forces. The deflection shall not

exceed 3 mm. Beam bottom shall be erected with an upward chamber of 2 mm per meter of the span.

The form work for a column may be erected.

One side shall. be left open and shall be built up in sections as placing of the concrete proceeds.

Before placing the concrete, bolts and fixtures shall be in .position, and cores and other devices, used

for forming openings, holes, chases, recesses and other cavities shall be filled to the formwork. No

holes shall be cut in any concrete unless approved. Approved mould oil or other material shall be

applied to faces of formwork in contact with unset concrete to prevent adherence of the non-staying

concrete. Such coating shall be insoluble in water, non-staying and non-detrimental to the concrete

and shall not be flaky or removed by wash water.

4.2.4 Tolerance in finished concrete

137

(As per IS code 456-2000, 0.1)

The form work shall be so made as to produce a finished concrete true to shape, lines, level, plumb

and dimensions as shown in the drawing subject to the following tolerances, unless otherwise

specified in drawings or directed by the Engineer-in-Charge.

For

Deviation from specified

Dimensions of cross-section of columns

And beams = -6mm

+12mm

b. Deviations of dimension of footings

(See Note)

Dimensions in plane = -12mm

+50mm

Eccentricity = 0.02 times the width of footing in the direction

of deviation but not more than 50 mm

Thickness = +/- 0.05 times the specified thickness

Note: Tolerances applied to concrete dimensions only, not to positioning of vertical reinforcing steel

or dowels.

4.2.5 False work and Centering

Detailed plans for false work or centering shall be supplied by the contractor if specifically asked for

by the Engineer-in-Charge at least 14 days in advance of the time the contractor begins construction

of the false work. Notwithstanding the approval by the Engineer-in-Charge of any designs for false

work submitted by the contractor, the contractor shall be solely responsible for the strength, safety and

adequacy of the false work or centering.

All false work shall be designed and constructed to provide the necessary rigidity and to support the

loads from the weight of green concrete and shuttering and incidental construction loads.

False work or catering shall be founded upon a solid footing safe against undermining and protected

from softening.

False work which cannot be founded on satisfactory footing shall be supported on piling which shall

be spaced, driven and removed in a manner approved by the Engineer-in-Charge. The Engineer-in-

Charge may require the contractor to employ screw jacks or hardwood wedges to make up any

settlement in the formwork either before or during the placing of concrete. Props of the upper storey

shall be placed directly over those in the storey immediately below.

False work shall be set to give the finished structure the required grade and camber specified on the

plans.

4.2.6 Formwork and Construction Joints

Where permanent or temporary joints are to be made in horizontal or inclined members, stout

stopping off boards shall be securely fixed across the mould to form a watertight joint. The form of

the permanent construction joint shall be as shown on the drawings. Temporary construction joints

shall have blocks of timber at least 75 mm thick, slightly tapered to facilitate withdrawal and securely

fixed to the face of the stopping off board. The area of the key or keys so formed shall be at least 30%

the area of the member. The blocks shall be kept back at least 50 mm from the exposed face of the

concrete.

138

Where reinforcement passes through the face of a construction joint the stopping off board shall be

drilled so that the bars can pass through, or the board shall be made in sections which a half round

indentation in the joint faces for each bar so that when laced, the board is a neat and accurate fit and

no grout leaks from the concrete through the bar holes or joints.

4.2.7 Removal of Forms and False work

In the determination of the time for the removal of forms, falsework and housing, consideration shall

be given to the location and character of the structure, the weather and other conditions influencing

the settings of the concrete and the materials used in the mix.

MS shuttering/formwork and scaffolding should be of standard reputed make to ensure better quality

of concrete finish.

Forms shall be removed in such a manner as not to injure the concrete and no formwork shall be

removed before the concrete has sufficiently set and hardened. The minimum periods which shall

elapse between the placing and compacting of normal Portland cement concrete for the various parts

of the structures are given in the following table, but compliance with these requirements shall not

relieve the contractor of the obligation to delay the removal of the forms if the concrete has not set

sufficiently hard.

Forms shall not be struck until the concrete has reached strength at least twice the stress to which the

concrete may be subject at the time of removal of formwork. In normal circumstance, generally where

the temperatures are above 20ºC and where ordinary Portland cement is used, form may generally be

removed after the expiry of the following periods, according to the Clause 10.3, IS: 456-2000.

Table 4.2 : Removal of the Forms

a. Walls columns and vertical faces of all

structural members

24 to 48 hours as may be decided by the

engineer-in-charge

b. Slabs (Props left under) 3 days

c. Beam soffit (props left under) 7 days

d. Removal of props under slabs

1. Spanning upto 4.5m

2. Spanning above 4.5 m

7 days

14 days

e. Removal of props under beams and arches

1. Spanning upto 4.5m

2. Spanning above 4.5 m

14 days

21 days

Where sulphate resistant cement is used, manufacturer‟s instructions are to be followed.

The Engineer-in-Charge may modify these requirements taking into account the type of cement and

method of compaction used, and contractor shall obtain the Engineer-in-Charge‟s written approval for

any decrease in time of stripping of the formwork given above. The contractor shall notify the

Engineer-in-Charge when he proposes to stripe of any formwork and no formwork shall be struck

except in the presence of the Engineer-in-Charge or his representative.

4.2.8 Reuse of Forms

Only mild steel formwork of best quality as per approved vendor list given by Engineer-in-Charge

shall be used for concreting purpose. These shuttering shall not be reused unless it is properly scraped

cleaned and repaired, so that it gives a plane, even, fair and dense concrete surface.

4.2.9 Cleaning and treatment of Forms

139

All forms shall be thoroughly cleaned of old concrete, wood shavings, sawdust, dirt and dust sticking

to them before these is fixed in position. All rubbish, loose concrete, chippings, shavings, saw dust

etc. should be scrupulously removed from the interior of the forms before concrete is poured. Wire

brushes, brooms, compressed air jet and/or water jet etc. shall be kept handy for cleaning, if directed

by the Engineer-In-Charge.

Before formwork is placed in position, the form surface that will be in contact with concrete shall be

treated with approved non-staining oil or composition, which is insoluble in water and not injurious to

concrete. Care shall be taken that the oil or composition does not come in contact with reinforcing

steel or stain the concrete surface. Burnt oil shall not be allowed to be used especially where the

concrete surface will require finishing and/or plaster.

4.3 Materials for Concrete

4.3.1 Water

Water used for cement concrete mortar, plaster, grout, curing or washing of sand shall be clear and

free from injurious amount of Oil, Acid, Alkali, Organic matter or other harmful substances in such

amounts that may impair the strength or durability of the structure.

Potable water shall generally be considered satisfactory for mixing and curing concrete. In case of

doubt regarding development of strength, the suitability of water for making concrete shall be

ascertained by compressive strength and initial setting time specified in the IS: 456 Code of Practice

for Plain and Reinforced concrete. The Engineer-in-Charge may require the contractor to get the water

tested from an approved laboratory at his own expense and in case the water contains any salts for an

excess of acid, alkali, any injurious substances etc., the Engineer-in-Charge may refuse its use. And

the contractor shall be required to arrange suitable water at his own cost.

4.3.2 Aggregate

General

Coarse and Fine Aggregates for concrete shall confirm in all respect to PWD Specifications / IS: 383

Specifications for Coarse and Fine Aggregates from Natural Sources for Concrete. Aggregates shall

be obtained from a source known to produce satisfactory material for concrete. Aggregates shall

consist of naturally occurring sand and gravel or stone, crushed or uncrushed or a combination

thereof. They shall be chemically inert, hard strong, dense, durable, clean and free from veins and

adherent coatings and of limited porosity. Flaky and elongated pieces shall not be used. Whenever

required by the Engineer-in-Charge the aggregates shall be washed by the Contractor before use in the

work.

The source of aggregates shall be approved by the Engineer-in-Charge and shall not be changed

during the course of the job without his approval. Rejected aggregates shall be promptly removed

from the work site by the contractor at his own expense.

4.3.2.1 Deleterious Materials

Aggregates shall not contain any harmful material, such as iron pyrites, coal, mica, shale or similar

laminated materials, clay, alkali, soft fragments, sea shells, organic impurities etc, in such quantities

as to affect the strength or durability of the concrete and in addition to the above, for reinforced

concrete, any material which might cause corrosion of the reinforcement. Aggregates which are

chemically reactive with the alkalis of cement shall not be used.

140

The maximum quantities of deleterious materials in the aggregate, shall be in accordance with IS:

2386 (Part II). Methods of Test for Aggregates for Concrete, shall not exceed the limit given in Table

I of IS: 383.

The sum of the percentages of all deleterious materials shall not exceed five. Deleterious materials

also include material passing 75 micron IS sieve.

4.3.2.2 Coarse Aggregates

Coarse aggregate is aggregate most of which is retained on 4.75 mm IS: sieve. Coarse aggregate for

concrete shall conform to IS: 383.

These may be obtained from crushed or uncrushed gravel or stone and shall be clean and free from

elongated, Flaky or laminated pieces, adhering coatings, clay lumps, coal residue, clinkers, slag,

alkali, mica, organic matter or other deleterious matter. Coarse aggregate shall be either in single size

or graded, in both cases the grading shall be within the following limits.

Table 4.3: Grading of Coarse Aggregates

IS Sieve

size (mm)

Percentage Passing For Single Sized Aggregate

of Normal Size

Percentage Passing for Graded

Aggregate of Normal Size

40mm 20mm 16mm 12.5mm 10mm 40mm 20mm 16mm 12.5mm

63 100 - - - - 100 - - -

40 85-100 100 - - - 95-100 100 - -

20 0-20 85-100 100 - - 30-70 95-100 100 -

16 - - 85-100 100 - - - 90-100 -

12.5 - - - 85-100 100 - - - 90-100

10 0-5 0-20 0-30 0-45 85-100 10-35 25-35 30-70 40-85

4.75 - 0-5 0-5 0-10 0-20 0-5 0-10 0-10 0-10

2-36 - - - - 0-5 - - - -

The Engineer-in-Charge may allow graded aggregates to be used provided they satisfy the

requirements and Table IV of IS: 383.

4.3.2.3 Fine Aggregates

Fine aggregates is aggregate most of which passes 4.75 mm IS sieve but not more than 10% passes

through 150 micron IS Sieve. These shall comply with the requirements of grading zones I, II and 1II

as given in Table III of 15:383. Fine aggregate conforming to grading zone IV shall not be normally

used in reinforced concrete unless tests have been made by the contractor to ascertain the suitability of

the proposed mix proportions and approved by the Engineer-in-Charge.

As per IS: 383 Table is given below:

Table 4.4: Grading of Aggregates

IS: Sieve Designation Grading

Zone-I

Grading

Zone-II

Grading

Zone-III

Grading

Zone-IV

10 mm 100 100 100 100

4.75 mm 90-100 90-100 90-100 95-100

2.36 mm 60-95 75-100 85-100 95-100

1.18 mm 30-70 5-90 75-100 90-100

600 microns 15-34 35-59 60-79 80-100

300 microns 5-20 8-30 12-40 15-50

150 microns 0-10 0-10 0-10 0-15

Note: To use the sand falling in Zone -IV, IS: 383 shall be followed.

141

Fine aggregates shall consist of natural sand resulting from natural disintegration of rock and which

has been deposited by streams or glacial agencies, or crushed stone sand or crushed gravel sand.

4.3.2.4 Sampling and Testing

Sampling and testing shall be carried out by the contractor, at the contractor‟s expense, in accordance

with:

IS: 516 METHOD OF TEST FOR STRENGTH OF CONCRETE

IS: 2386 Methods of Test for Aggregates for concrete

4.3.2.5 Storage of Aggregates

The contractor shall at all times maintain at the site of work such quantities of aggregates as are

considered by the Engineer-in-Charge to be sufficient to ensure continuity of work.

Each type and grade of aggregate shall be stored separately on hard firm ground having sufficient

slope to provide adequate drainage to rain water.

Any aggregate delivered to site in a wet condition or becoming wet at site due to rain shall be kept in

storage for at least 24 hours to obtain adequate drainage, before it is used for concreting, or the water

content of mix must be suitably adjusted as directed by Engineer-in-Charge.

4.3.3 Cement

4.3.3.1 General

The cement used shall be ordinary Portland cement conforming to IS: 8112 or as specified in the

particular specifications/drawings or as directed by the Engineer-in-charge.

4.3.3.2 Storage on the site

The cement shall be stored in a suitable weatherproof building and in such a manner as to permit easy

access for proper inspection and counting. The cement shall be stored in such a manner as to prevent

deterioration. Cement of different types and brands shall be kept in separate stacks and marked

accordingly. Cement older than two months shall not be used on site.

All cement stored on the site shall be arranged in batches, and used in the same order as received from

the manufacturer. A cement register shall be maintained at site in which all entries shall be completed

day to day, showing the quantities received date of receipt, source of receipt, type of cement etc, and

also the daily cement consumption on site. This register shall be accessible to the Engineer-in-charge

for his certification. The godown / room in which cement shall be kept, shall be locked double; one of

UPJN and another of contractor.

4.3.3.3 Rejection of Cement

The Engineer-in-charge may reject any cement as a result of any tests, thereof, not withstanding the

manufacturer‟s certificate. He may also reject cement, which has deteriorated owing to inadequate

protection during storage from moisture or due to intrusion of foreign matter or other causes. Any

such cement which is considered defective by the Engineer-in-Charge shall not be used, and shall be

promptly removed from the site of the work by the contractor at his own expense.

4.3.4 Other Materials

AI materials including admixtures, joint filters and joint sealants not fully specified herein and which

may be used in the work shall be of quality approved by the Engineer-in-Charge and he shall have the

right to determine whether all or any of the materials offered or delivered for use in the works are

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suitable for the purpose. Contractor shall give the samples of materials to the Engineer-in-Charge and

shall get them approved before procurement and use.

4.3.5 Reinforcement

All reinforcement shall be clean and free from pitting, loose mill scales, dust and coats of paints. oil or

other coating which may destroy or reduce the bond.

4.3.5.1 Welded Joints

Welding of joints in reinforcement for bars of 28 mm dia and below shall not be allowed. However, in

case of using welded joints for bars 32 mm and above the approval of the Engineer-in-Charge shall be

obtained. The Engineer-in-Charge may require the Contractor, prior to the use of welded joints to

have tests carried out at he contractor‟s expense to prove that the joints are of the full strength of the

bars connected. The welding of the reinforcement shall be done in accordance with the

recommendation of IS: 2751 code of practice for welding of mild steel bars for reinforced concrete

construction. Special precautions are required in the welding of cold worked reinforcing bars. No

extra payment for welded joints shall be made to the contractor unless specifically mentioned in the

schedule of rates or bill of quantities and approved by the Engineer-in-Charge. Tack welding may be

permitted by the Engineer-in-Charge under certain conditions for fixing reinforcements.

4.3.5.2 Reinforcement Splices

Laps & anchorage length of reinforcing bars shall be in accordance with IS: 456, unless otherwise

specified. If the bars in a lap are not of the same diameter, the smaller dia will guide the lap lengths.

Laps shall be staggered as far as practicable and as directed by Engineer-in-Charge and not more than

50% of the bars shall be lapped at a particular section. Mechanical connections, for splicing

reinforcement bars in congested locations may be used by the contractor, only if approved by the

Engineer-in-Charge. Reinforcement bars shall not be lapped unless the length required exceeds the

maximum available lengths of the bars at site.

Unless otherwise specified the splices shall be wired contact lap splices as per the relevant standards.

No splicing of vertical bars shall be allowed except at specified or approved horizontal construction

joints. Splices in horizontal bars shall be lapped with atleast one continuous bar between adjacent

splices. The minimum spacing of splices in anyone run of bar shall be 6.0 m with splices in adjacent

bars offset at least 3.0 m where walls or slab contain two layers of reinforcement, splices in opposite

layer shall be offset by atleast 1.50m.

4.3.5.3 Fabrication and placement

Bars shall be pre fabricated accurately to dimensions, forms and shapes, Bending procedure shall be

approved by the Engineer-In-Charge. Placing and typing of reinforcement shall conform to IS: 2502-

1963 Code of practice for bending and fixing of bars for concrete reinforcement. Bar bending

schedules for the reinforced concrete works shown on the drawings shall be prepared by the

contractors and furnished to the Engineer-in-Charge at least two weeks before the commencement of

bending. Dimensions shown as furnished by the contractor‟s shall be his responsibility and approval

of the schedule shall not constitute the approval of the dimensions thereon.

4.3.5.4 Field Control

The contractor shall appoint a qualified Engineer experienced in reinforcement cutting, bending and

placing the same correctly, binding and cleaning before pouring the concrete. The reinforcement shall

be continuously kept in correct position during connections.

4.3.5.5 Steel Reinforcement

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The reinforcement shall be High Yield Strength Deformed (HYSD) bars. Grade Fe-415 conforming to

IS: 1786-1985 shall be used unless otherwise specified.

Placement of reinforcement should be as per IS: 456 Clause 11.3.

Approved Manufacturers: TISCO, SAIL, Rashtriya Ispat Nigam, Tata

4.3.5.6 Structural Steel

Structural steel shall conform to IS: 226 and IS: 2062.

Electrodes for welding shall conform to IS: 814 or IS: 815 or equivalent.

All bolts and nuts shall conform to IS: 1367. Stainless steel nuts and bolts shall be of SS 307 type. All

materials shall be of new and unused stocks. Manufacturer‟s test certificate shall be made available to

the Engineer-in-charge when called for.

4.3.5.7 Storage

The steel reinforcement and structural steel shall be stored in steel yard in such a way as to prevent

deterioration and corrosion, preferably at least 150 mm above ground by supporting on wooden or

concrete sleepers at contractor‟s expenses.

4.4 Proportioning of Concrete

The determination of the water-cement ratio and proportions of the aggregates to obtain the required

strength shall be made from preliminary tests by designing the concrete mix as per provisions laid

down in IS: 456-2000 & IS: 10262 or its latest revision. Design mix shall be admissible only if

contractor is able to manage the quality control of design mix e.g. weighbridge, proper water

measuring device etc. and designing the concrete mix as and when source of any of the consistent of

concrete is changed. If contractor fails to comply with the requirements of design mix concrete, he

shall have to follow the nominal mix as tabulated below:

Table- 4.5 Recommended Water-Cement Ratio (As per IS: 456-2000)

Grade of Concrete Nominal Mix of

Concrete

Quantity of Water per 50 Kg. of cement

(Max)

M 5 1:5:10 60 litres

M 7.5 1:4:8 45 litres

M 10 1:3:6 34 litres

M 15 1:2:4 32 litres

M 20 1:1.5:3 30 litres

M-25 1:1:2 26 litres

Cube tests shall be carried out by the contractor on the trail mixes before the actual concreting

operation starts. Based on the strength of the concrete mix sanction for its use has to be obtained from

Engineer-in-charge.

If during the execution of the works it is found necessary to revise the mix because of the cube tests

lower strengths than the required one due to inconsistency of quality of material or otherwise, the

Engineer-in-charge shall ask for fresh trial mixes to be made by the contractor. No extra claim shall be

entertained due to such change in mix variations, as it is the contractor‟s responsibility to produce the

concrete of the required grade.

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Great care shall be exercised when mixing the actual works concrete using the proportions of the

selected trial mix. The final concrete mix shall have the same proportions of cement, fine and coarse

aggregates and water as that of the approved selected mix.

Where the weight of cement is determined by accepting the manufacturer‟s weight per bag, a

reasonable number of bags should be weighed separately to check the next weight. Proper control of

mixing water is deemed to be of paramount importance. If mixers with automatic addition of water

are used water should be either measured by volume in calibrated buckets, tins or weighed. All

measuring equipment shall be maintained in a clean serviceable condition and their accuracy

periodically checked and certified and the Engineer-in-Charge‟s approval obtained.

The Engineer-in-Charge may require the contractor to carry out moisture content tests in both fine and

coarse aggregates. The amount of the added water shall then be adjusted to compensate for any

observed variations in the moisture contents. For the determination of moisture content IS: 2386 shall

be referred to.

No substitution in material, used on the work or alternation in the established proportions shall be

made without additional tests to show that the quality and strength of concrete are satisfactory. No

alternations shall be permitted .without the prior sanction of the Engineer-in-Charge.

4.5 Mixing of Concrete

The mixing of concrete shall be strictly carried out in an approved type of mechanical concrete mixer.

The mixing equipment shall be capable of combining the aggregates, cement and water within the

specified time into a thoroughly mixed and uniform mass, and of discharging the mixture without

segregation. The entire batch shall be discharged before recharging. Mixing periods shall be measured

from the time when all of the solid materials are in the mixing time has elapsed. The mixing time in

no case shall be less than two minutes. The mixer speed shall not be less than 14 and not more than 20

revolutions per minute.

Mixing shall be continued until there is a uniform distribution of the materials and the mass is uniform

in colour and consistency. Hand mixing of concrete shall not be permitted at all.

4.6 Grades of Concrete

The different grades of concrete shall conform to the strength as required by IS: 456-2000. Standard

deviation shall be calculated as stated in clause 14.5 of IS: 456-2000. The acceptable criteria for

concrete shall be as stated in clause 15 of IS: 456-2000.

The assumed standard deviations as given in table 6 of 18:456-2000 have to be followed. and are

given hereunder :

Table 4.6 : Assumed Standard Deviation

Grade of Concrete Assumed standard Deviation N/mm2

M 10 2.3

M 15 3.5

M 20 4.6

M 25 5.3

In order to get a quick idea of quality of concrete, the optional tests are conducted as stipulated in

14.1.1 of IS: 456-2000 and the results are analysed according to table 5 of IS: 456-2000.

4.6.1 Concrete

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In general design mix concrete shall be used conforming to IS: 456-2000. Nominal Mix concrete

batching by volume can only be allowed if the contractor is not able to adhere to the quality control

provisions of the design mix with prior approval from Engineer on in writing request of the contractor

mentioning reasons, for which no extra payment shall be made.

The mix proportions for all grades of nominal mix concrete shall be provided corresponding to the

values specified in Table -4.7 below, for respective grades of concrete.

Table - 4.7 Characteristics Compressive strength of Concrete

Grade

Designation

Proportion of cement : fine

aggregate: coarse aggregate

Specified characteristic compressive

strength at 28 days (N/mm2)

M 15 1:2:4 15

M 20 1:1.5:3 20

M 25 1:1:2 25

The maximum water-cement ratio for all concrete works shall be as specified in IS: 456-2000 and

required by the Engineer-in-Charge.

To keep the water cement ratio to the designed value, allowance shall be made for the moisture

contents in both fine and coarse aggregates and determination of the same shall be made as frequently

as directed by the Engineer-in-charge. The determination of moisture contents shall be according to

IS: 2386 (Part III).

4.6.1.1 Controlled concrete-

Controlled concrete shall be used on all concreting works except where specified otherwise.

The mix proportions for all grades of concrete shall be designed to obtain strengths corresponding to

the values specified in Table 4.7.1 below for respective grades of concrete.

Table –4.7.1

Grade of Concrete Specified characteristic compressive strength at

28 days [N/mm2]

M 15 15

M20 20

M25 25

M30 30

The maximum water cement ration for all controlled concrete works shall be as specified in IS: 456-

2000 and preliminary tests as specified in the IS codes and required by the Engineer shall be carried

out, sufficiently ahead of the actual commencement of the work with different grades of concrete,

made from representative sample of aggregates and cement expected to be used on the job to ascertain

the ratios by weight of cement, of total quantity of fine and coarse aggregates and the water cement

ratio required to produce a concrete of specified strength and desired workability.

The minimum cement content for each grade of concrete shall be as per Table-4.7.2 below. If the

requirement of cement is found to be more than that specified below then such excess quantities of

cement shall be used and for which no extra payment shall be made.

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Table –4.7.2 Minimum Cement Content In Concrete

Grade of Concrete Minimum cement content as per IS: 456 in kg./ cu. m of finished

Concrete

M 15 310

M20 360

M25 410

M30 500

At least 4 (four) trial batches are to be made and 7 (seven) test cubes taken for each batch noting the

slump on each mix. These cubes shall then be properly cured and two cubes for each mix shall be

tested in a testing laboratory approved by the Engineer at 7 (seven) days and others at 28 (twenty

eight) days for obtaining the ultimate compressive strength. The test reports shall be submitted to the

Engineer. The cost of mix design and testing shall be borne by the contractor.

On the basis of the preliminary test reports for trial mix, a proportion of mix by weight and water

cement ratio will be approved by the Engineer, which shall be expected to give the required strength,

consistency and workability and the proportions so decided for different grades of concrete shall be

adhered to, during all concreting operations. If however, at any time the Engineer feels that the quality

of material being used has been changed from those used for preliminary mix design, the contractor

shall have to run similar trial mixes to ascertain the mix proportions and consistency.

The mix once approved must not be varied without prior approval of the Engineer. However, should

the contractor anticipate any change in the quality of future supply of materials than that used for

preliminary mix design, he shall inform the same to Engineer and bring fresh samples sufficiently

ahead to carry out fresh trial mixes. The Engineer shall have access to all places and laboratory where

design mix is prepared. Design mix will indicate by means of graphs and curves etc. the extent of

variation in the grading of aggregates which can be allowed. In designing the mix proportions of

concrete, the quantity of both cement, and aggregate and water shall be determined by weight. All

measuring equipment shall be maintained in clean and serviceable condition and their accuracy

periodically checked.

To keep the water cement ratio to the designed value, allowance shall be made for the moisture

contents in both fine and coarse aggregates and determination of the same shall be made as frequently

as directed by the Engineer. The determination of moisture contents shall be according to IS: 2386

(Part III).

4.6.2 Strength Requirements

Where Ordinary Portland cement conforming to IS: 269 is used the compressive strength

requirements for various grades of concrete shall be as shown in Table -2 of IS: 456 -2000 where

rapid hardening Portland cement is used the 28 days compressive strength requirements specified in

Table-2 shall be met in 7 days. The strength requirements specified in Table-2 as previously given

shall apply to both controlled concrete and ordinary concrete.

Other requirements of concrete strength as may be desired by the Engineer-in-Charge shall be in

accordance with India Standard IS: 456-2000. The acceptance of strength of concrete shall be as per

clause 14 “Sampling and Strength Test of Concrete” and clause. 15 “Acceptance Criteria” of IS: 456-

2000 subject to stipulations and/or modifications stated elsewhere in this specification. if any.

Concrete work found unsuitable for acceptance shall have to be dismantled and replaced to the

satisfaction of the Engineer-in-charge by the contractor free of cost to the Department. No payment

for the dismantled concrete, the relevant formwork and reinforcement, embedded fixtures, etc. washed

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in the dismantled portion shall be made. In the course of dismantling if any damage is done to the

embedded items or adjacent structures, the same shall also be made good free of charge by the

contractor to the satisfaction of the Engineer-in-charge. If the water quantity has to be increased in

special cases, cement also be increased proportionately to keep the ratio of water to cement same as

adopted in trial mix design for each grade of concrete. No extra payment for the additional cement

shall be made.

4.6.3 Workability

The workability of concrete shall be checked at frequent intervals by slump test. Where facilities exist

and if required by the Engineer-in-Charge, alternatively the Compacting Factor test in accordance

with IS: 1199 shall be carried out. The degree of workability necessary to allow the concrete to be

well consolidated and to be worked into the corners of formwork and round the reinforcement to give

the required surface finish shall depend on the type and nature of the structure and shall be based on

experience and tests. The limits of consistency for structures are as specified in Table 4.8 below:

Table 4.8: Limits of Consistency (as per IS : 456)

Placing Conditions Degree of

Workability

Values of Workability

Concreting of shallow sections with

vibration

Very low 20.1 0 seconds, vee-bee time or

0.75.- 0.60 compacting factor

Concreting of lightly reinforced

sections with vibration

Low 10-05 seconds, vee-bee time or

0.80 - 0.85 compacting factor

Concreting of lightly reinforced

sections without vibration or heavily

reinforced section with vibration

Medium 05-02 seconds, vee-bee time or

0.85 - 0.92 compacting factor or

25-75mm, slump for 20mm aggregate

Concreting of heavily reinforced

sections with vibration

High Above 0.92 compacting factor or

75 - 125 m, slump or 20 mm *aggregate

* For smaller aggregate the values shall be lower.

4.7 Workmanship

All workmanship shall be according to the latest relevant standards. Before starting a pour the

contractor shall obtain the approval of the Engineer-in-Charge or his representative in a “Pour Card”

maintained for this purpose. He shall obtain complete instructions about the material and proportion to

be used, slump, workability, quantity of water per unit of cement, number of test cubes to be taken,

finishing to be done, any admixture to be added, etc.

4.8 Transportation and Pouring

The concrete mixer shall be as close to the place of concreting as possible but not as close as to

produce vibration and disturbance to the shuttering and reinforcements. It shall be located at such a

position that time lapse for transportation of unloaded concrete mix from the mixer to the place of

deposition of concrete is minimum.

When there is a difference in level between the unloading platform of concrete from the mixer to the

actual place of deposition of concrete, the concrete shall be transported manually as by means of

builders‟ hoist/crane or concrete pump to the actual level of concreting, depending on requirement as

approved by Engineer-in-charge.

Chutes for transporting the concrete shall not normally be used. The Engineer-in-Charge‟s written

permission shall be taken for transporting by means of chutes. If use of chutes is permitted then the

concrete shall be again thoroughly mixed by using spades manually before placing the concrete in the

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moulds/shuttering to avoid segregation of concrete. It shall be ensured that initial setting of the

concrete shall not take place and the mix of the concrete is as good as that of freshly poured concrete

delivered directly into the moulds/shuttering. It shall be ensured that the drop of concrete is not from

an excessive height and that the vibration and deposition of concrete are simultaneously carried out.

Before placing concrete, all equipment for mixing and transporting the concrete shall be cleaned and

all debris shall be removed from the place to be occupied by the concrete. All form and soil surface

shall be finished to desired levels and shall be thoroughly wetted immediately prior to placing of

concrete.

No concrete shall be placed until the Engineer-in-Charge has approved the excavation formwork and

the reinforcement. The competent formwork maker and steel fixer shall be in attendance during

concreting operation.

Concrete shall be handled from the place of mixing to the place of final deposit as rapidly as

practicable by methods, which shall prevent the segregation or loss of any of the ingredients. If

segregation does occur during transport, the concrete shall be remixed before being placed. The

concrete shall be place and compacted before setting commences and shall not be subsequently

disturbed.

To ensure bond and water tightness between old concrete surface and the concrete to be place PVC

water stops of approved make and size 150 mm wide, 10 mm thick should be used. The bonding of

old and new concrete shall be done by applying cement slurry after thoroughly watering the old

concrete surface and. removing all loose particles.

In specified cases, with approval of Engineer-in-charge the surface shall be cleaned and roughened by

initial green cut by wire brushes or chipping. The initial green cutting may be done after 6 hours of

placing concrete in order to facilitate the work. The old concrete walls/members shall be given a shear

of 50 x 65 mm deep. This key shall also be thoroughly cleaned with wire brush in green stage before

next lift pouring to avoid percolation of works.

4.7.1 Special methods of Concreting

Should be contractor propose to use the special methods of concreting not included in this

specification, such as pumping concrete or using vacuum moulds he shall obtain the Engineer‟s

approval before commencing work and comply with any subsequent specifications made by the

Engineer for this special methods of concreting. Contractor is advised to use modern techniques in

adapting methods of laying/finishing concrete in raft/wall etc., e.g. in raft, us of any other acceptable

and proven method will be welcomed. The contractor may elaborate same on while quoting the offer.

4.8.1 Placing of concrete in slabs and beams

Concrete in slabs shall be placed in one continuous operation for each span unless otherwise directed.

Longitudinal construction joints, if required by reason of the width to be placed shall be located as

shown on the drawings or as directed by the Engineer-in-Charge.

Concrete in the stem and slab of T -beam shall be placed in one continuous operation and shall be

deposited uniformly for the full length of the beam and brought up evenly in horizontal layers.

Where the size of the member is such that it cannot be made in one pour, transverse vertical

construction joints shall preferably be located within the area of contra flexure. For continuous spans,

where required by design considerations the concrete placing sequence shall be approved by the

Engineer-in-Charge.

4.8.2 Concreting floors

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Concreting in floor shall be done in a chess board pattern, allowing sufficient time to elapse before the

adjacent band in cast. The panel size is restricted to 7.5m in reinforced concrete slab.

Concreting shall not be started unless the electrical conduits or any other piping Puddle Collars

wherever required or laid by the concerned agency. The civil contractor shall afford all the facilities

and maintain co-ordination of work with other agencies engaged in electrical and such other works as

directed by the Engineer-in-Charge.

Where concrete is placed on soil it shall be placed only on firm undisturbed ground. Any concrete that

is placed on a well compacted fill shall have the prior approval of the Engineer-in-Charge. Concrete

shall not be placed in standing water, on sub-grade or in foundation Excavation.

4.9 Compaction

Concrete during and immediately after depositing shall be thoroughly compacted. The compaction

shall be done by mechanical vibration subject to the following provisions:

a. The vibration shall be internal unless special authorization of other methods is given by the

Engineer-in-charge or as provided herein.

b. Vibrators shall be of type and design approved by the Engineer-in-charge. They shall be capable

of transmitting vibration to the concrete at frequencies of not less than 4,500 impulses per

minute.

c. The intensity of vibration shall be such as to visibly affect a mass of concrete of 25 mm slump

over a radius of at least 0.5m

d. The contractor shall provide a sufficiently number of vibrators to properly compact each batch

immediately after it is placed in the forms.

e. Vibrators shall be manipulated so as to the thoroughly work the concrete around the

reinforcement and embedded fixtures, and into the corners and angles of the forms.

Vibration shall be applied at the point of deposit and in the area of freshly deposited concrete.

The vibrators shall be inserted into and withdrawn out of the concrete slowly. The vibration shall

be of sufficient duration and intensity to thoroughly compact the concrete but shall not be

continued so as to cause segregation. Vibration shall not be continued at any one point to the

extent that localized areas of grout are formed.

Application of vibration shall be at points uniformly spaced and not further apart than twice the

radius over which the vibration is visibly effective.

f. Vibration shall not be applied directly or through the reinforcement to sections or layers of

concrete which have hardened to the degree that the concrete ceases to be plastic under vibration.

It shall not be used to make concrete flow in forms over distances so great as to cause segregation

and vibrators shall not be used to transport concrete in the forms.

g. Vibration shall be supplemented by such rodding/ spading as necessary to ensure smooth surface

and dense concrete along form surfaces and in corners and locations impossible to reach with the

vibrators.

The whole process starting from the mixing of concrete to the placing and compaction shall not

take more than 20 minutes and the process shall be completed before the initial setting takes

place.

4.10 Curing

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Curing shall be accomplished in accordance with IS: 456-2000 by keeping the concrete covered with

a layer of sacking canvas, Hessian or similar absorbent materials and kept constantly wet for at least

seven days from the date of placing of concrete unless otherwise specified. The approval of the

Engineer-in-Charge shall be obtained for the method of curing the contractor proposes to use on the

work. In very hot weather precautions shall be taken to see that temperature of wet concrete does not

exceed 38ºC while placing.

Heavy loads shall not be placed on or moved across over the floor slabs until curing is complete. Care

shall be taken to prevent floor surface from being marred during curing period. Freshly laid concrete

form work shall not be jarred. Concrete placed in trenches or Excavation shall be protected from

falling earth during and after placing.

4.11 Consistency

The consistency of concrete shall be frequently checked by means of a slump test performed as per

the relevant Indian Standard by the Engineer-in-Charge. The maximum and minimum slump for each

class of concrete shall be as directed by the Engineer-in-Charge, and any concrete as represented by

the slump test which fails to comply with these directions shall be removed from the site and disposal

off at the contractors cost.

4.12 Finishing Concrete

On striking the formwork, all blowholes and honeycombing observed shall be brought to the notice of

Engineer-in-Charge. The Engineer-in-Charge may, at his discretion allow such honeycombing or

blowholes to be rectified by necessary chippings and packing or grouting with concrete or cement

mortar. If mortar is used, it shall be 1:2 mix or as specified by Engineer-in-Charge. However, if honey

combing or blowholes are of such extent as being undesirable, the Engineer-in-Charge may reject the

work totally and his decision shall be binding. No extra payment shall be made for rectifying these

defects. All burrs and uneven faces shall be rubbed smooth with the help of carborundum stone.

The surface of non-shuttered faces shall be smoothened with a wooden float to give a finish equal to

that of the rubbed down shuttered faces. Concealed concrete faces shall be Ieft as from the shuttering

except that honeycombed surface shall be made good as detailed above. The top faces of slabs not

intended to be surfaced shall be leveled and floated to a smooth finish at the levels or falls shown on

the drawings or elsewhere. The floating shall not be executed to the extent of bringing excess fine

material to the surface.

The top faces of slabs intended to be covered with screed, granolithic or similar faces shall be left

with a rough finish.

4.13 Work in Extreme Weather

During hot weather (atmospheric temperature above 40 degree centigrade) or cold weather

(atmospheric temperature at 5 degree centigrade and below) the concreting shall be done as per the

procedure and precautions set out in IS: 7861 (Part I and II).

Dependence shall not be placed on salt or other chemicals for the prevention of freezing. Calcium

chloride shall not be used as an accelerator except with the approval of the Engineer-in-Charge.

Recommendation given in relevant clauses of IS: 456 shall be strictly adhered to.

4.14 Loading of the Structures

No concrete structures shall be loaded until the concrete is at least 28 days old and only then with the

approval of the Engineer-in-Charge and subject to such conditions as he may lay down.

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4.15 Testing and Acceptance Criteria of Concrete

The sampling of concrete making the test specimens, curing and testing procedures etc. shall be in

accordance with IS: 1199, IS: 3085 and IS: 516, the size of specimen being 15 cm cubes. Normally

only compression tests shall be performed in accordance with IS: 516.

For each grade of concrete and for each 8 hours of work or portion thereof the following samples shall

be taken.

At least six specimens shall be taken from the first 15.0 m3 or part thereof and three of these shall be

tested at 7 days and the remaining at 28 days. Four additional specimens shall be taken from each

additional 15.0 m3 of concrete or portion thereof of which 2 specimens shall be tested at 7 days and

the remaining at 28 days.

To control the consistency of concrete from every mixing plant slump tests, and/or compacting factor

tests in accordance with IS: 1199 shall be carried out by the contractor every two hours or as directed

by the Engineer-in-Charge. Slumps corresponding to the test specimens shall be recorded for

reference. The acceptance criteria of concrete shall be in accordance with IS: 456-2000.

Concrete work found unsuitable for acceptance shall have to be dismantled and replacement is to be

done as per specifications by the contractor. No payment for the dismantled concrete, the relevant

formwork and reinforcement embedded fixtures etc. shall be paid.

In the course of dismantling if any damage is done to, the embedded items or adjacent structures the

same shall be made good free of charge by the contractor to the satisfaction of the Engineer-in-

Charge.

4.16 Load Test of Structures

The Engineer-in-Charge may instruct for a load test to be carried out on any structure if in his opinion

such a test is deemed necessary for any of the following reasons.

The works site made concrete test-cube failing to attain the specified strength, as per the criteria laid

down in IS: 456-2000.

Suspected overloading during construction of the structure under review

Shuttering being prematurely removed and not as per the specification

The concrete is being improperly cured.

Visible deficiencies of the concrete

If the results of the load test be unsatisfactory, the Engineer-in-Charge may instruct the Contractor to

demolish and reconstruct the structure or part thereof at the contractor‟s cost. The load test of

structures shall be carried out as per the clause 16.5 of IS: 456-2000.

4.17 Special methods of concreting

The contractor should propose to use special methods of concreting not included in the specifications,

such as pumping concrete or using vacuum moulds, he shall obtain the Engineer-in-Charge‟s approval

before commencing work and comply with any subsequent specification made by the Engineer-in-

Charge for this special method of concreting. Contractor is advised to use modern techniques in

adopting methods of laying/finishing concrete in raft/walls etc. e.g. in raft use of any other acceptable

and proven method will be welcomed. The contractor may elaborate same on while quoting the offer.

4.18 CONCRETE FOR WATER RETAINING STRUCTURES

152

4.18.1 Materials for construction

Materials for concrete viz. Cement, sand aggregate, water etc. shall be as er the specifications of

reinforced concrete works described in section 4 and IS : 3320 Part I. However, super-sulphated

cement shall be used when ground water contains sulphates more than the permissible limit as

indicated in IS: 456-1978.

4.18.2 Design

The design of the structure shall be based as per IS: 3370 (part I to Part IV) code of practice for

concrete structures for storage of liquids.

4.18.3 Aggregates

Maximum size of the aggregate shall be 20 mm for thickness of the section upto 40 mm. above this

limit 40 mm size aggregate may be used in the quantities as approved by the Engineer.

4.18.4 Controlled concrete

Controlled concrete of grade not weaker than M 20 is to be used in the structures with minimum

quantity of cement in the concrete mix to be not less than 330 kg/cum, for the reinforced concrete

work, 360 kg/ cum in post-tensioned pre-stressed work and 380 kg/cum in pre-tensioned concrete

work. The maximum quantity of cement in the concrete mix shall preferably not exceed 530 kg/cum

of concrete. The design should be such that the resultant concrete is dense and impervious. The mix of

concrete should be fully compacted. The use of needle type of internal vibrators is recommended.

4.18.5 Cover

Cover to the reinforcement shall be as stated in the drawing and in conformation to IS: 3370 (part-I to

IV)

4.18.6 Admixtures

Admixtures such as plastic may be added to improve the workability only with the permission of the

Engineer.

4.18.7 Joints

The Maximum spacing between the partial contraction joints shall be not more than 7.5 m and

between the full contraction joint 15.0 m. Alternatively, temporary short gaps of width 0.5 m in walls

be left out to the filled in after the concrete has hardened on sides. Vertical joint shall be avoided by

casting a lift of approximately 1.0m deep in continuous operation for circular structures.

4.18.8 Shuttering

Scope

Form work shall be composed of steel and /or best quality shuttering wood of non-absorbent type.

Timber shall be free of knots and shall be of medium grain as far as possible. Hard woods shall be

used for caps and wedges under or over posts. Marine plywood shuttering or equivalent shall be used

where specified to obtain smooth surfaces for exposed concrete work. Struts shall generally be mild

steel tubes, and strong Sal bellies. Bamboos, small diameter bellies etc. shall not be used unless

approved by the Engineer in specific cases.

General Requirements

153

If, it is so desired by the Engineer the contractor shall design and prepare, before commencement of

actual work, the drawings for form work and centering and get them approved by the Engineer. The

form work shall conform to the shape, lines and dimensions as shown in the drawings.

The centering shall be true, rigid and thoroughly braced both horizontally and diagonally. The forms

shall be sufficiently strong to carry, without undue deformation, the dead weight of the concrete at the

time of casting as well as working load. Where the concrete is vibrated, the form work shall be strong

enough to withstand the effects of vibration without appreciable deflection, bugging distortion of

loosening of its components. The joints in the form work shall be sufficiently tight to prevent any

leakage of mortar. The form work shall be such as to ensure a smooth uniform surface free from

honeycombs, air bubbles, bulges, fins and other blemishes, Any blemish or defect found on the

surface of the concrete must be brought to the notice of the Engineer immediately by the contractor

and rectified, free of charge, as directed by him. To achieve the desired rigidity, tie bolts, spacer

blocks, tie wires and clamps as approved by the Engineer shall be used but they must in no way

impair the strength of concrete or leave stains or marks on the finished surface.

Where there are chances of these fixtures being embedded, only mild steel or concrete of adequate

strength shall be used. Bolts passing completely through liquid retaining walls/ slabs for the purpose

of securing and aligning the form work should not be used.

For exposed interior and exterior concrete surfaces or beams, columns and walls, plywood or other

approved forms, thoroughly cleaned and tied shall be used. Rigid care shall be exercised in ensuring

that all columns are in plumb and true and thoroughly cross braced to keep them so. All floor and

beam centering shall be crowned not less than 8 mm in all directions for every 5 m span. Temporary

openings for cleaning, inspection and for pouring concrete shall be provided at the base of vertical

forms and at other places where they are necessary and as may be directed by the Engineer. The

temporary openings shall be so formed that they can be conveniently closed when required and must

not leave any mark on the concrete.

Cleaning and Treatment of forms

All forms shall be thoroughly cleaned of old concrete, wood shavings, saw dust, dirt and dust sticking

to them before they are fixed in position. All rubbish, loose concrete, chipping, shavings, sawdust etc.

shall b scrupulously removed from the interior of the forms before the concrete is poured, along with

wire brushes, brooms etc. compressed air jet and / or water jet shall be kept handy for the cleaning, if

so directed by the Engineer.

Before shuttering is placed in position, the form surface in contact with concrete shall be treated with

approved form removing non-staining oil or composition. Care shall be taken that the oil or

composition does not come in contact with reinforcing steel or existing concrete surfaces. They shall

not be allowed to accumulate at the bottom of the shuttering.

The form work shall be so designed and erected that the forms for slabs and the sides of beams,

columns and walls may be removed first, leaving the shuttering to the soffits of beams and their

supports in position. Re-propping of beams shall not be done except with the approval of the Engineer

and props can be reinstated in anticipation of abnormal conditions, if form work for column is erected

to the full height of the columns, one side shall be left open and built up in sections, as placing of

concrete proceeds: Wedges, spacer, bolts, clamps or other suitable means shall be provided to allow

accurate adjustment of the form work and to allow, it to be removed gradually without jarring the

concrete.

Pipe inserts to be laid at the time of concreting

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For pipes to be laid in the walls during concrete, relevant drawings shall be followed.

Openings shall be provided in the shuttering plates at suitable positions. It is to be noted here that

special shuttering plates for this purpose may have to be used, and the number of uses of shuttering

material, for working out the rate, shall be calculated accordingly.

Removal of forms

The contractor shall record on the drawings or in other approved manner, the date on which the

concrete is placed in each part of the work and the date on which the form work is removed there from

and have this record checked and counter signed by the Engineer. The contractor shall be responsible

for the safe removal of the form work but the Engineer may delay the time, if considers it necessary.

Any work showing sign of damage through premature removal of form work for loading shall be

entirely reconstructed by the contractor without any extra cost of the owner.

Forms for various types of structural components shall be removed before the minimum periods

specified below (table V) which shall also be subject to the approval of the Engineer. Engineer at his

discretion may extend this maximum period for removal of form work and contractor shall retain the

form work for a longer period as desired by the Engineer at no extra cost to the owner.

Table 5 Minimum period for Removal of Form work

Part of structure Temperature in degrees Celsius (0C)

Above

400

Days

400 to

200

Days

200

50

Days

to Below

50

Days

1 2 3 4 5

A. Ordinary Portland Cement

Concrete

1. Column and walls 2 1 1 Do not remove forms until site

2. Beams sides 3 2 3 cured test cylinder / cubes

3. Slabs 125 mm 10 7 8 develop 50%

thick or less of 28 days strength

4. Slabs over 125 mm 18 14 16

thick and soffit of

Minor beams.

5. Soffit of main beams 24 21 22

B. Rapid Hardening Portland Cement concrete

1. Columns and walls 1 1.5 1

2. Beams sides 2 1 1 Do not remove forms until site

3. Slab 125 mm thick or less 7 4 5 cured test cylinder / cubes

develop 50%

4. Slab over 125 12 8 9 of 28 days strength

mm thick and

soffit of minor Beams

5. Soffit of main 14 10 12

beams

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Note : For Ordinary Portland Cement the removal time should be suitably increased over the time

giver for ordinary Portland Cement, as directed by the Engineer.

Reuse of forms

Before reuse, all forms shall be thoroughly scrapped, cleaned, joints examined etc. and when

necessary, repaired and inside surface treated as specified herein before. Form work shall not be used/

reused, if declared unfit or unserviceable by the Engineer.

Classification of form work

a. Ordinary

These shall be used in places where ordinary surface finish is required and shall be composed of steel

and / or approved good quality seasoned wood.

b. Plywood

These shall be used in exposed surfaces, where specially good finish is required and shall be made

mostly of approved brand of heavy quality shuttering/ marine plywood to produce a perfectly level,

uniform and smooth surface.

Ordinary form work shall be used for all underground structures and „plywood‟ form work shall be

used for all structure above ground.

Acceptance of form work and finished concrete shall be true to shape, lines, levels, plumb and

dimensions as shown on drawings. All embedded fixtures shall be correct type and in correct position

as shown in drawings. Finished concrete surface shall be free from blemishes like honeycombs, air

bubbles, fins, etc. Exposed decorative concrete surfaces shall be free from rust, stains, grease and

mould oil stains, etc. and shall have uniform pleasing appearance to satisfaction of the Engineer. If

desired, the finished concrete shall conform in all respects to the accepted sample.

Where exposed surface of concrete can be effectively sealed to prevent loss of water the periods

specified for temperature above 400 C can be reduced to those for the temperature range of 20

0 to 40

0

C subject to approval of the Engineer. Before removing any form work, the contractor must notify the

Engineer well in advance to enable him to inspect the concrete, if he so desires.

Tolerance in finished concrete

Tolerance in finished concrete shall be exactly same as for reinforced concrete structures in section

2.5.3.3.and 2.5.11.

4.18.9 Curing

Curing etc. of the structures shall be exactly same as for reinforced concrete structures in section 2.5.9

4.18.10 Vertical joints

All vertical joints shall extend full height of the wall in unbroken alignment.

4.18.11 Removal of Shuttering

Removal of the form work shall confirm of IS: 456-1978 and para 2.5.3.9 Bolts and fasteners passing

completely through liquid retaining slabs for the purpose of securing and aligning the form work

should not be used unless effective precautions are taken to ensure the water tightness after the

removal of pipes or other fittings. Puddle flange in concreting shall be placed at correct positions,

before concreting and verified by the Engineer.

4.18.12 Water Tightness

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The test for water tightness of the structure shall be carried out as per clause 10 f IS 3370 part 3.

4.19 Epoxy coating and bituminous painting

EPOXY COATING

4.19.1 General

Epoxy coating is to be applied to the internal surface of MS pipes. The thickness of epoxy film shall

be 400 microns.

4.19.2 Materials

A solvent free epoxy coating like “Araldite GY 255 manufactured by Hindustan CIBA Geigy Ltd.

Bombay or equivalent is to be used for forming the film. In case of use of an equivalent it should be

got approved by the employer before placing supply orders.

Materials used and process of application on the concrete of other surface should be strictly according

ot the instructions of the supplier of the epoxy.

Araldite GY 25 one part by weight is to be mixed with 1 part by weight of Hardener HY 45.

4.19.3 Subsurface Preparation

The concrete surfaces should be cleaned thoroughly by sand blasting. The mild steel parts are also to

be cleaned to be free of grease and thoroughly sand blasted. The coverage should be move than 6 sq.

meters for concrete and 5 sq. meters for mild steel per kg. of epoxy respectively.

4.19.4 Curing

The curing should be done for 7 days at room temperature. If the temperature is less than 150 C the

space should be warmed up by incandescent lamps, heaters, blowers or infrared lamp.

The instructions of both the supplier/ manufacturer of the product, for use of materials and application

take priority over the above instructions and they should be followed very rightly.

4.19.5 Bituminous Painting

Two coats of bituminous paint of 80/100 grade, with 1.65 kg/sq. m spread will be provided on internal

and / or external surface of the pipes and on piers, in the reach, where MS/ GRP pipes are proposed,

and where concrete / structure is exposed to weathering or foul conditions.

4.19.6 Application

All corners and junctions shall be properly rounded off to present a uniform and smooth finish. After

complete curing of the paint, it shall be allowed to dry up. After drying, the moisture content shall be

brought to a value less than 4% by using a blow lamp. The surface should be well cleaned with

smooth brushed to make it dust free. The coating shall be allowed to dry and kept in dry condition till

final setting takes place. The sub-surface preparation and curing is to be done as specified is para

2.7.3 and 2.7.4 respectively above.

4.20 Codes and Standards

All applicable standards, specifications, etc. and codes of practice shall generally be the latest

editions, including all applicable official amendments and revisions. A complete set of all these

documents shall generally be available at site, with the contractor.

All work shall be carried out as per the stipulations contained in various sections of these

specifications and the latest Indian Standards, Acts, Codes and best practices.

157

In case of conflict between the stipulations contained in various‟ sections of these specifications and

stipulations of Indian Standard, Codes, etc. the requirements of stipulations contained in various

sections of these specifications, shall prevail over that of Indian Standards, Codes, etc.

Some of the applicable Indian Standard Codes, etc. are referred to here below:

IS:73 Specification for paving bitumen

IS:2060 Specification for structural steel

IS:8112 Specification for Ordinary Portland cement 43 grade.

IS:280 Specification for mild steel wire for general engineering purposes

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

concrete

IS:432 (Part I & II) Specification for mild steel and medium tensile steel bars and hard drawn

steel wire for concrete reinforcement

IS:455 Specification for Portland Slag Cement

IS:456 Code of practice for plain and reinforced concrete

IS:457 Code of Practice for general construction of plain & reinforced concrete for

dams and other massive structure.

IS:516 Method of test for strength of Concrete

IS:650 Specification for standard sand for testing of cement

IS:702 Specification for industrial bitumen

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

steel

IS:1199 Methods of sampling and analysis of concrete

IS:1200 (Part II, V,

VIII, XVIII, SVIII)

Method of measurement of building and civil engineering works, water

proofing and damp proofing

IS:1367 Technical supply conditions for threaded steel fasteners

IS:1489 Specification for Portland puzzolana cement (Part I) Fly ash based & (Part

II) Calcified clay based

IS:1566 Specification for Hard drawn steel wire fabric for concrete reinforcement

IS:1609 Code of practice for laying damp proof treatment. using bitumen felts.

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

reinforcement

IS:1791 General requirements for batch type concrete mixer.

IS: 1838 Specification for performed fillers for expansion joints in concrete

pavements and structures (non-extruding and resilient type)

IS:2204 Code of practice for construction of reinforced concrete shell roof

IS:2210 Criteria for the design of reinforced concrete shell structures and folded plate

IS:2386 (Part 1 to

VIII)

Methods for test of aggregates for concrete

IS:2438 Specification for roller pan mixer

IS:2502 Code of practice of bending and fixing of bars for concrete reinforcement

IS:2505 General requirements for concrete vibrators, immersion type

IS:2506 General requirements for concrete vibrators, screen board type

IS:2514 Specification for concrete vibrating tables

IS:2571 Code of practice for laying in situ cement concrete flooring

IS:2645 Specification for integral cement water proofing compounds

IS:2722 Specification for portable swing weigh batchers for concrete (single and

double bucket type)

IS:2750 Specification for steel scaffoldings

IS:2751 Code of practice for welding of mild steel plain and deformed bars for

reinforced concrete construction

IS:3025 Methods of sampling and test waste water

IS:3067 Code of practice for general design details and preparatory work for damp

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proofing & water proofing of buildings

IS:3150 Specification for hexagonal wire netting for general purposes

IS:3366 Specification for pan vibrators

IS:3370 (Part I & II) Code of practice for concrete structures for the storage of liquids

IS:3384 Specification for bitumen primer for use in water proofing & damp proofing

IS:3414 Code of practice for design and installation of joints in buildings

IS:3550 Methods of test for routine control for water used in industry

IS:3558 Code of practice for use in immersion vibrators for consolidating concrete

IS:3696 (Part I & II) Safety code for scaffolds and ladders

IS:4014 (Part I & II) Code of practice for steel tubular scaffolding

IS:4031 Methods for physical tests for hydraulic cement

IS:4130 Safety code for demolition of buildings.

IS:4326 Code of practice for earthquake resistant design and construction of

buildings

IS:4461 Code of practice for joints in surface hydroelectric power stations

IS:4656 Specification for form vibrators for concrete

IS:4925 Specification for batching and mixing plant

IS:4990 Specification for plywood for concrete shuttering work

IS:4995 (Part I & II) Criteria for design of reinforced concrete bins for the storage of granular and

powdery materials

IS:5121 Safety code for piling and other deep foundations

IS:5256 Code of practice for sealing joints in concrete lining on canals

IS:5525 Recommendations for detailing of reinforcement in reinforced concrete work

IS:5624 Specification for foundation bolts

IS:6461 Glossary of terms relating to cement concrete

IS:6494 Code of practice for water proofing of underground water reservoirs and

swimming pools

IS:6509 Code of practice for installation of joints in concrete payments

IS:7193 Specification for glass fibre base coal tar pitch and bitumen felts

IS:7293 Safety code for working with construction machinery

IS:7861 (Part I & II) Code of practice for extreme weather concreting

IS:9012 Recommended practice for shuttering

IS:9103 Specification for admixtures for concrete

IS:9417 Recommendations for welding cold worked steel bars for reinforced

concrete construction.

IS:9595 Recommendations for metal-arc welding of carbon and carbon manganese

steels

IS:10262 Recommended guidelines for concrete mix design

IS:11384 Code of practice for composite construction in structural steel and concrete

IS:12118 Specification for two parts poly sulphide

IS:122000 Code of practice for provision of water slops at transverse contraction joints

in masonry and concrete dams

IS:12269 53 grade ordinary Portland cement

IS:12600 Portland cement, low heat

IS:23 Handbook of concrete mixes

IS:24 Explanatory Handbook on IS:456-1978

IS:34 Handbook on concrete reinforcement and detailing.

5. BITUMINOUS, CC, BOE & INTERLOCKING TILE ROAD

5.1 All work shall be carried out as per IRC detailed specifications where there are no IRC

specifications M.O.S.T. specifications/P.W.D. specifications will be followed unless otherwise

specified or directed by the Engineer in charge.

159

5.2 The contractor shall take all necessary measures for the safety of traffic during construction and

provide, erect and maintain such barricades, including signs, marking flags, lights and flagman,

as necessary at either end of work site and at such intermediate points as directed by the

Engineer in charge for the proper identification of the construction area. He shall be responsible

for all damages and accidents caused due to negligence on his part. The temporary warning

lamps or reflective barriers or sign boards shall be installed at all barricades during the hours of

darkness.

5.3 Stone ballast / Stone grit should be stacked at site for satisfaction regarding quantity of material

to Engineer in charge.

5.4 The material collected for use in the work shall satisfy all requirements for the particular work,

failing which the material will be rejected. The gauge of stone ballast shall be as per detailed

specification for the respective items and deduction will be made for the under gauge/ over

gauge material as per Engineer in charge.

5.5 During construction care shall be taken to ensure there is least disturbance to the traffic.

Adequate barriers, red flags in day time and light in night hours shall be provided to guide and

inform the traffic. All necessary precautions shall be taken to avoid any road accident at work-

site but if there happens any the responsibility will be of the contractor and he shall be

responsible for all consequences and damages/ claims etc.

5.6 The consolidation will be in specified layers. Proper and adequate camber or super elevation

etc. shall be provided as per directions of Engineer in charge.

5.7 Next coat of consolidation shall be allowed after checking of the crust and quality of previously

consolidated layer by the Engineer in charge and found satisfactory.

5.8 The material of the different layer will be spread in required loose thickness so as to achieve the

desired compacted thickness.

5.9 The binding material for consolidation shall be soil having plasticity index not more than 6

which is to be arranged by the contractor from a suitable place as directed by Engineer in

charge. The soil shall be got approved from the Engineer in charge before start of consolidation

and nothing extra shall be paid either for the cost of binding material or for its cartage.

5.10 Proper arrangement of water and its storage for consolidation shall have to be made by the

contractor at his own cost.

5.11 The stone ballast shall confirm to the following sieves.

Name of metal Percentage by weight passing

90 mm 63 mm 53 mm 45 mm 22.4 mm 1.2 mm

1. 63-45 mm gauge 10% 90-100% 25-75% 0-15% 0-5% -

2. 53-22.4 mm gauge - 100% 95-100% 65-90% 0-10% 0-5%

5.12 (a) 16-22.4 mm size grit shall pass 100% from 22.4 mm square mesh and all

retained on 16 mm square mesh sieve.

(b) 10-16 mm size shingle / grit shall pass 100% from 16 mm square Sieve and all retained

on 10 mm square mesh sieve.

5.13(A) Material for Ist coat painting shall be as follows:-

(i) Grit 16-22.4 mm size (crushed) 1.9 cum per% sqm

160

(ii) Bitumen

(a) For Pre coating 15 kg per cum of shingle/grit

(b) For tack coat 180 kg per% sqm.

(B) Material for IInd coat painting shall be as follows:-

(i) Grit /Shingle 10-16 mm size 1.20 cum per% sqm.

(ii) Bitumen

(a) For Pre coating 15 kg per cum of shingle/grit

(b) For tack coat 110 kg per% sqm.

(C) Material for open Graded Premix Carpet shall be as follows:-

(i) Aggregates for Carpet

(a) Stone chippings 13.2 mm size, passing 22.4mm sieve and retained on 11.2

mm sieve 1.8 cum per% sqm

(b) Stone chippings 11.2 mm size, passing 13.2 mm Sieve and retained on 5.6

mm sieve 0.9 cum per% sqm

(ii) Bitumen

(a) For tack coat 180 kg per% sqm

(b) For stone chipping of 13.2 mm size 52 kg per cum

(c) For stone chipping of 11.2 mm size 56 kg per cum

(D) Material for type „A‟ seal coat shall be as follows:-

(i) Stone chippings 6.7 mm size passing through 11.2 mm sieve and retained on 2.36

mm sieve - 0.9 cum per% sqm

(ii) Bitumen - 98 kg per % sqm

(E) Material for type „B‟ seal coat shall be as follows:-

(i) Chippings aggregates passing 2.36 mm sieve and be retained on 180 micron sieve

-0.6 cum per% sqm

(ii) Bitumen -68 kg per % sqm

5.14 Stone ballast/Grit/Shingle of approved quarry only, confirming to I.R.C. Specifications shall be

used. Before using stone ballast/Stone Grit/River shingle the quality & size has to be approved

by the Engineer in charge.

5.15 Contractor shall always cooperate in procurement of sample, conduction of tests as may be

directed and no extra payment shall be made for the same. Test samples shall be taken carefully

in accordance with the standard method of taking the test sample.

5.16 The contractor shall at all times keep the premises free from accumulated waste materials or

rubbish caused by his employee on the works and on completion of the work, he shall clear

away and remove from site all surplus materials, rubbish and temporary works of any kind and

fill up borrow pits dug by his. He shall leave whole of the site and work clean and in a

workman like condition to the entire satisfaction of the Engineer in charge.

161

5.17 The cement concrete road shall be constructed with concrete mix of M-20 grade as per IS code-

456.

5.18 The permanent reinstatement of all types of roads shall be executed as per UPPWD

specifications. Where UPPWD specifications are not available CPWD specifications shall be

followed. The material used shall be conforming to relevant IS codes with its latest revision.

5.19 C.C. Road will be prepared with 10 cm thick P.C.C. 1:2:4 Cement: Coarse Sand & 20 mm Stone

grit over base concrete 15 cm. P.C.C. 1:4:8 with cement coarse sand & 40 mm stone ballast

after compacting the earth surface properly. The C.C. surface must be compacted with surface

vibrator.

Interlocking Tile: Tiles must be of the thickness & grade of the disconnected tiles over base

concrete 75 mm thick 1:6:12 Cement: Local Sand: Brick Ballast Tiles must be fixed over 40

mm thick local sand layer with proper pointing.

162

(D). DETAILED SPECIFICATIONS OF SEWER WORKS:

1.0 EXCAVATION:

(i) The excavation in sewer trenches for the laying of sewers, manhole chamber, sumps, gully pits

in all types of soil i.e. loam, clay, sand mixed with mooram, shingle, boulders and all type of

rocks etc. shall be dug. Different rates for 1.5m intervals below ground level shall be applicable

for the purpose of measurement and payment according to the classification of soil under the

respective schedule or quantities. The sides of the excavated trenches shall be left plumb where

the nature of soil admits of it, but the sides must be sloped back or shored up carefully where

the soil appears likely to fall in or the depth exceeds 3.30 meters. The excavated materials be

placed 1.5 m away from the excavated earth or half the depth of trench whichever is more from

each edge the excavated trench or as directed by the Engineer-in-charge.

(ii) BOTTOM FINISHING OF TRENCHES :

The bottom of the trenches must be perfectly leveled both longitudinally and transversely

according to the level pillars given on the ground level in the alignment longitudinally. The

bottom of the trench shall be slightly watered (where necessary) and well rammed. If any soft

places come to light on inspection they will be dugout and dealt with as ordered by the

Engineer. The contractor shall sort out and remove boulders, or any other serviceable material

found during excavation as well as during preparation of bed, the bed of such places be again

leveled and hard dressed after consolidation or as per direction of Engineer.

If however, the contractor without the sanction of the Engineer makes the excavation deeper or

wider than the desired one, he shall fill the extra depth or width with cement concrete 1:4:8 (1

cement, 4 coarse sand & 8 approved stone ballast 40 mm) at his own cost. Roots of all trees and

plants encountered in digging trenches shall be removed completely, if possible, otherwise they

shall be cut upto a distance of 300 mm beyond side/ bottom of trench and shall then be burnt

and smeared with boiling coal/tar at the expense of the contractor. The hole thus occurring in

the trench shall be filled with cement concrete 1:4:8 (1 cement, 4 coarse sand & 8 approved

stone ballast 40 mm) to made it finished with the bottom or side of trench for which no

payment will be made to the contractor.

(iii) FINDS:

Any finds found on the site such as antique, relics, coins and fossils or any other valuable

article shall be immediately handed over to the care of Engineer for safe custody on behalf of

Govt.

(iv) WIDTH OF TRENCHES:

In case of pipe line, sewer, rising main etc. the width of trenches for depth up to 1.5 meter

below ground level shall be outer diameter of the pipe plus 30 cms rounded to nearest cm. For

depth greater than 1.5 meter below ground level, the trenches shall be excavated in telescopic

form in intervals from the ground level with off-sets of 250 mm at every 1.5 m depth on either

side of the trench and the width of lower most section will be governed by the above criteria.

The actual width or as described above whichever is less shall be measured for payment. The

depth of excavation shall be measured from the invert level to the ground level. Any extra

width excavated shall not he paid to contractor.

163

(v) This item of work also includes the work and expenses on laying out, making level pillars,

fixing of telltales, photographs of nearby building site clearance before taking up the work and

completion of the work.

(vi) The rates quoted by the contractor are inclusive of the filling back of trenches in 15 cm. layers

after laying and jointing of pipes, watering, ramming, dressing and disposal of surplus earth

with in the specified distance. The extra lead and lift shall be paid, as per item given separately.

The pumping of water from trenches which finds its way in to the trenches from drains or rains

or by any means (except sub-soil water) shall be done by the contractor at his own cost.

(vii) Cutting of road surfaces including sorting out of serviceable materials etc. will be paid extra

and the depth of excavation in such cases shall be measured from the bottom of the lower most

soling layer of the road.

(viii) Proper barricading and fencing shall be done along with the excavation. Red flags and caution

board during day and red lights during night shall be displayed so as to avoid any accident etc.

Contractor shall undertake all responsibility for slips or subsidence and shall make good all

damages to any adjoining property and pay compensation for loss of life and property at his

own cost and to the satisfaction of Engineer. The contractor shall be held liable to indemnify

the owner for any damage done to any adjoining property or to any of the works in progress or

partly completed by and settlement of ground which is in the opinion of the Engineer

attributable to any of the excavation, trenching work, timbering or refilling done by the

contractor.

2.0 TIMBERING (OPEN & CLOSED) :

Normally trenches upto 1.50 meter depth shall be excavated without timbering, but where the depth of

excavation exceed from 1.50 meter, timbering shall be provided, open or close, as the case may be.

Where the sides of the trenches covered shall be 33-1/3 percent it will be called open timbering and

where the sides of trenches covered shall be 100% by the timbering materials it will be called close

timbering. Open / close timbering shall be providing as per site and soil conditions. The thickness of

country wood planks shall be 40 mm up to 3.30 meter and 50 mm where the trenches depth exceeds

3.30 meter from the ground level. The sizes of Wallers and struts at various depths have been given in

the respective item of works.

The contractor will have to provide the timbering, open and close as per direction of Engineer. In case

there is sufficient space available for excavation of trenches at site, the contactor may be required to

excavate the trenches in requisite slopes in lieu of timbering as per direction of Engineer.

The contractor are advised to see the site and working conditions, specification and quote their rates

accordingly which should be including the cost of all timbering materials, labour for making the

timbering as and when required, and removal of timbering after completion of laying, jointing etc. in

any case no weakened polling board, wallers and strut will be used.

As already indicated under the item of bill of quantities both sides of timbering shall be measured as

one side for the purpose of measurement and payment. The removal of timbering shall be started as

per direction of the Engineer.

3.0 LAYING OF SEWER:

3.1 LAYING & JOINTING RCC NP-2 and NP- 3 S&S Pipe:

The laying and jointing of pipe shall be strictly as per 1.S. 783-1985 or its latest amendment. The

contractor will make the suitable arrangement of carting upto the site / alignment of work including

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loading & unloading in such a way so as to avoid damage to any portion of the pipes and will then

place along the excavated trench for laying of these pipes in to the trenches in accordance detailed

specification laid in sewerage manual & U.P. Jal Nigam detailed specification (sewerage).

For laying of sewer, the center of each manhole shall be marked by a peg. Two wooden posts

100x100x1800 mm high shall be fixed on both side at nearly equal distance from the peg and

sufficiently clear of all excavation. The sight rail-when fixed on these posts shall cross the center of

manhole. The sight rails made from 250 mm wide x 40 mm thick wooden planks and screwed with

the top edge against the level marks shall be fixed at distances more than 30 m apart along the sewer

alignment. The center line of the sewer shall be marked on the sight rail. These vertical posts and the

sight rails shall be perfectly square and planed smooth on all sides. The sight rails shall be painted half

white and half black alternately on both the sides and the tee heads and cross pieces of the boning rods

shall be painted black. When the sewers converging to a manhole come in at various levels there shall

be a rail fixed for every different level.

The boning rods with section 75 mm x 50 mm of various lengths shall be prepared from wood. Each

length shall be certain number of meters and shall have a fixed tee head and fixed intermediate

crosspieces, each about 300 mm long. The top edge of the cross pieces shall be fixed at a distance

below the top edge to the top edge equal to, the outside dia of the pipe, the thickness of the concrete

bedding or the bottom of excavation, as the case may be. The boning staff shall be marked on both

sides to indicate its full length.

The contractor shall get checked the levels of bedding before and after laying of bedding and after

laying and jointing of pipes by Engineer in charge.

The posts and the sight rails, shall in no case be removed until the trench is excavated, the pipes are

laid, jointed and filling is started.

Pipes damaged during transit from store/site or during lowering shall be rejected/ removed from the

site and shall not be allowed to be laid. The contractor shall have to replace such pipes at his own cost

or the cost of such pipes shall be recovered from the contractor from his bills as per terms and

conditions mentioned in the tender document. Contractors are also advised in their own interest to

inspect each pipe before laying and jointing.

3.2 HDPE PIPE:

The laying and jointing of pipe shall be strictly as per relevant IS code or Manual of sewer manual &

treatment. The contractor will make the suitable arrangement of carting upto the site / alignment of

work including loading & unloading in such a way so as to avoid damage to any portion of the pipes

and will then place along the excavated trench for laying of these pipes in to the trenches in

accordance detailed specification laid in sewerage manual & U.P. Jal Nigam detailed specification

(sewerage).

staff shall be marked on both sides to indicate its full length.

Measurement & Payment :

The work of laying and jointing of RCC pipes shall be recorded from the inner surface of the first

M.H. wall to the inner face of the wall of the next M.H. in meters and paid as per rates marked/

quoted in bill of quantities for the respective depth (invert level) of work below ground level.

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TESTING:

Each length of sewer line from manhole to manhole shall be tested by contractor at his own cost as

per relevant I.S. specification / sewerage manual by filling the water in to the sewer. The results of

testing shall be produced by the contractor properly signed by engineer in charge. The water required

for testing of sewers will have to be arranged by the contractor at his own cost.

As soon as a stretch of sewer is laid and tested a double disc or solid or closed cylinder of 75 mm less

in dimension than the internal dimensions of the sewer pipe shall be run though the stretch of the

sewer to ensure that it is free from any obstruction.

4 PIPE BEDDING:

As soon as the bed of trenches is ready according to the desired slope, depth and width, the bottom

shall be got leveled and rammed properly. After preparation of bed, P.C.C. or R.C.C. bedding of

specified mix or of any type of bedding shall be laid as per specification and as per direction of

Engineer in proper thickness, width and bed slope before laying of the pipe on it.

In case of concrete/RCC cradle beddings, pipes shall be allowed to be laid at least 10 hours after the

laying of base concrete bedding following type of bedding shall be provided.

Concrete Cradle: - It will consist of 1:2:4 (1 cement 2 coarse sand and 4 hard stone grit) cement

concrete with carefully compact back fill as mentioned in bill of quantities

After laying the first layer of bedding, laying of RCC pipes and jointing shall be done. As soon as the

jointing of pipes has been completed after proper leveling, the portion of concrete of bedding

(between pipe and trench face) on both the sides of pipe shall be done as per drawing and as directed

by Engineer.

4.1 RCC BEDDING:

1:1-1/2:3 RCC bedding shall be provided where sub soil condition exists during laying of sewer line.

In such case 0.8% steel in total (0.4% on each faces of bottom and top) shall have to be provided for

which no extra payment shall be admissible.

The measurement of the bedding shall be recorded and paid as per rates in bill of quantities on the

basis of volumetric quantity.

5 MANHOLES AND SEWER CONNECTING CHAMBERS :

All manholes and sewer connecting chambers shall be constructed in accordance with the dimensions

shown in the approved drawing, All the works related to construction of manhole should be carried

out in accordance with detailed specifications for the respective items of works. The inner surface of

the wall of M.H. /S.C.C. shall be plastered in mortar of mix as specified in Schedule –G. The plaster

below sub-soil water level must be finished with a floating coat of neat cement on both sides along

with the water proofing compound as per direction of Engineer. The manhole covers shall be precast

RCC heavy duty circular type conforming to I.S. 2592. However on highways and on important roads

extra heavy duty manhole covers shall be provided as desired by E/I. The footsteps shall be of

C.I./P.V.C. coated MS conforming to relevant I.S. code as per approval and direction of E/I. The

spacing of C.I. footsteps shall not exceed 25-cm. No separate measurement for manhole cover and

footsteps shall be made as they are part of manhole as per bill of quantities. If the manholes are

constructed in sub soil conditions, the PCC 1:2:4 shall be replaced by RCC 1:1½:3 with nominal

reinforcement on both faces of R.C.C. foundation. The plaster shall be 20mm thick on both sides in

sub soil conditions.

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5.1 MANHOLE SHAFT:

The contractor shall quote rates per meter run of shaft for manholes. These rates shall be used for

regulating payments for variation of depth of manholes.

5.2 BRICK WORK :

The brick work in manholes and sewer connecting chambers shall consist of M-100 class bricks in

mortar of mix as specified in Schedule G. The bricks shall conform to the PWD detailed specification

and mortar to relevant I.S. specification according to the type of mortar specified. The work shall be

executed as per I.S. detailed specification.

6.0 DISMANTLING OF ROADS :

Dismantling of various road surfaces before the excavation in trenches shall be carried out in

following two parts:-

(i) Breaking and sorting out the top coat and stacking the dismantled materials properly so as to be

placed at the top of trench after re-filling with excavated earth in 20 cm. layers and its proper

compaction by watering and ramming.

(ii) Breaking and sorting out the serviceable materials from inter and soling coat of the road, carting

and stacking the same up to 50 m. from the trench, which shall also be used after re-filling and

compaction of trench as soon as the pipe laying is completed.

The payment for dismantling of road surfaces will be made per sq.m. as per rate quoted in bill of

quantities. The thickness of road cutting during dismantling of road surfaces will not be measured in

the item of excavation. The thickness of road may vary up to any extent as per site condition, so

contractor should make allowance for same while quoting rates for this item. No extra claim in this

item shall be entertained on any ground. As soon as the laying of pipe, refilling of trenches and

consolidation of the excavated earth is completed, the road materials of different coats which were

sorted out at the time of cutting of road will be placed on top in layers as they were in original

position to avoid inconvenience to the public/ traffic. No extra payment to the contractor will be made

on this account.

7 DRY BRICK BALLAST PADDING :

The work of dry brick ballast 65 mm gauge broken from the Ist class and over burnt bricks bats only

shall be spread over the entire area of trench before laying of R.C.C or P.C.C. of the specified mix and

after preparation of base of trench. The measurement shall be taken as per consolidated thickness of

the ballast padding in entire area of trench specified for the purpose. The payment shall be made as

per rates marked and quoted in schedule „G‟.

8 DISPOSAL OF SURPLUS EARTH:

The Contractor will dispose off the extra/surplus earth from the site of work to the place or places

specified by the Engineer. The Contractor is advised to quote his rates inclusive of loading carting,

unloading & spreading the surplus earth. The measurement shall be recorded on basis of earth

volume disposed off by the Contractor in any of the following methods-

(1) Where the disposal of earth is to be done in a large area the contour plan shall be prepared &

record measurements of levels shall be taken prior to start of the work and after completion of the

work and the volume of earth shall be worked out.

(2) Where the disposal is to done in a small area, volume of earth disposal shall be got measured in

respective vehicle or any other means of disposal.

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In both the methods as mentioned above 20% reduction towards the bulk age of earth shall be done to

arrive at the quantity of earth to be actually paid for disposal.

9 OTHER WORKS:

Other works which have/have not been specified in schedule „G‟ and are essential to be executed shall

be carried out as per U.P. Jal Nigam, (LSGED) or PWD/CPWD specifications, along with the

procedure of measurements and payment.

For extra items of works the Contractor profit on the issue rate of materials shall not be added while

working out the extra rate in case the material is issued from the Deptt. For purpose of payment of

quantities of P.C.C. & R.C.C. cradle and brick padding in various lifts, the center line of the thickness

of particular quantity of the item shall be considered for measurement & payment of the same.

10 DEWATERING FOR REDUCTION OF SUB-SOIL WATER LEVEL DURING

CONSTRUCTION:

Dewatering is the removal of excess water from saturated soil mass, which is necessitated to make

working easier in wet conditions and possible below natural water level, during construction. The

Dewatering work is done as per the site conditions to enable for laying of sewer system and the

construction of RCC / brick structures in dry conditions and maintain factor of safety against uplifting

of structure. The subsoil water will be disposed off by the contractor as decided by Engineer-in-

Charge. The Dewatering shall be done as per IS: 9759-1981.

The choice of the dewatering system depends upon the type of the soil and its characteristics and

depth of water table to be lowered. The objective and main purpose of well point dewatering is to

drain out water only at the actual site of work. This avoids excessive dewatering over a large area and

provides dry working conditions to enhance the workability and manpower and machinery in a very

short time, and in most economical way. Accordingly dewatering whenever required shall be done by

well point equipment as per direction of E/I.

Extra payment shall be made for dewatering for excavation in sub soil condition during excavation,

laying of R.C.C, cradle, laying and jointing of pipes, construction of manholes, testing and back-

filling etc. shall be admissible for the sewer line under sub soil only and the contractor should quote

their price accordingly. No extra payment on this account shall be admissible for other sewer lines.

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Mechanical Equipment General

and Particular Specifications

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Mechanical Equipment General and Particular

Specifications

Schedule-II

Part-B

1.0 MECHANICAL WORKS DESIGN

1.1 Scope

The General Mechanical Works Specification covers the minimum requirements for

design, procurement, testing at manufacturer's works, supply, site testing and

commissioning of the Mechanical Works. Compliance with this specification shall not

relieve the Selected Bidder from any of his contractual obligations and responsibilities

towards fulfilling the performance requirements.

1.2 General Arrangement of the Works

The Selected Bidder shall provide and arrange the Works to comply with the

following general guidelines:

• Sufficient space shall be provided between items of Plant and adjacent Plant or fixed

structures to permit safe and convenient access for operation and maintenance.

• Layout of the site structures/equipment shall be cognisant of code distances required

between non-hazardous and hazardous structures/plant/equipment, etc.

• An area adjacent to all mechanical Plant shall be provided as a maintenance lay down

area.

• Electrically operated cranes, fixed runways, lifting eyes or other means shall be

provided to permit the removal of larger items of STP that may logically be required

to be removed during the course of its normal operational life for maintenance or

replacement purposes.

• Areas where leakage of water is likely to occur, whether in normal use or during

maintenance, shall be provided with covered drainage channels which shall direct

spillage either to a suitable drain or to a sump from where it can be pumped to an

appropriate place for safe disposal.

• Where necessary, the equipment shall be provided with removable acoustic coverings

to limit the noise produced during normal operation to the limits detailed elsewhere.

• Pipework shall be designed and installed to prevent blockages and to permit their

clearance without dismantling pipework or equipment.

• The Selected Bidder shall take due regard to the potential of hazardous mixing of

chemicals, particularly as a result of leaks and spillages, and their drainage and

containment.

• Chemical pipework shall be secured to racks or trays, to walls of tanks and walls of

buildings as necessary. It shall be arranged to facilitate maintenance and removal of

individual runs without dismantling adjacent pipes.

• All chemical pipes shall be colour banded and suitably labelled to enable individual

lines to be identified throughout their run.

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• The Selected Bidder shall provide all signage necessary to inform of chemical and

operational hazards and to comply with statutory legislation.

1.3 Pumping systems

The Selected Bidder shall provide pumping systems with isolation valves, non-return

valves, gates with actuator and all necessary pipework and fittings.

The Selected Bidder shall provide pipe supports, hangers and anchors to support and

control movement of pipes and valves all in accordance with recognized international

piping standards.

Unless otherwise specified, the Selected Bidder shall provide all pumping systems

with standby pump sets of the same type and capacity as the duty pumps, providing a

standby capacity of not less than 50% of the total duty. All pumps shall operate at

high efficiency throughout their duty range and they shall be capable of continuous

operation throughout their required operational range. The minimum diameter of pipe

for sludge transfer shall be 150mm.

Lubrication arrangements shall be designed to avoid any contamination of pumped

fluid.

Dry well mounted pumps shall provide effective means for collecting gland/seal

leakage water which shall be piped to a floor drain or sump.

Design of pumps with suitable head and discharge should be done by selected bidder

as per CPHEEO manual considering (4 working + 50% standby) pumps .

1.4 Materials of construction

All materials of construction for tanks, vessels, pipelines, pumps, valves, etc. shall

be suitable for long term contact with the liquid or chemical concerned and at the

prevailing concentrations. Equipment shall be coated and protected in accordance

with Painting and Protective Coatings.

All pipework employed shall comply with the schedule below unless agreed with the

Independent Engineer. It is the responsibility of the Selected Bidder to ensure

compatibility of all pipelines with fluids or sludge carried and with external and

internal loadings and pressures.

Service Size range Pipe material

Potable and raw water

including supernatant

Up to and including DN 300 Ductile iron (DI)

Poly-ethylene (PE)

DN 300 – DN 600 Ductile iron (DI)

Steel

Poly-ethylene (PE)

Greater than DN 600 Ductile iron (DI)

Sewage (pumped below

ground)

Up to and including DN 300 Ductile iron (DI)

Greater than DN 300 Ductile iron (DI)

Above ground pipe-work

and within structures

Up to and including DN 300 Ductile iron (DI)

uPVC

Stainless steel (304L)

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Service Size range Pipe material

Greater than DN 300 Ductile iron (DI)

Steel

All sewage pipework

underneath structures

Up to and including DN 300 Ductile iron (DI)

Greater than DN 300 Ductile iron (DI)

Steel

Stainless Steel (316L)

All pipes under roadways & structures to be

concrete encased.

Compressed air All diameters SS 304

Sampling All diameters (uPVC)

Instrumentation process

piping

All diameters Copper (plain/coated)

uPVC

Nylon

Stainless steel

Chemical dosing All diameters Sch. 80 PVC &According to manufact-

urer‟s recommendations

Natural Gas MDPE below ground

Stainless steel or steel above ground/inside

buildings

Sludge All diameters Ductile iron NP 16 rated below ground

Stainless steel (304L) above ground/inside

buildings

Biogas All diameters Stainless steel 316L (below ground,

inside/outside buildings)

Process Air piping Blower discharge and

common header– All

diameters

SS 304/316L (within building)

Transfer to and distribution

piping around aeration tanks

-All diameters

Stainless steel (316L)

1.5 Isolation and drain down

The Selected Bidder shall provide facilities for isolating and draining down all

pipework, chambers and storage tanks. Wherever duty/standby equipment is provided,

it shall be possible to isolate and drain-down each of the duty or standby items while

the other items are in service.

2.0 Particular Specifications

2.1. Medium and Fine Screens

2.1.1 Scope of Supply The scope of supply shall provide complete automatic mechanical screen systems

with all accessories and appurtenances, including, but not limited to:

Mechanically operated screen;

Screenings collection, washing and disposal system;

Automatic screen control system;

Electrical & Instrumentation for compliance of Automatic System (Electrical wiring between

all screen components, instruments, control devices and the local control panels and the

screen controls; )

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2.1.2 Guaranteed Flow Rate and Head Loss The screen shall effectively screen all flows up to the design flow. The Selected

Bidder shall guarantee the following screen performance parameters:

Clean water flow rate capacity (l/s) at the maximum allowable water depth downstream of the

screen

Clean water head loss at the max flow rate and maximum allowable water depth downstream of

the screen

2.1.3 Screening Arrangements Selected Bidder shall provide automatic mechanical fine screen to remove particles

larger than 6mm size.

It is proposed to install sufficient number of appropriately sized automatically

operated mechanical fine screens (stainless steel grade – SS316) of opening size

6mm for screening out floating materials such as plastic pouches, bags, rags, floating

debris, weeds, paper wastes and other floating materials from the raw sewage coming

from the pumping station. Capacity of each channel shall be equal to of average flow.

Fully automatic mechanical screen along with the level sensing instrument for

automatic operation of screen mechanical and allied accessories, (local control panel

near screen,) shaft less screw conveyor with/cum compactor are to be provided.

The fixed as well as movable bars/ perforated band, mechanism, support frame,

fixings discharge chute shall be manufactured from stainless steel grade 304 for long

life in the aggressive sewage environment.

Automatic Screen Clearing and Screenings Removal

The screen shall be provided with the necessary controls and sensors to anticipate

blockage of the screen, and automatically clear the screen and remove the

accumulated screenings from the screen surface. The screen shall operate

automatically when the upstream water level increases beyond a pre-set limit and it

shall stop when the upstream level decreases to pre-set low level.

Screenings Conveyance, Compaction and Dewatering

The screening system shall be supplied with a duty and standby shaft less screw

conveyor that will be used to convey the screenings to the automatic screenings press

and discharge system that compacts, dewaters and discharges the screenings through

a chute to the screenings storage system.

The screenings dewatering and compaction system shall compress and dewater the

screenings such that the screenings from a consolidated mass with no free water

entering the screenings bag.

Screen Washing System

The Selected Bidder shall supply and install spray washing system that effectively

cleans the screen area and screening press. The Selected Bidder shall provide a high-

pressure clean water supply for the washing system.

Dewatered Screenings Discharge Chute

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The screenings discharge chute shall terminate 1.5 meters above ground level. A

plastic screenings bag shall be secured around the chute, thereby creating a totally

enclosed screenings collection system.

Screen Covers

All screenings equipment shall be supplied with integral stainless steel covers that

prevent access to moving and wash water sprays. The covers need to be airtight to

ensure that no odours emanate from the screen.

Portable Screenings Container

Portable screenings containers made of galvanised steel duly epoxy painted shall be

provided to store the screenings until time of pick up. The container shall have

capacity of approximate 5 m3 and shall be of a convenient height to permit the

discharge of screenings directly into the container without having to transfer the

screenings manually. The containers shall have hinged covers and their design shall

permit them being lifted by an overhead hoist or packer truck. The container will

have four wheels each of about 20 cm diameter and two of which shall be swivel

castors. The maximum height of container including wheels shall be 0.6m. The sides

shall be constructed of minimum 12 gauge steel. The bottom of container shall be

made minimum of 6mm plate steel. The containers shall be reinforced with 50mm x

50mm x 5mm angle iron.

Electrical Motor

The motor shall be TEFC type with IP 55 protection & Class F insulation and shall be

suitable for operation on 3 phase, 415V + 10% and frequency of 50Hz + 5%. Motors

shall be squirrel cage type conforming to IS 325. The power rating of motor shall be

at least 125% of maximum power requirement.

Control Panel

The Control Panel shall have IP 65 protection, painted with Epoxy paint and shall be

comprise:

- Mushroom Head Emergency stop.

- Overload relays for motor protection.

- MCB‟s, HRC Fuses and Glass Fuses.

- Circuitry to operate the screen with level sensors.

- Selector Switch to operate the screen on JOG mode.

2.1.4 Access

Safe access shall be provided to all screen equipment and instruments to allow for

cleaning, inspection and maintenance activities.

2.1.5 Corrosion Resistance

All metal parts of the screen equipment that are in contact with the sewage shall be

constructed of a suitable grade of corrosion resistant stainless steel.

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2.1.6 Installation, Testing, Commissioning and Training

It is the Selected Bidder‟s responsibility to install the screen system correctly and

achieve the required operation. The Selected Bidder shall provide a representative

who has knowledge and experience in the proper installation, start-up and operation

of the screen equipment to inspect the final installation and supervise the

commissioning tests.

2.2. Grit Removing Equipment

Grit chambers shall be of vortex type with centre drive and independent washer or

classifier. Grit Basin equipment, complete with all accessories including, but not

necessarily limited to, gear motor, turntable, propeller drive tube, axial flow

propeller shall be provided.

2.2.1. Vortex type with central drive grit removal system

The Vortex Grit Basin equipment shall be installed in concrete basins. The

equipment to be supplied shall be suitable for installation in these basins. The grit

chamber shall be designed to operate on the vortex principle. Drives, bearings, and

support equipment for grit mechanism shall be supported by and readily accessible

from a concrete walkway above the water surface.

2.2.2. Grit Separator:

The grit chambers shall conform to the following construction, operation guidelines

and have the accessories as indicated below:

Vortex Type Grit removal chamber with low head loss systems shall be proposed

for this project. Each grit chamber shall be complete with the minimum equipment

but not limited to gear motor, gear head, axial flow propeller and scrapper with

drive, grit removal pump and auxiliary equipment required for operation. The grit

removal unit shall have low head loss and shall be capable of removing grit from

raw waste or process water and depositing the grit in a storage hopper. An integral

grit transporting means shall be provided to transport the grit from the storage

hopper to the disposal means. To minimize the possibility of clogging, all internal

openings in the piping to the grit pumping device as well as the grit pumping device

shall be large enough to pass a 100 mm sphere. No bends or elbows will be allowed

in the piping on the suction side of the grit pump. All drives, lubrication and

bearings shall be readily accessible from walkways above the operating water level.

To minimize the possibility of organic capture, the floor of the grit separation

chamber shall be flat and there shall be no greater than a 80 mm opening for grit to

pass through to the storage hopper. Sloping floors in the upper chamber will not be

allowed due to reduced grit removal efficiency and extra construction costs. To

ensure the efficient transport of the grit and simultaneous lifting and discharge of

the organic material, the bottom of the upper chamber covering the storage hopper

shall be constructed suitable corrosion proof / or thick steel plate , free from

rotation, and shall be flat. The grit moving across the bottom of the chamber shall

be hydraulically scoured by an air lift pump or a propeller pump. The grit shall pass

from the removal chamber through an opening in the transition plate and drop into a

grit storage hopper. The flow in the removal chamber shall travel between the inlet

and the outlet a minimum (270°), providing maximum travel of the liquid for

effective grit removal. The Grit Chamber shall handle all flows equal to or less than

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a hydraulic peak flow. The influent flume, transporting the liquid waste to the grit

chamber, shall be of the size and shape shown on the contract drawings to assure

that grit does not settle in the inlet flume and to provide for proper operation of the

grit chamber. A grit storage hopper with a 60° sloped bottom shall be provided with

effective grit storage for the designed flow. , grit pump will be either an air lift

educator pump or a turbo grit pump close-coupled, vacuum primed type with

curved multi vane impeller. Grit Classifier / Washer shall be rake or Shaft less

screw type. The material of construction of all wetted parts shall be in SS 316.

2.2.3. Operating Conditions The grit chamber shall operate on the vortex principle. To maximize grit removal

efficiency, the grit chamber hydraulics shall incorporate a toroidal flow path enhanced

by a slow vortex.

The grit removal device shall be capable of removing the following at the specified

hydraulic peak flow rate, and no decrease in efficiency will be allowed at flows less

than this design rate.

- 95% of the grit greater than 150 microns in size,

- 75-85% of the grit greater than 100 but less than 150 microns in size,

The displacement type blower shall have the capacity to provide sufficient quantities

of air at the required pressure to ensure efficient operation of the air wash/airlift

system.

Grit Trap

Item Description MOC

Air Lift Pump Stainless Steel

Geared Motor Assembly STD

3 Way Valve Stainless Steel

Screw Classifier Stainless Steel

2.3. Clarifier Mechanism

The Clarifier Mechanism shall be suitable for installation in RCC tank and circular

radial flow fixed bridge with scum collector, central turn table type clarifiers shall be

provided. Clarifier should be rugged and robust in design and should be provided with

high capacity drive head having high torque rating, centrally located with positive

sludge raking by means of two raking arms. Both the raking arms should have scraper

blades fitted at the bottom, so that the sludge from one scraper blade is pushed to the

other on every rotation. The centre drive head mechanism arrangements should consist

of a turn table base casting mounted on top of the centre pier and having an annular

ball bearing on which the internal gear that supports the underwater mechanism turns.

The pinion meshing with the internal gear should be driven through a worm gear

reduction unit mounted on top of the turn-table drive unit. The balls should ride on

hardened steel strips set into groves in the base and gear castings so that they can be

readily replaced whenever it is necessary. An overload alarm containing switches

controlling the alarm ball and motor in case of excessive load should be mounted on

the worm gear housing. An overload alarm device should be provided with mechanism

to indicate the overload conditions on the scrappers.

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The mechanism shall comprise but not limited to the following main components:

- Bridge Superstructure spanning half the tank diameter with central maintenance platform

- Drive assembly complete with drive head, chain & sprocket, geared motor etc.

- Feed Well

- Center cage

- Cone scraper

- Rake arms

- Tie rods for rake arms

- Plow blades & squeegees

- Scum Blade & Skimmer assembly

- A-frame supports for the skimmer assembly

- Scum trough and ramp with support angle

- Scum baffle with supports

- Weir plate

Bridge Superstructure:

The bridge shall span half the diameter of the tank. The width of the walkway shall be

minimum 1.5 M. The bridge shall rest on the clarifier wall at the one end and the

drive at the center. The bridge shall be of truss type welded steel construction with

walkway of gratings supported by cross members. The truss bridge shall be provided

with one row of handrail in the middle. The bridge shall be provided with a drive

maintenance platform at the center.

Drive Assembly with Drive Head :

The central drive head shall rest on the RCC center pier and supports the bridge at the

center. The drive head shall be coupled to a geared motor through chain & sprocket

and shall support the center cage at the bottom for rotating the rake arms.

Feed Well:

A fixed feed well shall be hung from the bridge superstructure. The inlet feed pipe

shall connect to the central inlet column at the bottom.

Center Cage:

The center cage shall be of welded steel construction. The center cage shall be bolted

to the drive head at the top and shall support the rake arms at the bottom.

Cone Scraper:

A cone scraper shall be attached to the bottom of the center cage and shall serve to stir

the sludge in the bottom hopper.

Rake Arms & Tie Rods:

Two sets of rake arms shall be attached to the center cage in diametrically opposite

direction through a hinged connection. The rake arms shall be attached to the center

cage through tie rods with provision for adjustment of inclination of the rake arms.

Each rake arm shall be provided with plow blades at the bottom and adjustable

renewable squeegees for scraping of sludge.

177

Skimmer Assembly & Scum Blade:

One set of skimmer assembly with scum blade shall be attached to the rake arm and

shall serve to skim the floating material. The scum blade shall span from outside of

the feed well to scum baffle at the periphery of the clarifier.

Scum trough and ramp with support angle:

One no. scum box comprising of scum trough with ramp shall be provided at one

point along the periphery of the clarifier and shall serve to collect the scum discharged

by the scum blade into the trough. The scum box shall be supported from the side wall

by support angles. The scum box shall be provided with flange connection of

specified size for connection of scum pipe connecting the scum box to the scum

sump.

Scum baffle with supports:

The scum baffle shall be provided along the periphery of the tank to prevent floating

matter from reporting into the overflow. The scum baffle shall be supported by

support brackets from tank wall.

Weir Plate:

V-notch weirs shall be provided along the periphery of the overflow collection

launder for uniform draw-off of the overflow. The weir plate shall be fixed to the

launder by means of plate washers.

Material of Construction :

Feed Well SS 304, minimum 3 mm thick

Bridge MS with Hot dip Galvanized (galvanizing minimum thickness

shall be 80 micron) (welded/nut bolted/riveted truss in a

consolidated single component and no site welding shall be

allowed)

Rake Arm MSEP, minimum 5 mm thick

Center Cage MSEP, minimum 5 mm thick

Rake Blades MSEP, minimum 5 mm thick, 1500 m wide x 150 mm ht

V-notch weir SS 304, minimum 6 mm thick and 300 mm wide

Squeegees Neoprene rubber, 10 mm thick, adjustable type

Walkway Heavy duty MS epoxy coating grating, radial upto centre

minimum 10 mm thick

Handrail (both ways in

two layers minimum 1 m

high)

32 NB SS Pipe (radial upto centre)

Scum skimmer assembly MSEP, minimum 5 mm thick and 300 mm wide

Scum Box MSEP, minimum 3 mm thick

Scum Baffle MSEP, minimum 3 mm thick and 400 mm wide

Fasteners – Under Water SS-316

Fasteners – Above Water SS-316

178

All MS parts shall be provided with one coat of epoxy primer followed by one coat of

epoxy paint after sand blasting prior to dispatch to a total DFT of minimum 225

microns.

2.4. Diffuser

The aeration system may be provided to meet the aeration requirement as per the

process design requirement. Sufficient design calculations are to be provided along

with manufacturer standard having supplied diffuser during last five years to various

waste water treatment plants.

Fine Bubble Aeration System

Design: The membrane diffuser shall be developed specifically for Releases 1~3mm

fine bubble in the wastewater treatment plant. All materials have been selected for

their ability to withstand the effects of the chemical, bio-chemical agents and

0~100°C used in wastewater tank. The diffuser can be placed in an evenly distributed

grid system over the entire aeration tank bottom. Air can be easily through the air

orifice and integrated non-return valve into the wastewater. The air orifice design to

maintain the diffuser standard airflow input prevented the max. air enter to damage

diffuser membrane. The membrane shall be secured onto the support dish with a

constrict flex rim and retaining ring designed to increase the tension on the point of

engagement as the diffuser air rate increases.

Construction: The materials of construction for both support dish and membrane

diaphragm are non-corrosive and UV resistant.

The fine/coarse bubble aeration system will comprise:

Stainless steel (SS316) droplegs and Headers.

PVC manifolds and air distributors.

PVC diffuser holders and retainer rings.

Stainless steel supports and anchors

Bolts, nuts and gaskets for aeration system flange connections.

Air distributor purge systems.

Membrane disc diffusers with integral O-ring gaskets and subplates.

The following design features will be incorporated in the fine/coarse bubble aeration

system:

Fabricated manifold with fixed threaded union joints for connection to the air distributors.

Manifold sections connected with fixed threaded union or flanged joints to prevent rotation

or blow apart.

Manifold, distributor connections and supports designed to resist thrust generated by

expansion/contraction of the air distributors over a temperature range of 70°C

Air distributors perpendicular to the air manifold

Fabricated distributors with single diffuser holders solvent welded to the crown of the air

distributor for complete air seal and strength.

Air distributor sections joined with positive locking fixed threaded union or flange type joints

for all submerged header joints to prevent blow apart and rotation. Bell and spigot, slip on or

expansion type joints are not acceptable for submerged joints.

179

Threaded union joints designed with spigot section connected to one end of the distribution

header, a threaded socket section connected to the mating distribution header, an “O” ring

gasket and a threaded screw on retainer ring. Solvent welding shall be done in the factory.

All supports designed to allow for thermal expansion and contraction forces over a

temperature range of 70°C and to minimize stress build up in the piping system

Supports designed to be adjustable without removing the air distributor from the support.

Diffuser assembly comprising: diffuser membrane with integral „O‟ ring, sub-plate, holder,

retaining ring and air flow control orifice.

Integral check valve incorporated into the membrane diffuser assembly

PVC support plate incorporated to form an air plenum under the diffuser and support for the

membrane when the air is off

Retainer ring threads designed with minimum cross section of 3mm and to allow for one

complete turn to engage threads.

A liquid purge system to drain the entire submerged aeration piping system for each aeration

grid including airlift purge eductor line and manual control valve.

All PVC joints will be factory solvent welded. Field solvent welding will NOT be permitted.

Circular membrane diffuser discs with integral O-ring will be manufactured of EPDM

synthetic rubber compound with precision die formed slits. Thermoplastic materials (i.e.

plasticized PVC or polyurethane) are not acceptable.

Carbon black will be added to the EPDM material for resistance to ultraviolet light.

The maximum tensile stress on the diffuser will be limited to 10 psi (69 kPa) when operating

at 2.4 SCFM/sq. ft. (43.9 Sm 3 /h per m 2 ) of material. Proportionately thicker material is to

be furnished for larger diameter disc diffusers to limit the maximum tensile stress and to resist

stretching.

2.5. Aeration Tank

2.5.1. Submersible Mixers in Aeration Tank / Sludge Storage Tank Submersible mixers are used in the bio reactor for the following purposes

1) In Anoxic Tank to keep the Solids in Suspension

2) In Aeration Tank to keep solids in suspension and to improve the aeration capacity .

3) In Sludge Storage Tank

The mixer design guidelines are as follows

Mixer Duty

Application

Minimum

Pumping Rate

Mixer Min Power

Transmitted to

fluid

Anoxic Bio Reactor 1.5

times tank Volume

Tip Vel not

more than 16 m

/ sec

0.75 watt / m3

pumping capacity

Aeration tank for

improving aeration

efficiency

0.5 to 0.75

times tank Volume

Tip Vel not

more than 3 m /

sec

0.75 watt / m3

pumping capacity

Sludge Sump

( digested / undigested

)

More than 5

times tank Volume

Tip Vel not

more than 16 m

/ sec

8 watts per m3 of

tank volume

Non less than 2 mixers hall be provided per tank .

180

The mixers shall be of robust construction, designed for continuous operation under

the most difficult operating conditions installed in three aeration basins.

The mixers shall be energy efficient with submersible type mixer with motor housing

in CI IS 210 Gr FG 260 and 2 or 3 blades propeller in SS 316 construction with

suitable IE3 premium efficiency motor at 415 ± 10% V, 50 C/S.

The submersible mixer shall be complete with lifting device comprising of MS Hot

galvanized minimum 60 mm tube, MS winch and steel rope and handle with all

accessories.

2.5.2. Air Blowers

The term "blower" is commonly used to define a device with a functional need for

additional airflow using a direct mechanical link as its energy source. The term

blower is used to describe different types of devices 1) Positive displacement Roots type: rotary twin /tri lobe

2) screw type

3) centrifugal / Turbo Type

Blowers are defined essentially air / gas compressing machines compressing air / gas

to a pressure of 0.9 kg/cm2 ( 9000 mm Water Colum )

For pressures exceeding 9000 mm WC Screw Compressors or reciprocating

compressors shall be used

Air blower can be 1) Regenerative / Side Channel Blowers

2) Positive displacement type: rotary twin /tri lobe

3) Centrifugal blowers / Turbo

The preference for blowers will be

S No Type of

Blowers

Suitable for Capacity

m3/hr

Delivery

Head mm

WC

Drive HP

1 Regenerative

Side Channel

Blowers

High Volume Low

Pressure

applications

Up to 400-500

m3/hr

Up to 4000

mm WC

Up to 20

2 Positive

displacement

type: rotary

twin /tri lobe

Low / Medium

Volume and

medium to high

pressure

applications s

Up to 500-

6000 m3/hr

Up to 6000-

7000 mm

WC

Up to 150

HP

3 Centrifugal

Turbo

High Volume /

Medium to High

pressures

Volumes in

Excess of

5000 m3/hr

upwards

Pressure of

5000 mm

WC upwards

150 HP and

More

181

2.5.3. General Requirements for All Types of Blowers All type of Blowers blowers should have - suction air filter and silencer,

- outlet silencer,

- pressure retied valve,

- delivery pressure gauge and

- delivery isolating and no-return valve and

- acoustic enclosure of proper design shall be provided, so that decibel level shall be

maintained as specified elsewhere.

A metallic bellow joint is provided on the delivery side of each blower. Vibration

pads shall be provided at foundation level to keep vibration of the equipment within

limits as specified elsewhere in the specification.

Casing of the blower shall be robust construction and shall be machined to proper

tolerance. Rotor along with other un-machined rotating part shall be properly

balanced so as not to cause any vibration during operation. Rotor shall be made in one

piece and securely keyed to the shaft. Means shall be provided to prevent loosening

during operation including rotation in reverse direction

The bidders should propose energy efficient air blowers/compressors of proven design

working satisfactorily with documentary evidence. For large aeration capacities

considering high efficiency, low maintenance cost, minimal foot print, minimize

breakdown time and over all low life cycle cost energy air efficient compressors shall

be preferred as per the duty application. The minimum number of standby blowers

should be 50 % if numbers of installed blowers are 2 or more otherwise 100 % stand

by .

As far as practicable the bidder should review the possibility of using same model /

rating of blowers in case there are more than 3-4 blowers for a particular application

with slidhtly different duty points so as to make a minimum type of blowers

2.5.4. Roots Types Blowers

The following specifications are essentially for Roods Type (twin lobe / Tri lobe

blowers , in case the bidder offers side channel blower or a centrifugal blower the

descriptive requirements would change accordingly .

Roots blowers shall be driven by squired case valves through a matched Ve-belt drive.

Motors shall be mounted on slide rails mounted on a common bed plate, to facilitate

the tensioning of the belts.

The horsepower rating of the blower motor (including the service factor) shall not be

less than 115 % of blower design point BHP

In case of positive displacement roots blowers the blower operating speed RPM

should not be more than

1200 RPM in case of air cooled units

1800 RMP in case of Water Cooled units

Inlet to blowers shall be at the top and discharge at the bottom, the axes of both being

vertical.

Connecting pipe work shall be designed for a maximum velocity of 20 to 25 m/sec.

Delivery end of the blower shall be flanged connection of appropriate specification.

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1) Special Requirements for Roots Type Blowers

i.) Though both air and water cooled units are acceptable, however the preference is for Air

Cooled unit, In case water cooled units are proposed the bidder shall provide details of

water quantity required and shall make the necessary arrangements for the same

ii.) Blower should be suitable for outdoor installation without any cover and be of suitable

construction and protection against rain

iii.) Power transmission : direct drive shall be preferred but alternative like V belt also

acceptable

iv.) The power rating of motor shall be at least 15 % above the maximum power requirement

by the blower

v.) Blower should be suitable for outdoor installation without any cover and be of suitable

construction and protection against rain

2) Material of construction

i.) Casing : C I conforming to IS: 210

Gr FG 260

ii.) Rotor : Alloy steel

iii.) Shaft : Carbon steel C40/EN

24/19

iv.) Timing gear : Cast alloy steel

v.) Pulley and gear side plates and cover : CI

conforming to IS 210 Gr FG 260

vi.) Manufacturing Code : BS 1571

3) Tests

i.) Hydrostatic tests Twice the maximum

working pressure

ii.) Strip test Clearances with tolerance limit

iii.) Performance test As per BS : 1571

iv.) Mechanical balancing ISO 1940 Gr. 6.3 or better

v.) Visual Inspection Before painting

2.5.5. Turbo Blower:

2.5.5.1. General Turbo Blower General Requirements / Specifications

i.) The high speed turbo blower should be gearless & direct driven with high frequency

permanent magnet motor. The PM motor should be high efficiency type with H class

insulation. Both, the PM motor & the blower should have lubrication-free air-foil bearing.

Super alloy material of construction of the shaft will be preferred.

ii.) The material of construction of the blower‟s impeller should be of stainless steel or

aluminium; however aerospace class high tensile strength (980 MPa) SUS630 stainless steel

17-4PH material will be preferred.

iii.) The PM motor should have perfectly matching integrated invertor (VFD) which should be

used for smooth start-up as well as capacity control from minimum of 40% to maximum of

100% output. VFD control shall be based upon constant motor current, not constant rpm.

iv.) The starting current should be less than 15% of full load current of the motor / blower.

v.) Both, the PM motor & Invertor (VFD) of air-cooled type will be preferred. All cooling shall

be accomplished with ambient air only. No provisions or requirements for water cooling of

any kind shall be required. Heated air from the motor & inverter shall not be mixed with

intake fresh air.

vi.) The blower package should be microprocessor controlled with graphical touch screen display

HMI. It should be able to control following parameters – constant pressure, constant flow,

constant power & dissolved oxygen control with direct connectivity to D.O. sensor.

183

vii.) The blower should have built-in flow meter which should continuously measure on-line flow

of air.

viii.) The blower should be equipped with pressure, differential pressure, vibration, speed, &

temperature monitoring devices.

ix.) Flow measurement should be an integral part of the blower and the flow measuring device

can be a orifice or a bell mouth the design with the flow being measured based on differential

pressure. Actual ambient & discharge temperatures should be measured using temperature

instrumentation. No assumptions or calculations regarding flow, pressure, temperatures or

relative humidity shall be made. All process & performance conditions shall be measured, not

calculated.

x.) The HMI should display set value, actual instantaneous value & on-line trend of discharge

pressure, flow, input power, rpm, suction temperature, performance curve / map with actual

instantaneous operating point. It should also have provision to send this data for logging

purpose.

xi.) Static pressure measurement should be carried out at exit of diffuser of the blower to ensure

that it is equivalent to the total discharge pressure.

xii.) The microprocessor controller should be able to accept external analogue input for remote

setting of the parameter to be controlled.

xiii.) The supplier should guarantee the total input power to the blower as per specified discharge

flow & pressure.

xiv.) Blower shall have built in automatic surge protection. Blower with high „rise to surge‟ will be

preferred.

xv.) Blower package shall be supplied with acoustic enclosure covering the entire blower package

to restrict the noise level up to 80 dBA at 1 mt distance. The enclosure shall be designed so as

to be able to install multiple blowers side-by-side with all maintenance done from the front or

back of the package.

xvi.) Each blower shall be factory tested by the standard methods based upon ASME PTC-10:1997

measuring kw input for Wire to Air power at the inlet of the package and/or applicable test

codes such as ISO 5389:2005, JIS B 8340. Acceptance criteria is 2% tolerance on power and

flow.

xvii.) All machines are Air Cooled. No additional cooling water circuit required either to cool the

VFD or the motor. This reduces the maintenance of water coolers which tend to get choked,

corroded, leakage in the long run depending upon the water quality being used for cooling. It

also ensures that the wire to air efficiency is complete since ppl do not add the cooling water

power consumption and cost while calculating the LCC and ROI

2.5.5.2. High Speed Tubro Motor

High Efficiency PM (Permanent Magnet) Motor .The permanent magnet will make it

possible to have very high efficiency (96-97%) over an entire operating range.

Due to high efficiency design and manufacturing, heat generation from the motor is

much smaller compared to other regular PM motors. Hence, air cooling was made

possible and is the standard for all the models up to 800 hp. Main benefits of an air

cooling system include higher safety and less maintenance.

PM motors will have low starting current to a maximum of 4 to 10 % of the Full Load

Current

Motor to be suitable for i.) Input Power: 3Ø, 415Vac, 50 Hz(± 5%)

ii.) Motor Power Range: 100 hp to 800 hp including 15 % 0verload of durty point FLC

184

iii.) Harmonics Frequency filters to be an integral part of the motors

iv.) Should have, optimized VFD needs very small starting current (< 5% Full load current) and

provides very High Efficiency (@96-97%), which helps to reduce electric facility costs.

Because our most advanced high efficiency motor design requires minimum cooling efforts,

the motor cooling air has a surplus capability allowing for cooling of the VFD before the air

is used for motor cooling

2.5.5.3. High Speed Tubro Blower Features i.) Oil-less Operation : due to air foil /permanent magnet bearings, ISO 8573-1

ii.) Flow Meter to be an integral part of blower showing flow rate with ±0.5% tolerance

iii.) Real High Rise-to-Surge : should have advanced current based control method enables an

active high rise-to-surge advantage. This is a critical feature required by Aeration

requirements .

iv.) Compactness of System :

The starting current is only 5% of FLC. This smooth starting enables to reduce the

starting load on electrical system.

v.) Semi-Permanent Life

These blowers can be used permanently with proper maintenance without

performance degradation.

vi.) Stainless steel impellers and packaging insure durability and allow for permanent life.

2.5.5.4. Material Of Construction

i.) Impeller :

Casted Stainless Impeller (17-4PH) or High Strength Aluminum allow for

impellers ii.) Shaft :

Stainless Steel or Tiatianum iii.) Permanent Magnet

Permanent Magnet to be used used in the rotor, which has very good high

temperature characteristics.

Even under very high temperature and high loading condition, Permanent

magnet are not demagnetized and very stable.. iv.) Bearing

Oil free Teflon-S Air foil or Permanent Magnet bearings made from corrosion

free material like nickel , titanium alloy steel . v.) Stainless steel Housing

Semi-permanent life time of the blower core require better package material. It

is recommended it should be stainless steel without painting.

VFD is mandatory for any of these blowers.

2.5.6. Single Stage Centrifugal Blower/compressors :

2.5.6.1. General The compressors shall be motor driven, single - stage centrifugal, integrally geared,

radially split type. Each compressor shall be provided with end-suction and side

discharge, with discharge adjustable radially increments. Each compressor shall be

equipped with an integral intake filter/silencer, modulating inlet guide e vanes and

discharge variable vane diffusers, integral speed-increasing gear, discharge cone -

silencer, direct coupled motor, coupling and guard, inlet and discharge flexible

connectors; discharge check valve, backflow barrier, motorized blow-off valve with

silencer, lube oil system, instrumentation and control system.

185

The compressor equipment shall include all the ancillaries with local control panels

for each compressor and the master sequence controller integrated in the local control

panels.

The compressor equipment specified herein is intended to pressurize ambient air for

the supply of oxygen to waste water treatment aeration tanks.

The compressors will receive filtered air and will discharge to the main header. The

capacity of each compressor shall be automatically controlled to provide the airflow

rate through the compressor as required by the process. The blow-off valve shall be

open during start-up and shutdown to allow unloaded start and stop, and to avoid

surge conditions All the piping system from the blowers shall be interconnected to

feed to all the basins.

Single Stage Centrifugal Blower should have variable frequency drive for variable

motor speed control and optimal efficiency for all operation points with soft start-up

function.

The capacity regulation shall be as per the process requirement of plant however not

less than from 120% to as low as 45% with best efficiency.

2.5.6.2. Impeller type The impeller shall be of the semi open radial flow type, induced S-shaped with strong

backward leaning blades, machined as one, not welded, casted or riveted.

The impeller shall be statically and dynamically balanced. The Supplier must demonstrate

that the impeller/shaft design is designed for operating at peripheral speeds up to 115% of the

rated operating speed. The axial gap between the impeller and compressor casing must be

adjustable by means of machined spacers in order to assure the prescribed gap. Gap

adjustments by means of machining of casings or shafts may not be accepted.

2.5.6.3. Shaft Seals The shaft seals shall be of double mechanical seal non-contact, multi-point, labyrinth

type with small clearances and sufficient touch points to minimize air leakage out of

or into the casing while the compressor is running in the specified operating range or

during start and shutdown and to ensure a 100% oil free air supply.

2.5.6.4. Gear Box

a) The gearbox shall be of ample size and rated to transmit the maximum torque and power input

requirements to the compressor under all operating conditions and continuous duty. The

service factor shall be minimum 1.4. All exposed machined surfaces shall be coated with a

corrosion-resistant compound prior to shipment.

b) The gear drive housing shall be of light weight aluminium di casted suitable for high

temperature and sufficiently rigid to maintain the shaft positions under maximum loads. The

gear housing shall be horizontally split in order to allow easy inspection and maintenance.

The gear housing assemblies shall be machined to close tolerances for bearing fit, gear

alignment and oil tightness.

186

2.5.6.5. Oil Lubrication System

a) A complete lube oil system shall be provided with each compressor. The system shall be

capable of supplying clean lube oil at suitable pressure and temperature to lubricate the speed

increasing gears and bearings. All components of the lubricating system shall be installed

integral with the compressor base plate and arranged to permit ease of accessibility for

operation, maintenance, inspection and cleaning.

b) The package shall include one gearbox drive shaft driven primary oil pump and one electric

motor driven pre-lubrication oil pump, each of adequate capacity to supply lubrication for the

air compressor/gearbox when operating under normal duty, during normal start/stop and

during run down in case of power loss. The electric motor driven oil pump will operate at

start/stop of compressor and at low oil pressure, activated by the control system located in the

local control panel.

c) The lube oil filter shall be duplex cartridge type suited for the oil pump capacity, with

replaceable cartridges which can be replaced without stopping the compressor. The filter

grade shall be capable of removing particles over 10 microns with a clean oil filter and a

pressure drop not exceeding 350 mbar at design temperature and flow. Filter cases shall be

suitable for operation at a pressure not less than the relief valve setting. A visual gauge or an

electric pressure switch shall indicate when the filters are contaminated and requires

replacement.

d) Strainers shall be manually cleaned and equipped with a magnetic trap. Design and

installation shall permit ready access for cleaning.

e) An oil cooler for each compressor shall be furnished and shall be of the air-to-oil type. The

cooler shall be capable of maintaining required cooling rate at all specified ambient

temperatures. Each cooler shall be rated to dissipate the total emitted heat from the

compressor gearbox. Air-to-oil cooler shall be furnished with an electric motor-driven air

blast fan.

2.5.6.6. Local Control Panel

a) Each compressor shall be furnished with an integrated and dedicated rack based PLC,

sequencing panel including in built variable frequency drive and soft starter. All controls shall

go into a safe condition by failure and not allow the machine to be operated with any

defective control.

b) The Local Control Panel set-up shall include the Load Sharing functionality with Master

Control Panel of adequate features.

c) The local control panel shall consist of the following:

d) Low voltage system -with main switch and motor overload relays for auxiliary equipment

such as blow-off valve, variable diffuser, and inlet guide vanes. Further, monitoring of the

drive motor's temperature sensors, and relay for control of drive motor's main switch, with

wiring to:

187

e) Control system - with automatic PLC, in built variable frequency drive and soft starter with

current overload circuit to limit power consumption of the compressor, and all necessary

control circuits for oil pressure, oil temperature, surge limit, and recirculation.

f) The front panel shall be equipped with Human Machine Interface with a screen of minimum

6" color touch panel with indication of process values Low voltage and control systems

mounted in a steel panel, IP55, and internally wired.

g) Terminal strip for external wiring.

2.5.6.7. Inlet filter / Silencer a) Each compressor shall be provided with an inlet filter / silencer designed for maximum air

flow at absolute minimum pressure drop and connected directly to the inlet of the compressor

via a flexible connection.

b) Filters shall be removable through easily accessible doors and have a removal efficiency of

99% on 10 micron. The filter has to have a minimum standard of EU3 in accordance to DIN

24185.

c) The compressor has to be installed with sand trap and pre-filter at the air intake.

2.5.6.8. Bearings The bearings could be

i.) Hydrodynamic type sleeve type bearings

ii.) Magnetic Bearings

iii.) Hydrofoil Bearings

The drive shaft radial and thrust bearings can be either Hydrodynamic type sleeve type

bearings or Duplex Roller bearings. The use of hydrodynamic thrust bearings on the high

speed shaft shall be avoided as to reduce the mechanical losses and instead the thrust load

from the high speed pinion shaft shall be transferred to the low speed shaft using high

precision thrust collars on the pinion shaft. Steel backed tilting pad radial bearings with white

metal on the bearing surfaces shall be used on the high speed pinion shaft. Radial and thrust

bearings shall be pressure lubricated with sufficient oil film thickness under all operating

conditions. All bearings shall be rated for a bearing life of minimum 150,000 hours.

Vibration levels (P≤ 300

kW) ≤

: In accordance to ISO 10816-1

Vibration levels (P>300 kW)

≤

: In accordance to ISO 10816-1

Noise level ≤ : In accordance to 85 dB at 1 m

Following has to be provided for each compressor by the supplier:

- Outlet pressure transmitters, inlet temperature transmitter and a thermal mass flow meter.

The unit should allow for communication to main SCADA control system.

- Inlet Air Filter Differential Pressure Switch

- Oil Temperature Transmitter

- Oil Pressure Transmitter

- Oil Filter Differential Pressure Switch - Variable Vane Diffuser Position Transmitter

188

- Inlet Guide Vane position transmitter

- Gear vibration accelerometer transmitter

- Blower reverse rotation detector

2.5.6.9. Material of Construction

Casing : Inner Volute Aluminium AlCu2MgNi,

Outer volute Aluminium AlCu2MgNi,

Impeller : Aluminium AlCu2MgNi, open radial flow type with

backward leaning blades.

Gearwheels : High tensile SS316

Shaft fast : High tensile SS316

Shaft slow : High tensile SS316

Coupling : Geared

Filter material : As required

Machine mounts : St. SIS 1312, for damping natural rubber hardness 60

Oil Cooling : Air cooled

Acoustic enclosure : Al-Zn coated steel, isolated with glass wool, IP55

enclosure

Motor : IE3 Premium efficiency motor, IP55, insulation class F

with temperature rise F and temperature measurement in

the winding as well as of anti-condensation heater.

Cone diffuser : Stainless Steel 316

Compensator : Stainless Steel 316

2.5.6.10. Performance Test run

One compressor in each type/model shall be fully inspected and functionally tested at the

factory for performance and proper operation by Engineer or Engineer‟s approval as per

approved QAP. Performance test and acceptance according to ISO 5389 should be performed

on manufacturer test stand to the satisfaction of the engineer. The design values of the

performance table according the contract must be within a manufacturing tolerance of ± 2%

and a measuring tolerance of ± 2%.

2.5.6.11. Electric Motor Driven Propeller Type Aerator with Blower Aspirator Aerators

General Description

The unit supplied must be able to operate both in mixing and in aeration mode controlled

completely independently of each other. Unit must have two distinct modes of operation;

189

simultaneous aeration and mixing mode, and mixing only mode. The aerator consists of an

electric motor and regenerative blower located above the water surface. The motor is

connected to a hollow shaft with a protective housing positioned at a 45° angle downward

into the water.

Aerators with submersible motors are not acceptable. No Gear Box mechanism should be

required. The hollow shaft drives a mixing propeller and Saturn Ring-type diffuser beneath

the water surface. Attached to the primary propeller is a Saturn ring diffuser, which disperses

the air as fine bubbles (2.0-2.5 mm diameter) into the stream of displaced water beneath the

water surface.

Aerator / Mixer Components:

Aerator Drive Motor

1) The motor shall deliver necessary horsepower as per process design requirement at

750 RPM nominal with no gear box mechanism and shall be rated for 415 volts,

50HZ/cycle, 3 phase service, IEC Motor.

2) Motor enclosure configuration shall be totally enclosed, fan cooled TEFC and meet

IP55/56 specifications.

3) Motor frame shall be made of cast iron end brackets and cast iron body. Fan material

shall be carbon steel, aluminium, or propylene with metal hub. Fan cover shall be

cast iron or carbon steel with epoxy polyester paint - 50 micrometres thick

minimum.

4) The noise level of the motor shall be less then 60DB and in accordance with IEC

specifications.

Blower

1) The equipment shall include a high efficiency regenerative blower sized to provide

sufficient airflow to yield the rated oxygen transfer capacity. Each blower includes

the following features:

a) Maintenance free and CE compliant - Declaration of Conformity on file

b) Aluminum alloy construction

c) Inlet and outlet sound attenuating silencers to minimize noise.

d) Inlet filters with epoxy-coated wire mesh media rated for 70 microns or better.

e) The blowers shall be tropicalized for corrosion resistance and deliver

necessary horsepower as per process design requirement maximum rated for

415 volts, 50 HZ cycle, 3 phase service. Blower motors shall be wired

separately.

Mounting Flange

1) The mounting flange shall be stainless steel and shall permit removal of the aerator

mechanism leaving the motor in place. The mounting flange will allow the aerator to

be rotated out of the water for inspection, maintenance or storage.

Shaft / Universal Joint Coupling

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1) The shaft shall be stainless steel full-welded to a forged carbon steel universal joint

coupling. The shaft must be hollow to promote maximum air flow and oxygen

transfer. Units with solid shafts are not acceptable. The shaft shall be dynamically

balanced.

2) The universal joint coupling shall include standard grease fitting for maintenance

lubrication. Units which utilize flexible couplings to attach to the shaft of the motor

are not acceptable.

3) Units supplied with couplings that require alignment are not acceptable.

4) The shaft shall be stabilized by a replaceable water lubricated bearing located within

one inch from the propeller hub. The area of the shaft supported by the bearing shall

be fitted with a replaceable hardened non-metallic sleeve.

Housing

1) The housing shall be stainless steel and flanged for mounting to the aerator. The

housing shall form a guard around the hollow shaft and support a field replaceable,

water-lubricated bearing press-fitted into the housing lower end. Water lubrication

holes shall penetrate the housing in the area surrounding the bearing.

Bearing

1) The aerator shall be supplied with a field replaceable water lubricated lower support

bearing. The bearing shall be constructed of an appropriate material for the

application inside a fibre backing. The bearing shall be press-fitted into the housing

to allow ease of replacement.

2) Units utilizing a cantilever design without a lower support bearing or regreaseable

tapered roller bearings are not acceptable.

Sleeve

1) The replaceable hardened non-metallic sleeve shall be the only moving part in

contact with the electrometric bearing and shall spin with the shaft as one unit. The

sleeve shall be solid and homogeneous.

Propellers

1) The stainless steel mixing propeller shall be specifically designed to maximize

oxygen transfer and mixing characteristics. Propellers shall be self-tightening such

that the propeller threads tighten on the shaft threads during normal operation. The

entire flow of air shall pass through the propeller via the hollow drive shaft along the

axis of the propeller hub.

2) The propeller design shall be tested in clean water and shown to draw a minimum of

85% of the recommended full motor amperage load at nameplate voltage and power

factor. The propeller shall be designed to allow easy removal and replacement in the

field.

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Saturn Ring / Diffuser

1) The Aerator shall be equipped with a stainless steel secondary Saturn Ring diffuser,

smaller than the mixing propeller, consisting of two concentric rings of differing

diameters fixed to the diffuser body. The rings shall be specially designed to

maximize oxygen transfer and to prevent self-aspiration when the regenerative

blower is turned off to accomplish anoxic mixing. The entire flow of forced air shall

exit through the propeller /atomizer opening.

Vortex Shield

1) A vortex shield shall be furnished with each mounting assembly to eliminate the

formation of vortices, maximize shaft airflow and prevent cavitations damage to the

propeller during operation. Units without vortex shields are not acceptable.

Bridge mount

1) The fixed bridge mount should be made of Galvanized steel, rails and mounting hardware.

The recommendation of fixed mount should be recommended by the Equipment supplier

according to the site conditions. Vortex shield cabled to the frame. The platform is fixed

type.

2.5.7. Gravity Sludge Thickener

Gravity Sludge thickener shall be Circular (radial), fixed bridge, central turn table type or

central drive. Selected Bidder may also provide alternatively the mechanical sludge

thickener.

(a) The circular reinforced concrete thickeners tapering at bottom shall be provided for

thickening process.

Design shall be such that the sludge after thickening can be extracted from the

bottom of the hopper portion. Interstitial liquid flows through peripheral weir at top.

Tanks shall be deep enough to allow the sludge to settle by gravity. At least 50 cm

freeboard shall be provided.

Provision shall be made for collection of thickened sludge and pumping it to the

dewatering units.

A full diameter bridge with central drive shall be provided with: central platform for

the installation of the scrapers and their drives and for the local control panel; a

radial scraper system with bottom scraper blades, suspended on the bridge.

(b) The thickener shall have a full diameter fixed bridge complete with walkway for

personnel access to the center, access stairs to ground level and hand railing, a motor

driven sludge scraper complete with all necessary controls, delivery pipe work, a

stilling well and overflow steel weir plates. Hand railing, walkways, access steps etc

shall be galvanized. Handrails shall be of tubular construction and made of

32NBpipes.

The scraping gear shall be supported from the tank base and from a fixed bridge

carrying the central electrical drive for the rotating gear. The equipment including

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driving motor, gears, shafting and scrapers shall be designed for continuous

operation and sized for the most arduous operating condition including starting from

rest with an accumulation of sludge in the thickeners.

The electric motor, gearbox etc., shall be provided with a sunshade.

The fixed bridge, hand railing, access steps and the feed well shall be galvanized

steel. The main drive shall be cast Iron construction and shall be enclosed in a

dustproof enclosure with oil bath lubrication. All underwater hardware shall be of

SS304.

Suitable overload protection for the drive shall be provided to ensure that the sludge

shall not overload the equipment and emergency stop pushbutton shall be provided.

The scrapers shall be fitted with rotation monitors and over torque protection to

alarm in the event of a failure.

Structural design calculations shall be submitted for all structures including scraper

arm, bridge etc. and also the calculation for drive head selection including the

Torque Rating.

V-notch weir in Reinforced fiberglass construction of size minimum 5mm thick and

200 mm wide shall be provided along the launders for uniform draw-off of the

overflow. The weir plate shall be fixed to the launder by means SS304 grade

clamping plates and fasteners.

The hydraulic equipment will consists of the DI inlet pipe(runs along the bridge) to

the central feed well of the thickener; sludge draw-off pipe with an manual &

Motorized Knife Gate valve for intermittent operation according to an adjustable

timer; a drain pipe with manually operated gate valve for the complete emptying of

the unit; a discharge pipe/channel from the peripheral collecting channel to the main

channel leading to the Supernatant sump.

The sludge thickener mechanism shall be generally in MS galvanized construction,

suitable for installation in a circular RCC tank and shall include the following:

Mechanism support beam spanning the diameter of the tank.

Walkway and handrail from the edge to the centre of the tank.

Drive mechanism with internal gear type.

Reduction gear box.

Chain and sprocket with guard.

Central shaft with scrapper arm and picket fence.

Skimmer Scum Baffle and Scum trough.

Overflow weir:

Vertical pickets.

Torque Indicating Device.

Overload Alarm protection.

Auto lifting device.

The minimum thickness of all the underwater parts shall be minimum 6mm thick

excluding allowance for corrosion.

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Material of Construction

Tank : Reinforced Cement Concrete

Feed Well : SS 304

Bridge : MS with Hot dip Galvanized (galvanizing minimum thickness

shall be 80 micron)

Center Cage : Mild Steel Epoxy Painted

V-notch weir : SS 304 or, minimum 6 mm thick and

Squeegees : Neoprene

Handrail : 32 NB MS Pipe with Hot Dip Galvanised (radial upto centre)

Anchor Bolt & fasternes : Stainless Steel -316

Walk way : Heavy duty MS epoxy coating up to center minimum thickness

10mm

2.5.8. Anaerobic Digesters

Digester shall be anaerobic, mesophillic, single stage and single phase type having fixed steel

cover. Bottom of the digester shall be conical.

2.5.8.1. Sludge Digestion and Gas Handling units

During all seasons, favourable temperature for the microorganisms shall be maintained.

Design basis temperature shall be maximum ambient temperature. Mixing of digester

contents shall be achieved by recycling of the bio gas through bio gas compressors at

adequate pressure. The minimum design pressure of the gas compressors shall be sufficient

even for de-clogging of the gas lancers (SS 304) after shut off period of digesters.

Rotary lobe PD with VFD or Single-stage centrifugal with dual-point (inlet guide vanes and

outlet valve) control type biogas mixing blowers shall be provided. All piping if used for gas

mixing system shall be SS304.(Lancer Tubes)

All electrical motors, local control units and associated instrumentation, etc. mounted in the

digester area shall be certified for use in a hazardous zone and having required protective

enclosure.

Mixing system shall be complete along with necessary accessories, spare parts and lowering/

hoisting arrangement required in the digestion units.

2.5.8.2. Gas Mixing System for Digesters

The gas mixing system shall be efficient in operation, simple in maintenance and suitable for

tropical climate. The gas re-circulation system shall provide complete and homogenous

mixing of the digester contents including intermixing of the raw and digesting solids and

breaking of scum blanket. For maximum intensity of mixing the full discharge of compressed

gas shall have upward action minimizing the scum formation.

Gas will be taken from the gas holder and conveyed by pipes to the gas compressors, from

where it will be fed to the digester. The pipe shall enter from top of digester dome / extracted

from roof , compressed and fed back at the bottom of digesters through diffuser such as to

mix the entire digester contents with practically no dead zones and to prevent sand build-up

on the floor. Gas flow indicator (sight glasses) to indicate flow of compressed gas through

each pipe and facility to clean individual pipe by water pressure or flexible rods in case of

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chokage, without interrupting digester operation, shall also be provided. All connected piping

with necessary fittings and support and safety/protective devices shall be provided.

All electrical motors, local control units and associated instrumentation, etc. mounted in the

digester area shall be certified for use in a zone 1 hazardous area and have an IP 55 enclosure.

Gas mixing system shall be complete along with necessary accessories such as gas meter for

each digester at outfall of each digester, drip traps at suction and discharge pipes, electric

controls, spare parts and lowering / hoisting arrangement required in the digesters.

2.5.8.3. Gas Compressors

Design Requirement

The Gas Compressors shall be provided with 100% standby considering the operational

capacity and rating as required. It shall be positive rotary or reciprocating type,/ sliding vane

type air cooled/ water cooled, single stage oil free gas compressors. The cylinder shall be cast

such that gas and water passage shall be separated by metallic wall and shall not have any

gasket separating the two.

The compressors shall be complete with compressor unit, motor base plate, cooling system,

gas and water pipe work, valves, water separators, and all regulating and control equipment

as required to provide an adequate and efficient compressed high pressure gas supply. The

compressors shall have water seals.

The compressors shall be designed to compress wet and sludge gas comprising mainly

methane and CO2 with traces of H, N & H2S etc. The gas shall be assumed to be water

saturated. All metal parts in contact with gas shall be of stainless steel (type CF8M or SS

316).

A full set of performance curves, along with certificates of performance, for the package shall

be provided. The performance curves shall include gas flow and pressure, cooling water flow,

pressure and temperature rise and guaranteed power curves.

Gas Compressor Gearbox

Gas compressor gearbox shall be suitable for continuous running and intermittent starting

under maximum load with the resultant high torque and shock loads. The gearbox shall have

a service factor of 2.0 (Minimum).

Pressure Relief System

A pressure relief system shall be included to operate on shut off pressure of compressors.

This shall consist of actuated bypass and main gas valves which shall operate to dissipate the

high pressure in the delivery main to the low pressure digestion tank.

Temperature Sensor

A temperature sensor shall be installed to give a warning alarm and shut down facility in the

event of the pressure relief valve failing to operate.

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Mode of Operation

Manual control via start/stop push buttons at the control panel with auto switch off in case of

temperature bypass or over pressure switch operating.

The compressors are to run on either a timed or continuous control selected by a two position

selector switch mounted on the control panel.

When „continuous‟ mode is selected, the compressor is to run continuously and when „timed‟

mode is selected the compressor is to run for fixed duration and to be off after fixed duration.

Compressor is to trip and lock out due to the following:

Electrical Overload

Earth fault

Motor over-temperature monitored by thermistors in each phase.

Over-temperature in the compressor gas delivery pipeline.

Cooling water over-temperature.

Rise in discharge pressure.

Vacuum in suction line.

Manual Reset of tripping shall be provided.

Mode of Operation

Motors shall be flame proof squirrel cage type conforming to IS 325. The power rating shall

be at least 125% of maximum power requirement. The other features of motors shall be as

follows:

Type of duty : Continuous (S1)

Method of starting : Start-Delta

Class of insulation : F (Temperature rise limited to Class B)

Type of enclosure : TEFC & Flame proof

Degree of protection : IP 55

2.5.9. Gas Holder

The gas holders shall be dual membrane type.The membrane cover(s) shall be stable under all

design load conditions, including localized static and dynamic loads. The external membrane

shall be designed to maintain a spherical shape that allows the cover(s) to support the

maximum possible applied loading taking into consideration dead load, Vacuum load, Wind

load and other static load.

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Membrane gasholder shall consist of two membranes. The internal membrane shall store and

should be impermeable to digester gas, and inflate and deflate as the gas supply and usage

change the stored volume. The external membrane shall be constantly inflated by pressurized

air supplied by a blower or by the plant‟s Air Low Pressure (ALP) system and at least two

normally open air flow valves mounted on the side of the external membrane shall regulate

and maintain the external membrane at constant pressure. The internal membrane is protected

by a weighted relief valve that allows the evacuation of the biogas in case of over

pressurization.

Anchoring of both the external and internal membranes shall be by a pair of flanges and seals

bolted to the top of the tank periphery. The lower flange shall be sealed to the top of the tank

wall using gasket material. The upper flange and a gasket shall seal the membrane material

between the two flanges. The flange sections shall form a continuous ring to seal the

membrane to the top of the tank wall. The restraining flanges and anchors shall be fabricated

of 304 stainless steel.

All structural steel for fixing the membrane to the tank shall be Type 304 stainless steel. Steel

fabrication and welding shall be in accordance with latest edition of Structural Welding Code.

Sharp projections of cut or sheared edges of metals shall be ground and smooth to avoid

damaging membranes and to ensure satisfactory coating adherence.

All steel design shall be in accordance with the latest editions of the ISA Manual of Steel

Construction and Uniform Building Code (UBC).

Membrane shall be fabricated using High frequency welding with a 37mm minimum width.

The manufacturing process will include a peeling test on a specimen which enables the

validation of the welding parameters. All welds will be visually inspected. Additionally, all

welds and seams shall be tested mechanically through the use of pressure and tension to

ensure each weld is complete and has developed full strength.

Membranes

Internal Membrane:

The internal or gas membrane shall be fabricated of a polyester fabric coated with polyvinyl

chloride (PVC) and sized to accommodate the specified volume of biogas and shall be

resistant and impermeable to digester gas. The internal membrane fabric shall be designed

and fabricated to resist all design loadings without use of support cables superstructures or

other restraining devices and shall meet the prescribed standards.

The internal membrane shall be welded in such manner as to prevent the diffusion of biogas

through the yarn forming the internal structure of the membrane. The lack of this feature will

not be accepted for the membrane continuously exposed to biogas.

External Membrane:

The external membrane shall be fabricated of a polyester fabric coated with polyvinyl

chloride (PVC) designed for use on air-supported structures and high-stress applications and

shall be resistant to ultraviolet degradation, abrasion, and weathering in an outdoor

environment while meeting the prescribed parameter.

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Membrane cover(s) accessories and appurtenances

The membrane cover(s) shall include the following appurtenances:

Two (2) low pressure centrifugal fans for the external membrane shall be provided with

adequate power and capacity with explosion proof motor at 415 ± V and 50 C/S.

The blower shall be complete with flexible collectors, air piping, check valve, inflation fan,

electro mechanical level sensor, air relief walls, air pressure transmitter, gas pressure

transmitter and gas detector.

2.5.10. Sludge Dewatering Units

Sludge dewatering shall be done by mechanical sludge dewatering units such as Solid Bowl

Centrifuge, Belt Filter Press. The dewatering units shall include but not limited to

the following equipments:

Powder or liquid Polymer storage tanks/ Bach tanks with mixers.

Polymer mertering pumps

Mixers and solution tanks.

Polymer service tanks.

Supply line & flush line.

Dry gravimetric or volumetric "atomizing" educator for polymer feeding

Plant Water supply pumps.

Sludge feeding pumps.

Dewatering unit

Belt conveyor.

Cake hopper.

Flow meters for feeding Sludge, and for feeding chemical solution.

Control valves on sludge feeding line, and on Chemical feeding line.

Drain system

Dewatered cake shall be conveyed by a belt conveyor to cake hopper for carrying out for

reuse.

The dewatering system should be so located that the dewatered sludge can be loaded into

trolleys/ drums/ bins directly – preferably the dewatering unit shall be so located that

the dewatered sludge falls into the containers/ bins without requirement of another

material handling unit.

The dewatered sludge should be truck-able & be suitable for disposal by open body truck and

should have a minimum solid concentration of 20% or more (measured as dry solids

w/w basis).

The dewatering unit should have a 95% solid recovery.

The centrifuge centrate should not contain more than 1000 mg/l solids.

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The centrifuge should be capable of being operated at lower solid feed concentration in case

of maintenance.

Dewatering units shall be provided in a separate Sludge Dewatering Building. Feed pump

station shall be provided at lower level/floor and dewatering units shall be provided at upper

level/ floor. Solid Bowl Centrifuge

The centrifuge shall comprise a conical cylindrical bowl and scroll feed horizontally mounted

in bearings on a frame. The centrifuge bowl and scroll support frame shall be mounted on a

fabricated steel sub-frame.

The bowl and scroll shall be made from stainless steel SS316 material. The leading faces of

the scroll shall be protected against abrasive wear by the application of a suitable hard-coated

material.

The whole rotating assembly shall be enclosed by a carbon steel fabricated casing

incorporating a Centrate discharge hopper and outlet pipe, and a rectangular solids hopper

which shall discharge the dewatered sludge into the disposal system.

The rotor shall consist of a solid bowl which is conical-cylindrical in shape and which rotates

about a central shaft. An inner scroll shall be provided to convey separated sludge from the

periphery of the cylindrical bowl to the beach at the conical end of the rotor.

The main scroll bearings shall be arranged for lubrication by an external lubrication system.

Wherever practicable greasing nipples shall be arranged together as a battery. The complete

rotating assembly shall be dynamically balanced and test certificates provided.

Sludge shall be fed into one end of the rotor through a centrally positioned feed tube and

dispersed to the bowl through an inlet chamber.

The bowl shall be provided with an adjustable 360o peripheral weir at its cylindrical end to

control the depth of the Centrate in the rotor.

The fixed outlet castings of the rotor shall be designed to collect the centrate and dewatered

sludge from the rotor. Baffles within the casing shall direct the separate phases to the relevant

discharge points and prevent cross-contamination.

The centrifuge shall be mounted on heavy-duty vibration isolators, located between the

machine and the supporting steelwork or foundations, to damp vibrations and prevent

vibration transmission. Two axis vibration monitors shall be provided to stop the centrifuge

automatically when excessive vibration is detected.

Flexible connections shall be provided on the sludge fed system and the Centrate system at

the centrifuge. The dewatered sludge discharge system shall incorporate flexible chutes.

(i) Variable Speed Drive

A variable speed drive shall be provided to accelerate the rotor to operational speed and

maintain that speed during the centrifuge‟s duty period. The bowl drive shall be electric or

hydraulic and shall be coupled to the drive shaft by a multiple „V‟ notch belt drive.

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(ii) Differential Scroll Drive

The scroll drive shall be provided with a separate drive mechanism to control its rotation in

the same direction but at a different speed to the outer bowl. The differential speed shall be

adjustable.

The drive shall be linked to the main bowl drive by an epicyclic gearbox. The differential

speed of the scroll shall be automatically and manually adjustable so that the moisture content

of the dewatered sludge can be controlled as required.

For safe operation, Selected Bidder shall provide control panel showing proper Sequence of

operation with interlocking.

Chutes and interconnecting piping shall be provided with flexible joint (minimum 10 mm

flexible in all direction) to avoid vibration.

2.5.11. Belt Filter Press/CENTRIFUGE The belt filter press shall dewater the sludge as gravity drainage and belt pressure system

without the need for vacuum dewatering.

Sludge is usually required to be conditioned using a polymer prior to dewatering on the belt

filter press. The optimum polymer dosage and type of for the specific sludge is determined

by testing. Typical polymer dosing rate ranges from 0 – 6 lbs/T of dry solids.

Each belt press is designed and sufficiently automated to require minimal operator attention.

The belt press shall incorporate the following components.

i. Main Structural Frame

The structural frame shall be of all welded construction and shall be fabricated from

channel designed to adequately support all components. The design permits roll

removal without requirement of disassembly of frame.

ii. Extended Gravity Drainage Section

To maximize gravity water removal, adequate gravity drainage area shall be provided.

A set of gravity dispersion device spaced on 6½” maximum centers shall be provided

to disperse sludge for effective removal of water. The devices shall be designed so

each one can be moved in either lateral direction and shall be a minimum of twelve

(12) inches long to turn the sludge over in the gravity section for maximum water

removal. Dispersion devices shall be constructed of ultra-high molecular weight

polyethylene. Each set of devices shall have the capability of being rotated out of the

flow by handles, for maintenance purposes or process flexibility. Sludge shall be

contained within the drainage section by a barrier equipped with replaceable rubber

seals on each side. The gravity drainage belt shall be supported by polyethylene grids

over the complete length and width of the gravity drainage section that are also used

for effective removal of gravity and capillary water.

iii. Adjustable Wedge

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Following gravity dewatering, adjustable wedge section for process flexibility is

incorporated into the press design. Gradual increased pressure shall be applied as

belts pass through the adjustable wedge section.

iv. Pressure Section

A minimum diameter roll shall be used as the initial roll in contact with gravity

concentrated sludge. A S-shaped roll configuration shall be used to apply maximum

pressure and shear.

To ensure optimum cake dryness, a minimum number of rolls shall be used in the

pressure area.

v. Filtration Belts

Each belt shall be a continuous design woven from monofilament polyester strands.

Each belt shall incorporate a mechanical seam that does not interfere with press

operation and also allows simple, periodic belt replacement.

vi. Doctor Blade

For removal of dewatered cake, the press shall incorporate doctor blade for each

filtration belt. Blade pressure shall be field adjustable against the belt by means of

spring tensioning mechanism and shall be replaceable, reversible with two useable

edges and fully accessible to the operator.

vii. Rolls

All rolls, including guide and tracking, shall be of low deflection design.

viii. Roller Bearings

All bearings shall be pillow block type with split, cast iron, two bolt housings. All

bearings shall be capable of compensating for misalignment without seal distortion.

Each bearing shall be grease lubricated.

ix. Filtrate Collection

Drainage pans shall be located under all gravity and pressure section of the press.

Drain pans with standard NPT connections shall collect gravity filtrate and pressure

filtrate to common drainage points.

x. Belt Washing Device

Following cake discharge, each polyester belt shall be continuously washed using a

100 psi pressure, low volume steel shower assembly. A Y-strainer to be provided in

wash water line to remove any particles which may enter the shower assembly. Each

shower assembly shall have replaceable brass or steel nozzles. The shower assembly

shall be designed to completely contain the high velocity water spray and remove any

solids trapped in the belt. Pumps required for belt washing are not included in our

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scope of supply.

xi. Belt Tracking

Belt positioning for each belt shall be continuously and automatically monitored by

suitable arrangement which shall be installed with guide devices. The guide device

shall ride the edge of the polyester cloth belt. The micro-torque unit shall sense belt

misalignment and shall automatically walk the belt back to the normal operating

position by means of a live hydraulic cylinder which shall be attached to tracking

rolls. The opposite end of the tracking roll shall incorporate self-aligning pillow block

bearings which allows the tracking rolls to pivot in a horizontal plane. Belt tracking

shall be automatically operated by the hydraulic power pack. A limit switch shall be

provided on each side of each belt to sense extreme belt travel and initiate a shut-

down signal and sound an alarm. The limit switches for the pressure section shall be

positioned to sense both belts simultaneously.

xii. Belt Tensioning

Each belt in the pressure section shall be equipped with a hydraulic cylinder belt

tension system operated by the hydraulic power pack to automatically ensure proper

preset belt tension while dewatering varying thickness of sludge. The belt tension

system shall assure parallel movement of the tension rolls by use of rack and pinion

system.

xiii. Belt Press Drive & Component Operation

The belt press drive comprises of an electric geared motor unit coupled to the drive

roll through a flexible coupling. A local electrical control panel complete with control

logic, variable frequency drive etc. is also supplied along with the belt filter press.

xiv. Painting All MS components shall be sand blasted and coaltar epoxy painted to a minimum

DFT of 120 Microns.

2.5.12. Bio Gas Scrubbing System

Bio Gas Scrubbing System

Hydrogen sulphide is a highly toxic and corrosive gas and is a major pollutant. At high

concentrations it will lead to almost instantaneous poisoning and death.

The system description consists of major equipment like Pre-Scrubber, Scrubber, Wash

Tower, Regenerator, Filter Press and Pumps. The system should be with zero liquid discharge

and no gases/ effluent emission in the process of scrubbing. Supplier/vendor supplied and

commissioned scrubbing would only be considered.

2.5.13. Gas Generating Set & Accessories

It is proposed to generate maximum possible power out of the available sewage gas by using

highly efficient gas generators. The power generated from Power Plant will be used for In-

house consumption of the Sewage treatment plant equipment.

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The Generators have to be designed to operate at maximum gas generation to give the

optimum power output from in house captive consumption.

The CH4 (Methane) content in Gas shall be in the range of 60% to 65%. The gas will also

have concentration of H2S @ 1.5% to 2.0%. This H2S which is highly corrosive in nature has

to be removed from the sewage gas before feeding the gas to the gas gen-sets. This H2S has

to be removed from this sewage gas by using chemical gas cleaning scrubbers.

The gensets have to be designed to run on base load operation continuously during the peak

gas generation; The H2S content in the sewage gas generated shall be removed by a H2S

scrubbing system. The scrubber shall be capable to reduce the concentration below 200 ppm

level.

Gas Engines shall be designed for running on 100% Sewage Gas with a high level of fuel

efficiency with lean burn combustion technology. Bidder shall provide gas engine for power

generation from the gas produced by proposed plant.Gas engine should be designed as per the

actual load considering 100% standby. Capacity of all gas engines shall be same & the gas

gensets shall not be overloaded more than 100% since gas gensets are meant for base load

operation and cannot be overloaded. Also there should be provision for DG set to black start

the gas engine during breakdown period

Gas engine shall be hooked to the main LT panel. Gas engines shall be running on continuous

operation. It will be preferred that the gas gensets along with the H2S Scrubber shall be

provided as a package.

The gensets shall be designed for running on 100% Sewage Gas with a high level of fuel

efficiency / electrical efficiency. The electrical efficiency of the gensets at the alternator

terminal under site conditions and 100 % load shall not be less than 40 % (Standard

tolerances shall be applicable).The engine shall be 4 stroke Otto gas V engine type.

Main Components of Gas Engine

Genset Components

Base Frame, Coupling, Pre – Lube Pump, Air Filter, Zero Pressure Gas Control Line with

Connection Accessories, Crankcase, Driving gear, Cylinder head, Valve drive, Ignition,

Carburetion, Mixture charging, Starter, Lube oil system, Sensor technology/actuator

technology and cabling etc.

Rotary Current Internal Pole Synchronous Generator

Three-phase synchronous generator, brushless, self-induced, self-adjusting, with dampening

cage for 30% inclined load and parallel operation, artificial star point, protection type IP 23,

with tropical atmosphere and humidity protection insulation, degree of radio shielding "N",

voltage target value setting ± 5%, Insulation Class H.

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Gen-Set Components

Base Frame Steel bend torsion-resistant construction

Coupling High stretch, axial plug in coupling for torsional elastic

connection of engine and generators

Pre – Lube Pump Electric pump

Air Filter Paper dry type air filter

Zero Pressure Gas Control Line with Connection Accessories

Crankcase Alloyed special cast iron

Driving gear Chrome molybdenum

Cylinder head Special cast Iron

Value drive Toothed-wheel driven camp shaft

Ignition Microprocessor control high voltage ignition system

Carburetion Drive type air filter

Lube oil system Pressure lubrication gear pump

Alternator

Brushless, Self-Excited, Self-Regulated, Double Bearing, Synchronous Alternator with

electronic AVR, 415 V, 1 Power Factor, 50 Hz, complete with standard accessories.

Flare System

A Comprehensive auto flare philosophy shall be submitted along with the GAS Engine

Power Generation Philosophy to complete the interlock of flaring with no power generation.

Gas Flow on the Gas flare line shall have interlock with the flame detector to conclude the

effective flaring.

The flare unit shall be designed for biogas flow generated during average flow conditions. It

shall be fabricated of suitable materials (carbon steel except for top portion which shall be in

SS 304). The design of flare unit will be such that it shall be conveniently mounted on the

steel supporting structure.

The velocity of biogas through the flare unit should be minimal considering 100-150 mm WC

pressure of biogas at flare inlet. Capacity of Gas flare system shall be provided for total gas

generated from the existing (Phase – I) and proposed plant (phase-II). Gas from existing

plant is not to be considered. Gas flare system shall be one working and one standby unit

alongwith all accessories.

A suitable spark ignition system should be provided at a convenient location. Biogas shall be

used as a pilot fuel. The pilot flame generated with the help of spark ignition systems shall

propagate through the flare unit to ignite main biogas. The control system involving control

panel, ignition transformer etc shall be provided for the said purpose.

H.T. Cable shall be provided from the secondary terminal of ignition transformer up to spark

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ignition system. Necessary ignition electrode OR 1 number 25 KVA generator set shall be

provided. The 25 KVA generator set can also be used to start the gas engine.

Moisture Traps

The moisture trap shall be designed to effectively separate out moisture in the biogas such

that moisture free biogas is made available at the outlet of a trap. It shall be of suitable

materials of construction and be provided with suitable drain connection.

Flame Traps

The flame trap shall be of suitable size for biogas application. It shall be used primarily in

pipe lines to prevent flash back during explosions.

This device shall be installed in horizontal or vertical pipe line and hence it should be

bidirectional.

It shall be of suitable materials of construction.

The flame arresting element shall be designed such that it results in minimal pressure loss

under normal operating condition but to ensure maximum security in the event of explosion,

the end connection shall be flanged.

2.5.14. Pumps 2.5.14.1. Sump Pump

The pumps shall run smooth without undue noise and vibration.

The power rating of the pump motor shall not be less than the maximum power required

from zero discharge to zero head.

Pump should be vertical, centrifugal, single stage, non-clog type.

It should be suitable for handling sewage containing stringy materials.

Plate type strainer should be provided to prevent large size solids entering into pump

The pump shaft journal bearings shall preferably be grease lubricated. No external water

will be made available for the lubrication of the bearings.

Delivery piping with gun metal non-return valve should be supplied.

Delivery pipe should be as per IS: 1239, medium class.

Pump should be operated automatically by providing float operated level switch .

The base plate shall not be directly fixed to the floor. Channels should be grouted in the

floor and the base plate should be attached to the channel.

Materials of Construction

Impeller : Stainless Steel

Casing : Cast Iron

Shaft : Stainless Steel

Cover plate : Steel

2.5.14.2. Submersible Pumps

4. Design of pumps of MPSwith suitable head and discharge should be done by

selected bidder as per CPHEEO manual considering (4 working + 50% standby) pumps .

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Design Requirements

Design consideration:

a. Submersible pumps shall be submersible, vertical shaped, centrifugal, non-clog type, suitable for

municipal sewage, design for continuous operation in submerged / partially submerged condition

and intermittent operation complete with motor control system, guide rail, anchoring brackets,

base elbow, power cable & pumping lifting cable/ SS chain with control panel and level switches

suitable for solid passage of 100mm diameter and above.

b. The efficiency / pump shall be high at duty point and remain reasonably high during the full duty

range at the pumping system.

c. The pump of MPS and STP shall be compatible with VFD and selected automation system.

d. The pump should be capable of developing the required total head at rated capacity. Pumps

should be suitable for single as well as parallel operation at any point.

e. The pump should deliver at least 125% of its rated capacity at 75% of the specified total head.

The H and Q curve should be continuously rising towards shut off head.

f. Operating range – system curve

g. The velocity of vibration should be less than 4.5mm/ sec. with noise level 85 dBA at resistance

of 1.85 meter.

h. The power rating of the pump motor should be the larger of the following:

i) The maximum power required by the pump from zero discharge to zero head.

ii) 115% of the power required at the duty point. Considering the combined efficiency

(motor & pump).

iii) System resistance curve shall be ap

i. The combined efficiency of the pump shall not be less than 70%. The motor efficiency shall not

be less than 92 % and pump efficiency shall not be less than 65-75%. The highest efficient pump

set shall be considered for selection.

j. For pumps that are run with variable frequency derive then System Curve shall be submitted

along with Motor Curve for the entire operative range of RPM for approval. Submission of pump

data sheet shall be tagged as variable frequency derive /Normal Operation.

k. The primary sludge pumps, dilution water pumps, treated effluent pumps, back wash pumps,

filter feed pump should have the efficiency of 60% and motor 87%. Only energy efficient motor

shall be accepted.

Material of Construction

Pumps Pump casing : Ductile iron

Discharge cover : Ductile iron

Impeller : stainless steel SS316

Shaft : stainless steel SS316

Bearing Bracket : Grey cast iron (CI IS: 210FG260/ Ductile iron)

Motor casing : Grey cast iron (CI IS: 210FG260/ Ductile iron)

Bolts, nuts : stainless steel SS316

Shaft protective sleeve : stainless steel SS316

Casing wear ring : Grey cast iron (CI IS: 210FG260/ Ductile iron)

O-ring : Nitrile rubber (NBR)

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Efficiency : Min. 75%

Shaft seal

Type of seal : Double mechanical seal

Arrangement : Tandem

Seal on medium side : With elastomer bellows

Mechanical seal, pump side : Silicon carbide

Mechanical seal, bearing side : Carbon/ silicon carbide

Monitoring

Thermal winding protection : Thermistors PT-100 in all three phase winding

Explosion proof protection :

Motor housing monitoring : By conductive moisture sensor electrode

Mechanical seal leakage detection: By float switch

Bearing temp monitoring : Thermistors PT 100 in upper bearing

Installation

Type of installation : wet well installation design for automatic connection to

a permanently installed discharge elbow will neoprene seal to avoid metal to metal contact

Flange dimension to : EN 1092-2, PN 10

Claw : Bolted to the pump

Installation depth : As per data provided

Guide system : Stainless Steel

Lifting device : Stainless steel lifting chain

Length of lifting device : Suitable

Lifting loops : suitable

Installation accessories : Discharge elbow, fasteners, claw, bracket, lifting

chain, guide bars etc. complete

Motor

Min. motor efficiency : 92% and pump efficiency 65-75%

Degree of protection : IP 68

Insulation class : F0

Coolant temp : </= 40 C

Starting mode : Direct

Rated voltage : 3ph, 415 V

Rated freq : 50 Hz

Nominal speed : Less than 1500- rpm (Synchronise)

Voltage tolerance : ±10%

Motor casing : Grey cast iron

Main cable : complete with cable length as per requirement

2.5.14.1. Mixed Liquor Pumps

Type of Pump Vertical Propeller Tube Type

Column Length & Column & Shaft

Assembly

Required

Type of fabrication Self-Water

RPM 590

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Pump Efficiency Min. 80%

Motor Efficiency Min. 92%

Pump housing Ductile cast iron

Impeller EN-GJS500-7, AISI 80-55-06

Pump Shaft Stainless Steel

Discharge Head MS Fabricated

Motor Cast iron, EN-JL1040, AISI A48 30

Voltage 415 ±10% 3 Phase

Frequency 50HZ

Note:

1. The Pumps will have VFD.

2. The primary and secondary scum pumps shall be submersible chopper pumps.

3. All above data are indicative and final design would be done after due

consideration of drawing/design as per site condition.

2.5.14.2. Horizontal Centrifugal Pumps

Design Requirements: a. The pump should be capable of developing the required total head at rated capacity. Pumps

should be suitable for single as well as parallel efficient operation at any point in between the

minimum and maximum system resistance indicated in the system resistance curves.

b. The total head capacity curve should be continuously rising towards the shut off. The pump

should deliver at least 125% of its rated capacity at 75% of the specified total head.

c. The required NPSH at duty point should be at least 1.0 M less than the available NPSH.

d. Pumps shall run smooth without undue noise and vibration. The velocity of vibration should

be within 4.5 mm/sec. The noise level should be limited to 85 dBA at a distance of 1.85 M.

e. Operating range - -system curve shall be submitted along with that of motor if the pump/s are

subjected to VFD application with the data sheet tagged as VFD application

f. The power rating of the pump motor should be the larger of the following:

i) The maximum power required by the pump from zero discharge to zero head.

ii) 115% of the power required at the duty point. Considering the combined efficiency of

pump and motor with zero negative tolerance.

g. The pump set should be suitable for starting with discharge valve open, as well as closed.

h. Design of pumps for MPS with suitable head and discharge should be done by

selected bidder as per CPHEEO manual considering (4 working + 50% standby)

pumps .

Features of Construction a. Pump should be suitable for applications in municipal sewage handling or sludge handling as

per process requirement, with back pull out design. It shall have end suction and side

discharge. It should be of self-venting type.

b. Pumps should be identical for particular application and suitable for parallel operation with

equal load division. Components of identical pumps should be interchangeable.

c. Pump casing should be of robust construction Liquid passages should be finished smooth and

designed so as to allow free passage of solids. The volute tongue should be straight across and

filed to a smooth rounded edge. Casing should be provided with hardened renewable wearing

ring.

d. Impeller should be suitable for application, enclosed type with smooth blunt edges and large

water ways so as to allow free passage of large size solids. It should be free from sharp

corners and projections likely to catch and hold rags and stringy materials. Impellers should

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be provided with hardened wearing ring. Hardness of the Impeller ring should be at least 50

BHN more than that of casing ring.

e. The first critical speed of the rotor should be 30% above the operating speed.

Complete rotor should be statically and dynamically balanced.

f. Replaceable shaft sleeves should be provided to protect the shaft where it passes through

stuffing boxes. Surface hardness of shaft sleeve should be minimum 350 BHN.

g. Pumps should be provided with anti-friction bearings. Bearings should be easily accessible for

inspection and maintenance. Bearings should be grease lubricated.

h. Stuffing box should be of such design that they can be repacked without removing any part

other than gland and lantern ring. Stuffing box drain with pipe connection should be provided

at the lowest point so that no leakage accumulates in it.

i. Lantern ring should be of axially split type. Grease should be used for stuffing box sealing.

Water will not be available for this purpose. Gland should be of split type.

j. Pump should be furnished complete with flexible coupling.

k. Coupling guard bolted to the base plate should be furnished.

l. Base plate for pump and motor should be common. Suitable holes should be provided for

grouting. Foundation bolts should be complete with nuts and washers.

m. Tapping should be provided at suction and discharge nozzles for pressure gauge connection.

n. Hand holes should be provided in the casing to allow easy access to the impeller as well as to

the casing throat. Casing drain connection with stainless steel collared plug should be

provided.

Material of Construction a. Casing : CI to IS:210 GR FG 260 with 1.5 to 2% Nickel.

b. Impeller : Stainless steel CF 8M STA STM A35/Gr.CF8M

c. Wearing rings : SS 316 STA STM A35/Gr.CF8M

d. Shaft : SS to AISI 431 STA STM A276 Type 410

e. Shaft sleeves : SS to AISI 410 STA STM A276 Type 410

f. Packing : Asbestos yarn coated with MoS2 (Molybdenum Di-Sulphide)

g. Packing : CI/MS fabricated.CI IS210 Gr F G260

h. Base plate : CI/MS fabricated IS 2062

i. Gland : Cast Iron CI IS 210 Gr F G260

j. Coupling : CI

2.5.14.3. Dewatering Pump a. Pump should be suitable for handling settled sewage containing grit and suspended particles.

b. The pump motor should be suitable for working with or without submergence in sewage. The

motor rating should be more than the maximum power required by the pump.

c. The pump set should be portable with necessary hooks.

d. The pump should be suitable for dewatering from a pit 900mm x 900mm x 100mm deep.

e. The pump should be vertical, centrifugal, non-clog type.

f. The pump impeller should be mounted on the extended shaft of the motor.

g. The pump should be provided with mechanical seal.

h. The pump should be supplied with flexible hose pipe of 50mm, 50M length.

i. Suitable cable of 50 M length should be supplied with the pump.

j. Materials of Construction :

a) Impeller : Stainless Steel

b) Casing : Cast Iron

c) Shaft : EN8 (as per IS: 970)

2.5.14.4. Progressive Cavity Pumps

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The progressive cavity pumps shall be self-priming and designed to handle abrasive, shear

sensitive and viscous materials, solids in suspension and liquid/solids mixtures.

Automatic Variable stroke frequency / stroke length arrangement shall be incorporated

wherever remote application with PLC/SCADA is envisaged and process demands these

changes through remote, Local Control Panel shall also be envisaged with each pump with

auto/manual selector switch and knob for these variations done manually.

The sludge will be a mixture of grit in the sludge that will be abrasive. The pump design shall

incorporate features that prevents ragging around pump connecting rod and rotor head and

include a shaft sleeve to protect the wear in these highly abrasive environments. These

conditions must be considered when selecting the pump. Pump should be screw type, slow

speed maximum 200 rpm having following construction features:

Casing : CI IS 210-FG 260

Rotor : SS316 Hard Chromed plated

Base Frame : ISMC Fabricated Epoxy coated

Bearing Housing : CI IS 210-FG 260

Shaft : SS 316

Foundation bolt : HTS GALVANIZED STEEL

Stator : Hypalon/Equivalent linning

Coupling : Flexible pin bush type

Coupling guard : MS Fabricated

The pumps must be sourced from a supplier that is ISO 9001:2000 certified to ensure that the

pump is manufactured to certified standards.

2.5.14.5. Polyelectrolyte solution preparation and Dosing System

Polyelectrolyte solution is needed to be prepared and dosed for aiding sludge thickening and

dewatering. The polyelectrolyte will be dosed online at the centrifuge inlet. Minimum dosage

of polyelectrolyte shall be worked out by the bidder. There shall be two poly-dosing tanks

each suitable for minimum 8 hrs. of operation. Each-tank shall be equipped with slow speed

mixer (100 RPM) to prepare polyelectrolyte solution. The solution will be fed using positive

displacement metering type dosing pumps. There shall be dedicated dosing pumps to each

centrifuge with one common standby. The pumps shall be interlocked with centrifuge so that

it can only be running in auto when centrifuge is on and should shut down when centrifuge

stops. The dosing system shall be housed in centrifuge house itself.

The polymer dosing required shall be as per peak requirement with 2 working and 2 standby.

Polymer dosing pumps hydraulically actuated diaphragm pumps simplex and duplex type

with maximum injection pressure of 5 kg/cm2 complete with PP head, PP / PVC fittings,

strainer, inbuilt PRV along with 415 V / 50 C / S suitable motor at 1000 RPM are required.

The system will also have storage bins, polymer batch tank and polymer batch tank mixers.

2.5.14.6. Dosing Pumps

Scope

The dosing pumps shall be selected to achieve optimum dosing technology and control safety

with safety relieve valve. The pump shall have a resistant plastic enclosure that can safely be

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used for the selected application and shall provide soft and low-pulsation dosing.

The pump shall incorporate sensitive sensors that monitor the dosing flow and the diaphragm

and provide process stability. The pumps shall be designed to have separation of hydraulics

and electronics, to protected process from equipment failure.

Diaphram Valve, Gasket : PTTE

Liquid End : Stainless Steen 316

Foundation Bolt : Mild Sleet Epoxy Paint

Wetted Part : SS 316

Base Frame : Carbon Steel, epoxy Painted.

Flanges : Carbon steel

Plunger : Carbon Steel

Accuracy : ±3%

Voltage : 415 ±10%

RPM : 1440

Polyelectrolyte Dosing

Head PP

Check Valves PVC

Balls Glass

Diaphragm Teflon Faced Nitrile

Motor Details Explosion Proof Motor

2.5.14.7. Sludge Sump Pump House and Sludge Dewatering

Sludge Sumps shall be provided to collect sludge from PST & FST. The pump house shall be

constructed above the sludge sump. Sludge transfer pumps shall be provided to feed

the mechanical dewatering devices. The pump shall be screw type suitable to handle

sludge of 1 – 2% solid consistency.

2.5.15. Pipework

2.5.15.1. General

The term pipe work shall include all necessary supports, saddles, slings, fixing bolts and

foundation bolts required to support the pipes and associated equipment. The pipe work shall

be laid out and designed to facilitate the erection, painting in situ and dismantling of any

section for maintenance and to give a constant and uniform flow of working fluid with a

minimum of head loss. Where steel pipe work is used, the number of flanges shall be kept to

a minimum and the size of each length of pipe work shall be determined by the ease of

handling, installation and general appearance of the completed pipe system. Positions of

flanges shall take account of any concrete pipe supports or thrust blocks needed. Flexible

joints shall be provided where needed to facilitate removal of equipment or to allow for

differential settlement of the building. Wherever practical, flexible joints shall be provided

with tie-bolts or other approved means to transfer thrust or tension axially along the pipe

work.

Where steel and cast flanges are to be bolted together, the steel flange shall be machined over

its full face after welding to its pipe is completed. Flanges shall be finished truly square with

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the pipe axis. Wherever possible, standard fittings shall be used in preference to special

fittings. Pipe work layout within pumping stations shall be prepared to meet the requirement

of the pump manufacturer. Valves, strainers and other devices mounted in the pipe work shall

be supported independently of the pipes to which they connect. Flanges shall be drilled in

accordance with the appropriate pressure rating. Where a pipe passes through a wall, a

retaining wall, or is subject to end thrust, it shall incorporate a puddle flange. Puddle flanges

shall be undrilled.

Material of Pipes, Sizing & Design Basis

Unless otherwise specified, the water velocity in the suction branches of a pump shall not

exceed 1.5m/s, delivery 1.8 m/s for horizontal pumps and in the discharge branch shall not

exceed 2.1 m/s for submersible pumps when the pump is operating within its specified

working range. There shall be no discernible noise due to hydraulic turbulence or cavitations

within the pump or its associated pipe work and valves.

Piping Sizing & Material

The piping and valves will be sized on the following basis for sizing.

Service / Flow Basis MOC

Gravity Lines for Sewage, Water

& Waste Water

Velocity between 0.6 to 1.2

m/s & designed as pipe line

flowing full

DI Class K 7

Pressure for Sewage, Water &

Waste Water

Velocity between 1.2 to 1.8

m/sec

DI Class K 9

Sludge line DI Suitable with

pressure rating

Air (Pressurized Lines)

[for Aeration Tank, Grit Chamber,

Gas Mixing System etc.,]

At velocities between 8 – 10

m/sec (desirable) with a

maximum of 15 m/sec in

small sections

Stainless Steel

Bio Gas At velocities between 3.5 to

4.5 m/sec (desirable)

Stainless Steel

Service Water Velocity between 1.4 to 2.0

m/sec

GI Class B

Chemical Feed Lines Velocity between 0.6 to 1.5

m/sec

PVC/ PP/ HDPE/ SS

2.5.15.2. Cast Iron Pipes

The cast iron pipes shall generally conform to IS:1537/IS:1536 and pipe fittings shall conform

to IS: 1538. All pipes and fittings above the ground level and inside pumping station shall be

flanged.

The material for cast iron pipes and fittings shall be of grey cast iron conforming to IS: 210,

Gr FG 200.

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The pipes shall be of uniform bore and straight in axis. Length of the straight double flanged

pipes shall be within a tolerance of + 3 mm.

The flanges of the straight pipes shall be square to the axis of the pipe. The face of the flanges

shall be parallel. The bolt hole circle shall be concentric with the bore and bolt holes equally

spaced. In straight pipes the bolt holes in one flange shall be located in line with those in the

other flange.

The faces of the flanges of the fittings shall be square to the directional axes. The holes shall

be located symmetrically off the center line. The intersecting axes of the tees shall be

perpendicular to each other.

The bolt holes on flanged pipes and fittings shall be drilled with the help of drilling jig. The

blank flanges are to be machined and drilled.

2.5.15.3. Ductile Iron Pipes

The DI Pipes conform to IS 8329 /ISO 2531/BS EN 545 & Fitting conform to IS 9523/BS

EN:545. These pipes can also be offered with standard thickness for smooth flow and

corrosion resistance.

2.5.15.4. Stainless Steel Pipes

All gas pipes, fittings and other related components inside the digester shall be of stainless

steel SS-304.

2.5.15.5. Steel Pipes

All steel pipes shall conform to IS:3589.ERW steel pipes (200mm to 2000mm) for gas, water

and sewage and laying should conform to IS:5822.

2.5.15.6. Unplasticised Polyvinyl Chloride (uPVC) Pipes

The materials used in the manufacture of uPVC pipes and fittings shall comply with the

physical properties indicated in relevant specification. They shall not contain any matter

which could impart taste, odour, toxicity or be harmful to health or adversely affect the water

conveyed.

Unless specified otherwise joints shall be of the complying with BS 4346/IS4985 having an

elastometric sealing ring. Joints shall be made in accordance with the Manufacturer‟s

instructions.

Fittings shall be injection-moulded in uPVC to the requirements of BS 4346/IS4985.

Fabricated uPVC fittings or fittings manufactured in other materials will only be permitted

when the material and method of manufacture are approved by the Independent engineer

2.5.15.7. Dismantling Joints

Where dismantling joints, flexible couplings or flange adaptors are used these shall be of the

Viking-Johnson type except where otherwise specified or approved. Pressure ratings shall

match the pressure rating of the pipework in which they are installed, and materials used and

methods of protection shall not be inferior to those used for the pipework. Where needed,

joints and couplings shall be provided with tie bolts to restrain the maximum axial thrust

arising when in service.

The dismantling joints for cast iron pipes shall be of cast iron with EPDM seal ring.

2.5.16. Valves and Appurtenances

All sluice gates, isolation valves, air release valves, check valves shall be designed for the

medium carried in the respective pipeline, according to the diameter and the design working

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pressure of the pipeline. Manual operation shall always be provided. Electrical drives shall be

provided as per requirement unless otherwise specified.

The valves shall be installed between flanges. The dismantling shall be possible by the use of

rigid or flexible dismantling pieces or flange adapters at one side. For this purpose, suitable

flange adapters may be provided. All valves shall be installed in the pipe work in such a

manner that they can easily be removed from the line for dismantling and maintenance.

The non-return valves on the pump delivery branches shall be spring loaded and have high

speed non slam closing characteristics.

Valves used in lines conveying chemical solutions and gases shall be manufactured of

material suitable for the purpose and to withstand the corrosive and aggressive action of the

medium. However for sludge pumps Knife gate valve can be accepted.

Valves used on sludge conveyance piping etc. shall be of straight through type and non-

logging. Butterfly/knife edge gate valves may also be used on sludge line.

The pressure rating of valves must at least be equal to the maximum expected pressure at the

point of installation.

The size of valves must not be less than the size of the respective main (suction, delivery)

pipes.

The material of construction of valve shall be as follows:

2.5.16.1. Sluice Valves

Sluice valves shall be generally conforming to IS: 14846:2000. Additionally they should

meet the specific requirement given below. The valves shall be double flanged machined and

drilled to IS-1538 Part IV & VI. The backside of the drill holes to be spot faced for proper

seating of bolts & nuts. Reasonable clearance behind the rear face of the flange on body and

bonnet to be kept to provide free access to use spanners for assembling and dismantling. No

tap hole is acceptable. The pressure rating of the Valves on the Suction side / discharge side

of the pump shall be as per design requirement. They should close with clockwise rotation of

hand wheel. The direction of closing shall cast on hand wheel. Nominal size, PN Rating and

Brand name should cast on the body. The valves shall be of Rising Spindle type. They shall

be with Back seat Bushing arrangement for replacement of packing without leakage. The

Valve of size 350 and above should be supplied with 2 nos. Single trust deep groove Ball

bearing on both end of spindle collar to reduce operating torque and vertical thrust on spindle.

The valves of sizes 450mm and above should be supplied with enclosed grease packed

bevel/worm gear box of suitable rating to ensure that the valve shall be operated with effort

not more than 7 KgM at the pinion shaft for manual valve only. The valves shall be provided

with position indicator for indication from full open to full close. They shall be provided with

cast iron cleaning door at the bottom of sluice valve body. The clearance between the wedge

nut housing lugs on the wedge and the inside surface of the valve body shall be adequate to

insert the wedge nut into the wedge lug recess either in the direction of water flow or in

perpendicular direction when the wedge is in closed position. The Valves shall be provided

with Air Release plug arrangement on the top of the bonnet. Sluice valves shall be electrically

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operated with manual override facility. All valves in the pump house and on discharge

/header shall be actuator operating. The valves which are operated rarely i.e. not regularly

shall be manually operated.

SLUICE GATES FOR MPS

Provision of CI Thimble Mounted Sluice Gate with motor, actuator operated, Rising Spindle

type. Sluice gates are as per IS 13349 Including all taxes, Freight, loading, unloading, fitting

in position including Sluice gates are upward opening wall thimble mounted suitable for

isolating the flow of sewer into out of the opening in the wall. It consists Gate frame, wall

thimble, gate slide, shutter, seating/sealing faces .The gates will be provided with pads on

sides, top and bottom to mount the wedges. The gate shall be designed in such a manner, so

that it can be operated at 2 meter head. Gate frame & Shutter of CI Grade IS 210 FG 260,

Head Stock assembly bolts & SS ASTM A276 Type316, Stem, Operating Nut SS ASTM

A276 Type 316., Duly tested for tensile strength, Tested for over all dimensions as per

approved GA drawing complete in all respect as per specification and direction of Engineer,

For screen channels

Sewage Water Application

a. General

1. Sluice valve shall be conforming to IS: 14846: 2000 and with ISI marking. Additionally they

should meet the specific requirement given here under.

2. Sluice valve must be from ISO-9001 certified company towards Quality Management

System.

3. The valves shall be double flanged machined and drilled to IS- 1538 Part 4 & 6. The back

side of the drill holes to be spot faced for proper seating of bolts & nuts. Reasonable

clearance behind the rear face of the flange on body and bonnet to be kept to provide free

access to use spanners for assembling & dismantling. No tap hole is acceptable.

4. The valves should close with clockwise rotation of hand wheel. The direction of closing shall

be cast on hand wheel.

5. Nominal size, PN rating & Brand name should cast on the body.

b. Design Requirement

1. The valve should be of PN 1.0 rating/based on working pressure in the pipeline.

2. The valves shall be of Non-rising Spindle type.

3. The valves shall be with back seat bushing arrangement for replacement of packing

without leakage.

215

4. The valve size 350 mm & above shall be provided with renewable Shoe & Channel

arrangement to reduce the clearance between body and wedge lugs.

5. The valve size 350 mm & above should be supplied with 2 nos. Single trust deep

groove Ball bearing on both end of spindle collar to reduce operating torque and

vertical trust on spindle.

6. The valve size 450 mm & above should be supplied with enclosed grease packed

bevel/worm gear box of suitable rating to ensure that the valve shall be operated with

effort not more than 7 KgM at the pinion shaft.

7. The valves shall be provided with position indicator for indication from full open to full

close.

8. The valves shall be provided with cast iron cleaning door at the bottom of Sluice valve

body.

9. The clearance between wedge nut housing lugs on the wedge and the inside surface of

the valve body shall be adequate to insert the wedge nut into the wedge lug recess

either in the direction of water flow or in perpendicular direction when the wedge is in

closed position.

10. The valve shall be provided with air release plug arrangement on the top of the bonnet.

11. The valves should also be compatible with Actuator system.

c. Material of Construction

1. Body : Cast Iron to IS: 210 Gr. FG200

2. Wedge : Cast Iron to IS: 210 Gr. FG200

3. Spindle : St. Steel to IS: 6603 04Cr18Ni10

4. Seat Rings : SS to CF8

5. Spindle Nut : High Tensile Brass to IS – 320 HT2

6. Back Seat Bush : SS to CF8

7. Shoe & Channel Lining : SS to CF8

d. Shop Testing Witnessing

1. Seat Leakage Test (2 Minutes) : 10Kg/cm2

2. Body Leakage Test (5 Minutes) : 15Kg/cm2

3. Back Seat Leakage Test (2 Minutes) : 10Kg/cm2

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SPECIFICATION OF CHECK VALVE

1. Checking valve shall be conforming to IS: 5312. Additionally they should meet the specific

requirement given below.

2. The valves shall be double flanged machined and drilled to IS- 1538 Part 4 & 6. The backside

of the drill holes to be spot faced for proper seating of bolts & nuts. Reasonable

clearance behind the rear face of the flange on body to be kept to provide free access to

use spanners for assembling & dismantling. No tap hole is acceptable.

3. The valve should be of PN 1.0 rating based on working pressure in the pipeline.

4. Nominal size, PN rating, Brand name & Direction of Flow should cast on the body.

5. The Valves shall be of Swing Check type.

6. The Valve sizes 50 to 600 mm should be of Single door design & above 600 mm should be

Multi door design.

7. The Check Valves shall be with Non Slam Characteristics. Non Slam Characteristics to be

achieved by combination of hydraulic passage and additional disposition of weight on

doors.

Material of Construction a. Body & Cover : Cast Iron IS: 210 Gr. FG 260

b. Door : Cast Iron IS: 210 Gr. FG 200

c. Hinge Pin : St. Steel to AISI – 316

d. Seat Rings : Gunmetal with 2% Nickel / IS: 318 Gr. LT B2

e. Bearing Bush : Teflon

f. Fastener : carbon steel

Shop Testing Witnessing 1. Seat Leakage Test (2 Minutes) : 10Kg/cm2

2. Body Leakage Test (5 Minutes) : 15Kg/cm2

SPECIFICATION OF KINETIC AIR VALVE

a. General

1. Kinetic Air valves shall be conforming to IS: 14845: 2000. Additionally they should meet

the specific requirement given her e under.

2. Kinetic Air valves should be from ISO – 9001 certified company towards Quality

Management System.

217

3. The Valves shall be flanged end machined and drilled to IS – 1538 Part 4 & 6

4. The valves should have an isolating Sluice Valve attached to it.

5. Nominal size, PN rating, Brand name should cast on the body.

b. Design Requirement

1. The valve should be of PN 1.0 rating /based on working pressure in the pipeline.

2. The Valves should double ball air valve consisting of large orifice (LP) & small orifice.

3. The large orifice chamber should have built-in Kinetic features to avoid blocking of the

large orifice during filling & emptying of pipeline. It should have a large timber ball

covered with rubber to be seated on a large orifice rubber ring.

4. The small orifice chamber should have a small timber ball covered with rubber to be

seated on gunmetal orifice plug.

c. Material of Construction

Body, Cover, Cowl : Grey Cast Iron. IS: 210 – 1993 Gr. – 260

Ball of small orifice : Seasoned timber ball covered with soft Vulcanite

Ball of large orifice : Seasoned timber ball covered with soft Vulcanite

Seat of large orifice : Neoprene Rubber

Nipple for small orifice : LTB. : IS 318 – 1980. LTB – 2./ AISI: 410

Isolating Gate valve : IS: 14846 (GM internals & AISI: 410 Spindle)

Bolt & Nut : M.S

d. Shop Testing Witnessing

Seat & Body Leakage Test (2 Minutes) : 10Kg/cm2

e. Painting & Coating

Pre – inspection

1st Step Surface Preparation

Blast cleaning to near white – SA 2 ½ Gr.

2nd

step Application of Primer Coating after blast cleaning

One coat of two component epoxy based primer

Post – inspection, if applicable

3rd

Step Application of Finish Coat

One coat of two component solvent free amine cured epoxy coating (Shade)

2.5.16.2. Butterfly Valves

Unless otherwise specified, valve body and disc shall be of close-grained gray cast iron.

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Valves shall be mounted with shafts horizontal. Valves shall be fitted with indicators to show

the position of the disc, clearly marked with „open‟ and „closed‟ positions. Valves shall not

contain any brasses containing more than 5% zinc. Gunmetal conforming to BS 1400 Grade

LG2, aluminum bronze, or nickel components may be used for internal components.

Resilient-seated valves shall have nitrile rubber seals.

For valves of 900mm and above, retaining rings shall be provided to enable the sealing ring

to be replaced without the need to remove the valve body from the pipe work. Metal seated

valves of 900mm and above, shall have seat clearances adjustable to obtain as near a

watertight condition as possible, without the need to remove the valve body from the pipe

work.

Percentage Opening - Flow Curve shall be submitted along with data sheet mentioning area

where such valves are subjected for any controlling of the fluid flow.

Component Material 1 Body Cast Iron : IS:210 Gr FG260

2 Inner lining Stainless steel : BS:970 Gr 304

3 Plate /DLSC Stainless steel : IS 3444 1987

4 Stem Stainless steel : IS 6603:1972

5 Seat ring / Boss Stainless steel : IS 6603:1972

6 Gland housing Cast Iron : IS:210 Gr FG260

7 Gland packing Teflon Impregnated with asbestos+Rubber

2.5.16.3. Pressure-Relief Valves (PRV)

Pressure-relief valves shall be designed to prevent the pressure in the pipeline upstream of the

valve rising above a preset level. The valve shall remain closed at lower pressures. The

pressure at which the valve opens shall be adjustable. A pressure gauge shall be provided to

indicate upstream pressure over the operating range of the valve. Safety valves shall comply

with BS 6759: Part 1.

They shall be designed to open at the specified pressure and re-close and prevent further

release of fluid after normal pressure has been restored. The pressure / temperature rating

shall be in accordance with relevant standards. Flanged ends shall be Class 900, raised-face

type complying with ANSI B16.25 or relevant standards.

Component Material 1 Body Cast Iron : IS:210 Gr FG260

2 Inner lining Stainless steel : BS:970 Gr 304

3 Knife gate/ plate Stainless steel : BS:970 Gr 304

4 Stem Stainless steel : BS:970 Gr 304

5 Seat ring / Boss Stainless steel : BS:970 Gr 304

6 Gland housing Cast Iron : IS:210 Gr FG260

7 Gland packing Teflon Impregnated with asbestos+Rubber

2.5.16.4. Ball Valves

Ball valves shall conform where applicable to relevant standards. Multi-piece bodies shall be

used where work on the ball and seats when installed may be needed. If valves need removal

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for servicing, one-piece bodies may be used. Seat materials shall be chosen for long life, with

erosion and corrosion resistance. Ball supports shall be of the floating ball or trunnion type. If

line pressure is too low to ensure a positive leak-free seal, built-in seat loading devices, or

specially shaped seatings shall be used to ensure sealing.

Component Material 1 Body Cast Iron : IS:210 Gr FG260

2 Inner lining Stainless steel : BS:970 Gr 304

3 Plate Stainless steel : BS:970 Gr 304

4 Stem Stainless steel : BS:970 Gr 304

5 Seat ring / Boss Stainless steel : BS:970 Gr 304

6 Gland housing Cast Iron : IS:210 Gr FG260

7 Gland packing Teflon Impregnated with asbestos+Rubber

2.5.16.5. Knife Gate Valves

The valve shall meet standards C105/A21.5-10, C520-10, C706-10, C707-10, C713-10 and

D106-10 and testing requirements of MSS SP 81.

Outer body may preferably be provided with inner liner in corrosion resistant stainless steel

which shall extend into the gland. The body shall be devoid of any wedge/ dead pockets to

avoid setting of suspended particles and solids in the service fluid.

The gate / plate shall be precision buffed and the edge contoured to a knife edge. The gate

shall move along / be guided by the seat ring to ensure that it scraps any deposit / scale

enabling smooth uninterrupted movement.

Seat shall be so designed that there is no recess / relieve groove to harbour deposition that

could build-up and swamp the valve. The design should also incorporate bosses that guide the

gate and avoid deflection ensuring positive shut-off. The stem shall have double start threads

cut in order to ensure smooth and speedy operation.

Gland packing shall offer minimal frictional resistance and precludes external lubrication. As

positive sealing elements, the packing shall also include a resilient rubber ring. The knife

edge and seat face in flow path shall be hard faced to a hardness of 400 to 450 BHN to

counter erosion. In such cases, provision shall also be made to ensure the fluid contact with

the seat ring is minimal.

Component Material 1 Body – Cast Iron : IS:210 Gr FG260

2 Knife gate/ plate – Stainless steel : BS:970 Gr 304

3 Stem – Stainless steel : BS:970 Gr 304

4 Seat ring / Boss – Stainless steel : BS:970 Gr 304

5 Gland housing – Cast Iron : IS:210 Gr FG260

6 Gland packing – Teflon Impregnated with asbestos + Rubber

2.5.16.6. Cast Iron Flap Valves (Circular Flap Valves)

The Flap Valves with circular aperture, single door and double flanges, shall be provided.

The flap valves upto 600mm dia shall have sealing faces in angular section and secured to the

frame and door by a force fit. For sizes above 700 to 2000mm dia the sealing faces are of

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rectangular section and are secured to the frame and door using countersunk taper headed

screws in the same material as the sealing face. The flap valve shall be suitable for mounting

on a vertical wall or flange for static seating heads up to 6 meters.

Material of Specification

Frame

Constructed in BS EN 1561 min. 250 cast iron designed for wall, thimble or pipe mounting

applications.

Door

Constructed in BS EN 1561 min. 250 cast iron designed to withstand static seating heads up

to 6 meters.

Sealing Faces

Copper alloy sealing faces to BS EN 1982 : 1999 are supplied as the standard material for

ranges up to 600mm dia and for the ranges 700 to 2000mm dia phosphor bronze to BS EN

12167 : 1998. Sealing faces are set to 0.1mm feeler gauge non-acceptance to provide an

effective seal.

Hinge Links

Manufactured in Spheroidal Graphite cast iron

Fasteners

Standard fasteners are supplied in stainless steel to BS EN 10088 : 1995 grade 1.4401 (316).

Hinge Pins

Manufactured from stainless steel to BS EN 10088 : 1995 grade 1.4401 (316).

2.5.16.7. Sluice Gates

Sluice gate shall be preferably wall thimble type. However for controlling/isolation of flow in

channels, channel type gates may also be accepted by Jal Nigam as per application

requirement.

The construction of Sluice Gates shall be in accordance specification and generally to

IS:13349. The Sluice Gate shall be designed for Seating & Unseating Head without

sacrificing reasonable degree of leak tightness. The frame of Sluice gate shall be flanged back

type and shall be machined on the rear face to bolt directly to the machined face of the wall

thimble. The seating faces shall be made of solid section strip of Stainless steel. They shall be

secure firmly by means of counter sunk fixing in finished grooves in the frame and slide face

in such a way as to ensure that they will remain permanently in place, free from distortion

and loosening during the life of the Sluice Gate. Sluice Gates shall be equipped with

adjustable Side & Top wedging devices as required to provide contact between the slide and

frame facing when the gate is in closed position. The gates shall be of Rising Spindle Type.

They shall be operated through a suitable operating mechanism. The Lifting mechanism shall

incorporate gearing arrangement, if required to keep the torque requirement within 7 KgM

except electrically actuated gate. In case of gearing, those to be enclosed grease packed Bevel

or Worm Gear box type. Lifting mechanism shall be provided with suitable position indicator

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to show the position of the gate from full open to full close. The indicator to be provided in

the head stock only. Stem Cover to be provided on the top of head stock for the rising

spindle. The cross section of the wall thimble shall have the shape of the English letter „F‟.

The Sluice gate shall be provided with Flush bottom seal. This is a solid square cornered

resilent rubber seal provided on the bottom facing of the slide. The seal may be secured

fastened to the bottom of the face of the slide by a retainer bar and fasteners. The top surface

of the bottom facing of frame shall be flush with invert of the gate opening. Bottom facing of

the slide shall be accurately machined to make contact with the seal when the slid is closed.

Gates shall be fixed for positive seating. Sluice gates shall be electrically operated with

manual override facility. The Sluice Gates shall be of Class – 2 i.e., suitable for maximum

unbalanced head needs as per calculation/design.

Material of Construction

The materials of construction of important components of gates will be as under: a. Frame & Shutter Cast Iron IS: 210 Gr. FG 200

b. Wall Thimble Cast Iron IS: 210 Gr. FG 200

c. Seating Faces & Counter Sunk Fixing Stainless Steel ASTM A276 type 316

d. Wedging Device Cast Iron IS: 210 Gr. FG 200

e. Wedge Linings Stainless Steel ASTM A276 type 316

f. Stem & Stem Coupling Stainless Steel ASTM A276 type 316

g. Stem Nut Stainless Steel ASTM A743 CF8M or SS316

h. Flush Bottom Rubber Seal EPDM ASTM D200

i. Seal retainer bar Stainless Steel ASTM A276 type 316

j. Fasteners, Studs Anchor Bolt & Nuts Stainless Steel ASTM A276 type 316

k. Lift Nut Bronze IS: 318 Type LTB-2

l. Headstock, Stem Guide Cast Iron IS: 210 Gr. FG 200

m. Hand wheel Mild Steel IS: 2062

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n. Painting Ordinary Black Bituminous Paint

Standard Painting

Unless otherwise specified elsewhere provide following standard painting.

- Surface preparation: Blast clean or Ground to near white metal finish

- Priming: 1 coat of red oxide primer before and after shop testing. Total priming thickness 75

microns.

- Finish painting for gate assembly: 2 coats of black bitumen paint for gate assembly. Total

paint thickness inclusive of priming 200 microns.

- Finish painting for headstock: Grey enamel paint. Total paint thickness inclusive of priming

150 microns.

Shop Testing Parameters

- Leakage test at operating pressure for gate leakage performance.

- Movement test for checking interference free movement of complete assembly.

- Seat clearance check for checking clearance between mating sealing faces.

- Positive Material Identification test for all material other than cast iron.

2.5.17. Electrical Overhead Traveling (EOT) Crane

The capacities of various EOT‟s shall be decided as per recommendations of IS: 875.

The crane shall be of single / double girder type designed from lowest sump level and up to

under size of the bridge.

Suitable crane rails complete with fixing bolts, nuts, washers and anchor plates shall be

supplied for each crane.

The bridge structure shall be formed by a single/double cross girder with the hoist units

traveling along the lower flange of the bridge girder.

The end carriages shall be fabricated adequately stiffened throughout their length to produce

a section with high torsional resistance designed to eliminate and tendency for the bridge to

cross whip. The carriage wheel shall be adequate proportioned in relation to its span to give a

widely distributed load on the crane rails.

Proper selection of reduction gears shall be done to run drive motors. Wherever required the

motor enclosure shall afford protection to IP: 55 of IS: 4691 and have cooling facility to IC:

41 of IS: 6362. Each drive motor shall be fitted with an automatic electro-magnetic brake to

stop the crane on interruption of the power supply, whether intentional or accidental power

failure.

Suitable end stoppers/buffers shall be provided on the bridge girder and at each end of crane

rails.

The crane and hoist shall conform to IS: 3177, IS: 3832 and IS: 3938, class 2, medium duty

and meet specified operational requirements.

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Power feed to the crane shall be form a shrouded conductor rail system and that to the hoist

shall be through close looped flexible suspension system with carriers sliding along a wire

across the full span of the crane.

Proper illumination of the area shall be done under the crane and on the crane.

All the crane and hoist functions and excluding the illumination lights shall be controlled

from a single pendant push button station. The pendant unit shall be suspended from a special

track spanning the bridge length using a non-metallic cord and not the control cables. The

pendant shall operate on a low voltage (typically 220 volts AC) source, incorporated with a

key operated switch to operate switch to prevent unauthorized operation and indicators to

indicate ail crane or hoist movements including start and stop.

EOT Operations and faults shall be interfaced with respective LCP about their operations.

Lifting speed Low 0.9 MPN

High 3 MPN

L.T. speed 10 – 15 MPN

C.T. speed 10 MPN (Max.)

However illumination lights to be operated by separate switch which will not be mounted on

pendant.

Other Common specification:

Brakes All brakes are electro-hydraulic thrusters/ECM brake

Operation Through pendent push button

Gear box Precise machine cut hardened material gear noiseless operation long

life

Cable All cables are insulated ISI Marked

Power supply All 415:440 4 phase 50 Hz. AC supply

Control voltage 220/230 volts-50 Hz

The hoist shall comply Class II with the performance requirement IS 3177/80, IS: 3938/IS:

3832 Class 2.

The electric hoist shall be fitted with right and left handed spiral grooved cast iron drum with

a rope hoist arrangement with spring loaded rope band and guards to ensure accurate rope

guidance and location.

Hoist rope shall be extra flexible, improved plog plough steel rope with well lubricated hemp

core and having 6 strands 37 wires per strand with an ultimate tensile strength of 160/180

kg/sq.mm. The braking load for the hoist rope shall be as per IS: 2266.

Electromagnetic brake shall be provided to hold suspended load instantly, securely and

automatically in the event of the electric current being cut off whether intentionally,

accidentally or due to power failure.

The lifting hooks shall be single „C‟ type complying with the requirement of IS: 15560 made

from grade C30/C20 carbon steel. The hook shall have a safety latch to prevent rope coming

off the hook.

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2.5.18. Chlorination System

Chlorination system shall consist of chlorine contact tanks for disinfection of wastewater

from secondary clarifier, chlorine building housing equipment like chlorinators, chlorine ton

cylinders, chlorine ejector, chlorine leak detector, ventilation system, emergency chlorine

scrubber etc,

Chlorine solution diffusers shall be installed at the dosing point. Inlet chamber of the contact

tank shall have rapid mechanical mixers. The chlorine dosing shall be designed with

minimum chlorine dose of 8 PPM at peak flow. The residual chlorine should be not less than

0.2 PPM.

Vacuum type gas feed chlorinators comprising differential vacuum regulated flow meter,

regulating valve for vacuum & pressure, injector flow meter etc. shall be required. The

chlorinator should be floor mounted complying requirement of IS 10553 - 1983. The

chlorinator should be accompanied with booster pumps and the entire discharge line. The

moist chlorine or chlorine solution shall be conveyed through silver or platinum tubing. A pit

and alkali absorption system shall be provided to neutralize the chlorine in the event of leak.

Chlorine gas leak detector shall be provided in the chlorine storage room. Forced ventilation

system shall be provided with exhaust system industrial pattern. Chlorine residual monitoring

system shall be provided at the plant outlet.

Chlorine Gas Feed System

Minimum chlorine dose mg/l 5

Peak chlorine feed rate kg/day 275

Chlorine Ton Cylinders

Average chlorine feed rate kg/day 135

Min. storage period days 15

Capacity per cylinder kg 200

Min. no of manifold cylinders 10

Min. of cylinder to meet min. storage period

requirement

12

Min. no. of cylinders – Mani folded with

automatic switching.

10

Chlorinators

Type of Chlorinator Vacuum type-Gas Feed

225

Total No. of units 4

30 Kg/ hr. working 2

Min no of units – Standby 2 100%

Chlorine Ejector

Type Inline vacuum induction

Chlorine tonner can be provided by Jal Nigam as the chlorine gas is being purchased for

various plants.

Chlorine Contact Tank

Chlorine Contact Tanks

Min No of Units 1 with baffle wall

Material of Construction Reinforced Cement

Concrete

Chlorination System

Trunnuion Roller Support

Bed

Roller

Shaft

Bush

Steel as per IS 2062

Steel IS 2062 – Cadimum Plated

EN 8 BS 970 – Cadimum Plated

Gun Metal

Auxiliary Container Valve with Yoke

Valve Body

Spindle

Gland Packing

Yoke

Aluminium Silicon Bronze

Monel 400

PTFE

Forged Steel

Electrical Auto Change Over Device with

the Following

Ball Valve

Body

Ball

Seat

Forged Carbon Steel

Monel 400

PTFE

Pressure Switch Isol. Valve

Type

Diaphragm Sealed

By pass valve

Type

Body

Ball

Carbon Steel

226

Ball

Seat

Monel 400

PTFE

Gas Filter

Body

Filter Element

Seamless Carbon Steel 80 Sch,

Glass Wool

Pressure Reducing Valve

Body

Spindle

Spring

Diaphragm

Carbon Steel

Glass Filled PTFE

Hastelloy – C Silver Plated

PTFE

Isolation Valve

Type

Body

Ball

Seat

Ball

Carbon Steel

Monel 400

PTFE

Chlorinator with following accessories:

Pressure Gauge with ISO l. Valve Type Monel 400 bourdon tube

Vaccum Regulator

Body

Diaphragm & Seat

Spindle

Spring

HDPE

PTFE

Glass Filled PTFE

Hastelloy – C Silver Plated

Pressure Relief Valve

Body

Seat

Spindle

Spring

PVC

PTFE

PTEFE

Hastelloy – C Silver Plated

Rotameter

End Fittings

Glass

Float

PVC

Borosilicate Tapered

PTFE

Flow Control Valve

Body & Spindle

Type

PVC

V- Notch

Differential Regulator

Body

Diaphragm & Seat

Spring

HDPE

PTFE

Hastelloy – C Silver Plated

Vaccum Relief Valve

Body & Spindle

Seat

Spring

PVC

PTFE

Hastelloy – C Silver Plated

227

Vaccum Gauge

Type

Monel 400 Bourdon tube

Check Valve

Body

Spring

Diaphragm & Seat

Addl. Float

PVC

Hastelloy – C Silver Plated

PTFE

HDPE

Drain Valve

Body

Float

PVC

PTFE

Injector

Body

Nozzle & Throat

PVC

PVC

Pipe with fittings UPVC

2.5.19. Safety Equipment Severe exposure and potential health hazards exists due to chlorine atmosphere. The various

safety equipment like gas masks, oxygen breathing apparatus, portable air blower and

inhalator shall be provided keeping in mind the safety of staff operating chlorination system.

The Equipment shall include the following:

Canister type Gas masks with full face piece for short exposure.

Self-contained breathing apparatus with full face piece and a cylinder of air or oxygen carried on

the body.

Two sets of approved positive airline breathing apparatus, each comprising body harness, face

masks and valves and 30m of airline. One air trolley, comprising wheeled frame with two air

cylinders, control manifold, airline hose and hose winding drum. Two spare cylinders suitable for

changeover shall be provided.

Suitable quantity of air cylinders of capacity 1200ltr for recharging air cylinders, compete with

quick release air hose couplings.

Four sets of safety clothing in various sizes, each comprising PVC overall, wellington boots with

steel toe caps, goggles, gloves and helmets.

Gas leak detectors portable type -2 no.s

2.5.20. Emergency Equipment (General)

2.5.20.1. Fire Extinguishers

The Bidder shall provide required no. of dry powder type CO2 fire extinguishers (10 kg) for

the pumping station and switchyards at the following locations after consultation with the

Independent engineer:

Outdoor switchyard

Indoor electrical room

Pump rooms (maintenance bay)

Control room

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GAS handling area

First Aid boxes and manual stretcher .

Besides above, Ionisation smoke, optical smoke & heat detectors shall be provided in control

room with fire alarm panel having appropriate battery back-up. Fire alarm detectors shall be

provided both below & above false ceiling, if any Fire alarm system and public address

system shall be provided at the

Plant.

All the smoke and heat sensors shall be wired up to nearest JB and interfaced to respective

PLC/DDC for alarm annunciations.

2.5.20.2. Spillage and Leakage

Chemical preparing, dosing and transfer equipment shall be designed and arranged so that

any leakage and spilling can be controlled and cannot enter ducts, channels, etc. and have a

corrosive impact on pipes, cables or other equipment of the plant.

At all lubrication or greasing points grease trays or pans shall be provided to collect excessive

lubricant or spillage onto the equipment or into sewage.

2.5.20.3. Installation Work:

Equipment shall be installed in a neat, workman like manner so that it is level, plumb, square

and properly aligned and oriented. Tolerance shall be as established in the manufactures

drawing or as stipulated by Jal Nigam . No equipment shall be permanently bolted down to

foundation of structure until the alignment has been checked and found acceptable by Jal

Nigam.

Manufacturer‟s drawings, instructions and recommendation shall be correctly followed in

handling, setting, testing and commissioning of equipment.

2.5.20.4. Leveling and Grouting of Machinery

The pumps, motors and other equipment shall be properly and accurately leveled and aligned

on the concrete plinth by means of tapered metal wedges and metal packing pieces before any

grout is poured. After correct alignment and leveling the foundation bolts shall be nipped up

to hold the machine firmly in position and it shall be the Selected Bidder's responsibility to

check that the position is maintained after the grout has been poured but before it sets. The

grout, which will contain an approved expanding agent, will be mixed and poured by the

Selected Bidder. Grouting material used for grouting should be as approved by Independent

engineer.

The horizontality of base plate top shall be within 0.05 mm/metre. The base plate top surface

and pump motor box are to be blue matched to get a contact area of at least 80%.

After the grouting mixture has set hard the foundation bolts shall be pulled up hard and the

alignment and level rechecked. The Engineer shall be informed at all times of the progress of

this work and when any checks on alignment and level are to be carried out so that he may

witness the checks if he so requires. The approval of the Engineer or his intimation that the

alignment or level of the machines is to his satisfaction shall in no way relieve the Selected

Bidder of his obligation under contract to properly install and align the machines and pipe-

work and shall in no way prejudice the Independent engineer's rights to order rectification of

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any installation work later found to be improperly carried out.

2.5.20.5. Tests on Completion

(i). General

When the Contract Plant has been installed on site and is ready for energising, the Selected

Bidder shall notify the Independent Engineer in writing that Tests on Completion are about

to commence. At least three days notice shall be given. The Independent Engineer may

attend the tests at his discretion.

(ii). Commissioning Tests

The Selected Bidder‟s representative shall subject the screen to the following tests. The tests

shall include, but not be limited to:

Checking alignment of all components and adjust if necessary;

Checking that all equipment, safety devices and equipment protection devices function

properly;

Examining protective coatings and repair as necessary;

Running equipment for an appropriate time and check for correct operation;

Checking the operation of all equipment under field control;

Demonstrating access cover removal.

All necessary corrections and adjustments made shall be recorded. A written report shall be

provided by the Selected Bidder‟s representative at the completion of the tests, certifying that

the equipment has been properly installed and operates satisfactorily all test records are to be

appended.

(iii). Reliability Tests

Reliability testing will not be commenced until the Tests on Completion have been completed

and approved by the Independent engineer.

The Plant shall be required to operate under the normal operating conditions within the limits

of performance offered by the Selected Bidder, and their continuous or intermittent

performance as may be more convenient for the operation of the works. The Plant shall

operate without failure of any kind for period of one calendar month.

Should any failure (other than that of an entirely minor nature) occur in any portion of the

Plant, due to or arising from faulty design, materials or workmanship or staff training (but not

otherwise) sufficient to prevent commercial use of the plant, the test shall be deemed to have

failed. The test period of one month will recommence after the Selected Bidder has remedied

the cause of the failure. The onus of proving that any failure is not due to faulty design,

materials, workmanship or training will lie with the Selected Bidder.

In cases where the responsibility for failure cannot be determined initially, the Selected

Bidder is to attend to such failures as though they were his responsibility. When the

Reliability Test has been completed to the Independent Engineer written approval, the

Defects Liability Period shall commence.

2.5.20.6. Relevant Standards

The design, manufacture, supply, storage of all equipments shall comply with all Indian

Standards, (or in the absence of Indian Standards, the appropriate International Standards)

Acts and Regulations in their latest amendment, including local statutes covering:

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Health and Safety

Dangerous Goods

Factories and Commercial Premises

Buildings

Electricity Regulations and Codes of Practice

The Standards referred shall form part of this Contract. Other Standards, Codes of Practice

and Regulations not referred to, but which would be applicable to the design, manufacture,

installation, testing or commissioning of the equipment under this contract shall be deemed

part of the Contract.

2.5.20.7. Working Stress and Design

The design of all parts shall ensure that under the most onerous of conditions they will not be

damaged or corroded.

Any joint that will need to be dismantled during maintenance shall be made by anti-corrosion

type fasteners.

All spare parts shall be fully interchangeable with the original part. If the spare part is

unavailable due to cease of production, the Selected Bidder shall give notice to the Employer

in writing, detailing the options available to the Selected Bidder.

All parts shall be designed to minimise the risk of fire and consequential damage. All parts

shall be designed to prevent the ingress of vermin, dust and dirt. All electrically live or

moving parts shall be adequately guarded to prevent accidental contact.

2.5.20.8. Name Plates

Each main and auxiliary item to the pumping station shall have permanently attached to it, in

a conspicuous position, a name plate and rating plate, each of weather-resistance and fire-

resistance material. Upon these shall be engraved or stamped the manufacturer's name, type

and serial number of equipment, details of the loading and duty at which designed to operate.

231

Mechanical Equipment General and Particular

Specifications

Schedule-II

Part-B

3.0 MECHANICAL WORKS DESIGN

1.6 Scope

The General Mechanical Works Specification covers the minimum requirements for

design, procurement, testing at manufacturer's works, supply, site testing and

commissioning of the Mechanical Works. Compliance with this specification shall

not relieve the Selected Bidder from any of his contractual obligations and

responsibilities towards fulfilling the performance requirements.

1.7 General Arrangement of the Works

The Selected Bidder shall provide and arrange the Works to comply with the

following general guidelines:

• Sufficient space shall be provided between items of Plant and adjacent Plant or fixed

structures to permit safe and convenient access for operation and maintenance.

• Layout of the site structures/equipment shall be cognisant of code distances required

between non-hazardous and hazardous structures/plant/equipment, etc.

• An area adjacent to all mechanical Plant shall be provided as a maintenance lay down

area.

• Electrically operated cranes, fixed runways, lifting eyes or other means shall be

provided to permit the removal of larger items of STP that may logically be required

to be removed during the course of its normal operational life for maintenance or

replacement purposes.

• Areas where leakage of water is likely to occur, whether in normal use or during

maintenance, shall be provided with covered drainage channels which shall direct

spillage either to a suitable drain or to a sump from where it can be pumped to an

appropriate place for safe disposal.

• Where necessary, the equipment shall be provided with removable acoustic coverings

to limit the noise produced during normal operation to the limits detailed elsewhere.

• Pipework shall be designed and installed to prevent blockages and to permit their

clearance without dismantling pipework or equipment.

• The Selected Bidder shall take due regard to the potential of hazardous mixing of

chemicals, particularly as a result of leaks and spillages, and their drainage and

containment.

232

• Chemical pipework shall be secured to racks or trays, to walls of tanks and walls of

buildings as necessary. It shall be arranged to facilitate maintenance and removal of

individual runs without dismantling adjacent pipes.

• All chemical pipes shall be colour banded and suitably labelled to enable individual

lines to be identified throughout their run.

• The Selected Bidder shall provide all signage necessary to inform of chemical and

operational hazards and to comply with statutory legislation.

1.8 Pumping systems

The Selected Bidder shall provide pumping systems with isolation valves, non-return

valves, gates with actuator and all necessary pipework and fittings.

The Selected Bidder shall provide pipe supports, hangers and anchors to support and

control movement of pipes and valves all in accordance with recognized international

piping standards.

Unless otherwise specified, the Selected Bidder shall provide all pumping systems

with standby pump sets of the same type and capacity as the duty pumps, providing a

standby capacity of not less than 50% of the total duty. All pumps shall operate at

high efficiency throughout their duty range and they shall be capable of continuous

operation throughout their required operational range. The minimum diameter of pipe

for sludge transfer shall be 150mm.

Lubrication arrangements shall be designed to avoid any contamination of pumped

fluid.

Dry well mounted pumps shall provide effective means for collecting gland/seal

leakage water which shall be piped to a floor drain or sump.

Design of pumps with suitable head and discharge should be done by selected bidder

as per CPHEEO manual considering (4 working + 50% standby) pumps .

1.9 Materials of construction

All materials of construction for tanks, vessels, pipelines, pumps, valves, etc. shall

be suitable for long term contact with the liquid or chemical concerned and at the

prevailing concentrations. Equipment shall be coated and protected in accordance

with Painting and Protective Coatings.

All pipework employed shall comply with the schedule below unless agreed with the

Independent Engineer. It is the responsibility of the Selected Bidder to ensure

compatibility of all pipelines with fluids or sludge carried and with external and

internal loadings and pressures.

Service Size range Pipe material

Potable and raw

water including

supernatant

Up to and including DN

300

Ductile iron (DI)

Poly-ethylene (PE)

DN 300 – DN 600 Ductile iron (DI)

Steel

Poly-ethylene (PE)

Greater than DN 600 Ductile iron (DI)

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Service Size range Pipe material

Sewage (pumped

below ground)

Up to and including DN

300

Ductile iron (DI)

Greater than DN 300 Ductile iron (DI)

Above ground pipe-

work and within

structures

Up to and including DN

300

Ductile iron (DI)

uPVC

Stainless steel (304L)

Greater than DN 300 Ductile iron (DI)

Steel

All sewage pipework

underneath

structures

Up to and including DN

300

Ductile iron (DI)

Greater than DN 300 Ductile iron (DI)

Steel

Stainless Steel (316L)

All pipes under roadways &

structures to be concrete encased.

Compressed air All diameters SS 304

Sampling All diameters (uPVC)

Instrumentation

process piping

All diameters Copper (plain/coated)

uPVC

Nylon

Stainless steel

Chemical dosing All diameters Sch. 80 PVC &According to

manufact-urer‟s recommendations

Natural Gas MDPE below ground

Stainless steel or steel above

ground/inside buildings

Sludge All diameters Ductile iron NP 16 rated below

groundStainless steel (304L) above

ground/inside buildings

Biogas All diameters Stainless steel 316L (below ground,

inside/outside buildings)

Process Air piping Blower discharge and

common header– All

diameters

SS 304/316L (within building)

Transfer to and

distribution piping

around aeration tanks -

All diameters

Stainless steel (316L)

1.10 Isolation and drain down

The Selected Bidder shall provide facilities for isolating and draining down all

pipework, chambers and storage tanks. Wherever duty/standby equipment is provided,

it shall be possible to isolate and drain-down each of the duty or standby items while

the other items are in service.

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4.0 Particular Specifications

2.6. Medium and Fine Screens

4.1.1 Scope of Supply The scope of supply shall provide complete automatic mechanical screen systems

with all accessories and appurtenances, including, but not limited to:

Mechanically operated screen;

Screenings collection, washing and disposal system;

Automatic screen control system;

Electrical & Instrumentation for compliance of Automatic System (Electrical wiring between

all screen components, instruments, control devices and the local control panels and the

screen controls;)

4.1.2 Guaranteed Flow Rate and Head Loss The screen shall effectively screen all flows up to the design flow. The Selected

Bidder shall guarantee the following screen performance parameters:

Clean water flow rate capacity (l/s) at the maximum allowable water depth downstream of the

screen

Clean water head loss at the max flow rate and maximum allowable water depth downstream of

the screen

4.1.3 Screening Arrangements Selected Bidder shall provide automatic mechanical fine screen to remove particles

larger than 6mm size.

It is proposed to install sufficient number of appropriately sized automatically

operated mechanical fine screens (stainless steel grade – SS316) of opening size

6mm for screening out floating materials such as plastic pouches, bags, rags, floating

debris, weeds, paper wastes and other floating materials from the raw sewage coming

from the pumping station. Capacity of each channel shall be equal to of average flow.

Fully automatic mechanical screen along with the level sensing instrument for

automatic operation of screen mechanical and allied accessories, (local control panel

near screen,) shaft less screw conveyor with/cum compactor are to be provided.

The fixed as well as movable bars/ perforated band, mechanism, support frame,

fixings discharge chute shall be manufactured from stainless steel grade 304 for long

life in the aggressive sewage environment.

Automatic Screen Clearing and Screenings Removal

The screen shall be provided with the necessary controls and sensors to anticipate

blockage of the screen, and automatically clear the screen and remove the

accumulated screenings from the screen surface. The screen shall operate

automatically when the upstream water level increases beyond a pre-set limit and it

shall stop when the upstream level decreases to pre-set low level.

Screenings Conveyance, Compaction and Dewatering

The screening system shall be supplied with a duty and standby shaft less screw

conveyor that will be used to convey the screenings to the automatic screenings press

and discharge system that compacts, dewaters and discharges the screenings through

a chute to the screenings storage system.

235

The screenings dewatering and compaction system shall compress and dewater the

screenings such that the screenings from a consolidated mass with no free water

entering the screenings bag.

Screen Washing System

The Selected Bidder shall supply and install spray washing system that effectively

cleans the screen area and screening press. The Selected Bidder shall provide a high-

pressure clean water supply for the washing system.

Dewatered Screenings Discharge Chute

The screenings discharge chute shall terminate 1.5 meters above ground level. A

plastic screenings bag shall be secured around the chute, thereby creating a totally

enclosed screenings collection system.

Screen Covers

All screenings equipment shall be supplied with integral stainless steel covers that

prevent access to moving and wash water sprays. The covers need to be airtight to

ensure that no odours emanate from the screen.

Portable Screenings Container

Portable screenings containers made of galvanised steel duly epoxy painted shall be

provided to store the screenings until time of pick up. The container shall have

capacity of approximate 5 m3 and shall be of a convenient height to permit the

discharge of screenings directly into the container without having to transfer the

screenings manually. The containers shall have hinged covers and their design shall

permit them being lifted by an overhead hoist or packer truck. The container will

have four wheels each of about 20 cm diameter and two of which shall be swivel

castors. The maximum height of container including wheels shall be 0.6m. The sides

shall be constructed of minimum 12 gauge steel. The bottom of container shall be

made minimum of 6mm plate steel. The containers shall be reinforced with 50mm x

50mm x 5mm angle iron.

Electrical Motor

The motor shall be TEFC type with IP 55 protection & Class F insulation and shall be

suitable for operation on 3 phase, 415V + 10% and frequency of 50Hz + 5%. Motors

shall be squirrel cage type conforming to IS 325. The power rating of motor shall be

at least 125% of maximum power requirement.

Control Panel

The Control Panel shall have IP 65 protection, painted with Epoxy paint and shall be

comprise:

- Mushroom Head Emergency stop.

- Overload relays for motor protection.

236

- MCB‟s, HRC Fuses and Glass Fuses.

- Circuitry to operate the screen with level sensors.

- Selector Switch to operate the screen on JOG mode.

4.1.4 Access

Safe access shall be provided to all screen equipment and instruments to allow for

cleaning, inspection and maintenance activities.

4.1.5 Corrosion Resistance

All metal parts of the screen equipment that are in contact with the sewage shall be

constructed of a suitable grade of corrosion resistant stainless steel.

4.1.6 Installation, Testing, Commissioning and Training

It is the Selected Bidder‟s responsibility to install the screen system correctly and

achieve the required operation. The Selected Bidder shall provide a representative

who has knowledge and experience in the proper installation, start-up and operation

of the screen equipment to inspect the final installation and supervise the

commissioning tests.

2.7. Grit Removing Equipment

Grit chambers shall be of vortex type with centre drive and independent washer or

classifier. Grit Basin equipment, complete with all accessories including, but not

necessarily limited to, gear motor, turntable, propeller drive tube, axial flow

propeller shall be provided.

2.2.4. Vortex type with central drive grit removal system

The Vortex Grit Basin equipment shall be installed in concrete basins. The

equipment to be supplied shall be suitable for installation in these basins. The grit

chamber shall be designed to operate on the vortex principle. Drives, bearings, and

support equipment for grit mechanism shall be supported by and readily accessible

from a concrete walkway above the water surface.

2.2.5. Grit Separator:

The grit chambers shall conform to the following construction, operation guidelines

and have the accessories as indicated below:

Vortex Type Grit removal chamber with low head loss systems shall be proposed

for this project. Each grit chamber shall be complete with the minimum equipment

but not limited to gear motor, gear head, axial flow propeller and scrapper with

drive, grit removal pump and auxiliary equipment required for operation. The grit

removal unit shall have low head loss and shall be capable of removing grit from

raw waste or process water and depositing the grit in a storage hopper. An integral

grit transporting means shall be provided to transport the grit from the storage

hopper to the disposal means. To minimize the possibility of clogging, all internal

openings in the piping to the grit pumping device as well as the grit pumping device

shall be large enough to pass a 100 mm sphere. No bends or elbows will be allowed

in the piping on the suction side of the grit pump. All drives, lubrication and

bearings shall be readily accessible from walkways above the operating water level.

To minimize the possibility of organic capture, the floor of the grit separation

237

chamber shall be flat and there shall be no greater than a 80 mm opening for grit to

pass through to the storage hopper. Sloping floors in the upper chamber will not be

allowed due to reduced grit removal efficiency and extra construction costs. To

ensure the efficient transport of the grit and simultaneous lifting and discharge of

the organic material, the bottom of the upper chamber covering the storage hopper

shall be constructed suitable corrosion proof / or thick steel plate , free from

rotation, and shall be flat. The grit moving across the bottom of the chamber shall

be hydraulically scoured by an air lift pump or a propeller pump. The grit shall pass

from the removal chamber through an opening in the transition plate and drop into a

grit storage hopper. The flow in the removal chamber shall travel between the inlet

and the outlet a minimum (270°), providing maximum travel of the liquid for

effective grit removal. The Grit Chamber shall handle all flows equal to or less than

a hydraulic peak flow. The influent flume, transporting the liquid waste to the grit

chamber, shall be of the size and shape shown on the contract drawings to assure

that grit does not settle in the inlet flume and to provide for proper operation of the

grit chamber. A grit storage hopper with a 60° sloped bottom shall be provided with

effective grit storage for the designed flow. , grit pump will be either an air lift

educator pump or a turbo grit pump close-coupled, vacuum primed type with

curved multi vane impeller. Grit Classifier / Washer shall be rake or Shaft less

screw type. The material of construction of all wetted parts shall be in SS 316.

2.2.6. Operating Conditions The grit chamber shall operate on the vortex principle. To maximize grit removal

efficiency, the grit chamber hydraulics shall incorporate a toroidal flow path enhanced

by a slow vortex.

The grit removal device shall be capable of removing the following at the specified

hydraulic peak flow rate, and no decrease in efficiency will be allowed at flows less

than this design rate.

- 95% of the grit greater than 150 microns in size,

- 75-85% of the grit greater than 100 but less than 150 microns in size,

The displacement type blower shall have the capacity to provide sufficient quantities

of air at the required pressure to ensure efficient operation of the air wash/airlift

system.

Grit Trap

Item Description MOC

Air Lift Pump Stainless Steel

Geared Motor Assembly STD

3 Way Valve Stainless Steel

Screw Classifier Stainless Steel

2.8. Clarifier Mechanism

The Clarifier Mechanism shall be suitable for installation in RCC tank and circular

radial flow fixed bridge with scum collector, central turn table type clarifiers shall be

provided. Clarifier should be rugged and robust in design and should be provided with

high capacity drive head having high torque rating, centrally located with positive

238

sludge raking by means of two raking arms. Both the raking arms should have scraper

blades fitted at the bottom, so that the sludge from one scraper blade is pushed to the

other on every rotation. The centre drive head mechanism arrangements should consist

of a turn table base casting mounted on top of the centre pier and having an annular

ball bearing on which the internal gear that supports the underwater mechanism turns.

The pinion meshing with the internal gear should be driven through a worm gear

reduction unit mounted on top of the turn-table drive unit. The balls should ride on

hardened steel strips set into groves in the base and gear castings so that they can be

readily replaced whenever it is necessary. An overload alarm containing switches

controlling the alarm ball and motor in case of excessive load should be mounted on

the worm gear housing. An overload alarm device should be provided with mechanism

to indicate the overload conditions on the scrappers.

The mechanism shall comprise but not limited to the following main components:

- Bridge Superstructure spanning half the tank diameter with central maintenance platform

- Drive assembly complete with drive head, chain & sprocket, geared motor etc.

- Feed Well

- Center cage

- Cone scraper

- Rake arms

- Tie rods for rake arms

- Plow blades & squeegees

- Scum Blade & Skimmer assembly

- A-frame supports for the skimmer assembly

- Scum trough and ramp with support angle

- Scum baffle with supports

- Weir plate

Bridge Superstructure:

The bridge shall span half the diameter of the tank. The width of the walkway shall be

minimum 1.5 M. The bridge shall rest on the clarifier wall at the one end and the

drive at the center. The bridge shall be of truss type welded steel construction with

walkway of gratings supported by cross members. The truss bridge shall be provided

with one row of handrail in the middle. The bridge shall be provided with a drive

maintenance platform at the center.

Drive Assembly with Drive Head :

The central drive head shall rest on the RCC center pier and supports the bridge at the

center. The drive head shall be coupled to a geared motor through chain & sprocket

and shall support the center cage at the bottom for rotating the rake arms.

Feed Well:

A fixed feed well shall be hung from the bridge superstructure. The inlet feed pipe

shall connect to the central inlet column at the bottom.

Center Cage:

The center cage shall be of welded steel construction. The center cage shall be bolted

to the drive head at the top and shall support the rake arms at the bottom.

239

Cone Scraper:

A cone scraper shall be attached to the bottom of the center cage and shall serve to stir

the sludge in the bottom hopper.

Rake Arms & Tie Rods:

Two sets of rake arms shall be attached to the center cage in diametrically opposite

direction through a hinged connection. The rake arms shall be attached to the center

cage through tie rods with provision for adjustment of inclination of the rake arms.

Each rake arm shall be provided with plow blades at the bottom and adjustable

renewable squeegees for scraping of sludge.

Skimmer Assembly & Scum Blade:

One set of skimmer assembly with scum blade shall be attached to the rake arm and

shall serve to skim the floating material. The scum blade shall span from outside of

the feed well to scum baffle at the periphery of the clarifier.

Scum trough and ramp with support angle:

One no. scum box comprising of scum trough with ramp shall be provided at one

point along the periphery of the clarifier and shall serve to collect the scum discharged

by the scum blade into the trough. The scum box shall be supported from the side wall

by support angles. The scum box shall be provided with flange connection of

specified size for connection of scum pipe connecting the scum box to the scum

sump.

Scum baffle with supports:

The scum baffle shall be provided along the periphery of the tank to prevent floating

matter from reporting into the overflow. The scum baffle shall be supported by

support brackets from tank wall.

Weir Plate:

V-notch weirs shall be provided along the periphery of the overflow collection

launder for uniform draw-off of the overflow. The weir plate shall be fixed to the

launder by means of plate washers.

Material of Construction :

Feed Well SS 304, minimum 3 mm thick

Bridge MS with Hot dip Galvanized (galvanizing minimum thickness

shall be 80 micron) (welded/nut bolted/riveted truss in a

consolidated single component and no site welding shall be

allowed)

Rake Arm MSEP, minimum 5 mm thick

Center Cage MSEP, minimum 5 mm thick

Rake Blades MSEP, minimum 5 mm thick, 1500 m wide x 150 mm ht

V-notch weir SS 304, minimum 6 mm thick and 300 mm wide

Squeegees Neoprene rubber, 10 mm thick, adjustable type

Walkway Heavy duty MS epoxy coating grating, radial upto centre

240

minimum 10 mm thick

Handrail (both ways in

two layers minimum 1 m

high)

32 NB SS Pipe (radial upto centre)

Scum skimmer assembly MSEP, minimum 5 mm thick and 300 mm wide

Scum Box MSEP, minimum 3 mm thick

Scum Baffle MSEP, minimum 3 mm thick and 400 mm wide

Fasteners – Under Water SS-316

Fasteners – Above Water SS-316

All MS parts shall be provided with one coat of epoxy primer followed by one coat of

epoxy paint after sand blasting prior to dispatch to a total DFT of minimum 225

microns.

2.9. Diffuser

The aeration system may be provided to meet the aeration requirement as per the

process design requirement. Sufficient design calculations are to be provided along

with manufacturer standard having supplied diffuser during last five years to various

waste water treatment plants.

Fine Bubble Aeration System

Design: The membrane diffuser shall be developed specifically for Releases 1~3mm

fine bubble in the wastewater treatment plant. All materials have been selected for

their ability to withstand the effects of the chemical, bio-chemical agents and

0~100°C used in wastewater tank. The diffuser can be placed in an evenly distributed

grid system over the entire aeration tank bottom. Air can be easily through the air

orifice and integrated non-return valve into the wastewater. The air orifice design to

maintain the diffuser standard airflow input prevented the max. air enter to damage

diffuser membrane. The membrane shall be secured onto the support dish with a

constrict flex rim and retaining ring designed to increase the tension on the point of

engagement as the diffuser air rate increases.

Construction: The materials of construction for both support dish and membrane

diaphragm are non-corrosive and UV resistant.

The fine/coarse bubble aeration system will comprise:

Stainless steel (SS316) droplegs and Headers.

PVC manifolds and air distributors.

PVC diffuser holders and retainer rings.

Stainless steel supports and anchors

Bolts, nuts and gaskets for aeration system flange connections.

Air distributor purge systems.

Membrane disc diffusers with integral O-ring gaskets and subplates.

The following design features will be incorporated in the fine/coarse bubble aeration

system:

Fabricated manifold with fixed threaded union joints for connection to the air distributors.

241

Manifold sections connected with fixed threaded union or flanged joints to prevent rotation

or blow apart.

Manifold, distributor connections and supports designed to resist thrust generated by

expansion/contraction of the air distributors over a temperature range of 70°C

Air distributors perpendicular to the air manifold

Fabricated distributors with single diffuser holders solvent welded to the crown of the air

distributor for complete air seal and strength.

Air distributor sections joined with positive locking fixed threaded union or flange type joints

for all submerged header joints to prevent blow apart and rotation. Bell and spigot, slip on or

expansion type joints are not acceptable for submerged joints.

Threaded union joints designed with spigot section connected to one end of the distribution

header, a threaded socket section connected to the mating distribution header, an “O” ring

gasket and a threaded screw on retainer ring. Solvent welding shall be done in the factory.

All supports designed to allow for thermal expansion and contraction forces over a

temperature range of 70°C and to minimize stress build up in the piping system

Supports designed to be adjustable without removing the air distributor from the support.

Diffuser assembly comprising: diffuser membrane with integral „O‟ ring, sub-plate, holder,

retaining ring and air flow control orifice.

Integral check valve incorporated into the membrane diffuser assembly

PVC support plate incorporated to form an air plenum under the diffuser and support for the

membrane when the air is off

Retainer ring threads designed with minimum cross section of 3mm and to allow for one

complete turn to engage threads.

A liquid purge system to drain the entire submerged aeration piping system for each aeration

grid including airlift purge eductor line and manual control valve.

All PVC joints will be factory solvent welded. Field solvent welding will NOT be permitted.

Circular membrane diffuser discs with integral O-ring will be manufactured of EPDM

synthetic rubber compound with precision die formed slits. Thermoplastic materials (i.e.

plasticized PVC or polyurethane) are not acceptable.

Carbon black will be added to the EPDM material for resistance to ultraviolet light.

The maximum tensile stress on the diffuser will be limited to 10 psi (69 kPa) when operating

at 2.4 SCFM/sq. ft. (43.9 Sm 3 /h per m 2 ) of material. Proportionately thicker material is to

be furnished for larger diameter disc diffusers to limit the maximum tensile stress and to resist

stretching.

2.10. Aeration Tank

2.5.21. Submersible Mixers in Aeration Tank / Sludge Storage Tank Submersible mixers are used in the bio reactor for the following purposes

4) In Anoxic Tank to keep the Solids in Suspension

5) In Aeration Tank to keep solids in suspension and to improve the aeration capacity .

6) In Sludge Storage Tank

The mixer design guidelines are as follows

Mixer Duty

Application

Minimum

Pumping Rate

Mixer Min Power

Transmitted to

fluid

Anoxic Bio Reactor 1.5

times tank Volume

Tip Vel not

more than 16 m

/ sec

0.75 watt / m3

pumping capacity

Aeration tank for 0.5 to 0.75 Tip Vel not 0.75 watt / m3

242

improving aeration

efficiency

times tank Volume more than 3 m /

sec

pumping capacity

Sludge Sump

( digested / undigested

)

More than 5

times tank Volume

Tip Vel not

more than 16 m

/ sec

8 watts per m3 of

tank volume

Non less than 2 mixers hall be provided per tank .

The mixers shall be of robust construction, designed for continuous operation under

the most difficult operating conditions installed in three aeration basins.

The mixers shall be energy efficient with submersible type mixer with motor housing

in CI IS 210 Gr FG 260 and 2 or 3 blades propeller in SS 316 construction with

suitable IE3 premium efficiency motor at 415 ± 10% V, 50 C/S.

The submersible mixer shall be complete with lifting device comprising of MS Hot

galvanized minimum 60 mm tube, MS winch and steel rope and handle with all

accessories.

2.5.22. Air Blowers

The term "blower" is commonly used to define a device with a functional need for

additional airflow using a direct mechanical link as its energy source. The term

blower is used to describe different types of devices 4) Positive displacement Roots type: rotary twin /tri lobe

5) screw type

6) centrifugal / Turbo Type

Blowers are defined essentially air / gas compressing machines compressing air / gas

to a pressure of 0.9 kg/cm2 ( 9000 mm Water Colum )

For pressures exceeding 9000 mm WC Screw Compressors or reciprocating

compressors shall be used

Air blower can be 4) Regenerative / Side Channel Blowers

5) Positive displacement type: rotary twin /tri lobe

6) Centrifugal blowers / Turbo

The preference for blowers will be

S No Type of

Blowers

Suitable for Capacity

m3/hr

Delivery

Head mm

WC

Drive HP

1 Regenerative

Side Channel

Blowers

High Volume Low

Pressure

applications

Up to 400-500

m3/hr

Up to 4000

mm WC

Up to 20

2 Positive

displacement

Low / Medium

Volume and

Up to 500-

6000 m3/hr

Up to 6000-

7000 mm

Up to 150

HP

243

type: rotary

twin /tri lobe

medium to high

pressure

applications s

WC

3 Centrifugal

Turbo

High Volume /

Medium to High

pressures

Volumes in

Excess of

5000 m3/hr

upwards

Pressure of

5000 mm

WC upwards

150 HP and

More

2.5.23. General Requirements for All Types of Blowers All type of Blowers blowers should have - suction air filter and silencer,

- outlet silencer,

- pressure retied valve,

- delivery pressure gauge and

- delivery isolating and no-return valve and

- acoustic enclosure of proper design shall be provided, so that decibel level shall be

maintained as specified elsewhere.

A metallic bellow joint is provided on the delivery side of each blower. Vibration

pads shall be provided at foundation level to keep vibration of the equipment within

limits as specified elsewhere in the specification.

Casing of the blower shall be robust construction and shall be machined to proper

tolerance. Rotor along with other un-machined rotating part shall be properly

balanced so as not to cause any vibration during operation. Rotor shall be made in one

piece and securely keyed to the shaft. Means shall be provided to prevent loosening

during operation including rotation in reverse direction

The bidders should propose energy efficient air blowers/compressors of proven design

working satisfactorily with documentary evidence. For large aeration capacities

considering high efficiency, low maintenance cost, minimal foot print, minimize

breakdown time and over all low life cycle cost energy air efficient compressors shall

be preferred as per the duty application. The minimum number of standby blowers

should be 50 % if numbers of installed blowers are 2 or more otherwise 100 % stand

by .

As far as practicable the bidder should review the possibility of using same model /

rating of blowers in case there are more than 3-4 blowers for a particular application

with slidhtly different duty points so as to make a minimum type of blowers

2.5.24. Roots Types Blowers

The following specifications are essentially for Roods Type (twin lobe / Tri lobe

blowers , in case the bidder offers side channel blower or a centrifugal blower the

descriptive requirements would change accordingly .

Roots blowers shall be driven by squired case valves through a matched Ve-belt drive.

Motors shall be mounted on slide rails mounted on a common bed plate, to facilitate

the tensioning of the belts.

The horsepower rating of the blower motor (including the service factor) shall not be

less than 115 % of blower design point BHP

In case of positive displacement roots blowers the blower operating speed RPM

should not be more than

1200 RPM in case of air cooled units

244

1800 RMP in case of Water Cooled units

Inlet to blowers shall be at the top and discharge at the bottom, the axes of both being

vertical.

Connecting pipe work shall be designed for a maximum velocity of 20 to 25 m/sec.

Delivery end of the blower shall be flanged connection of appropriate specification.

4) Special Requirements for Roots Type Blowers

vi.) Though both air and water cooled units are acceptable, however the preference is for Air

Cooled unit, In case water cooled units are proposed the bidder shall provide details of

water quantity required and shall make the necessary arrangements for the same

vii.) Blower should be suitable for outdoor installation without any cover and be of suitable

construction and protection against rain

viii.) Power transmission : direct drive shall be preferred but alternative like V belt also

acceptable

ix.) The power rating of motor shall be at least 15 % above the maximum power requirement

by the blower

x.) Blower should be suitable for outdoor installation without any cover and be of suitable

construction and protection against rain

5) Material of construction

vii.) Casing : C I conforming to IS: 210

Gr FG 260

viii.) Rotor : Alloy steel

ix.) Shaft : Carbon steel C40/EN

24/19

x.) Timing gear : Cast alloy steel

xi.) Pulley and gear side plates and cover : CI

conforming to IS 210 Gr FG 260

xii.) Manufacturing Code : BS 1571

6) Tests

vi.) Hydrostatic tests Twice the maximum

working pressure

vii.) Strip test Clearances with tolerance limit

viii.) Performance test As per BS : 1571

ix.) Mechanical balancing ISO 1940 Gr. 6.3 or better

x.) Visual Inspection Before painting

2.5.25. Turbo Blower:

2.5.5.5. General Turbo Blower General Requirements / Specifications

xviii.) The high speed turbo blower should be gearless & direct driven with high frequency

permanent magnet motor. The PM motor should be high efficiency type with H class

insulation. Both, the PM motor & the blower should have lubrication-free air-foil bearing.

Super alloy material of construction of the shaft will be preferred.

xix.) The material of construction of the blower‟s impeller should be of stainless steel or

aluminium; however aerospace class high tensile strength (980 MPa) SUS630 stainless steel

17-4PH material will be preferred.

xx.) The PM motor should have perfectly matching integrated invertor (VFD) which should be

used for smooth start-up as well as capacity control from minimum of 40% to maximum of

100% output. VFD control shall be based upon constant motor current, not constant rpm.

xxi.) The starting current should be less than 15% of full load current of the motor / blower.

xxii.) Both, the PM motor & Invertor (VFD) of air-cooled type will be preferred. All cooling shall

be accomplished with ambient air only. No provisions or requirements for water cooling of

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any kind shall be required. Heated air from the motor & inverter shall not be mixed with

intake fresh air.

xxiii.) The blower package should be microprocessor controlled with graphical touch screen display

HMI. It should be able to control following parameters – constant pressure, constant flow,

constant power & dissolved oxygen control with direct connectivity to D.O. sensor.

xxiv.) The blower should have built-in flow meter which should continuously measure on-line flow

of air.

xxv.) The blower should be equipped with pressure, differential pressure, vibration, speed, &

temperature monitoring devices.

xxvi.) Flow measurement should be an integral part of the blower and the flow measuring device

can be a orifice or a bell mouth the design with the flow being measured based on differential

pressure. Actual ambient & discharge temperatures should be measured using temperature

instrumentation. No assumptions or calculations regarding flow, pressure, temperatures or

relative humidity shall be made. All process & performance conditions shall be measured, not

calculated.

xxvii.) The HMI should display set value, actual instantaneous value & on-line trend of discharge

pressure, flow, input power, rpm, suction temperature, performance curve / map with actual

instantaneous operating point. It should also have provision to send this data for logging

purpose.

xxviii.) Static pressure measurement should be carried out at exit of diffuser of the blower to ensure

that it is equivalent to the total discharge pressure.

xxix.) The microprocessor controller should be able to accept external analogue input for remote

setting of the parameter to be controlled.

xxx.) The supplier should guarantee the total input power to the blower as per specified discharge

flow & pressure.

xxxi.) Blower shall have built in automatic surge protection. Blower with high „rise to surge‟ will be

preferred.

xxxii.) Blower package shall be supplied with acoustic enclosure covering the entire blower package

to restrict the noise level up to 80 dBA at 1 mt distance. The enclosure shall be designed so as

to be able to install multiple blowers side-by-side with all maintenance done from the front or

back of the package.

xxxiii.) Each blower shall be factory tested by the standard methods based upon ASME PTC-10:1997

measuring kw input for Wire to Air power at the inlet of the package and/or applicable test

codes such as ISO 5389:2005, JIS B 8340. Acceptance criteria is 2% tolerance on power and

flow.

xxxiv.) All machines are Air Cooled. No additional cooling water circuit required either to cool the

VFD or the motor. This reduces the maintenance of water coolers which tend to get choked,

corroded, leakage in the long run depending upon the water quality being used for cooling. It

also ensures that the wire to air efficiency is complete since ppl do not add the cooling water

power consumption and cost while calculating the LCC and ROI

2.5.5.6. High Speed Tubro Motor

High Efficiency PM (Permanent Magnet) Motor .The permanent magnet will make it

possible to have very high efficiency (96-97%) over an entire operating range.

Due to high efficiency design and manufacturing, heat generation from the motor is

much smaller compared to other regular PM motors. Hence, air cooling was made

possible and is the standard for all the models up to 800 hp. Main benefits of an air

cooling system include higher safety and less maintenance.

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PM motors will have low starting current to a maximum of 4 to 10 % of the Full Load

Current

Motor to be suitable for v.) Input Power: 3Ø, 415Vac, 50 Hz(± 5%)

vi.) Motor Power Range: 100 hp to 800 hp including 15 % 0verload of durty point FLC

vii.) Harmonics Frequency filters to be an integral part of the motors

viii.) Should have, optimized VFD needs very small starting current (< 5% Full load current) and

provides very High Efficiency (@96-97%), which helps to reduce electric facility costs.

Because our most advanced high efficiency motor design requires minimum cooling efforts,

the motor cooling air has a surplus capability allowing for cooling of the VFD before the air

is used for motor cooling

2.5.5.7. High Speed Tubro Blower Features vii.) Oil-less Operation : due to air foil /permanent magnet bearings, ISO 8573-1

viii.) Flow Meter to be an integral part of blower showing flow rate with ±0.5% tolerance

ix.) Real High Rise-to-Surge : should have advanced current based control method enables an

active high rise-to-surge advantage. This is a critical feature required by Aeration

requirements .

x.) Compactness of System :

The starting current is only 5% of FLC. This smooth starting enables to reduce the

starting load on electrical system.

xi.) Semi-Permanent Life

These blowers can be used permanently with proper maintenance without

performance degradation.

xii.) Stainless steel impellers and packaging insure durability and allow for permanent life.

2.5.5.8. Material Of Construction

vi.) Impeller :

Casted Stainless Impeller (17-4PH) or High Strength Aluminum allow for

impellers vii.) Shaft :

Stainless Steel or Tiatianum viii.) Permanent Magnet

Permanent Magnet to be used used in the rotor, which has very good high

temperature characteristics.

Even under very high temperature and high loading condition, Permanent

magnet are not demagnetized and very stable.. ix.) Bearing

Oil free Teflon-S Air foil or Permanent Magnet bearings made from corrosion

free material like nickel , titanium alloy steel . x.) Stainless steel Housing

Semi-permanent life time of the blower core require better package material. It

is recommended it should be stainless steel without painting.

VFD is mandatory for any of these blowers.

2.5.26. Single Stage Centrifugal Blower/compressors :

2.5.6.12. General The compressors shall be motor driven, single - stage centrifugal, integrally geared,

radially split type. Each compressor shall be provided with end-suction and side

discharge, with discharge adjustable radially increments. Each compressor shall be

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equipped with an integral intake filter/silencer, modulating inlet guide e vanes and

discharge variable vane diffusers, integral speed-increasing gear, discharge cone -

silencer, direct coupled motor, coupling and guard, inlet and discharge flexible

connectors; discharge check valve, backflow barrier, motorized blow-off valve with

silencer, lube oil system, instrumentation and control system.

The compressor equipment shall include all the ancillaries with local control panels

for each compressor and the master sequence controller integrated in the local control

panels.

The compressor equipment specified herein is intended to pressurize ambient air for

the supply of oxygen to waste water treatment aeration tanks.

The compressors will receive filtered air and will discharge to the main header. The

capacity of each compressor shall be automatically controlled to provide the airflow

rate through the compressor as required by the process. The blow-off valve shall be

open during start-up and shutdown to allow unloaded start and stop, and to avoid

surge conditions All the piping system from the blowers shall be interconnected to

feed to all the basins.

Single Stage Centrifugal Blower should have variable frequency drive for variable

motor speed control and optimal efficiency for all operation points with soft start-up

function.

The capacity regulation shall be as per the process requirement of plant however not

less than from 120% to as low as 45% with best efficiency.

2.5.6.13. Impeller type The impeller shall be of the semi open radial flow type, induced S-shaped with strong

backward leaning blades, machined as one, not welded, casted or riveted.

The impeller shall be statically and dynamically balanced. The Supplier must demonstrate

that the impeller/shaft design is designed for operating at peripheral speeds up to 115% of the

rated operating speed. The axial gap between the impeller and compressor casing must be

adjustable by means of machined spacers in order to assure the prescribed gap. Gap

adjustments by means of machining of casings or shafts may not be accepted.

2.5.6.14. Shaft Seals The shaft seals shall be of double mechanical seal non-contact, multi-point, labyrinth

type with small clearances and sufficient touch points to minimize air leakage out of

or into the casing while the compressor is running in the specified operating range or

during start and shutdown and to ensure a 100% oil free air supply.

2.5.6.15. Gear Box

c) The gearbox shall be of ample size and rated to transmit the maximum torque and power input

requirements to the compressor under all operating conditions and continuous duty. The

service factor shall be minimum 1.4. All exposed machined surfaces shall be coated with a

corrosion-resistant compound prior to shipment.

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d) The gear drive housing shall be of light weight aluminium di casted suitable for high

temperature and sufficiently rigid to maintain the shaft positions under maximum loads. The

gear housing shall be horizontally split in order to allow easy inspection and maintenance.

The gear housing assemblies shall be machined to close tolerances for bearing fit, gear

alignment and oil tightness.

2.5.6.16. Oil Lubrication System

f) A complete lube oil system shall be provided with each compressor. The system shall be

capable of supplying clean lube oil at suitable pressure and temperature to lubricate the speed

increasing gears and bearings. All components of the lubricating system shall be installed

integral with the compressor base plate and arranged to permit ease of accessibility for

operation, maintenance, inspection and cleaning.

g) The package shall include one gearbox drive shaft driven primary oil pump and one electric

motor driven pre-lubrication oil pump, each of adequate capacity to supply lubrication for the

air compressor/gearbox when operating under normal duty, during normal start/stop and

during run down in case of power loss. The electric motor driven oil pump will operate at

start/stop of compressor and at low oil pressure, activated by the control system located in the

local control panel.

h) The lube oil filter shall be duplex cartridge type suited for the oil pump capacity, with

replaceable cartridges which can be replaced without stopping the compressor. The filter

grade shall be capable of removing particles over 10 microns with a clean oil filter and a

pressure drop not exceeding 350 mbar at design temperature and flow. Filter cases shall be

suitable for operation at a pressure not less than the relief valve setting. A visual gauge or an

electric pressure switch shall indicate when the filters are contaminated and requires

replacement.

i) Strainers shall be manually cleaned and equipped with a magnetic trap. Design and

installation shall permit ready access for cleaning.

j) An oil cooler for each compressor shall be furnished and shall be of the air-to-oil type. The

cooler shall be capable of maintaining required cooling rate at all specified ambient

temperatures. Each cooler shall be rated to dissipate the total emitted heat from the

compressor gearbox. Air-to-oil cooler shall be furnished with an electric motor-driven air

blast fan.

2.5.6.17. Local Control Panel

h) Each compressor shall be furnished with an integrated and dedicated rack based PLC,

sequencing panel including in built variable frequency drive and soft starter. All controls shall

go into a safe condition by failure and not allow the machine to be operated with any

defective control.

i) The Local Control Panel set-up shall include the Load Sharing functionality with Master

Control Panel of adequate features.

j) The local control panel shall consist of the following:

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k) Low voltage system -with main switch and motor overload relays for auxiliary equipment

such as blow-off valve, variable diffuser, and inlet guide vanes. Further, monitoring of the

drive motor's temperature sensors, and relay for control of drive motor's main switch, with

wiring to:

l) Control system - with automatic PLC, in built variable frequency drive and soft starter with

current overload circuit to limit power consumption of the compressor, and all necessary

control circuits for oil pressure, oil temperature, surge limit, and recirculation.

m) The front panel shall be equipped with Human Machine Interface with a screen of minimum

6" color touch panel with indication of process values Low voltage and control systems

mounted in a steel panel, IP55, and internally wired.

n) Terminal strip for external wiring.

2.5.6.18. Inlet filter / Silencer d) Each compressor shall be provided with an inlet filter / silencer designed for maximum air

flow at absolute minimum pressure drop and connected directly to the inlet of the compressor

via a flexible connection.

e) Filters shall be removable through easily accessible doors and have a removal efficiency of

99% on 10 micron. The filter has to have a minimum standard of EU3 in accordance to DIN

24185.

f) The compressor has to be installed with sand trap and pre-filter at the air intake.

2.5.6.19. Bearings The bearings could be

iv.) Hydrodynamic type sleeve type bearings

v.) Magnetic Bearings

vi.) Hydrofoil Bearings

The drive shaft radial and thrust bearings can be either Hydrodynamic type sleeve type

bearings or Duplex Roller bearings. The use of hydrodynamic thrust bearings on the high

speed shaft shall be avoided as to reduce the mechanical losses and instead the thrust load

from the high speed pinion shaft shall be transferred to the low speed shaft using high

precision thrust collars on the pinion shaft. Steel backed tilting pad radial bearings with white

metal on the bearing surfaces shall be used on the high speed pinion shaft. Radial and thrust

bearings shall be pressure lubricated with sufficient oil film thickness under all operating

conditions. All bearings shall be rated for a bearing life of minimum 150,000 hours.

Vibration levels (P≤ 300

kW) ≤

: In accordance to ISO 10816-1

Vibration levels (P>300 kW)

≤

: In accordance to ISO 10816-1

Noise level ≤ : In accordance to 85 dB at 1 m

Following has to be provided for each compressor by the supplier:

- Outlet pressure transmitters, inlet temperature transmitter and a thermal mass flow meter.

The unit should allow for communication to main SCADA control system.

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- Inlet Air Filter Differential Pressure Switch

- Oil Temperature Transmitter

- Oil Pressure Transmitter

- Oil Filter Differential Pressure Switch - Variable Vane Diffuser Position Transmitter

- Inlet Guide Vane position transmitter

- Gear vibration accelerometer transmitter

- Blower reverse rotation detector

2.5.6.20. Material of Construction

Casing : Inner Volute Aluminium AlCu2MgNi,

Outer volute Aluminium AlCu2MgNi,

Impeller : Aluminium AlCu2MgNi, open radial flow type with

backward leaning blades.

Gearwheels : High tensile SS316

Shaft fast : High tensile SS316

Shaft slow : High tensile SS316

Coupling : Geared

Filter material : As required

Machine mounts : St. SIS 1312, for damping natural rubber hardness 60

Oil Cooling : Air cooled

Acoustic enclosure : Al-Zn coated steel, isolated with glass wool, IP55

enclosure

Motor : IE3 Premium efficiency motor, IP55, insulation class F

with temperature rise F and temperature measurement in

the winding as well as of anti-condensation heater.

Cone diffuser : Stainless Steel 316

Compensator : Stainless Steel 316

2.5.6.21. Performance Test run

One compressor in each type/model shall be fully inspected and functionally tested at the

factory for performance and proper operation by Engineer or Engineer‟s approval as per

approved QAP. Performance test and acceptance according to ISO 5389 should be performed

on manufacturer test stand to the satisfaction of the engineer. The design values of the

performance table according the contract must be within a manufacturing tolerance of ± 2%

and a measuring tolerance of ± 2%.

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2.5.6.22. Electric Motor Driven Propeller Type Aerator with Blower Aspirator Aerators

General Description

The unit supplied must be able to operate both in mixing and in aeration mode controlled

completely independently of each other. Unit must have two distinct modes of operation;

simultaneous aeration and mixing mode, and mixing only mode. The aerator consists of an

electric motor and regenerative blower located above the water surface. The motor is

connected to a hollow shaft with a protective housing positioned at a 45° angle downward

into the water.

Aerators with submersible motors are not acceptable. No Gear Box mechanism should be

required. The hollow shaft drives a mixing propeller and Saturn Ring-type diffuser beneath

the water surface. Attached to the primary propeller is a Saturn ring diffuser, which disperses

the air as fine bubbles (2.0-2.5 mm diameter) into the stream of displaced water beneath the

water surface.

Aerator / Mixer Components:

Aerator Drive Motor

1) The motor shall deliver necessary horsepower as per process design requirement at

750 RPM nominal with no gear box mechanism and shall be rated for 415 volts,

50HZ/cycle, 3 phase service, IEC Motor.

2) Motor enclosure configuration shall be totally enclosed, fan cooled TEFC and meet

IP55/56 specifications.

3) Motor frame shall be made of cast iron end brackets and cast iron body. Fan material

shall be carbon steel, aluminium, or propylene with metal hub. Fan cover shall be

cast iron or carbon steel with epoxy polyester paint - 50 micrometres thick

minimum.

4) The noise level of the motor shall be less then 60DB and in accordance with IEC

specifications.

Blower

1) The equipment shall include a high efficiency regenerative blower sized to provide

sufficient airflow to yield the rated oxygen transfer capacity. Each blower includes

the following features:

a) Maintenance free and CE compliant - Declaration of Conformity on file

b) Aluminum alloy construction

c) Inlet and outlet sound attenuating silencers to minimize noise.

d) Inlet filters with epoxy-coated wire mesh media rated for 70 microns or better.

e) The blowers shall be tropicalized for corrosion resistance and deliver

necessary horsepower as per process design requirement maximum rated for

415 volts, 50 HZ cycle, 3 phase service. Blower motors shall be wired

separately.

Mounting Flange

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1) The mounting flange shall be stainless steel and shall permit removal of the aerator

mechanism leaving the motor in place. The mounting flange will allow the aerator to

be rotated out of the water for inspection, maintenance or storage.

Shaft / Universal Joint Coupling

1) The shaft shall be stainless steel full-welded to a forged carbon steel universal joint

coupling. The shaft must be hollow to promote maximum air flow and oxygen

transfer. Units with solid shafts are not acceptable. The shaft shall be dynamically

balanced.

2) The universal joint coupling shall include standard grease fitting for maintenance

lubrication. Units which utilize flexible couplings to attach to the shaft of the motor

are not acceptable.

3) Units supplied with couplings that require alignment are not acceptable.

4) The shaft shall be stabilized by a replaceable water lubricated bearing located within

one inch from the propeller hub. The area of the shaft supported by the bearing shall

be fitted with a replaceable hardened non-metallic sleeve.

Housing

1) The housing shall be stainless steel and flanged for mounting to the aerator. The

housing shall form a guard around the hollow shaft and support a field replaceable,

water-lubricated bearing press-fitted into the housing lower end. Water lubrication

holes shall penetrate the housing in the area surrounding the bearing.

Bearing

1) The aerator shall be supplied with a field replaceable water lubricated lower support

bearing. The bearing shall be constructed of an appropriate material for the

application inside a fibre backing. The bearing shall be press-fitted into the housing

to allow ease of replacement.

2) Units utilizing a cantilever design without a lower support bearing or regreaseable

tapered roller bearings are not acceptable.

Sleeve

1) The replaceable hardened non-metallic sleeve shall be the only moving part in

contact with the electrometric bearing and shall spin with the shaft as one unit. The

sleeve shall be solid and homogeneous.

Propellers

1) The stainless steel mixing propeller shall be specifically designed to maximize

oxygen transfer and mixing characteristics. Propellers shall be self-tightening such

that the propeller threads tighten on the shaft threads during normal operation. The

entire flow of air shall pass through the propeller via the hollow drive shaft along the

axis of the propeller hub.

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2) The propeller design shall be tested in clean water and shown to draw a minimum of

85% of the recommended full motor amperage load at nameplate voltage and power

factor. The propeller shall be designed to allow easy removal and replacement in the

field.

Saturn Ring / Diffuser

1) The Aerator shall be equipped with a stainless steel secondary Saturn Ring diffuser,

smaller than the mixing propeller, consisting of two concentric rings of differing

diameters fixed to the diffuser body. The rings shall be specially designed to

maximize oxygen transfer and to prevent self-aspiration when the regenerative

blower is turned off to accomplish anoxic mixing. The entire flow of forced air shall

exit through the propeller /atomizer opening.

Vortex Shield

1) A vortex shield shall be furnished with each mounting assembly to eliminate the

formation of vortices, maximize shaft airflow and prevent cavitations damage to the

propeller during operation. Units without vortex shields are not acceptable.

Bridge mount

2) The fixed bridge mount should be made of Galvanized steel, rails and mounting hardware.

The recommendation of fixed mount should be recommended by the Equipment supplier

according to the site conditions. Vortex shield cabled to the frame. The platform is fixed

type.

2.5.27. Gravity Sludge Thickener

Gravity Sludge thickener shall be Circular (radial), fixed bridge, central turn table type or

central drive. Selected Bidder may also provide alternatively the mechanical sludge

thickener.

(b) The circular reinforced concrete thickeners tapering at bottom shall be provided for

thickening process.

Design shall be such that the sludge after thickening can be extracted from the

bottom of the hopper portion. Interstitial liquid flows through peripheral weir at top.

Tanks shall be deep enough to allow the sludge to settle by gravity. At least 50 cm

freeboard shall be provided.

Provision shall be made for collection of thickened sludge and pumping it to the

dewatering units.

A full diameter bridge with central drive shall be provided with: central platform for

the installation of the scrapers and their drives and for the local control panel; a

radial scraper system with bottom scraper blades, suspended on the bridge.

(b) The thickener shall have a full diameter fixed bridge complete with walkway for

personnel access to the center, access stairs to ground level and hand railing, a motor

driven sludge scraper complete with all necessary controls, delivery pipe work, a

stilling well and overflow steel weir plates. Hand railing, walkways, access steps etc

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shall be galvanized. Handrails shall be of tubular construction and made of

32NBpipes.

The scraping gear shall be supported from the tank base and from a fixed bridge

carrying the central electrical drive for the rotating gear. The equipment including

driving motor, gears, shafting and scrapers shall be designed for continuous

operation and sized for the most arduous operating condition including starting from

rest with an accumulation of sludge in the thickeners.

The electric motor, gearbox etc., shall be provided with a sunshade.

The fixed bridge, hand railing, access steps and the feed well shall be galvanized

steel. The main drive shall be cast Iron construction and shall be enclosed in a

dustproof enclosure with oil bath lubrication. All underwater hardware shall be of

SS304.

Suitable overload protection for the drive shall be provided to ensure that the sludge

shall not overload the equipment and emergency stop pushbutton shall be provided.

The scrapers shall be fitted with rotation monitors and over torque protection to

alarm in the event of a failure.

Structural design calculations shall be submitted for all structures including scraper

arm, bridge etc. and also the calculation for drive head selection including the

Torque Rating.

V-notch weir in Reinforced fiberglass construction of size minimum 5mm thick and

200 mm wide shall be provided along the launders for uniform draw-off of the

overflow. The weir plate shall be fixed to the launder by means SS304 grade

clamping plates and fasteners.

The hydraulic equipment will consists of the DI inlet pipe(runs along the bridge) to

the central feed well of the thickener; sludge draw-off pipe with an manual &

Motorized Knife Gate valve for intermittent operation according to an adjustable

timer; a drain pipe with manually operated gate valve for the complete emptying of

the unit; a discharge pipe/channel from the peripheral collecting channel to the main

channel leading to the Supernatant sump.

The sludge thickener mechanism shall be generally in MS galvanized construction,

suitable for installation in a circular RCC tank and shall include the following:

Mechanism support beam spanning the diameter of the tank.

Walkway and handrail from the edge to the centre of the tank.

Drive mechanism with internal gear type.

Reduction gear box.

Chain and sprocket with guard.

Central shaft with scrapper arm and picket fence.

Skimmer Scum Baffle and Scum trough.

Overflow weir:

Vertical pickets.

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Torque Indicating Device.

Overload Alarm protection.

Auto lifting device.

The minimum thickness of all the underwater parts shall be minimum 6mm thick

excluding allowance for corrosion.

Material of Construction

Tank : Reinforced Cement Concrete

Feed Well : SS 304

Bridge : MS with Hot dip Galvanized (galvanizing minimum thickness

shall be 80 micron)

Center Cage : Mild Steel Epoxy Painted

V-notch weir : SS 304 or, minimum 6 mm thick and

Squeegees : Neoprene

Handrail : 32 NB MS Pipe with Hot Dip Galvanised (radial upto centre)

Anchor Bolt & fasternes : Stainless Steel -316

Walk way : Heavy duty MS epoxy coating up to center minimum thickness

10mm

2.5.28. Anaerobic Digesters

Digester shall be anaerobic, mesophillic, single stage and single phase type having fixed steel

cover. Bottom of the digester shall be conical.

2.5.8.4. Sludge Digestion and Gas Handling units

During all seasons, favourable temperature for the microorganisms shall be maintained.

Design basis temperature shall be maximum ambient temperature. Mixing of digester

contents shall be achieved by recycling of the bio gas through bio gas compressors at

adequate pressure. The minimum design pressure of the gas compressors shall be sufficient

even for de-clogging of the gas lancers (SS 304) after shut off period of digesters.

Rotary lobe PD with VFD or Single-stage centrifugal with dual-point (inlet guide vanes and

outlet valve) control type biogas mixing blowers shall be provided. All piping if used for gas

mixing system shall be SS304.(Lancer Tubes)

All electrical motors, local control units and associated instrumentation, etc. mounted in the

digester area shall be certified for use in a hazardous zone and having required protective

enclosure.

Mixing system shall be complete along with necessary accessories, spare parts and lowering/

hoisting arrangement required in the digestion units.

2.5.8.5. Gas Mixing System for Digesters

The gas mixing system shall be efficient in operation, simple in maintenance and suitable for

tropical climate. The gas re-circulation system shall provide complete and homogenous

mixing of the digester contents including intermixing of the raw and digesting solids and

breaking of scum blanket. For maximum intensity of mixing the full discharge of compressed

gas shall have upward action minimizing the scum formation.

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Gas will be taken from the gas holder and conveyed by pipes to the gas compressors, from

where it will be fed to the digester. The pipe shall enter from top of digester dome / extracted

from roof , compressed and fed back at the bottom of digesters through diffuser such as to

mix the entire digester contents with practically no dead zones and to prevent sand build-up

on the floor. Gas flow indicator (sight glasses) to indicate flow of compressed gas through

each pipe and facility to clean individual pipe by water pressure or flexible rods in case of

chokage, without interrupting digester operation, shall also be provided. All connected piping

with necessary fittings and support and safety/protective devices shall be provided.

All electrical motors, local control units and associated instrumentation, etc. mounted in the

digester area shall be certified for use in a zone 1 hazardous area and have an IP 55 enclosure.

Gas mixing system shall be complete along with necessary accessories such as gas meter for

each digester at outfall of each digester, drip traps at suction and discharge pipes, electric

controls, spare parts and lowering / hoisting arrangement required in the digesters.

2.5.8.6. Gas Compressors

Design Requirement

The Gas Compressors shall be provided with 100% standby considering the operational

capacity and rating as required. It shall be positive rotary or reciprocating type,/ sliding vane

type air cooled/ water cooled, single stage oil free gas compressors. The cylinder shall be cast

such that gas and water passage shall be separated by metallic wall and shall not have any

gasket separating the two.

The compressors shall be complete with compressor unit, motor base plate, cooling system,

gas and water pipe work, valves, water separators, and all regulating and control equipment

as required to provide an adequate and efficient compressed high pressure gas supply. The

compressors shall have water seals.

The compressors shall be designed to compress wet and sludge gas comprising mainly

methane and CO2 with traces of H, N & H2S etc. The gas shall be assumed to be water

saturated. All metal parts in contact with gas shall be of stainless steel (type CF8M or SS

316).

A full set of performance curves, along with certificates of performance, for the package shall

be provided. The performance curves shall include gas flow and pressure, cooling water flow,

pressure and temperature rise and guaranteed power curves.

Gas Compressor Gearbox

Gas compressor gearbox shall be suitable for continuous running and intermittent starting

under maximum load with the resultant high torque and shock loads. The gearbox shall have

a service factor of 2.0 (Minimum).

Pressure Relief System

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A pressure relief system shall be included to operate on shut off pressure of compressors.

This shall consist of actuated bypass and main gas valves which shall operate to dissipate the

high pressure in the delivery main to the low pressure digestion tank.

Temperature Sensor

A temperature sensor shall be installed to give a warning alarm and shut down facility in the

event of the pressure relief valve failing to operate.

Mode of Operation

Manual control via start/stop push buttons at the control panel with auto switch off in case of

temperature bypass or over pressure switch operating.

The compressors are to run on either a timed or continuous control selected by a two position

selector switch mounted on the control panel.

When „continuous‟ mode is selected, the compressor is to run continuously and when „timed‟

mode is selected the compressor is to run for fixed duration and to be off after fixed duration.

Compressor is to trip and lock out due to the following:

Electrical Overload

Earth fault

Motor over-temperature monitored by thermistors in each phase.

Over-temperature in the compressor gas delivery pipeline.

Cooling water over-temperature.

Rise in discharge pressure.

Vacuum in suction line.

Manual Reset of tripping shall be provided.

Mode of Operation

Motors shall be flame proof squirrel cage type conforming to IS 325. The power rating shall

be at least 125% of maximum power requirement. The other features of motors shall be as

follows:

Type of duty : Continuous (S1)

Method of starting : Start-Delta

Class of insulation : F (Temperature rise limited to Class B)

Type of enclosure : TEFC & Flame proof

Degree of protection : IP 55

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2.5.29. Gas Holder

The gas holders shall be dual membrane type.The membrane cover(s) shall be stable under all

design load conditions, including localized static and dynamic loads. The external membrane

shall be designed to maintain a spherical shape that allows the cover(s) to support the

maximum possible applied loading taking into consideration dead load, Vacuum load, Wind

load and other static load.

Membrane gasholder shall consist of two membranes. The internal membrane shall store and

should be impermeable to digester gas, and inflate and deflate as the gas supply and usage

change the stored volume. The external membrane shall be constantly inflated by pressurized

air supplied by a blower or by the plant‟s Air Low Pressure (ALP) system and at least two

normally open air flow valves mounted on the side of the external membrane shall regulate

and maintain the external membrane at constant pressure. The internal membrane is protected

by a weighted relief valve that allows the evacuation of the biogas in case of over

pressurization.

Anchoring of both the external and internal membranes shall be by a pair of flanges and seals

bolted to the top of the tank periphery. The lower flange shall be sealed to the top of the tank

wall using gasket material. The upper flange and a gasket shall seal the membrane material

between the two flanges. The flange sections shall form a continuous ring to seal the

membrane to the top of the tank wall. The restraining flanges and anchors shall be fabricated

of 304 stainless steel.

All structural steel for fixing the membrane to the tank shall be Type 304 stainless steel. Steel

fabrication and welding shall be in accordance with latest edition of Structural Welding Code.

Sharp projections of cut or sheared edges of metals shall be ground and smooth to avoid

damaging membranes and to ensure satisfactory coating adherence.

All steel design shall be in accordance with the latest editions of the ISA Manual of Steel

Construction and Uniform Building Code (UBC).

Membrane shall be fabricated using High frequency welding with a 37mm minimum width.

The manufacturing process will include a peeling test on a specimen which enables the

validation of the welding parameters. All welds will be visually inspected. Additionally, all

welds and seams shall be tested mechanically through the use of pressure and tension to

ensure each weld is complete and has developed full strength.

Membranes

Internal Membrane:

The internal or gas membrane shall be fabricated of a polyester fabric coated with polyvinyl

chloride (PVC) and sized to accommodate the specified volume of biogas and shall be

resistant and impermeable to digester gas. The internal membrane fabric shall be designed

and fabricated to resist all design loadings without use of support cables superstructures or

other restraining devices and shall meet the prescribed standards.

The internal membrane shall be welded in such manner as to prevent the diffusion of biogas

through the yarn forming the internal structure of the membrane. The lack of this feature will

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not be accepted for the membrane continuously exposed to biogas.

External Membrane:

The external membrane shall be fabricated of a polyester fabric coated with polyvinyl

chloride (PVC) designed for use on air-supported structures and high-stress applications and

shall be resistant to ultraviolet degradation, abrasion, and weathering in an outdoor

environment while meeting the prescribed parameter.

Membrane cover(s) accessories and appurtenances

The membrane cover(s) shall include the following appurtenances:

Two (2) low pressure centrifugal fans for the external membrane shall be provided with

adequate power and capacity with explosion proof motor at 415 ± V and 50 C/S.

The blower shall be complete with flexible collectors, air piping, check valve, inflation fan,

electro mechanical level sensor, air relief walls, air pressure transmitter, gas pressure

transmitter and gas detector.

2.5.30. Sludge Dewatering Units

Sludge dewatering shall be done by mechanical sludge dewatering units such as Solid Bowl

Centrifuge, Belt Filter Press. The dewatering units shall include but not limited to

the following equipments:

Powder or liquid Polymer storage tanks/ Bach tanks with mixers.

Polymer mertering pumps

Mixers and solution tanks.

Polymer service tanks.

Supply line & flush line.

Dry gravimetric or volumetric "atomizing" educator for polymer feeding

Plant Water supply pumps.

Sludge feeding pumps.

Dewatering unit

Belt conveyor.

Cake hopper.

Flow meters for feeding Sludge, and for feeding chemical solution.

Control valves on sludge feeding line, and on Chemical feeding line.

Drain system

Dewatered cake shall be conveyed by a belt conveyor to cake hopper for carrying out for

reuse.

The dewatering system should be so located that the dewatered sludge can be loaded into

trolleys/ drums/ bins directly – preferably the dewatering unit shall be so located that

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the dewatered sludge falls into the containers/ bins without requirement of another

material handling unit.

The dewatered sludge should be truck-able & be suitable for disposal by open body truck and

should have a minimum solid concentration of 20% or more (measured as dry solids

w/w basis).

The dewatering unit should have a 95% solid recovery.

The centrifuge centrate should not contain more than 1000 mg/l solids.

The centrifuge should be capable of being operated at lower solid feed concentration in case

of maintenance.

Dewatering units shall be provided in a separate Sludge Dewatering Building. Feed pump

station shall be provided at lower level/floor and dewatering units shall be provided at upper

level/ floor. Solid Bowl Centrifuge

The centrifuge shall comprise a conical cylindrical bowl and scroll feed horizontally mounted

in bearings on a frame. The centrifuge bowl and scroll support frame shall be mounted on a

fabricated steel sub-frame.

The bowl and scroll shall be made from stainless steel SS316 material. The leading faces of

the scroll shall be protected against abrasive wear by the application of a suitable hard-coated

material.

The whole rotating assembly shall be enclosed by a carbon steel fabricated casing

incorporating a Centrate discharge hopper and outlet pipe, and a rectangular solids hopper

which shall discharge the dewatered sludge into the disposal system.

The rotor shall consist of a solid bowl which is conical-cylindrical in shape and which rotates

about a central shaft. An inner scroll shall be provided to convey separated sludge from the

periphery of the cylindrical bowl to the beach at the conical end of the rotor.

The main scroll bearings shall be arranged for lubrication by an external lubrication system.

Wherever practicable greasing nipples shall be arranged together as a battery. The complete

rotating assembly shall be dynamically balanced and test certificates provided.

Sludge shall be fed into one end of the rotor through a centrally positioned feed tube and

dispersed to the bowl through an inlet chamber.

The bowl shall be provided with an adjustable 360o peripheral weir at its cylindrical end to

control the depth of the Centrate in the rotor.

The fixed outlet castings of the rotor shall be designed to collect the centrate and dewatered

sludge from the rotor. Baffles within the casing shall direct the separate phases to the relevant

discharge points and prevent cross-contamination.

The centrifuge shall be mounted on heavy-duty vibration isolators, located between the

machine and the supporting steelwork or foundations, to damp vibrations and prevent

vibration transmission. Two axis vibration monitors shall be provided to stop the centrifuge

automatically when excessive vibration is detected.

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Flexible connections shall be provided on the sludge fed system and the Centrate system at

the centrifuge. The dewatered sludge discharge system shall incorporate flexible chutes.

(i) Variable Speed Drive

A variable speed drive shall be provided to accelerate the rotor to operational speed and

maintain that speed during the centrifuge‟s duty period. The bowl drive shall be electric or

hydraulic and shall be coupled to the drive shaft by a multiple „V‟ notch belt drive.

(ii) Differential Scroll Drive

The scroll drive shall be provided with a separate drive mechanism to control its rotation in

the same direction but at a different speed to the outer bowl. The differential speed shall be

adjustable.

The drive shall be linked to the main bowl drive by an epicyclic gearbox. The differential

speed of the scroll shall be automatically and manually adjustable so that the moisture content

of the dewatered sludge can be controlled as required.

For safe operation, Selected Bidder shall provide control panel showing proper Sequence of

operation with interlocking.

Chutes and interconnecting piping shall be provided with flexible joint (minimum 10 mm

flexible in all direction) to avoid vibration.

2.5.31. Belt Filter Press/CENTRIFUGE The belt filter press shall dewater the sludge as gravity drainage and belt pressure system

without the need for vacuum dewatering.

Sludge is usually required to be conditioned using a polymer prior to dewatering on the belt

filter press. The optimum polymer dosage and type of for the specific sludge is determined

by testing. Typical polymer dosing rate ranges from 0 – 6 lbs/T of dry solids.

Each belt press is designed and sufficiently automated to require minimal operator attention.

The belt press shall incorporate the following components.

xv. Main Structural Frame

The structural frame shall be of all welded construction and shall be fabricated from

channel designed to adequately support all components. The design permits roll

removal without requirement of disassembly of frame.

xvi. Extended Gravity Drainage Section

To maximize gravity water removal, adequate gravity drainage area shall be provided.

A set of gravity dispersion device spaced on 6½” maximum centers shall be provided

to disperse sludge for effective removal of water. The devices shall be designed so

each one can be moved in either lateral direction and shall be a minimum of twelve

(12) inches long to turn the sludge over in the gravity section for maximum water

removal. Dispersion devices shall be constructed of ultra-high molecular weight

polyethylene. Each set of devices shall have the capability of being rotated out of the

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flow by handles, for maintenance purposes or process flexibility. Sludge shall be

contained within the drainage section by a barrier equipped with replaceable rubber

seals on each side. The gravity drainage belt shall be supported by polyethylene grids

over the complete length and width of the gravity drainage section that are also used

for effective removal of gravity and capillary water.

xvii. Adjustable Wedge

Following gravity dewatering, adjustable wedge section for process flexibility is

incorporated into the press design. Gradual increased pressure shall be applied as

belts pass through the adjustable wedge section.

xviii. Pressure Section

A minimum diameter roll shall be used as the initial roll in contact with gravity

concentrated sludge. A S-shaped roll configuration shall be used to apply maximum

pressure and shear.

To ensure optimum cake dryness, a minimum number of rolls shall be used in the

pressure area.

xix. Filtration Belts

Each belt shall be a continuous design woven from monofilament polyester strands.

Each belt shall incorporate a mechanical seam that does not interfere with press

operation and also allows simple, periodic belt replacement.

xx. Doctor Blade

For removal of dewatered cake, the press shall incorporate doctor blade for each

filtration belt. Blade pressure shall be field adjustable against the belt by means of

spring tensioning mechanism and shall be replaceable, reversible with two useable

edges and fully accessible to the operator.

xxi. Rolls

All rolls, including guide and tracking, shall be of low deflection design.

xxii. Roller Bearings

All bearings shall be pillow block type with split, cast iron, two bolt housings. All

bearings shall be capable of compensating for misalignment without seal distortion.

Each bearing shall be grease lubricated.

xxiii. Filtrate Collection

Drainage pans shall be located under all gravity and pressure section of the press.

Drain pans with standard NPT connections shall collect gravity filtrate and pressure

filtrate to common drainage points.

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xxiv. Belt Washing Device

Following cake discharge, each polyester belt shall be continuously washed using a

100 psi pressure, low volume steel shower assembly. A Y-strainer to be provided in

wash water line to remove any particles which may enter the shower assembly. Each

shower assembly shall have replaceable brass or steel nozzles. The shower assembly

shall be designed to completely contain the high velocity water spray and remove any

solids trapped in the belt. Pumps required for belt washing are not included in our

scope of supply.

xxv. Belt Tracking

Belt positioning for each belt shall be continuously and automatically monitored by

suitable arrangement which shall be installed with guide devices. The guide device

shall ride the edge of the polyester cloth belt. The micro-torque unit shall sense belt

misalignment and shall automatically walk the belt back to the normal operating

position by means of a live hydraulic cylinder which shall be attached to tracking

rolls. The opposite end of the tracking roll shall incorporate self-aligning pillow block

bearings which allows the tracking rolls to pivot in a horizontal plane. Belt tracking

shall be automatically operated by the hydraulic power pack. A limit switch shall be

provided on each side of each belt to sense extreme belt travel and initiate a shut-

down signal and sound an alarm. The limit switches for the pressure section shall be

positioned to sense both belts simultaneously.

xxvi. Belt Tensioning

Each belt in the pressure section shall be equipped with a hydraulic cylinder belt

tension system operated by the hydraulic power pack to automatically ensure proper

preset belt tension while dewatering varying thickness of sludge. The belt tension

system shall assure parallel movement of the tension rolls by use of rack and pinion

system.

xxvii. Belt Press Drive & Component Operation

The belt press drive comprises of an electric geared motor unit coupled to the drive

roll through a flexible coupling. A local electrical control panel complete with control

logic, variable frequency drive etc. is also supplied along with the belt filter press.

xxviii. Painting All MS components shall be sand blasted and coaltar epoxy painted to a minimum

DFT of 120 Microns.

2.5.32. Bio Gas Scrubbing System

Bio Gas Scrubbing System

Hydrogen sulphide is a highly toxic and corrosive gas and is a major pollutant. At high

concentrations it will lead to almost instantaneous poisoning and death.

The system description consists of major equipment like Pre-Scrubber, Scrubber, Wash

Tower, Regenerator, Filter Press and Pumps. The system should be with zero liquid discharge

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and no gases/ effluent emission in the process of scrubbing. Supplier/vendor supplied and

commissioned scrubbing would only be considered.

2.5.33. Gas Generating Set & Accessories

It is proposed to generate maximum possible power out of the available sewage gas by using

highly efficient gas generators. The power generated from Power Plant will be used for In-

house consumption of the Sewage treatment plant equipment.

The Generators have to be designed to operate at maximum gas generation to give the

optimum power output from in house captive consumption.

The CH4 (Methane) content in Gas shall be in the range of 60% to 65%. The gas will also

have concentration of H2S @ 1.5% to 2.0%. This H2S which is highly corrosive in nature has

to be removed from the sewage gas before feeding the gas to the gas gen-sets. This H2S has

to be removed from this sewage gas by using chemical gas cleaning scrubbers.

The gensets have to be designed to run on base load operation continuously during the peak

gas generation; The H2S content in the sewage gas generated shall be removed by a H2S

scrubbing system. The scrubber shall be capable to reduce the concentration below 200 ppm

level.

Gas Engines shall be designed for running on 100% Sewage Gas with a high level of fuel

efficiency with lean burn combustion technology. Bidder shall provide gas engine for power

generation from the gas produced by proposed plant.Gas engine should be designed as per the

actual load considering 100% standby. Capacity of all gas engines shall be same & the gas

gensets shall not be overloaded more than 100% since gas gensets are meant for base load

operation and cannot be overloaded. Also there should be provision for DG set to black start

the gas engine during breakdown period

Gas engine shall be hooked to the main LT panel. Gas engines shall be running on continuous

operation. It will be preferred that the gas gensets along with the H2S Scrubber shall be

provided as a package.

The gensets shall be designed for running on 100% Sewage Gas with a high level of fuel

efficiency / electrical efficiency. The electrical efficiency of the gensets at the alternator

terminal under site conditions and 100 % load shall not be less than 40 % (Standard

tolerances shall be applicable).The engine shall be 4 stroke Otto gas V engine type.

Main Components of Gas Engine

Genset Components

Base Frame, Coupling, Pre – Lube Pump, Air Filter, Zero Pressure Gas Control Line with

Connection Accessories, Crankcase, Driving gear, Cylinder head, Valve drive, Ignition,

Carburetion, Mixture charging, Starter, Lube oil system, Sensor technology/actuator

technology and cabling etc.

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Rotary Current Internal Pole Synchronous Generator

Three-phase synchronous generator, brushless, self-induced, self-adjusting, with dampening

cage for 30% inclined load and parallel operation, artificial star point, protection type IP 23,

with tropical atmosphere and humidity protection insulation, degree of radio shielding "N",

voltage target value setting ± 5%, Insulation Class H.

Gen-Set Components

Base Frame Steel bend torsion-resistant construction

Coupling High stretch, axial plug in coupling for torsional elastic

connection of engine and generators

Pre – Lube Pump Electric pump

Air Filter Paper dry type air filter

Zero Pressure Gas Control Line with Connection Accessories

Crankcase Alloyed special cast iron

Driving gear Chrome molybdenum

Cylinder head Special cast Iron

Value drive Toothed-wheel driven camp shaft

Ignition Microprocessor control high voltage ignition system

Carburetion Drive type air filter

Lube oil system Pressure lubrication gear pump

Alternator

Brushless, Self-Excited, Self-Regulated, Double Bearing, Synchronous Alternator with

electronic AVR, 415 V, 1 Power Factor, 50 Hz, complete with standard accessories.

Flare System

A Comprehensive auto flare philosophy shall be submitted along with the GAS Engine

Power Generation Philosophy to complete the interlock of flaring with no power generation.

Gas Flow on the Gas flare line shall have interlock with the flame detector to conclude the

effective flaring.

The flare unit shall be designed for biogas flow generated during average flow conditions. It

shall be fabricated of suitable materials (carbon steel except for top portion which shall be in

SS 304). The design of flare unit will be such that it shall be conveniently mounted on the

steel supporting structure.

The velocity of biogas through the flare unit should be minimal considering 100-150 mm WC

pressure of biogas at flare inlet. Capacity of Gas flare system shall be provided for total gas

generated from the existing (Phase – I) and proposed plant (phase-II). Gas from existing

plant is not to be considered. Gas flare system shall be one working and one standby unit

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alongwith all accessories.

A suitable spark ignition system should be provided at a convenient location. Biogas shall be

used as a pilot fuel. The pilot flame generated with the help of spark ignition systems shall

propagate through the flare unit to ignite main biogas. The control system involving control

panel, ignition transformer etc shall be provided for the said purpose.

H.T. Cable shall be provided from the secondary terminal of ignition transformer up to spark

ignition system. Necessary ignition electrode OR 1 number 25 KVA generator set shall be

provided. The 25 KVA generator set can also be used to start the gas engine.

Moisture Traps

The moisture trap shall be designed to effectively separate out moisture in the biogas such

that moisture free biogas is made available at the outlet of a trap. It shall be of suitable

materials of construction and be provided with suitable drain connection.

Flame Traps

The flame trap shall be of suitable size for biogas application. It shall be used primarily in

pipe lines to prevent flash back during explosions.

This device shall be installed in horizontal or vertical pipe line and hence it should be

bidirectional.

It shall be of suitable materials of construction.

The flame arresting element shall be designed such that it results in minimal pressure loss

under normal operating condition but to ensure maximum security in the event of explosion,

the end connection shall be flanged.

2.5.34. Pumps 2.5.14.8. Sump Pump

The pumps shall run smooth without undue noise and vibration.

The power rating of the pump motor shall not be less than the maximum power required

from zero discharge to zero head.

Pump should be vertical, centrifugal, single stage, non-clog type.

It should be suitable for handling sewage containing stringy materials.

Plate type strainer should be provided to prevent large size solids entering into pump

The pump shaft journal bearings shall preferably be grease lubricated. No external water

will be made available for the lubrication of the bearings.

Delivery piping with gun metal non-return valve should be supplied.

Delivery pipe should be as per IS: 1239, medium class.

Pump should be operated automatically by providing float operated level switch .

The base plate shall not be directly fixed to the floor. Channels should be grouted in the

floor and the base plate should be attached to the channel.

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Materials of Construction

Impeller : Stainless Steel

Casing : Cast Iron

Shaft : Stainless Steel

Cover plate : Steel

2.5.14.9. Submersible Pumps

5. Design of pumps of MPSwith suitable head and discharge should be done by

selected bidder as per CPHEEO manual considering (4 working + 50% standby) pumps .

Design Requirements

Design consideration:

l. Submersible pumps shall be submersible, vertical shaped, centrifugal, non-clog type, suitable for

municipal sewage, design for continuous operation in submerged / partially submerged condition

and intermittent operation complete with motor control system, guide rail, anchoring brackets,

base elbow, power cable & pumping lifting cable/ SS chain with control panel and level switches

suitable for solid passage of 100mm diameter and above.

m. The efficiency / pump shall be high at duty point and remain reasonably high during the full duty

range at the pumping system.

n. The pump of MPS and STP shall be compatible with VFD and selected automation system.

o. The pump should be capable of developing the required total head at rated capacity. Pumps

should be suitable for single as well as parallel operation at any point.

p. The pump should deliver at least 125% of its rated capacity at 75% of the specified total head.

The H and Q curve should be continuously rising towards shut off head.

q. Operating range – system curve

r. The velocity of vibration should be less than 4.5mm/ sec. with noise level 85 dBA at resistance

of 1.85 meter.

s. The power rating of the pump motor should be the larger of the following:

iv) The maximum power required by the pump from zero discharge to zero head.

v) 115% of the power required at the duty point. Considering the combined efficiency

(motor & pump).

vi)

t. The combined efficiency of the pump shall not be less than 70%. The motor efficiency shall not

be less than 92 % and pump efficiency shall not be less than 65-75%. The highest efficient pump

set shall be considered for selection.

u. For pumps that are run with variable frequency derive then System Curve shall be submitted

along with Motor Curve for the entire operative range of RPM for approval. Submission of pump

data sheet shall be tagged as variable frequency derive /Normal Operation.

v. The primary sludge pumps, dilution water pumps, treated effluent pumps, back wash pumps,

filter feed pump should have the efficiency of 60% and motor 87%. Only energy efficient motor

shall be accepted.

Material of Construction

Pumps

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Pump casing : Ductile iron

Discharge cover : Ductile iron

Impeller : stainless steel SS316

Shaft : stainless steel SS316

Bearing Bracket : Grey cast iron (CI IS: 210FG260/ Ductile iron)

Motor casing : Grey cast iron (CI IS: 210FG260/ Ductile iron)

Bolts, nuts : stainless steel SS316

Shaft protective sleeve : stainless steel SS316

Casing wear ring : Grey cast iron (CI IS: 210FG260/ Ductile iron)

O-ring : Nitrile rubber (NBR)

Efficiency : Min. 75%

Shaft seal

Type of seal : Double mechanical seal

Arrangement : Tandem

Seal on medium side : With elastomer bellows

Mechanical seal, pump side : Silicon carbide

Mechanical seal, bearing side : Carbon/ silicon carbide

Monitoring

Thermal winding protection : Thermistors PT-100 in all three phase winding

Explosion proof protection :

Motor housing monitoring : By conductive moisture sensor electrode

Mechanical seal leakage detection: By float switch

Bearing temp monitoring : Thermistors PT 100 in upper bearing

Installation

Type of installation : wet well installation design for automatic connection to

a permanently installed discharge elbow will neoprene seal to avoid metal to metal contact

Flange dimension to : EN 1092-2, PN 10

Claw : Bolted to the pump

Installation depth : As per data provided

Guide system : Stainless Steel

Lifting device : Stainless steel lifting chain

Length of lifting device : Suitable

Lifting loops : suitable

Installation accessories : Discharge elbow, fasteners, claw, bracket, lifting

chain, guide bars etc. complete

Motor

Min. motor efficiency : 92% and pump efficiency 65-75%

Degree of protection : IP 68

Insulation class : F0

Coolant temp : </= 40 C

Starting mode : Direct

Rated voltage : 3ph, 415 V

Rated freq : 50 Hz

Nominal speed : Less than 1500- rpm (Synchronise)

Voltage tolerance : ±10%

Motor casing : Grey cast iron

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Main cable : complete with cable length as per requirement

2.5.14.1. Mixed Liquor Pumps

Type of Pump Vertical Propeller Tube Type

Column Length & Column & Shaft

Assembly

Required

Type of fabrication Self-Water

RPM 590

Pump Efficiency Min. 80%

Motor Efficiency Min. 92%

Pump housing Ductile cast iron

Impeller EN-GJS500-7, AISI 80-55-06

Pump Shaft Stainless Steel

Discharge Head MS Fabricated

Motor Cast iron, EN-JL1040, AISI A48 30

Voltage 415 ±10% 3 Phase

Frequency 50HZ

Note:

3. The Pumps will have VFD.

4. The primary and secondary scum pumps shall be submersible chopper pumps.

3. All above data are indicative and final design would be done after due

consideration of drawing/design as per site condition.

2.5.14.2. Horizontal Centrifugal Pumps

Design Requirements: i. The pump should be capable of developing the required total head at rated capacity. Pumps

should be suitable for single as well as parallel efficient operation at any point in between the

minimum and maximum system resistance indicated in the system resistance curves.

j. The total head capacity curve should be continuously rising towards the shut off. The pump

should deliver at least 125% of its rated capacity at 75% of the specified total head.

k. The required NPSH at duty point should be at least 1.0 M less than the available NPSH.

l. Pumps shall run smooth without undue noise and vibration. The velocity of vibration should

be within 4.5 mm/sec. The noise level should be limited to 85 dBA at a distance of 1.85 M.

m. Operating range - -system curve shall be submitted along with that of motor if the pump/s are

subjected to VFD application with the data sheet tagged as VFD application

n. The power rating of the pump motor should be the larger of the following:

iii) The maximum power required by the pump from zero discharge to zero head.

iv) 115% of the power required at the duty point. Considering the combined efficiency of

pump and motor with zero negative tolerance.

o. The pump set should be suitable for starting with discharge valve open, as well as closed.

p. Design of pumps for MPS with suitable head and discharge should be done by

selected bidder as per CPHEEO manual considering (4 working + 50% standby)

pumps .

Features of Construction

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o. Pump should be suitable for applications in municipal sewage handling or sludge handling as

per process requirement, with back pull out design. It shall have end suction and side

discharge. It should be of self-venting type.

p. Pumps should be identical for particular application and suitable for parallel operation with

equal load division. Components of identical pumps should be interchangeable.

q. Pump casing should be of robust construction Liquid passages should be finished smooth and

designed so as to allow free passage of solids. The volute tongue should be straight across and

filed to a smooth rounded edge. Casing should be provided with hardened renewable wearing

ring.

r. Impeller should be suitable for application, enclosed type with smooth blunt edges and large

water ways so as to allow free passage of large size solids. It should be free from sharp

corners and projections likely to catch and hold rags and stringy materials. Impellers should

be provided with hardened wearing ring. Hardness of the Impeller ring should be at least 50

BHN more than that of casing ring.

s. The first critical speed of the rotor should be 30% above the operating speed.

Complete rotor should be statically and dynamically balanced.

t. Replaceable shaft sleeves should be provided to protect the shaft where it passes through

stuffing boxes. Surface hardness of shaft sleeve should be minimum 350 BHN.

u. Pumps should be provided with anti-friction bearings. Bearings should be easily accessible for

inspection and maintenance. Bearings should be grease lubricated.

v. Stuffing box should be of such design that they can be repacked without removing any part

other than gland and lantern ring. Stuffing box drain with pipe connection should be provided

at the lowest point so that no leakage accumulates in it.

w. Lantern ring should be of axially split type. Grease should be used for stuffing box sealing.

Water will not be available for this purpose. Gland should be of split type.

x. Pump should be furnished complete with flexible coupling.

y. Coupling guard bolted to the base plate should be furnished.

z. Base plate for pump and motor should be common. Suitable holes should be provided for

grouting. Foundation bolts should be complete with nuts and washers.

aa. Tapping should be provided at suction and discharge nozzles for pressure gauge connection.

bb. Hand holes should be provided in the casing to allow easy access to the impeller as well as to

the casing throat. Casing drain connection with stainless steel collared plug should be

provided.

Material of Construction k. Casing : CI to IS:210 GR FG 260 with 1.5 to 2% Nickel.

l. Impeller : Stainless steel CF 8M STA STM A35/Gr.CF8M

m. Wearing rings : SS 316 STA STM A35/Gr.CF8M

n. Shaft : SS to AISI 431 STA STM A276 Type 410

o. Shaft sleeves : SS to AISI 410 STA STM A276 Type 410

p. Packing : Asbestos yarn coated with MoS2 (Molybdenum Di-Sulphide)

q. Packing : CI/MS fabricated.CI IS210 Gr F G260

r. Base plate : CI/MS fabricated IS 2062

s. Gland : Cast Iron CI IS 210 Gr F G260

t. Coupling : CI

2.5.14.3. Dewatering Pump k. Pump should be suitable for handling settled sewage containing grit and suspended particles.

l. The pump motor should be suitable for working with or without submergence in sewage. The

motor rating should be more than the maximum power required by the pump.

m. The pump set should be portable with necessary hooks.

n. The pump should be suitable for dewatering from a pit 900mm x 900mm x 100mm deep.

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o. The pump should be vertical, centrifugal, non-clog type.

p. The pump impeller should be mounted on the extended shaft of the motor.

q. The pump should be provided with mechanical seal.

r. The pump should be supplied with flexible hose pipe of 50mm, 50M length.

s. Suitable cable of 50 M length should be supplied with the pump.

t. Materials of Construction :

a) Impeller : Stainless Steel

b) Casing : Cast Iron

c) Shaft : EN8 (as per IS: 970)

2.5.14.4. Progressive Cavity Pumps

The progressive cavity pumps shall be self-priming and designed to handle abrasive, shear

sensitive and viscous materials, solids in suspension and liquid/solids mixtures.

Automatic Variable stroke frequency / stroke length arrangement shall be incorporated

wherever remote application with PLC/SCADA is envisaged and process demands these

changes through remote, Local Control Panel shall also be envisaged with each pump with

auto/manual selector switch and knob for these variations done manually.

The sludge will be a mixture of grit in the sludge that will be abrasive. The pump design shall

incorporate features that prevents ragging around pump connecting rod and rotor head and

include a shaft sleeve to protect the wear in these highly abrasive environments. These

conditions must be considered when selecting the pump. Pump should be screw type, slow

speed maximum 200 rpm having following construction features:

Casing : CI IS 210-FG 260

Rotor : SS316 Hard Chromed plated

Base Frame : ISMC Fabricated Epoxy coated

Bearing Housing : CI IS 210-FG 260

Shaft : SS 316

Foundation bolt : HTS GALVANIZED STEEL

Stator : Hypalon/Equivalent linning

Coupling : Flexible pin bush type

Coupling guard : MS Fabricated

The pumps must be sourced from a supplier that is ISO 9001:2000 certified to ensure that the

pump is manufactured to certified standards.

2.5.14.5. Polyelectrolyte solution preparation and Dosing System

Polyelectrolyte solution is needed to be prepared and dosed for aiding sludge thickening and

dewatering. The polyelectrolyte will be dosed online at the centrifuge inlet. Minimum dosage

of polyelectrolyte shall be worked out by the bidder. There shall be two poly-dosing tanks

each suitable for minimum 8 hrs. of operation. Each-tank shall be equipped with slow speed

mixer (100 RPM) to prepare polyelectrolyte solution. The solution will be fed using positive

displacement metering type dosing pumps. There shall be dedicated dosing pumps to each

centrifuge with one common standby. The pumps shall be interlocked with centrifuge so that

it can only be running in auto when centrifuge is on and should shut down when centrifuge

stops. The dosing system shall be housed in centrifuge house itself.

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The polymer dosing required shall be as per peak requirement with 2 working and 2 standby.

Polymer dosing pumps hydraulically actuated diaphragm pumps simplex and duplex type

with maximum injection pressure of 5 kg/cm2 complete with PP head, PP / PVC fittings,

strainer, inbuilt PRV along with 415 V / 50 C / S suitable motor at 1000 RPM are required.

The system will also have storage bins, polymer batch tank and polymer batch tank mixers.

2.5.14.6. Dosing Pumps

Scope

The dosing pumps shall be selected to achieve optimum dosing technology and control safety

with safety relieve valve. The pump shall have a resistant plastic enclosure that can safely be

used for the selected application and shall provide soft and low-pulsation dosing.

The pump shall incorporate sensitive sensors that monitor the dosing flow and the diaphragm

and provide process stability. The pumps shall be designed to have separation of hydraulics

and electronics, to protected process from equipment failure.

Diaphram Valve, Gasket : PTTE

Liquid End : Stainless Steen 316

Foundation Bolt : Mild Sleet Epoxy Paint

Wetted Part : SS 316

Base Frame : Carbon Steel, epoxy Painted.

Flanges : Carbon steel

Plunger : Carbon Steel

Accuracy : ±3%

Voltage : 415 ±10%

RPM : 1440

Polyelectrolyte Dosing

Head PP

Check Valves PVC

Balls Glass

Diaphragm Teflon Faced Nitrile

Motor Details Explosion Proof Motor

2.5.14.7. Sludge Sump Pump House and Sludge Dewatering

Sludge Sumps shall be provided to collect sludge from PST & FST. The pump house shall be

constructed above the sludge sump. Sludge transfer pumps shall be provided to feed

the mechanical dewatering devices. The pump shall be screw type suitable to handle

sludge of 1 – 2% solid consistency.

2.5.35. Pipework

2.5.15.8. General

The term pipe work shall include all necessary supports, saddles, slings, fixing bolts and

foundation bolts required to support the pipes and associated equipment. The pipe work shall

be laid out and designed to facilitate the erection, painting in situ and dismantling of any

section for maintenance and to give a constant and uniform flow of working fluid with a

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minimum of head loss. Where steel pipe work is used, the number of flanges shall be kept to

a minimum and the size of each length of pipe work shall be determined by the ease of

handling, installation and general appearance of the completed pipe system. Positions of

flanges shall take account of any concrete pipe supports or thrust blocks needed. Flexible

joints shall be provided where needed to facilitate removal of equipment or to allow for

differential settlement of the building. Wherever practical, flexible joints shall be provided

with tie-bolts or other approved means to transfer thrust or tension axially along the pipe

work.

Where steel and cast flanges are to be bolted together, the steel flange shall be machined over

its full face after welding to its pipe is completed. Flanges shall be finished truly square with

the pipe axis. Wherever possible, standard fittings shall be used in preference to special

fittings. Pipe work layout within pumping stations shall be prepared to meet the requirement

of the pump manufacturer. Valves, strainers and other devices mounted in the pipe work shall

be supported independently of the pipes to which they connect. Flanges shall be drilled in

accordance with the appropriate pressure rating. Where a pipe passes through a wall, a

retaining wall, or is subject to end thrust, it shall incorporate a puddle flange. Puddle flanges

shall be undrilled.

Material of Pipes, Sizing & Design Basis

Unless otherwise specified, the water velocity in the suction branches of a pump shall not

exceed 1.5m/s, delivery 1.8 m/s for horizontal pumps and in the discharge branch shall not

exceed 2.1 m/s for submersible pumps when the pump is operating within its specified

working range. There shall be no discernible noise due to hydraulic turbulence or cavitations

within the pump or its associated pipe work and valves.

Piping Sizing & Material

The piping and valves will be sized on the following basis for sizing.

Service / Flow Basis MOC

Gravity Lines for Sewage, Water

& Waste Water

Velocity between 0.6 to 1.2

m/s & designed as pipe line

flowing full

DI Class K 7

Pressure for Sewage, Water &

Waste Water

Velocity between 1.2 to 1.8

m/sec

DI Class K 9

Sludge line DI Suitable with

pressure rating

Air (Pressurized Lines)

[for Aeration Tank, Grit Chamber,

Gas Mixing System etc.,]

At velocities between 8 – 10

m/sec (desirable) with a

maximum of 15 m/sec in

small sections

Stainless Steel

Bio Gas At velocities between 3.5 to

4.5 m/sec (desirable)

Stainless Steel

Service Water Velocity between 1.4 to 2.0

m/sec

GI Class B

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Chemical Feed Lines Velocity between 0.6 to 1.5

m/sec

PVC/ PP/ HDPE/ SS

2.5.15.9. Cast Iron Pipes

The cast iron pipes shall generally conform to IS:1537/IS:1536 and pipe fittings shall conform

to IS: 1538. All pipes and fittings above the ground level and inside pumping station shall be

flanged.

The material for cast iron pipes and fittings shall be of grey cast iron conforming to IS: 210,

Gr FG 200.

The pipes shall be of uniform bore and straight in axis. Length of the straight double flanged

pipes shall be within a tolerance of + 3 mm.

The flanges of the straight pipes shall be square to the axis of the pipe. The face of the flanges

shall be parallel. The bolt hole circle shall be concentric with the bore and bolt holes equally

spaced. In straight pipes the bolt holes in one flange shall be located in line with those in the

other flange.

The faces of the flanges of the fittings shall be square to the directional axes. The holes shall

be located symmetrically off the center line. The intersecting axes of the tees shall be

perpendicular to each other.

The bolt holes on flanged pipes and fittings shall be drilled with the help of drilling jig. The

blank flanges are to be machined and drilled.

2.5.15.10. Ductile Iron Pipes

The DI Pipes conform to IS 8329 /ISO 2531/BS EN 545 & Fitting conform to IS 9523/BS

EN:545. These pipes can also be offered with standard thickness for smooth flow and

corrosion resistance.

2.5.15.11. Stainless Steel Pipes

All gas pipes, fittings and other related components inside the digester shall be of stainless

steel SS-304.

2.5.15.12. Steel Pipes

All steel pipes shall conform to IS:3589.ERW steel pipes (200mm to 2000mm) for gas, water

and sewage and laying should conform to IS:5822.

2.5.15.13. Unplasticised Polyvinyl Chloride (uPVC) Pipes

The materials used in the manufacture of uPVC pipes and fittings shall comply with the

physical properties indicated in relevant specification. They shall not contain any matter

which could impart taste, odour, toxicity or be harmful to health or adversely affect the water

conveyed.

Unless specified otherwise joints shall be of the complying with BS 4346/IS4985 having an

elastometric sealing ring. Joints shall be made in accordance with the Manufacturer‟s

instructions.

Fittings shall be injection-moulded in uPVC to the requirements of BS 4346/IS4985.

Fabricated uPVC fittings or fittings manufactured in other materials will only be permitted

when the material and method of manufacture are approved by the Independent engineer

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2.5.15.14. Dismantling Joints

Where dismantling joints, flexible couplings or flange adaptors are used these shall be of the

Viking-Johnson type except where otherwise specified or approved. Pressure ratings shall

match the pressure rating of the pipework in which they are installed, and materials used and

methods of protection shall not be inferior to those used for the pipework. Where needed,

joints and couplings shall be provided with tie bolts to restrain the maximum axial thrust

arising when in service.

The dismantling joints for cast iron pipes shall be of cast iron with EPDM seal ring.

2.5.36. Valves and Appurtenances

All sluice gates, isolation valves, air release valves, check valves shall be designed for the

medium carried in the respective pipeline, according to the diameter and the design working

pressure of the pipeline. Manual operation shall always be provided. Electrical drives shall be

provided as per requirement unless otherwise specified.

The valves shall be installed between flanges. The dismantling shall be possible by the use of

rigid or flexible dismantling pieces or flange adapters at one side. For this purpose, suitable

flange adapters may be provided. All valves shall be installed in the pipe work in such a

manner that they can easily be removed from the line for dismantling and maintenance.

The non-return valves on the pump delivery branches shall be spring loaded and have high

speed non slam closing characteristics.

Valves used in lines conveying chemical solutions and gases shall be manufactured of

material suitable for the purpose and to withstand the corrosive and aggressive action of the

medium. However for sludge pumps Knife gate valve can be accepted.

Valves used on sludge conveyance piping etc. shall be of straight through type and non-

logging. Butterfly/knife edge gate valves may also be used on sludge line.

The pressure rating of valves must at least be equal to the maximum expected pressure at the

point of installation.

The size of valves must not be less than the size of the respective main (suction, delivery)

pipes.

The material of construction of valve shall be as follows:

2.5.16.8. Sluice Valves

Sluice valves shall be generally conforming to IS: 14846:2000. Additionally they should

meet the specific requirement given below. The valves shall be double flanged machined and

drilled to IS-1538 Part IV & VI. The backside of the drill holes to be spot faced for proper

seating of bolts & nuts. Reasonable clearance behind the rear face of the flange on body and

bonnet to be kept to provide free access to use spanners for assembling and dismantling. No

tap hole is acceptable. The pressure rating of the Valves on the Suction side / discharge side

of the pump shall be as per design requirement. They should close with clockwise rotation of

hand wheel. The direction of closing shall cast on hand wheel. Nominal size, PN Rating and

Brand name should cast on the body. The valves shall be of Rising Spindle type. They shall

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be with Back seat Bushing arrangement for replacement of packing without leakage. The

Valve of size 350 and above should be supplied with 2 nos. Single trust deep groove Ball

bearing on both end of spindle collar to reduce operating torque and vertical thrust on spindle.

The valves of sizes 450mm and above should be supplied with enclosed grease packed

bevel/worm gear box of suitable rating to ensure that the valve shall be operated with effort

not more than 7 KgM at the pinion shaft for manual valve only. The valves shall be provided

with position indicator for indication from full open to full close. They shall be provided with

cast iron cleaning door at the bottom of sluice valve body. The clearance between the wedge

nut housing lugs on the wedge and the inside surface of the valve body shall be adequate to

insert the wedge nut into the wedge lug recess either in the direction of water flow or in

perpendicular direction when the wedge is in closed position. The Valves shall be provided

with Air Release plug arrangement on the top of the bonnet. Sluice valves shall be electrically

operated with manual override facility. All valves in the pump house and on discharge

/header shall be actuator operating. The valves which are operated rarely i.e. not regularly

shall be manually operated.

SLUICE GATES FOR MPS

Provision of CI Thimble Mounted Sluice Gate with motor, actuator operated, Rising Spindle

type. Sluice gates are as per IS 13349 Including all taxes, Freight, loading, unloading, fitting

in position including Sluice gates are upward opening wall thimble mounted suitable for

isolating the flow of sewer into out of the opening in the wall. It consists Gate frame, wall

thimble, gate slide, shutter, seating/sealing faces .The gates will be provided with pads on

sides, top and bottom to mount the wedges. The gate shall be designed in such a manner, so

that it can be operated at 2 meter head. Gate frame & Shutter of CI Grade IS 210 FG 260,

Head Stock assembly bolts & SS ASTM A276 Type316, Stem, Operating Nut SS ASTM

A276 Type 316., Duly tested for tensile strength, Tested for over all dimensions as per

approved GA drawing complete in all respect as per specification and direction of Engineer,

For screen channels

Sewage Water Application

e. General

6. Sluice valve shall be conforming to IS: 14846: 2000 and with ISI marking. Additionally they

should meet the specific requirement given here under.

7. Sluice valve must be from ISO-9001 certified company towards Quality Management

System.

8. The valves shall be double flanged machined and drilled to IS- 1538 Part 4 & 6. The back

side of the drill holes to be spot faced for proper seating of bolts & nuts. Reasonable

clearance behind the rear face of the flange on body and bonnet to be kept to provide free

access to use spanners for assembling & dismantling. No tap hole is acceptable.

9. The valves should close with clockwise rotation of hand wheel. The direction of closing shall

be cast on hand wheel.

10. Nominal size, PN rating & Brand name should cast on the body.

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f. Design Requirement

12. The valve should be of PN 1.0 rating/based on working pressure in the pipeline.

13. The valves shall be of Non-rising Spindle type.

14. The valves shall be with back seat bushing arrangement for replacement of packing

without leakage.

15. The valve size 350 mm & above shall be provided with renewable Shoe & Channel

arrangement to reduce the clearance between body and wedge lugs.

16. The valve size 350 mm & above should be supplied with 2 nos. Single trust deep

groove Ball bearing on both end of spindle collar to reduce operating torque and

vertical trust on spindle.

17. The valve size 450 mm & above should be supplied with enclosed grease packed

bevel/worm gear box of suitable rating to ensure that the valve shall be operated with

effort not more than 7 KgM at the pinion shaft.

18. The valves shall be provided with position indicator for indication from full open to full

close.

19. The valves shall be provided with cast iron cleaning door at the bottom of Sluice valve

body.

20. The clearance between wedge nut housing lugs on the wedge and the inside surface of

the valve body shall be adequate to insert the wedge nut into the wedge lug recess

either in the direction of water flow or in perpendicular direction when the wedge is in

closed position.

21. The valve shall be provided with air release plug arrangement on the top of the bonnet.

22. The valves should also be compatible with Actuator system.

g. Material of Construction

8. Body : Cast Iron to IS: 210 Gr. FG200

9. Wedge : Cast Iron to IS: 210 Gr. FG200

10. Spindle : St. Steel to IS: 6603 04Cr18Ni10

11. Seat Rings : SS to CF8

12. Spindle Nut : High Tensile Brass to IS – 320 HT2

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13. Back Seat Bush : SS to CF8

14. Shoe & Channel Lining : SS to CF8

h. Shop Testing Witnessing

4. Seat Leakage Test (2 Minutes) : 10Kg/cm2

5. Body Leakage Test (5 Minutes) : 15Kg/cm2

6. Back Seat Leakage Test (2 Minutes) : 10Kg/cm2

SPECIFICATION OF CHECK VALVE

8. Checking valve shall be conforming to IS: 5312. Additionally they should meet the specific

requirement given below.

9. The valves shall be double flanged machined and drilled to IS- 1538 Part 4 & 6. The backside

of the drill holes to be spot faced for proper seating of bolts & nuts. Reasonable

clearance behind the rear face of the flange on body to be kept to provide free access to

use spanners for assembling & dismantling. No tap hole is acceptable.

10. The valve should be of PN 1.0 rating based on working pressure in the pipeline.

11. Nominal size, PN rating, Brand name & Direction of Flow should cast on the body.

12. The Valves shall be of Swing Check type.

13. The Valve sizes 50 to 600 mm should be of Single door design & above 600 mm should be

Multi door design.

14. The Check Valves shall be with Non Slam Characteristics. Non Slam Characteristics to be

achieved by combination of hydraulic passage and additional disposition of weight on

doors.

Material of Construction g. Body & Cover : Cast Iron IS: 210 Gr. FG 260

h. Door : Cast Iron IS: 210 Gr. FG 200

i. Hinge Pin : St. Steel to AISI – 316

j. Seat Rings : Gunmetal with 2% Nickel / IS: 318 Gr. LT B2

k. Bearing Bush : Teflon

l. Fastener : carbon steel

Shop Testing Witnessing 3. Seat Leakage Test (2 Minutes) : 10Kg/cm2

4. Body Leakage Test (5 Minutes) : 15Kg/cm2

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SPECIFICATION OF KINETIC AIR VALVE

f. General

6. Kinetic Air valves shall be conforming to IS: 14845: 2000. Additionally they should meet

the specific requirement given her e under.

7. Kinetic Air valves should be from ISO – 9001 certified company towards Quality

Management System.

8. The Valves shall be flanged end machined and drilled to IS – 1538 Part 4 & 6

9. The valves should have an isolating Sluice Valve attached to it.

10. Nominal size, PN rating, Brand name should cast on the body.

g. Design Requirement

5. The valve should be of PN 1.0 rating /based on working pressure in the pipeline.

6. The Valves should double ball air valve consisting of large orifice (LP) & small orifice.

7. The large orifice chamber should have built-in Kinetic features to avoid blocking of the

large orifice during filling & emptying of pipeline. It should have a large timber ball

covered with rubber to be seated on a large orifice rubber ring.

8. The small orifice chamber should have a small timber ball covered with rubber to be

seated on gunmetal orifice plug.

h. Material of Construction

Body, Cover, Cowl : Grey Cast Iron. IS: 210 – 1993 Gr. – 260

Ball of small orifice : Seasoned timber ball covered with soft Vulcanite

Ball of large orifice : Seasoned timber ball covered with soft Vulcanite

Seat of large orifice : Neoprene Rubber

Nipple for small orifice : LTB. : IS 318 – 1980. LTB – 2./ AISI: 410

Isolating Gate valve : IS: 14846 (GM internals & AISI: 410 Spindle)

Bolt & Nut : M.S

i. Shop Testing Witnessing

Seat & Body Leakage Test (2 Minutes) : 10Kg/cm2

j. Painting & Coating

Pre – inspection

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1st Step Surface Preparation

Blast cleaning to near white – SA 2 ½ Gr.

2nd

step Application of Primer Coating after blast cleaning

One coat of two component epoxy based primer

Post – inspection, if applicable

3rd

Step Application of Finish Coat

One coat of two component solvent free amine cured epoxy coating (Shade)

2.5.16.9. Butterfly Valves

Unless otherwise specified, valve body and disc shall be of close-grained gray cast iron.

Valves shall be mounted with shafts horizontal. Valves shall be fitted with indicators to show

the position of the disc, clearly marked with „open‟ and „closed‟ positions. Valves shall not

contain any brasses containing more than 5% zinc. Gunmetal conforming to BS 1400 Grade

LG2, aluminum bronze, or nickel components may be used for internal components.

Resilient-seated valves shall have nitrile rubber seals.

For valves of 900mm and above, retaining rings shall be provided to enable the sealing ring

to be replaced without the need to remove the valve body from the pipe work. Metal seated

valves of 900mm and above, shall have seat clearances adjustable to obtain as near a

watertight condition as possible, without the need to remove the valve body from the pipe

work.

Percentage Opening - Flow Curve shall be submitted along with data sheet mentioning area

where such valves are subjected for any controlling of the fluid flow.

Component Material 1 Body Cast Iron : IS:210 Gr FG260

2 Inner lining Stainless steel : BS:970 Gr 304

3 Plate /DLSC Stainless steel : IS 3444 1987

4 Stem Stainless steel : IS 6603:1972

5 Seat ring / Boss Stainless steel : IS 6603:1972

6 Gland housing Cast Iron : IS:210 Gr FG260

7 Gland packing Teflon Impregnated with asbestos+Rubber

2.5.16.10. Pressure-Relief Valves (PRV)

Pressure-relief valves shall be designed to prevent the pressure in the pipeline upstream of the

valve rising above a preset level. The valve shall remain closed at lower pressures. The

pressure at which the valve opens shall be adjustable. A pressure gauge shall be provided to

indicate upstream pressure over the operating range of the valve. Safety valves shall comply

with BS 6759: Part 1.

They shall be designed to open at the specified pressure and re-close and prevent further

release of fluid after normal pressure has been restored. The pressure / temperature rating

shall be in accordance with relevant standards. Flanged ends shall be Class 900, raised-face

type complying with ANSI B16.25 or relevant standards.

Component Material

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1 Body Cast Iron : IS:210 Gr FG260

2 Inner lining Stainless steel : BS:970 Gr 304

3 Knife gate/ plate Stainless steel : BS:970 Gr 304

4 Stem Stainless steel : BS:970 Gr 304

5 Seat ring / Boss Stainless steel : BS:970 Gr 304

6 Gland housing Cast Iron : IS:210 Gr FG260

7 Gland packing Teflon Impregnated with asbestos+Rubber

2.5.16.11. Ball Valves

Ball valves shall conform where applicable to relevant standards. Multi-piece bodies shall be

used where work on the ball and seats when installed may be needed. If valves need removal

for servicing, one-piece bodies may be used. Seat materials shall be chosen for long life, with

erosion and corrosion resistance. Ball supports shall be of the floating ball or trunnion type. If

line pressure is too low to ensure a positive leak-free seal, built-in seat loading devices, or

specially shaped seatings shall be used to ensure sealing.

Component Material 1 Body Cast Iron : IS:210 Gr FG260

2 Inner lining Stainless steel : BS:970 Gr 304

3 Plate Stainless steel : BS:970 Gr 304

4 Stem Stainless steel : BS:970 Gr 304

5 Seat ring / Boss Stainless steel : BS:970 Gr 304

6 Gland housing Cast Iron : IS:210 Gr FG260

7 Gland packing Teflon Impregnated with asbestos+Rubber

2.5.16.12. Knife Gate Valves

The valve shall meet standards C105/A21.5-10, C520-10, C706-10, C707-10, C713-10 and

D106-10 and testing requirements of MSS SP 81.

Outer body may preferably be provided with inner liner in corrosion resistant stainless steel

which shall extend into the gland. The body shall be devoid of any wedge/ dead pockets to

avoid setting of suspended particles and solids in the service fluid.

The gate / plate shall be precision buffed and the edge contoured to a knife edge. The gate

shall move along / be guided by the seat ring to ensure that it scraps any deposit / scale

enabling smooth uninterrupted movement.

Seat shall be so designed that there is no recess / relieve groove to harbour deposition that

could build-up and swamp the valve. The design should also incorporate bosses that guide the

gate and avoid deflection ensuring positive shut-off. The stem shall have double start threads

cut in order to ensure smooth and speedy operation.

Gland packing shall offer minimal frictional resistance and precludes external lubrication. As

positive sealing elements, the packing shall also include a resilient rubber ring. The knife

edge and seat face in flow path shall be hard faced to a hardness of 400 to 450 BHN to

counter erosion. In such cases, provision shall also be made to ensure the fluid contact with

the seat ring is minimal.

Component Material

282

1 Body – Cast Iron : IS:210 Gr FG260

2 Knife gate/ plate – Stainless steel : BS:970 Gr 304

3 Stem – Stainless steel : BS:970 Gr 304

4 Seat ring / Boss – Stainless steel : BS:970 Gr 304

5 Gland housing – Cast Iron : IS:210 Gr FG260

6 Gland packing – Teflon Impregnated with asbestos + Rubber

2.5.16.13. Cast Iron Flap Valves (Circular Flap Valves)

The Flap Valves with circular aperture, single door and double flanges, shall be provided.

The flap valves upto 600mm dia shall have sealing faces in angular section and secured to the

frame and door by a force fit. For sizes above 700 to 2000mm dia the sealing faces are of

rectangular section and are secured to the frame and door using countersunk taper headed

screws in the same material as the sealing face. The flap valve shall be suitable for mounting

on a vertical wall or flange for static seating heads up to 6 meters.

Material of Specification

Frame

Constructed in BS EN 1561 min. 250 cast iron designed for wall, thimble or pipe mounting

applications.

Door

Constructed in BS EN 1561 min. 250 cast iron designed to withstand static seating heads up

to 6 meters.

Sealing Faces

Copper alloy sealing faces to BS EN 1982 : 1999 are supplied as the standard material for

ranges up to 600mm dia and for the ranges 700 to 2000mm dia phosphor bronze to BS EN

12167 : 1998. Sealing faces are set to 0.1mm feeler gauge non-acceptance to provide an

effective seal.

Hinge Links

Manufactured in Spheroidal Graphite cast iron

Fasteners

Standard fasteners are supplied in stainless steel to BS EN 10088 : 1995 grade 1.4401 (316).

Hinge Pins

Manufactured from stainless steel to BS EN 10088 : 1995 grade 1.4401 (316).

2.5.16.14. Sluice Gates

Sluice gate shall be preferably wall thimble type. However for controlling/isolation of flow in

channels, channel type gates may also be accepted by Jal Nigam as per application

requirement.

The construction of Sluice Gates shall be in accordance specification and generally to

IS:13349. The Sluice Gate shall be designed for Seating & Unseating Head without

283

sacrificing reasonable degree of leak tightness. The frame of Sluice gate shall be flanged back

type and shall be machined on the rear face to bolt directly to the machined face of the wall

thimble. The seating faces shall be made of solid section strip of Stainless steel. They shall be

secure firmly by means of counter sunk fixing in finished grooves in the frame and slide face

in such a way as to ensure that they will remain permanently in place, free from distortion

and loosening during the life of the Sluice Gate. Sluice Gates shall be equipped with

adjustable Side & Top wedging devices as required to provide contact between the slide and

frame facing when the gate is in closed position. The gates shall be of Rising Spindle Type.

They shall be operated through a suitable operating mechanism. The Lifting mechanism shall

incorporate gearing arrangement, if required to keep the torque requirement within 7 KgM

except electrically actuated gate. In case of gearing, those to be enclosed grease packed Bevel

or Worm Gear box type. Lifting mechanism shall be provided with suitable position indicator

to show the position of the gate from full open to full close. The indicator to be provided in

the head stock only. Stem Cover to be provided on the top of head stock for the rising

spindle. The cross section of the wall thimble shall have the shape of the English letter „F‟.

The Sluice gate shall be provided with Flush bottom seal. This is a solid square cornered

resilent rubber seal provided on the bottom facing of the slide. The seal may be secured

fastened to the bottom of the face of the slide by a retainer bar and fasteners. The top surface

of the bottom facing of frame shall be flush with invert of the gate opening. Bottom facing of

the slide shall be accurately machined to make contact with the seal when the slid is closed.

Gates shall be fixed for positive seating. Sluice gates shall be electrically operated with

manual override facility. The Sluice Gates shall be of Class – 2 i.e., suitable for maximum

unbalanced head needs as per calculation/design.

Material of Construction

The materials of construction of important components of gates will be as under: o. Frame & Shutter Cast Iron IS: 210 Gr. FG 200

p. Wall Thimble Cast Iron IS: 210 Gr. FG 200

q. Seating Faces & Counter Sunk Fixing Stainless Steel ASTM A276 type 316

r. Wedging Device Cast Iron IS: 210 Gr. FG 200

s. Wedge Linings Stainless Steel ASTM A276 type 316

t. Stem & Stem Coupling Stainless Steel ASTM A276 type 316

u. Stem Nut Stainless Steel ASTM A743 CF8M or SS316

v. Flush Bottom Rubber Seal EPDM ASTM D200

w. Seal retainer bar Stainless Steel ASTM A276 type 316

284

x. Fasteners, Studs Anchor Bolt & Nuts Stainless Steel ASTM A276 type 316

y. Lift Nut Bronze IS: 318 Type LTB-2

z. Headstock, Stem Guide Cast Iron IS: 210 Gr. FG 200

aa. Hand wheel Mild Steel IS: 2062

bb. Painting Ordinary Black Bituminous Paint

Standard Painting

Unless otherwise specified elsewhere provide following standard painting.

- Surface preparation: Blast clean or Ground to near white metal finish

- Priming: 1 coat of red oxide primer before and after shop testing. Total priming thickness 75

microns.

- Finish painting for gate assembly: 2 coats of black bitumen paint for gate assembly. Total

paint thickness inclusive of priming 200 microns.

- Finish painting for headstock: Grey enamel paint. Total paint thickness inclusive of priming

150 microns.

Shop Testing Parameters

- Leakage test at operating pressure for gate leakage performance.

- Movement test for checking interference free movement of complete assembly.

- Seat clearance check for checking clearance between mating sealing faces.

- Positive Material Identification test for all material other than cast iron.

2.5.37. Electrical Overhead Traveling (EOT) Crane

The capacities of various EOT‟s shall be decided as per recommendations of IS: 875.

The crane shall be of single / double girder type designed from lowest sump level and up to

under size of the bridge.

Suitable crane rails complete with fixing bolts, nuts, washers and anchor plates shall be

supplied for each crane.

The bridge structure shall be formed by a single/double cross girder with the hoist units

traveling along the lower flange of the bridge girder.

The end carriages shall be fabricated adequately stiffened throughout their length to produce

a section with high torsional resistance designed to eliminate and tendency for the bridge to

cross whip. The carriage wheel shall be adequate proportioned in relation to its span to give a

widely distributed load on the crane rails.

Proper selection of reduction gears shall be done to run drive motors. Wherever required the

285

motor enclosure shall afford protection to IP: 55 of IS: 4691 and have cooling facility to IC:

41 of IS: 6362. Each drive motor shall be fitted with an automatic electro-magnetic brake to

stop the crane on interruption of the power supply, whether intentional or accidental power

failure.

Suitable end stoppers/buffers shall be provided on the bridge girder and at each end of crane

rails.

The crane and hoist shall conform to IS: 3177, IS: 3832 and IS: 3938, class 2, medium duty

and meet specified operational requirements.

Power feed to the crane shall be form a shrouded conductor rail system and that to the hoist

shall be through close looped flexible suspension system with carriers sliding along a wire

across the full span of the crane.

Proper illumination of the area shall be done under the crane and on the crane.

All the crane and hoist functions and excluding the illumination lights shall be controlled

from a single pendant push button station. The pendant unit shall be suspended from a special

track spanning the bridge length using a non-metallic cord and not the control cables. The

pendant shall operate on a low voltage (typically 220 volts AC) source, incorporated with a

key operated switch to operate switch to prevent unauthorized operation and indicators to

indicate ail crane or hoist movements including start and stop.

EOT Operations and faults shall be interfaced with respective LCP about their operations.

Lifting speed Low 0.9 MPN

High 3 MPN

L.T. speed 10 – 15 MPN

C.T. speed 10 MPN (Max.)

However illumination lights to be operated by separate switch which will not be mounted on

pendant.

Other Common specification:

Brakes All brakes are electro-hydraulic thrusters/ECM brake

Operation Through pendent push button

Gear box Precise machine cut hardened material gear noiseless operation long

life

Cable All cables are insulated ISI Marked

Power supply All 415:440 4 phase 50 Hz. AC supply

Control voltage 220/230 volts-50 Hz

The hoist shall comply Class II with the performance requirement IS 3177/80, IS: 3938/IS:

3832 Class 2.

The electric hoist shall be fitted with right and left handed spiral grooved cast iron drum with

a rope hoist arrangement with spring loaded rope band and guards to ensure accurate rope

guidance and location.

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Hoist rope shall be extra flexible, improved plog plough steel rope with well lubricated hemp

core and having 6 strands 37 wires per strand with an ultimate tensile strength of 160/180

kg/sq.mm. The braking load for the hoist rope shall be as per IS: 2266.

Electromagnetic brake shall be provided to hold suspended load instantly, securely and

automatically in the event of the electric current being cut off whether intentionally,

accidentally or due to power failure.

The lifting hooks shall be single „C‟ type complying with the requirement of IS: 15560 made

from grade C30/C20 carbon steel. The hook shall have a safety latch to prevent rope coming

off the hook.

2.5.38. Chlorination System

Chlorination system shall consist of chlorine contact tanks for disinfection of wastewater

from secondary clarifier, chlorine building housing equipment like chlorinators, chlorine ton

cylinders, chlorine ejector, chlorine leak detector, ventilation system, emergency chlorine

scrubber etc,

Chlorine solution diffusers shall be installed at the dosing point. Inlet chamber of the contact

tank shall have rapid mechanical mixers. The chlorine dosing shall be designed with

minimum chlorine dose of 8 PPM at peak flow. The residual chlorine should be not less than

0.2 PPM.

Vacuum type gas feed chlorinators comprising differential vacuum regulated flow meter,

regulating valve for vacuum & pressure, injector flow meter etc. shall be required. The

chlorinator should be floor mounted complying requirement of IS 10553 - 1983. The

chlorinator should be accompanied with booster pumps and the entire discharge line. The

moist chlorine or chlorine solution shall be conveyed through silver or platinum tubing. A pit

and alkali absorption system shall be provided to neutralize the chlorine in the event of leak.

Chlorine gas leak detector shall be provided in the chlorine storage room. Forced ventilation

system shall be provided with exhaust system industrial pattern. Chlorine residual monitoring

system shall be provided at the plant outlet.

Chlorine Gas Feed System

Minimum chlorine dose mg/l 5

Peak chlorine feed rate kg/day 275

Chlorine Ton Cylinders

Average chlorine feed rate kg/day 135

Min. storage period days 15

Capacity per cylinder kg 200

Min. no of manifold cylinders 10

287

Min. of cylinder to meet min. storage period

requirement

12

Min. no. of cylinders – Mani folded with

automatic switching.

10

Chlorinators

Type of Chlorinator Vacuum type-Gas Feed

Total No. of units 4

30 Kg/ hr. working 2

Min no of units – Standby 2 100%

Chlorine Ejector

Type Inline vacuum induction

Chlorine tonner can be provided by Jal Nigam as the chlorine gas is being purchased for

various plants.

Chlorine Contact Tank

Chlorine Contact Tanks

Min No of Units 1 with baffle wall

Material of Construction Reinforced Cement

Concrete

Chlorination System

Trunnuion Roller Support

Bed

Roller

Shaft

Bush

Steel as per IS 2062

Steel IS 2062 – Cadimum Plated

EN 8 BS 970 – Cadimum Plated

Gun Metal

Auxiliary Container Valve with Yoke

Valve Body

Spindle

Gland Packing

Yoke

Aluminium Silicon Bronze

Monel 400

PTFE

Forged Steel

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Electrical Auto Change Over Device with

the Following

Ball Valve

Body

Ball

Seat

Forged Carbon Steel

Monel 400

PTFE

Pressure Switch Isol. Valve

Type

Diaphragm Sealed

By pass valve

Type

Body

Ball

Seat

Ball

Carbon Steel

Monel 400

PTFE

Gas Filter

Body

Filter Element

Seamless Carbon Steel 80 Sch,

Glass Wool

Pressure Reducing Valve

Body

Spindle

Spring

Diaphragm

Carbon Steel

Glass Filled PTFE

Hastelloy – C Silver Plated

PTFE

Isolation Valve

Type

Body

Ball

Seat

Ball

Carbon Steel

Monel 400

PTFE

Chlorinator with following accessories:

Pressure Gauge with ISO l. Valve Type Monel 400 bourdon tube

Vaccum Regulator

Body

Diaphragm & Seat

Spindle

Spring

HDPE

PTFE

Glass Filled PTFE

Hastelloy – C Silver Plated

Pressure Relief Valve

Body

Seat

Spindle

Spring

PVC

PTFE

PTEFE

Hastelloy – C Silver Plated

Rotameter

End Fittings

Glass

Float

PVC

Borosilicate Tapered

PTFE

Flow Control Valve

289

Body & Spindle

Type

PVC

V- Notch

Differential Regulator

Body

Diaphragm & Seat

Spring

HDPE

PTFE

Hastelloy – C Silver Plated

Vaccum Relief Valve

Body & Spindle

Seat

Spring

PVC

PTFE

Hastelloy – C Silver Plated

Vaccum Gauge

Type

Monel 400 Bourdon tube

Check Valve

Body

Spring

Diaphragm & Seat

Addl. Float

PVC

Hastelloy – C Silver Plated

PTFE

HDPE

Drain Valve

Body

Float

PVC

PTFE

Injector

Body

Nozzle & Throat

PVC

PVC

Pipe with fittings UPVC

2.5.39. Safety Equipment Severe exposure and potential health hazards exists due to chlorine atmosphere. The various

safety equipment like gas masks, oxygen breathing apparatus, portable air blower and

inhalator shall be provided keeping in mind the safety of staff operating chlorination system.

The Equipment shall include the following:

Canister type Gas masks with full face piece for short exposure.

Self-contained breathing apparatus with full face piece and a cylinder of air or oxygen carried on

the body.

Two sets of approved positive airline breathing apparatus, each comprising body harness, face

masks and valves and 30m of airline. One air trolley, comprising wheeled frame with two air

cylinders, control manifold, airline hose and hose winding drum. Two spare cylinders suitable for

changeover shall be provided.

Suitable quantity of air cylinders of capacity 1200ltr for recharging air cylinders, compete with

quick release air hose couplings.

Four sets of safety clothing in various sizes, each comprising PVC overall, wellington boots with

steel toe caps, goggles, gloves and helmets.

Gas leak detectors portable type -2 Nos.

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2.5.40. Emergency Equipment (General)

2.5.20.9. Fire Extinguishers

The Bidder shall provide required no. of dry powder type CO2 fire extinguishers (10 kg) for

the pumping station and switchyards at the following locations after consultation with the

Independent engineer:

Outdoor switchyard

Indoor electrical room

Pump rooms (maintenance bay)

Control room

GAS handling area

First Aid boxes and manual stretcher .

Besides above, Ionisation smoke, optical smoke & heat detectors shall be provided in control

room with fire alarm panel having appropriate battery back-up. Fire alarm detectors shall be

provided both below & above false ceiling, if any Fire alarm system and public address

system shall be provided at the

Plant.

All the smoke and heat sensors shall be wired up to nearest JB and interfaced to respective

PLC/DDC for alarm annunciations.

2.5.20.10. Spillage and Leakage

Chemical preparing, dosing and transfer equipment shall be designed and arranged so that

any leakage and spilling can be controlled and cannot enter ducts, channels, etc. and have a

corrosive impact on pipes, cables or other equipment of the plant.

At all lubrication or greasing points grease trays or pans shall be provided to collect excessive

lubricant or spillage onto the equipment or into sewage.

2.5.20.11. Installation Work:

Equipment shall be installed in a neat, workman like manner so that it is level, plumb, square

and properly aligned and oriented. Tolerance shall be as established in the manufactures

drawing or as stipulated by Jal Nigam . No equipment shall be permanently bolted down to

foundation of structure until the alignment has been checked and found acceptable by Jal

Nigam.

Manufacturer‟s drawings, instructions and recommendation shall be correctly followed in

handling, setting, testing and commissioning of equipment.

2.5.20.12. Leveling and Grouting of Machinery

The pumps, motors and other equipment shall be properly and accurately leveled and aligned

on the concrete plinth by means of tapered metal wedges and metal packing pieces before any

grout is poured. After correct alignment and leveling the foundation bolts shall be nipped up

to hold the machine firmly in position and it shall be the Selected Bidder's responsibility to

check that the position is maintained after the grout has been poured but before it sets. The

grout, which will contain an approved expanding agent, will be mixed and poured by the

Selected Bidder. Grouting material used for grouting should be as approved by Independent

engineer.

291

The horizontality of base plate top shall be within 0.05 mm/metre. The base plate top surface

and pump motor box are to be blue matched to get a contact area of at least 80%.

After the grouting mixture has set hard the foundation bolts shall be pulled up hard and the

alignment and level rechecked. The Engineer shall be informed at all times of the progress of

this work and when any checks on alignment and level are to be carried out so that he may

witness the checks if he so requires. The approval of the Engineer or his intimation that the

alignment or level of the machines is to his satisfaction shall in no way relieve the Selected

Bidder of his obligation under contract to properly install and align the machines and pipe-

work and shall in no way prejudice the Independent engineer's rights to order rectification of

any installation work later found to be improperly carried out.

2.5.20.13. Tests on Completion

(iv). General

When the Contract Plant has been installed on site and is ready for energising, the Selected

Bidder shall notify the Independent Engineer in writing that Tests on Completion are about

to commence. At least three days notice shall be given. The Independent Engineer may

attend the tests at his discretion.

(v). Commissioning Tests

The Selected Bidder‟s representative shall subject the screen to the following tests. The tests

shall include, but not be limited to:

Checking alignment of all components and adjust if necessary;

Checking that all equipment, safety devices and equipment protection devices function

properly;

Examining protective coatings and repair as necessary;

Running equipment for an appropriate time and check for correct operation;

Checking the operation of all equipment under field control;

Demonstrating access cover removal.

All necessary corrections and adjustments made shall be recorded. A written report shall be

provided by the Selected Bidder‟s representative at the completion of the tests, certifying that

the equipment has been properly installed and operates satisfactorily all test records are to be

appended.

(vi). Reliability Tests

Reliability testing will not be commenced until the Tests on Completion have been completed

and approved by the Independent engineer.

The Plant shall be required to operate under the normal operating conditions within the limits

of performance offered by the Selected Bidder, and their continuous or intermittent

performance as may be more convenient for the operation of the works. The Plant shall

operate without failure of any kind for period of one calendar month.

Should any failure (other than that of an entirely minor nature) occur in any portion of the

Plant, due to or arising from faulty design, materials or workmanship or staff training (but not

otherwise) sufficient to prevent commercial use of the plant, the test shall be deemed to have

failed. The test period of one month will recommence after the Selected Bidder has remedied

292

the cause of the failure. The onus of proving that any failure is not due to faulty design,

materials, workmanship or training will lie with the Selected Bidder.

In cases where the responsibility for failure cannot be determined initially, the Selected

Bidder is to attend to such failures as though they were his responsibility. When the

Reliability Test has been completed to the Independent Engineer written approval, the

Defects Liability Period shall commence.

2.5.20.14. Relevant Standards

The design, manufacture, supply, storage of all equipments shall comply with all Indian

Standards, (or in the absence of Indian Standards, the appropriate International Standards)

Acts and Regulations in their latest amendment, including local statutes covering:

Health and Safety

Dangerous Goods

Factories and Commercial Premises

Buildings

Electricity Regulations and Codes of Practice

The Standards referred shall form part of this Contract. Other Standards, Codes of Practice

and Regulations not referred to, but which would be applicable to the design, manufacture,

installation, testing or commissioning of the equipment under this contract shall be deemed

part of the Contract.

2.5.20.15. Working Stress and Design

The design of all parts shall ensure that under the most onerous of conditions they will not be

damaged or corroded.

Any joint that will need to be dismantled during maintenance shall be made by anti-corrosion

type fasteners.

All spare parts shall be fully interchangeable with the original part. If the spare part is

unavailable due to cease of production, the Selected Bidder shall give notice to the Employer

in writing, detailing the options available to the Selected Bidder.

All parts shall be designed to minimise the risk of fire and consequential damage. All parts

shall be designed to prevent the ingress of vermin, dust and dirt. All electrically live or

moving parts shall be adequately guarded to prevent accidental contact.

2.5.20.16. Name Plates

Each main and auxiliary item to the pumping station shall have permanently attached to it, in

a conspicuous position, a name plate and rating plate, each of weather-resistance and fire-

resistance material. Upon these shall be engraved or stamped the manufacturer's name, type

and serial number of equipment, details of the loading and duty at which designed to operate.

293

Schedule-II

Part-C

Electrical System General and Particular Specifications

294

1. Electrical System General and Particular Specifications

1.1 General

The scope of work includes design, equipment selection, manufacture, inspection at Bidder's

or his Sub-Bidder's works, supply, installation (including storing, unloading and transferring

the material / equipment to Bidder‟s storage area, maintaining equipment / material in safe

custody and assembling the elements of the equipment and installing at the place of work),

testing and commissioning of the plant equipment/ electrical system. After successful

commissioning and trial run of the plant, it should be handed over to the JAL NIGAM or

their representative. The Bidder shall submit their design calculations/ drawings based on

„Design criteria for electrical equipment/ system‟ for JAL NIGAM or their representative‟s

review and approval. These specification covers , 11kV switchboard, LV switchboards, LV

energy efficient motors, LV soft starters, LV capacitors, APFC,HV, and LV power cables and

control cables, DC supply system and other allied equipment, etc. along with the

specifications for workmanship, laying cables, lighting system, earthing systems, lightning

protection etc. It shall be the responsibility of the Bidder to design the electrical system based

on the selection of the mechanical equipment.

The Bidder shall make his own estimate of sizes, ratings and quantities for 11kV system,

equipment, all plant items and miscellaneous systems such as earthing, lightning protection,

lighting, However, facility for upgrade/ expansion of all equipment to cater any future

requirements load shall have to be considered during design-engineering stage. It should be

clearly understood that the Contract will be on „turnkey‟ basis and no variation will be

allowed for items of works not foreseen or omitted by the Bidder at the bidding stage, except

where specifically indicated in the bid documents.

All equipment offered shall comply with the requirements specified in the latest editions of

applicable Indian/ International Standards and shall also comply with the good engineering

practices.

The drawings enclosed with the specifications are for general guidance of the Bidder only.

Bidder shall design the electrical system on the basis of „Design Criteria‟ and to be submitted

for JAL NIGAM or their representative‟s approval. Bidder shall incorporate any changes/

suggestions in the drawings to suit site conditions and design criteria and standard

engineering practice and resubmit for approval to JAL NIGAM or their representative.

The Bidder shall possess the valid electrical Bidder‟s license of appropriate class from the

concerned statutory bodies governing the area of work place. The Bidder shall fully comply

with the relevant statutory rules and regulations.

All type (as applicable), routine and acceptance tests shall be conducted in the presence of

JAL NIGAM or their representative / Third Party Inspector on all the equipment as per latest

applicable IS/IEC at no extra cost. Typical type test reports for other equipment shall be

submitted by the Bidder for approval by JAL NIGAM or their representative.

All commissioning tests shall be carried out in the presence of JAL NIGAM or their

representative and approval for the same shall be obtained before commissioning and

installation. All test reports shall be properly maintained by the Bidder duly approved by the

statutory bodies and shall be handed over to the JAL NIGAM or their representative after

completion of the job. All instrument and accessories required for testing and commissioning

295

of the equipment specified herein shall be provided by the Bidder at no extra cost to the JAL

NIGAM or their representative.

Liaison with electricity board and other Government organization/ statutory bodies for

obtaining Power supply/ other clearance shall be Bidder‟s scope. After completion of

installation work, the Bidder shall arrange for inspection and obtain approval from the

concerned statutory bodies. Any fees that are to be paid to such statutory bodies for testing,

inspection or calibration shall be paid by the Bidder. Any modification / revision in the

equipment / installation of equipment as required by the statutory bodies shall be carried out

by the Bidder. All such costs / fees for revisions / modifications shall be deemed to be

included in the prices of supply, installation, testing and commissioning of equipment as

quoted by the Bidder.

1.1.1 Power Supply Information

The proposed power supplies are as follows:

(i) 11 kV AC System Voltage variation +10 to -

10% Freq. Variation +5 to

-5%

Three Phase, 50 Hz, effectively

earthed AC System SC. Rating of 350

MVA

(ii) 415V AC System Voltage variation +10 to -

10% Freq. Variation +5 to

-5%

Three Phase and neutral, 50 Hz,

effectively earthed system, SC. rating

of 20 MVA

(iii) 240V AC System Voltage variation+10% to

10%

Freq. Variation + 5% to -

5%

Single phase and neutral, 50 Hz,

effectively earthed system

(iv) 110V DC Supply Voltage variation +/- 15% Unearthed two wire system

All equipment shall have rated withstand capacity based on above criteria.

1.1.2 Design Criteria for Electrical Equipment/ System

The Design Criteria described below covers the electrical equipment/system;

General Power Distribution Scheme

Estimation of Load

The following assumptions have been be made to arrive at the estimated load of the different

sites.

a) Load Factor

i) Motor : 0.9

ii) Auxiliary load, valve motors, etc. : 0.9

iii) Lighting load : 1.0

b) Diversity Factor

i) Motor : 1.0

ii) Auxiliary load, valve motors, etc. : 1.5

iii) Lighting load : 1.2

c) Power factor of Motors : As per Manufacturer‟s Catalogue

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d) Efficiency of Motors : As per Manufacturer‟s Catalogue

(Energy efficient eff1 or eff2)

(Energy efficient, high performance motors (minimum eff2 category) shall be

provided for optimum utilization of energy).

e) Protections

The following protections are proposed for various switchboards, transformers,

motors and other plant feeders.

1) 11 kV Switchboard

i) IDMT over current and earth fault protection for incomers

ii) IDMT and instantaneous over current and earth fault protection for

outgoing transformer feeders

2) LV switchboard

i) Over current, short circuit and earth fault protection on ACBs/ MCCBs

3) Motors

i) Overload protection by thermal (bimetal) relays in all the three phases

to trip with single phase preventer (SPP) and short circuit protection in

all the three phases through motor protection circuit breakers/ MCCBs

Alternatively, microprocessor based motor protection relay shall also

be used.

ii) Thermal, locked rotor, short circuit, negative sequence, under voltage,

over voltage and earth fault for each motor feeder of rating 90kW and

above.

f) Metering

The following metering shall be provided.

1) 11 kV Switchboard

Multifunction meter (for incomer) containing -

i) Ammeter

ii) Voltmeter

iii) kW meter

iv) Frequency meter

v) Power factor meter

vi) Kilowatthour meter

vii) kVAr meter

viii) kVA meter

For outgoing feeder

i) Ammeter with selector switch

2) LV Incomers

297

i) Ammeters with selector switch

ii) Voltmeter with selector switch

iii) kW meter

iv) Power factor meter

vi) Kilowatt-hour meter

vii) Frequency meter

3) LV Outgoing Feeders

i) Ammeter with ammeter selector switch

Multifunction meter shall be equipped with interfacing capability for RS-485

port.

g) Indicating Lamps

The following indication shall be provided:

1) 11kV Incomer, Bus Coupler and Outgoing feeders

i) Circuit breaker ON, OFF and TRIP, spring charged, control supply

healthy and trip circuit healthy (Mains ON (R,Y,B) indication for

incomer only)

2) LV Incomers

i) Mains ON (red, yellow and blue)

3) Motor Feeders

i) Motor ON, OFF and Trip indication (Red, green and Amber)

ii) Motor ON, OFF and Trip indication (Red, green and Amber), control

supply healthy and trip circuit healthy for breaker feeder.

All electrical equipment will be rated for 500 C design ambient temperatures.

All power cables shall be sized based on continuous current capacity, permissible voltage

drop and short circuit current rating. The voltage drop shall be limited to 2.5 % at rated

equipment current rating.

The other rating factors for variation in ground temperature, variation in ambient air

temperature, grouping of cables, depth of laying, etc. shall also be considered for cable

sizing.

The illumination levels proposed for various areas are as follows:

Area Illumination level (Lux)

Pump House 300

Office/Conference Room 500

Switchboard Room 300

All other indoor areas 150

Outdoor plant area and Road 10 – 20

Component of luminaries shall be „energy efficient low loss‟ type. LED type of luminaries

shall be used for office/ all indoor areas except pump house area. LED luminaries shall be

used for pump house area and other outdoor areas. Decorative fixtures/ receptacles shall be

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used for office areas and industrial type fixtures/ receptacles shall be used for remaining

areas. Street/ area lighting shall be controlled by time switch/ photocell for automatic

switching of luminaries. Emergency light shall be provided for safe evacuation of the people

in case of fire or panic (blackout, total power failure, etc.) Emergency lighting shall be

automatically switched ON when mains power supply fails.

The values of fault level for designing the electrical system shall be based on transformer

capacity, its impedance and system fault level. Fault clearing time for sizing of earth

conductor will be taken as one second.

The material of earthing conductor shall be hot dip Galvanized Steel. All connections

between the earth conductors buried in earth/concrete and between earth conductor and earth

leads shall be of welded type. While sizing the buried earth conductor, a corrosion allowance

of at least 20% shall be taken. Plant earthing system shall be designed such that the overall

earthing grid resistance is maximum one ohm.

Main earthing conductors outside and inside the building shall be planned in such a manner

that various equipment is connected to earthing system by two connections in a reliable

manner.

1.1.3 System Description

11 kV power sub-station shall be constructed in plant, The 11 kV switchboard shall feed

11/0.433 kV transformer(s) with off load tap changer, which in turn will feed the 0.433 kV

indoor switchboard. 100% redundant transformer shall be available to feed the entire load of

the STP. The 11 kV indoor switchboard shall consist of incomer VCBs (with line VTs), a

bus coupler VCB and VTs on both the bus sections alongwith of outgoing VCB feeders.

A 415 V PCC shall receive power from 11KV/0.433 kV transformer(s) and to feed the

individual loads through different switchboards located at different locations and sufficient

space for installation of these switchboards should be made available at site.

LV capacitor banks with control panel consisting of automatic power factor correction

(APFC) relay are to be proposed across each LV bus section of the LV switchboards i.e.PCC.

Necessary metering, protection and indication/ annunciation are to be provided on all the

switchboards.

1.1.4 Units of Measurement

Metric units of measurement (System International) shall be used in all Contract

documentation. Angular measurement shall be in degrees with 90 degrees comprising one

right angle.

1.1.5 Reference Standards

All equipment / systems supplied under this Contract shall conform to the latest editions of

the International Electro-technical Commission (IEC) Standards or equivalent Indian

Standards or other International Standards, provided they promise to confirm equal or

superior performance. If standards other than IEC are referred, then the Bidder shall enclose

English Version of the standard with the bid.

299

1.1.6 Inspection and Testing at Manufacturer‘s Works and Dispatch

The Bidder will follow the approved QA/QC Plan for the Inspection and Testing of

Equipment at Manufacturer‟s Works which is to the satisfaction of ENGINEER/

ENGINEER‟S representative and after getting dispatch clearance from the engineer ,that

equipment would be dispatch.

Construction Power Supply

Bidder shall make his own arrangements for construction power supply from electricity board

authority.

All power and lighting circuits shall be constructed with due regard for personnel safety and

shall comply with recognized codes of practice and local regulations. All circuits shall be

fitted with earth leakage systems.

SUBSTATION FOR MPS

The selected bidder should propose for 11 KV indoor substation with provision of HT

PANEL ,TRANSFORMER (1W+1S) and other accessories for MPS whose design must be

according to MANUAL and IS.

For POWER BACKUP during unavailability of electric supply, the selected bidder should

supply DIESEL GENERATOR of capacity to run the MPS for peak flow with suitable design

considering the starter current.

1.2 Power Transformers

1.2.1 Standards

Transformers and its accessories shall comply with the following International Standards,

including those referred to therein.

IEC 60076, 60214, 60296 / IS 2026, IS 335 / BS 148, 171 and IS specification and latest IEC

standard.

The technical parameters of transformers shall be as below:

Description Unit Particulars

General

Quantity required 2 no.(1W+1S)

Installation (Indoor / Outdoor) Outdoor

Ratings

Rated power

(*) Selected Bidder shall

submit their design calculation

for rating of each equipment

for JAL NIGAM or their

representative for approval.

kVA

No load voltage Primary kV 11

Secondary kV 0.433

Number of phases 3

Rated frequency Hz 50

Impedance voltage % As per IEC/BIS

300

Description Unit Particulars

Vector group Dyn11

Winding material Electric Grade Copper

Type of cooling ONAN

System Voltage

Nominal system voltage

Primary

kV 11

Secondary kV 0.415

Highest system voltage -

Primary

kV 12

-

Secondary

kV

Transformer Secondary

Neutral Earthing

Effectively earthed

Insulation Withstand

Rated lightning impulse

withstand voltage

kV

(peak)

75

- Secondary kV (rms)

3.5

Temperature Rise

Reference design ambient 0C 50

Temperature rise over design

ambient temperature of 50 0

C

- Average winding

temperature rise (by resistance

measurement)

0C 55

- Top oil temperature rise (by

thermometer)

0C 50

Tap Changing Gear

Type of tap changer Off Circuit tap Changer

Tapping range % 10%

Tapping steps % 2.5

Bushings

Rated voltage – Primary kV 12

– Secondary kV 1.1

One minute power frequency

withstand voltage (dry and

wet) – Primary

kV (rms) 28

- Secondary (Line and

Neutral)

kV (rms) 2.5

Rated lightning impulse

withstand voltage

kV

(peak)

75

Nominal creepage distance mm/kV 31

Terminal Connections

Primary line end Cable box

Secondary line end Cable box/Bus Duct

Secondary neutral end One bushing each inside and outside cable box

Type of wheels Plain – Bi-directional

301

(*) Values to be ascertained by the Selected Bidder after Submitting design calculations

subject to approval.

1.2.2 Design Features Transformers will be located outdoor and shall also be rated for satisfactory operation at 50

0C

design ambient temperature.

1.2.3 Accessories and Fittings Each main power transformer shall have the following fittings and accessories including but

not limited to:

a) A conservator of sufficient volume with

i. oil level gauge with potential free contacts for initiating alarm for low oil level

ii. weather-proof dehydrating breathers for both compartments with activated

alumina or silica gel as the dehydrating breather

iii. shut off valves

iv. filling plug and drain valves

The conservator shall be designed to maintain an oil seal upto a temperature of 1000

C.

b) Gas and oil actuated Buchholz relay with

i. necessary shut off valves

ii. test cock with pipe connections for sampling

iii. potential free contacts for initiation of alarm in case of slow gas formation and

trip in case of fast oil and gas surges

c) Dial type thermometer with

i. maximum temperature indicator and its resetting device

ii. potential free contacts for initiating alarm on high temperature and trip on very

high temperature

d) Winding temperature indicator with

i. necessary sensing, compensating and calibrating devices

ii. potential free contacts for initiating alarm on high temperature and trip on very

high temperature

iii. WTI transmitter for remote indication on remote tap changing panel

f) Detachable type of radiators including but not limited to:

i. Shut-off valves and blanking plates on transformer tank at each point of

connection of inlet and outlet header

ii. Top and bottom shut-off valves and blanking plate on each radiator

iii. Lifting lugs

iv. Top oil filling plug, 19 mm size

v. Air release plug at top

vi. Oil drain plug at bottom, 19 mm size

vii. Earthing terminals

g) Pressure relief device for transformer tank

h) Weather - proof marshaling box mounted on transformer tank

i) Name plate, rating plate and Diagram plate

j) Valves and plugs as below:

i. Drain valve

ii. Filter valve

iii. Oil sampling valves at top and bottom

iv. Valves between radiators and tank (in case of detachable radiators)

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v. Air release plug

vi. Twin outlets (with plug) for applying vacuum with attachments.

k) Earthing pads of copper or non-corrodible material for transformer tank (2 places) and

radiator banks

l) Inspection manholes as required

m) Lifting arrangement for

i. fully assembled transformer

ii. core and coil

iii. tank

n) Hauling eyes on each face of the transformer

o) Bi-directional flanged wheels

p) Anti-earthquake clamping devices

q) Jacking pads

Each auxiliary transformer shall have the following fittings and accessories including, but not

limited to:

a) Conservator with oil level gauge

b) Dehydrating silica gel breather

c) Oil temperature indicator

d) Thermometer pocket

e) Explosion vent diaphragm / pressure relief valve

f) Sampling and drainage valves

g) A plug or blank flange at the top for connecting valve for filtration

h) Two earthing terminals

i) Rating plate (Name plate and diagram plate)

j) Lifting lugs

k) Removable plain rollers

l) Adequate number of air vents for relieving trapped air during oil filling and during

maintenance.

m) Accessories for clamping the wheel to the foundation channel in order to withstand

earthquake forces.

1.2.4 Windings

The windings shall be of electrical grade copper.

Materials used in insulation and assembly shall be insoluble, non-catalytic and chemically

inactive in the hot transformer oil and shall not soften or otherwise be affected under

operating conditions. Windings and insulation shall be so arranged that free circulation of oil

is possible between coils, between windings, and between winding and core.

Leads from winding to the terminal board and bushings shall be rigidly supported to prevent

injury from vibration. Guide tubes shall be used where practicable.

Windings shall be subjected to shrinking and seasoning processes so that no further shrinkage

occurs during service. Adjustable devices shall be provided to take up possible shrinkage in

service. High voltage end - windings shall be suitably braced to withstand short circuit

stresses.

1.2.5 Core

The magnetic circuit shall be constructed from high grade, cold rolled, non-ageing, grain

oriented silicon steel laminations. Each sheet shall have an insulating coating resistant to the

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action of hot oil. Each lamination shall be coated with insulation which is unaffected by the

temperature attained by the transformer during service.

The insulation structure for the core to bolts and core to clamp plates shall be such as to

withstand appropriate dielectric test. All steel sections used for supporting the core shall be

thoroughly shot or sand blasted after cutting, drilling and welding. Core laminations shall be

annealed and burrs removed after cutting. Cut edges shall be insulated. The framework and

clamping arrangements of core and coil shall be securely earthed inside the tank by a copper

strap connected to the tank. The core clamping structure shall be designed to minimize eddy

current loss. The core shall be provided with lugs suitable for lifting the complete core and

coil assembly. The framework and clamping arrangements shall be securely earthed.

The core and coil assembly shall be dried out and impregnated under vacuum.

1.2.6 Tank

The transformer tank shall be made from high-grade sheet steel, suitably reinforced by

stiffeners made of structural steel sections. All seams, flanges, lifting lugs, braces, and other

parts attached to the tank shall be welded. The interior of the tank shall be cleaned by shot

blasting and painted with two coats of heat resistant, oil insoluble paint. Adequately sized

manholes shall be provided for ease of inspection and maintenance. Steel bolts and nuts

exposed to atmosphere, shall be galvanized.

Tank together with radiators, conservator, bushings and other fittings shall be designed to

withstand without permanent distortion the following conditions:

a) Full vacuum of 760 mm of Hg for filling with oil under vacuum

b) Internal gas pressure of 0.35 kg/cm² with oil at operating level

Tank shall be provided with a pressure release device, which shall operate at a pressure below

the test pressure for the tank and radiators. The device shall be provided with a device visible

from ground to indicate operation. An equalizer pipe connecting the pressure relief device to

the conservator shall be supplied. The device shall be provided with potential free contacts

for alarm and tripping. Alternatively, a separate pressure relay shall be provided for this

purpose.

The tank cover shall be bolted type and not welded, sealed type. The tank cover shall be

removable and shall be suitably sloped so that it does not retain rainwater.

1.2.7 Radiators

Radiators shall be designed to withstand the vacuum pressure conditions specified for the

tank. They shall be so designed as to completely drain oil into the soak pit and to prevent

formation of gas pockets when the tank is being filled.

Transformers of rating above 1500 kVA shall be equipped with detachable or separately

mounted radiator banks. Radiators for the main transformers shall be with bolted and gasket

flange connections. Transformers of rating 1500 kVA and below shall be provided with fixed

type radiators. Fins of the radiators shall not have sharp edges and shall be rounded in shape.

When transformers are provided with separately mounted radiators, flexible joints shall be

provided on the main oil pipes connecting the transformer tank to the radiator banks, to

reduce vibration and facilitate erection and dismantling. The interconnecting pipes shall be

provided with drain plug and air release vents.

Off-circuit tap changer

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Off circuit tap changer shall be provided for auxiliary transformers. It shall comprise

a) Operating handle or wheel accessible from ground level

b) Tap position indicator

c) Padlocking arrangement with padlock.

1.2.8 Marshalling Box

The marshalling box shall be tank mounted, weather proof, vermin proof, dust proof, sheet

steel (2 mm thick), enclosed and with hinged door having padlock. Door and gland plate shall

be fitted with neoprene gaskets. Bottom shall be at least 600 mm from grade level. Top

surface shall be sloped. The degree of protection shall be IP65.

Contacts / terminals of electrical devices / relays, etc. mounted on the transformer shall be

wired to the marshalling box. Interconnecting wires between the marshalling box and the

accessories / devices shall be either PVC insulated wires in GI conduits or PVC insulated,

armoured cables together with provision of double compression type, brass cable glands at

the marshalling box. The above mentioned cables as well as terminating the cables shall be

the Selected Bidder's responsibility.

All contacts for alarm, trip and indication circuits shall each be electrically free, designed for

the auxiliary DC supply of 110 V and brought out to separate terminals in the marshalling

box. Terminals shall be rated for 10 A. Disconnecting / shorting type terminal block shall be

used for CT circuits.

In case of main transformers, provision for remote annunciation shall be provided with two

changeover contacts for alarm condition and two changeover contacts for trip condition for

each of the following conditions including but not limited to:

a) Buchholz alarm

b) Buchholz Trip

c) Oil Temperature high

d) Oil Temperature very high

e) Oil level low

f) Pressure relief device operated

g) Winding temperature high

h) Winding temperature very high

i) Conservator oil level low

1.2.9 Cable Terminations

Cable boxes shall have sufficient space for segregating the cable cores and for adequate

clearance in air between bare conductors at the terminals. Cable boxes shall be complete with

necessary glands, lugs and armour grips.

Air filled cable boxes shall be of adequate dimensions and designed in such a manner that

they can be opened for inspection without disturbing the gland plate or incoming cable.

Disconnecting chamber shall be provided for disconnecting and moving away the main

transformer, without removing the cables or the cable box. Provision shall be made for

earthing the body of each cable box.

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1.2.10 Tests

All tests required by the specification including repeated tests and inspection that may be

necessary owing to the failure to meet any tests specified, shall be carried out at the Selected

Bidder's expense.

The following tests shall be carried out on the assembled transformer during inspection at the

manufacturer‟s works.

a) Temperature rise test on one transformer

b) Measurement of resistance of windings at principal and extreme taps

c) Ratio at each tap, polarity and phase relationships

d) Measurement of impedance voltage at principal and extreme taps

e) Measurement of no load current and no load losses at rated frequency and at both the

rated voltage and 110 % rated voltage

f) Measurement of efficiency and regulation at ½, ¾ and full load

g) Measurement of insulation resistance

h) Induced over voltage withstand test

i) Separate source voltage withstand test

j) Magnetic balance test

k) Test on OLTC

Type test certificates shall be provided for verification. Whenever two nos. or more identical

transformers are being offered, type tests on one of them shall be carried out, including heat

run test.

All auxiliaries and accessories such as temperature indicators, Buchholz and pressure relays

shall be tested as per the applicable standards and test certificates shall be furnished to the

Employer‟s Representative for approval.

1.2.11 Rejection

The Employer may reject the transformer if anyone of the following conditions arises during

testing:

a) Any of the quantities / parameters of transformers subject to tolerances are outside the

tolerances given in the applicable standards or such tolerance as guaranteed in the

Selected Bidder's bid.

b) Winding and / or top oil temperature rise exceeds the specified / guaranteed value;

and

c) Transformer fails to withstand any of the dielectric tests.

Additional tests shall be conducted to locate the failure and after rectification, all tests shall

be repeated to prove that the rebuilt transformer meets the specification in all respects, all at

the Selected Bidder‟s expense.

JAL NIGAM reserves the right to have the transformer replaced or repaired by the Selected

Bidder within reasonable period to Employer's satisfaction at no extra cost to the Employer.

The Selected Bidder shall also bear the costs, including but not limited to, incurred by the

Employer in re-inspection / re-testing such as travel and incidental expense, etc. The Selected

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Bidder shall note that any delay in completion time due to such repair / replacement shall be

subject to liquidated damages as specified in the Conditions of Contract.

1.3 MV Indoor Switchboard

MV indoor VCB switchboard shall comply with the following Standards, including those

referred to therein.

IEC 61869, 60265, 60282, 62271, 60529, 60694, 60787, 62271 IEC/TR2 61211 and IS 9046,

9920, 9921, 13118, 3427, 4237, 2156, 2705, 3156, 10118, 722, 13118.

There must be provision for LT panel and APFC PANEL FOR MOTOR OF MPS with

suitable BUS BAR and BREAKER along with proper rating of cables.

The technical parameters of HV switchboards shall be as below:

HV switchboard

Description Unit Particulars

General

Type Metal enclosed, compartmentalized,

draw-out type

Rated voltage, no. of phases and

rated frequency

kV / - / Hz 12 kV, 3 Phase, 50Hz

System neutral earthing Effectively Earthed

Rated Insulation Levels

- Rated short duration power

frequency withstand voltage

kV (rms) 70

- Rated lightning impulse withstand

voltage kV (peak) 170

Rated normal current of bus bars under

design ambient temperature of 500C and

material of busbar

A / - (*),Aluminium - suitable for 100% load

including future loads

Rated short-time withstand current and

time kA (rms) /

sec

16 kA for 1 sec

Dynamic rating kA (peak) 40

Constructional Requirements

Minimum thickness of sheet steel in

mm Cold rolled

(Frame/Enclosure/Covers)

mm Frame – 2

Doors/Covers – 2.0

Degree of protection of enclosure IP-5X

Color finish shade

- Interior Glossy White

- Exterior Light Grey Semi Glossy

Cable connection Bottom entry and exit

Circuit Breakers

Type Vacuum/ SF6

Rated current inside the cubicle

under design ambient temperature at

50C

A (*) – (Breakers shall be rated for final

ratings of motors in STP)

Rated operating sequence O–3 Min–CO-3 Min-CO

Rated short time breaking current kA (rms) 16

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Description Unit Particulars

Rated short time making current kA (peak) 40

Rated short-time withstand current

and time

kA (rms) /

sec

16 kA for 1 sec

Rated peak withstand current kA (peak) 40

Min. no. of auxiliary contacts 6 NO + 6 NC after internal use by

manufacturer

Type of operating mechanism

- Normal Spring charging for closing and tripping

- Emergency Manual and Spring charged for closing

and tripping

Auxiliary control voltage

- Closing coil / Tripping coil V 110V DC

- Spring charging motor V 110V DC

- Space heater and lighting V 230V AC

Earthing switch Required

Current and Voltage Transformers

Details of ratio, taps, burden,

accuracy

As per Single Line Diagram (*)

Protective Relays

Type Numerical (Microprocessor based)

Auxiliary supply V 110V DC

Details of protective relays As per Single Line Diagram

Switch-Disconnector

Rated current under design ambient

temperature of 50C

A (*)

Rated making current kA (peak) 40

Rated peak withstand capacity kA (peak) 40

Rated short-time withstand current

and time

kA (rms) /

sec

16 kA for 1 sec

Insulation levels

Rated lightning impulse withstand

voltage

- Across the isolating distance kV (peak) 70

- Phase to phase, between phases

and across open switching devices

kV (peak) 60

Rated short duration power

frequency withstand voltage

- Across the isolating distance kV(rms) 23

- Phase to phase, between phases

and across open switching devices

kV(rms) 20

Operating mechanism

- Closing and opening Spring charged

- Control voltage V 110V DC

Earthing switch Required

HV Fuses

Application Indoor

Type HRC

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Description Unit Particulars

Rated current A (*)

Rated voltage kV 36

Rated breaking capacity kA (rms) 16

(*) Value to be ascertained by the Bidder after submitting design calculations subject to

approval.

1.3.1 Circuit Breaker

Circuit breakers shall preferably vacuum type. Circuit breaker along with its operating

mechanism shall be mounted on a wheeled carriage moving on guides, designed to align

correctly and allow easy movement. Plugs and sockets for power circuits shall be silver faced

and shall be insulated with suitable insulating material shrouds. All corresponding

components of circuit breaker cubicles of same rating shall be interchangeable with one

another.

There shall be „Service‟, „Test‟ „Fully withdrawn‟ positions for the breakers. In the „Test‟

position the circuit breaker shall be capable of being tested for operation without energizing

the power circuits, i.e. the control circuits shall remain undisturbed while the power contacts

shall remain disconnected. Separate limit switches, each having a minimum of 2 „NO‟ + 2

„NC‟ contacts, shall be provided for both „Service‟ and „Test‟ positions of the circuit breakers

for future SCADA.

Electrical tripping shall be performed by shunt trip coils. “Local / Remote” selector switch

lockable in “Local” position shall be provided on the cubicle door. `Red‟ and `Green‟

indicating lamps shall be provided on cubicle door to indicate breaker close and open

positions. Breaker “Service” and “Test” positions shall be indicated by separate indicating

lamps on the cubicle door, in case mechanical indication of “Service” and “Test” positions

are not available on the cubicle door.

Connection of the control / interlocking circuits between the fixed portion of the cubicle and

the breaker carriage shall be preferably by means of plug socket arrangement.

Operating Mechanism Control

a) Circuit breakers shall be operated by a motor spring charging type of mechanism. The

mechanism shall be complete with motor, opening spring, closing spring and all

accessories to make the mechanism a complete operating unit

b) Operating mechanism shall normally be operated from the breaker cubicle itself.

c) The tripping spring shall be charged by the closing action, to enable quick tripping.

Closing of the circuit breaker shall automatically initiate recharging of the springs to

enable the mechanism to be ready for the next closing stroke. Charging time for the

springs shall not exceed 30 seconds. It shall be possible to manually charge the

springs in an emergency. Transfer from motor to manual charging shall automatically

disconnect the charging motor. All operating mechanisms shall be provided with

"ON" - "OFF" mechanical indication. The charging mechanism shall be provided with

mechanical indicators to show "charged" and "discharged" conditions of the spring.

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Failure of any spring, vibration or mechanical shock shall not cause tripping or

closing of the circuit breaker.

d) Only one closing operation of the circuit breaker shall result from each closing

impulse (manual or electrical), even if the breaker trips while the control device

(manual or electrical) is being held in the "close" position.

e) The circuit breaker mechanism shall make one complete closing operation, once the

push button (PB) or control switch has been operated and the first device in the

control scheme has responded, even though the PB or control switch is released

before the closing operation is complete, subject to the condition that there is no

counter- impulse for tripping.

f) Means shall be provided to manually open and close the breakers slowly, when the

operating power is not available, for maintenance and adjustments. A local manual

trip device shall also be provided on the operating mechanism.

g) Circuit breaker control shall be on 110 V DC. Closing coils and other auxiliary

devices shall operate satisfactorily at all voltages between 85-110 % of the control

voltage. Trip coils shall operate satisfactorily between 70 -110 % the rated control

voltage.

h) Provision for remote control shall be provided for future SCADA.

1.3.1.1 Safety Interlocks and Features

a) Withdrawal or engagement of a circuit breaker / switch disconnector shall not be

possible unless it is in the open position.

b) Operation of a circuit breaker / switch disconnector shall not be possible unless it is in

service position, withdrawn to test position or fully drawn out. It shall not be possible

to close the circuit breaker electrically in the service position, without completing the

auxiliary circuit between the fixed and moving portions.

c) Circuit breaker / switch disconnector cubicles shall be provided with safety shutters

operated automatically by the movement of the circuit breaker / switch disconnector

carriage to cover the stationary isolated contacts when the breaker / switch

disconnector is withdrawn. Padlocking facilities shall be provided for locking the

shutters positively in the closed position. It shall, however, be possible to open the

shutters intentionally against spring pressure for testing purposes.

d) The circuit breaker / switch disconnector carriage shall be earthed before the circuit

breaker / switch disconnector reaches the test position from fully withdrawn position.

In case of breakers / switch disconnector with automatic disconnecting type of

auxiliary disconnects, the carriage shall be earthed before the auxiliary disconnects

are made and the carriage earthing shall break only after the auxiliary disconnects

break.

e) Caution nameplate, “Caution Live Terminals” shall be provided at all points where

the terminals are likely to remain live and isolation is possible only at remote end, i.e.

incomer to the switchboard. Suitable interlock shall be wired for the purpose.

1.3.2 Current and Voltage Transformers

CTs and VTs shall have polarity marks indelibly marked on each transformer and at the

associated terminal block. Facility shall be provided for short-circuiting and earthing the CT

secondary at the terminal blocks.

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CT shall be able to withstand the thermal and mechanical stresses resulting from the

maximum short circuit current. Core laminations shall be of high grade silicon steel.

VTs shall be of the single phase type and mounted on a draw out trolley. VTs shall be

protected on their primary and secondary sides by current limiting fuses with interrupting

ratings corresponding to breaker rating. It shall be possible to replace the secondary fuses

safely when the switchboard is energized. Alternatively, MCB having auxiliary contact shall

be provided. Primary side fuses shall be replaceable only in the de-energized position.

Secondary winding of voltage transformer (VT) shall be rated for a three phase line to line

voltage of 110 V.

Identification labels giving type, ratio, output and serial numbers shall be provided for CTs

and VTs.

1.3.3 Relays

Protection relays shall be Numerical (microprocessor based) type. Relays shall have

interfacing facilities to communicate data to SCADA system.

All relays shall be enclosed in rectangular shaped, dustproof cases and shall be suitable for

flush mounting.

All relays shall be accessible from the front for setting and resetting. Access to setting

devices shall be possible only after the front covers of the relays are removed.

All protective relays shall be of the draw-out type and shall be provided with operation

indicators visible from the front.

1.3.3.1 Over Current / Earth Fault Protection

a) This relay shall be of the multi-characteristics type which has a flexible mode

selection facility so that it is possible to select one mode for the over current elements

and another for the earth fault element.

b) Phase current range shall cover at least 50-300% of „In‟ in steps of not more than 10%

while the earth current range shall cover at least 5-100% of „In‟ in steps of not more

than 5%.

c) The time setting range of the definite time mode shall not be less than 5 seconds in

steps of 0.1 second each.

d) The time multiplier setting for the inverse time-current characteristic modes shall

have a range not less than 0.05- 1.6 in steps of 0.05.

e) Over current and earth fault relays shall have separate timers and operation indicators.

f) The high set element shall have a range of 2 - 15 times the nominal current in steps of

„In‟ and shall be of low transient overreach, with a tripping time of less than 25 ms

and possible to be selected on "blocked" position. Reset time shall be not more than

50 ms for both elements.

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g) The relays that are installed on the transformer neutral side shall be of single phase

version, but they shall have the same characteristics as the phase side relays.

1.3.3.2 Restricted Earth Fault Protection

a) The restricted earth fault relay shall be operated from a completely separate core of

line and neutral current transformers. The dedicated CTs shall be of class PS and have

the same magnetization characteristics with a knee „emf‟ value higher than the highest

possible setting of the relay. Intermediate CTs for ratio correction are not acceptable.

CT sizing shall be matched with the requirements of the relay.

b) For this protection, 1-phase high impedance relay shall be provided and all the aspects

regarding stability of the protection, dimensioning of current transformer, considering

the peak short circuit current, etc. and all the auxiliary equipment such as non-linear

VDR resistor for voltage limiting, filter for harmonics and DC component suppression

and variable shunt resistor for sensitivity adjustment, if required, shall be provided.

The total fault clearing time shall not exceed 20 m sec. at 3 x In.

c) The stability of this protection against out-zone faults shall be confirmed. A

calculation to show the proper selection of the relay up to the maximum short circuit

of the switchboard shall be submitted.

1.3.3.3 Under Voltage Relays

a) Suitable voltage operated relays for sensing loss of voltage shall be provided. The

relay shall have a drop off to pick up ratio of the order 90%. The relays shall be fast

operating type and shall be fitted with operation indication. The indication shall come

on drop off or loss of voltage.

b) Additional potential free contacts for all the relay outputs i.e. trip as well as alarm

signals shall be provided for connection to future SCADA.

1.3.3.4 Motor Protection Relay

a) It shall be designed to protect the motor against thermal overload, locked rotor, over

current and earth fault protection, under voltage, over voltage, phase reversal and

negative sequence.

b) Thermal setting range shall cover at least 50% to 200% of „In‟ in steps of not more

than 5 % of „In‟.

c) Phase current range shall cover at least 5-200% of „In‟ in steps of not more than 1%

while the earth current range shall cover at least 1-100% of „In‟ in steps of not more

than 5%.

1.3.3.5 Auxiliary Relays and Timers

a) Following auxiliary relays shall be provided on each breaker cubicle:

i. Trip circuit supervision relay

ii. Anti- pumping relay

b) Hand reset type lockout (tripping) relays and timers shall be provided as required in

addition to the protection relays given in the single line diagram.

c) Auxiliary relays and timers shall be rated to operate satisfactorily between 70 % and

110 % of the rated voltage.

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d) Voltage operated relays with sufficient contacts to initiate tripping, alarm,

annunciation for various trip functions like Buchholz relay operation. Each relay shall

have four (4) pairs of self-reset contacts except for Buchholz and "PRD" trip which

shall have hand-reset contact. The relays shall have hand-reset operation indicators.

e) Voltage operated relays with sufficient contacts to initiate alarm and data logging for

various alarm functions for transformers, etc. shall be provided. Each relay shall have

four (4) normally open self reset contacts. The auxiliary relay for Buchholz alarm

shall be slugged to have delay on drop off at 100 ms. The relays shall have hand reset

operation indicator.

1.3.4 Switch Disconnectors and Fuses

.

Switch disconnectors when switched, shall be of the load break, fault make, grouping

operated type. For use on 3-phase systems, the switches shall be of the triple pole type with a

link for neutral connection.

Switch disconnectors shall be of the heavy duty, quick make and quick break type. It shall be

electrically and manually operated. Their contacts shall be silver plated, and contact springs

shall be of stainless steel. Their handles shall have provision for locking in both fully open

and fully closed positions. Mechanical „ON-OFF‟ indication shall be provided.

For combination units of switch disconnector and fuses, the following interlocks shall be

incorporated:

a) The fuses should not be accessible unless the switch disconnector is in fully open

condition.

b) It should not be possible to close the switch disconnector when the fuse cover is open,

but an authorized person may override the interlock and operate the switch

disconnector. After such an operation, the cover shall be prevented from closing if the

switch disconnector is left in the "ON" position.

All fuses shall be of the HRC cartridge type in accordance with IEC 60269 mounted on plug-

in type of fuse bases. Fuses shall be provided witM Visible indicators to show that they have

operated. Current vs. time characteristics of all types of fuses shall be furnished to the JAL

NIGAM or their representative.

Fuses and links functionally associated with the same circuit shall be mounted side by side.

An adequate number of spare fuse cartridges of each rating shall be supplied and fitted in

clips inside the panel.

1.3.5 Constructional Features of Switchboard

Switchboard design shall comprise metal enclosed, fully compartmental and draw out

execution having separate sections for each circuit. Compartments with doors for access to

operating mechanism shall be so arranged as not to expose high Voltage circuits.

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Switchboard cubicle shall be provided with hinged door on the front with facility for locking

door handle.

Switchboard shall be dust and vermin-proof and shall have a degree of protection of

enclosure of IP 4X.

All removable covers shall be gasketed all around with neoprene or superior gaskets.

Instruments, relays and control devices shall be flush-mounted on hinged door of the

metering compartment located in the front portion of cubicle. The metering compartment

shall be properly shielded to prevent mal-operation of electronic equipment such as numerical

/ static relays due to electro-magnetic fields. Separate signal earth shall be provided for such

devices, if necessary.

Each switchboard cubicle shall be fitted with a label on the front and rear of the cubicle. Each

switchboard shall also be fitted with label indicating the switchboard designation, rating and

duty. Each relay, instrument, switch, fuse and other devices shall be provided with separate

label.

Sheet steel used for fabrication of switchboards, control cabinets, marshalling boxes, etc shall

be cold rolled.

All panels, cabinets, kiosks and boards shall comprise rigid welded structural frames made of

structural steel sections or of pressed and formed cold rolled sheet steel of thickness not less

than 2 mm. The frames shall be enclosed by sheet steel of at least 2 mm thickness. Stiffeners

shall be provided wherever necessary.

All doors, removable covers, gland plates, etc. shall be of at least 2 mm thickness and shall be

gasketed all round the perimeter.

All doors shall be supported by strong hinges of the disappearing or internal type and braced

in such a manner as to ensure freedom from sagging, bending and general distortion of panel

or hinged parts.

All floor mounted panels / boards shall be provided with a channel base frame.

It shall be possible to extend the switchboard on both sides.

The fully draw-out modules shall have all the circuit components mounted on withdrawable

type steel chassis. All power and control connections shall be of the draw out type. It shall be

possible to withdraw the chassis mounted circuit components without disconnecting any

connections. All draw-out contacts shall be of silver plated copper.

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In case of circuit breaker compartments, suitable barriers shall be provided between breaker

and all control, protective and indication circuit equipment including instrument transformers

such that no live parts are accessible. External cable connections shall be through separate

cable compartments for power and control cables.

One metal sheet shall be provided between two adjacent vertical sections running to the full

height of the switchboard except for the horizontal busbar compartment. However, each

shipping section shall have metal sheets at both ends.

After isolation of the power and control connections of a circuit, it shall be possible to carry

out maintenance in a compartment safely, with the bus bars and adjacent circuits alive.

1.3.6 Earthing

A copper earthing bus shall be provided and extended throughout the length of the

switchboard. It shall be bolted to the framework of each unit and brazed to each breaker

earthing contact bar. It shall be located at the bottom of the board.

The earth bus shall have sufficient cross section to carry the momentary short circuit and

short time fault current for at least 1 second or higher as specified, without exceeding

maximum allowable temperature rise. The earth bus shall be properly supported to withstand

stresses induced by the momentary short circuit current.

Suitable clamp type terminals at each end of the earth bus shall be provided to suit the size of

the earthing conductors.

Bolted joints, slices, tap, etc. to the earth bus shall be made with at least two bolts.

Positive earthing of circuit breaker frame shall be maintained when it is in the connected

position and in all other positions whilst the auxiliary circuits are not totally disconnected.

Hinged doors shall be earthed through flexible earthing braid of adequate cross section.

All non-current carrying metal work of the switchboard shall be effectively bonded to the

earth bus.

Positive connection of the frames of all the equipment mounted in the switchboard to the

earth busbar shall be maintained through insulated conductors of size equal to the earth

busbar or the load current carrying conductor, whichever is smaller.

All instrument and relay cases shall be connected to earth busbar by means of 1100V grade,

green colored, PVC insulated, stranded, tinned copper, 2.5 sq. mm conductor looped through

each of the earth terminals.

1.3.7 Circuit / Busbar Earthing Facility

It shall be possible to connect each circuit or set of 3 phase bus bars of the switchboard to

earth through earthing switches.

Earthing switches / earthing devices shall be mechanically interlocked with the associated

breakers / switch disconnector to prevent accidental earthing of live circuit or bus bars.

In case the earthing facility comprises earthing trucks to be inserted in place of circuit

breakers, separate earthing trucks shall be supplied for each type / size of breaker.

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The earthing facilities proposed to be provided by the Bidder shall be clearly detailed in the

Bid and shall be subject to JAL NIGAM or their representative 's approval.

Auxiliary contacts (min. 2 NO + 2 NC) shall be provided on each earth switch / earthing

device and shall be wired to the terminal block for interlocking purpose.

1.3.8 Annunciators

Annunciators shall be of facia type with translucent plastic window for each alarm point.

Annunciator facia plates shall be engraved in block lettering with respective alarm

inscriptions. The inscriptions shall be clearly readable and visible when the respective facia

light is lighted.

Each annunciation window shall be provided with two lamps to provide redundancy against

lamp failure. Lamps shall be replaceable from the front. Lamps shall be of clustered LED

type.

All facia annunciator points shall be suitable to accept external contacts of either „NO‟ or

„NC‟ self or hand reset type for initiating the annunciation sequence. Annunciators shall be

suitable for accepting fleeting faults of duration as less as 15 millisecond.

For static annunciator schemes, special precaution shall be taken by the Bidder to ensure that

spurious alarm conditions do not appear due to influence of external magnetic fields on the

annunciator wiring and switching disturbances from the neighboring circuits within the

panels / desks.

A “Lamp Test” push button shall be provided for each individual panel‟s group of

annunciators to limit the sudden drain on the battery.

Provision of testing facilities for flasher and audible alarm circuits of annunciators is

desirable. The Bidder shall give the details of the offered scheme.

Annunciators shall have following features:

a) Suitable for annunciating subsequent faults immediately after the sound cancel of the

previous fault.

b) During lamp test, if a fault occurs, the corresponding lamp circuit shall be

automatically disconnected from the “lamp test” circuit and shall start flashing.

c) Designed to prevent mal-operation of the scheme or sequence when the push buttons

are pressed incorrectly or in the wrong order.

d) "Alarm Supply Failure” Alarm scheme similar to the normal annunciation sequence,

but shall operate on a different DC supply or on AC auxiliary supply.

1.3.9 Instruments

All electrical instruments and meters shall comply with IEC 60051, 61010 and IS 722, 1248.

All indicating and recording instruments shall be flush mounted in dust proof cases

complying with IEC 60068 and dimensions to IEC 61554. All digital instruments shall have

interface facilities to communicate data to SCADA system.

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1.3.9.1 Indicating Instruments

a) Electrical indicating instruments shall be 96 or 110 mm square with 2400 scale. Taut

band type of instruments is preferred. Taut band moving coil instruments for use on

AC systems shall incorporate built-in transducers.

b) Instrument dials shall be white with black numbers and lettering. A red line shall be

drawn on each scale to represent rated conditions.

c) Normal maximum meter reading shall be of the order of 60 % normal full scale

deflection. Ammeters for motor feeders shall have suppressed scale to show current

from full load up to six times the full load current.

d) Instruments shall have accuracy class of 1.0 or better. The design of the scales shall

be such that it can read to a resolution corresponding to 50% of the accuracy class

index.

e) Ammeters and current coils of Watt meters and Voltmeters shall continuously

withstand 120% of rated current and 10 times the rated current for 0.5 sec., without

loss of accuracy. Voltmeters and potential coils of Watt meters and Varmeters shall

withstand 120% of rated voltage continuously and twice the rated voltage for 0.5 sec.

without loss of accuracy.

f) Alternatively, instruments can be electronic / digital type with LCD display. These

instruments should have high performance ratio and can be equipped with digital

output (for alarms) or with interfacing facilities for communication and remote

reading of parameters.

1.3.9.2 Metering instruments

a) Watt-hour meters shall be of the induction type and shall be provided with reverse

running stops.

b) Watt-hour and Varhour meters shall be of the three phase two element type of

accuracy class 1.0, suitable for measurement of unbalanced loads in three phase three

wire circuits.

c) Watt-hour and Varhour meters shall be suitable for operation from the secondary of

CTs and VTs. They shall be provided with a separate 3 phase 4 wire type test

blocks for the testing of the meters without disturbing the CT and VT

secondary connections.

d) Meters shall have digital or cyclometer type of registers. They shall read kWh,

kVARh or MWh, MVARh as the case may be without the use of additional

multiplying factors. Multiplying factors if unavoidable shall be multiples of 10 (ten).

Number of digits provided shall be adequate to cover at least 1000 hrs. of operation.

g) Alternatively, instruments can be electronic / digital type with LCD display. These

instruments should have high performance ratio and can be equipped with digital

output (for alarms) or with interfacing facilities for communication and remote

reading of parameters.

1.3.10 Control and Selector Switches

Control and instrument switches shall be rotary type, provided with escutcheon plates clearly

marked to show operating position and suitable for semi-flush mounting with only the switch

front plate and operating handle projecting out. The connections shall be from the back. The

contact assembly at the back of the switch shall be enclosed in dust tight removable covers.

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The control switches shall be 3 position, spring return to neutral type. They shall be provided

with contacts to close in „normal after close‟ and „normal after trip‟ position. Each switch

shall have external red and green indicating lamps, (except when discrepancy type switches

are called for). In addition, a semaphore indicator shall be provided for earthing switch.

Contacts of the switches shall be spring assisted and contact faces shall be of silver / silver

alloy. Springs shall not be used as current carrying parts. Contact rating and configurations of

the switches shall be adequate for the functions desired.

Instrument selector switches shall be of the maintained (stay-put) type. Ammeter selector

switches shall have make-before-break type contacts so as to prevent open circuiting of CT

secondary when changing the position of the switch.

Lockable type switches, which can be locked in a particular position, shall be provided, if

required.

Emergency stop buttons, if any, shall incorporate „stay-put‟ features with independent reset

facilities.

1.3.11 Indicating Lamps / Pilot Lights

Indicating lamp shall be of the double contact, bayonet cap type rated for operation at either

230 V AC or at the specified DC system voltage as applicable. Lamps shall be provided with

translucent lamp covers.

Clustered LED type lamps shall be provided Lenses shall be glass or plastic in standard

colors, red, green, blue, white and amber, in accordance with IEC 60073.

Bulbs and lenses shall be interchangeable and easily replaceable from the front of the panel.

Tools, if any, which are required for replacing the bulbs and lenses, shall also be included in

the scope of supply.

Miniature pilot lamps may be provided with plastic marking plate contained inside square (or

rectangular) front lens to provide indication of legend or symbols engraved on the marking

plate.

The basis of colors shall be as follows:

Red : Flow of energy.

Green : No flow of energy.

White : Supervision of power available, relay coil healthy, etc.

Amber : Disagreement with original condition, „abnormal‟ condition or

„sequence–on‟ condition.

1.3.12 Push Buttons

Push buttons shall be of momentary contact type with rear terminal connections. The color of

the push button actuator shall be red for „OPEN / STOP‟ and green for „CLOSE / START‟

and for other applications shall be as per specified requirements. The push button knob shall

be suitably shrouded to prevent inadvertent operation. The push buttons shall be provided

with integral inscription plates engraved with their designation.

All push buttons shall have independent, potential free, 2NO + 2NC contacts. The contact

faces shall be of silver / silver alloy. The contacts shall be rated 10A and capable of breaking

inductive load of 1A at 110V DC and 5A at 110V AC.

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1.3.13 Space Heaters

Adequately rated anti-condensation space heaters shall be provided for each switchboard /

cubicle.

Space heater shall be of the industrial strip continuous duty type, rated for operation on a 230

V, 1 phase, 50 Hz, AC system.

Space heater shall be provided with a single pole MCB with overload and short circuit

release, a neutral link and a thermostat to cut off the heaters at 350 C.

1.3.14 Cubicle Lighting / Receptacle

Each cubicle shall be provided with interior lighting by means of 18 W fluorescent tube

lighting fixture. An MCB shall be provided for the lighting circuit. The lighting fixture shall

be suitable for operation from a 230 V, 1 ph, 50 Hz, AC supply.

A 230 V, 1 phase, AC receptacle (socket) plug point shall be provided in the interior of each

panel with an MCB.

1.3.15 Power and Control Cable Terminations

Terminals for power connections shall be complete with adequate phase segregating

insulating barriers, shrouds and suitable crimping type of lugs for terminating the cables.

Double compression type glands with armour and bonding clamps for the termination of all

solid dielectric multicore cables shall be provided. They shall be designed to secure the

armour wires to provide electrical continuity between the armour and the threaded fixing

component of the gland and to provide watertight seals between the cable outer sheath and

gland and between the inner sheath and threaded fixing component. The gland shall

preferably project above the gland plate to avoid entry of moisture.

Earthing connectors between cable armour and earth shall be routed outside the cable gland

in an approved manner. Gland insulation shall be capable of withstanding test for appropriate

higM Voltage for one minute.

Cable terminations for HV / MV cables shall be heat / cold shrinkable type. Adequately sized

shrouds/ bolts shall be provided at connections to completely cover the terminations.

Where core-balance type current transformers are provided on the feeder cables for earth fault

protection, glands for cables shall be insulated from earth in an approved manner.

1.3.16 Wiring for Control and Protective Circuits

All low voltage wiring for control, protection and indication circuits shall be carried out with

1100 V grade, PVC insulated cable with stranded, tinned copper conductor of minimum 1.5

sq. mm size. The size of conductor for CT circuits shall be minimum 2.5 sq. mm.

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All wiring shall be run on the sides of panels and shall be neatly bunched and cleated without

affecting access to equipment mounted in the panel.

The wiring shall be bound and supported by clamping, roughing or lacing. Spiral wrapping

will not be accepted. Wireways shall not be more than 50% full. Adequate slack wire shall be

provided to allow for one restripping and reconnection at the end of each wire. When

screened cables or wires are necessary, an insulating sheath shall be included.

Wiring and supports shall be of fire resistant material.

Wiring shall only be jointed or teed at terminals. Terminals of the clamp type shall not have

more than two wires connected.

1.3.17 Terminations and Ferrules

Engraved core identification ferrules, marked to correspond with the wiring diagram, shall be

fitted to each wire and each core of multicore cables terminated on the panels.

Moisture and oil resisting insulating material shall be used. The ferrules shall be of the

interlocking type and shall grip the insulation firmly without falling off when the wire is

removed.

All wires forming part of a tripping circuit shall be distinctively marked.

Spare auxiliary contacts of electrical equipment shall be wired to terminal blocks.

1.3.18 Control Wiring Terminal Blocks

Terminal blocks shall be of 1000 V grade and stud type. Brass stud of at least 6 mm dia. with

fine threads shall be used and securely locked within the mounting base to prevent turning.

Each terminal shall comprise two threaded studs, with a link between them, washers, and

matching nuts and locknuts for each stud. Connections to the terminals shall be at the front.

Terminals shall be numbered for identification, grouped according to function. Engraved

„black on-white‟ labels shall be provided on the terminal blocks describing the function of the

circuit.

Terminals for circuits with Voltage exceeding 110 V shall be shrouded. Terminal blocks at

different voltages shall be segregated into groups and distinctively labeled.

Terminals used for connecting current transformer secondary leads shall be „disconnecting

and shorting‟ type with a facility for earthing the secondary.

Terminal blocks shall be arranged with 100 mm clearance, between any two sets.

Separate terminal stems shall be provided for internal and external wiring respectively.

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All wiring shall be terminated on terminal blocks, using crimping type lugs or claw type of

terminations.

1.3.19 Electronic Equipment

Electronic equipment shall be capable of withstanding randomly phased transient over

voltages of either polarity on the power supply or interruptions of the power supply without

damage or impairment to the equipment's subsequent performance. In the case of controls, no

mal-operation shall occur.

Where manufacturers require that electronic equipment supplied under this Contract should

not be subjected to insulation resistance tests ('Meggering'), suitable warning notices shall be

provided and installed in appropriate locations. When specified by manufacturers, separate

shield / signal earthing shall be provided.

It shall be possible to remove / replace cards from / to electronic equipment without damage

and without interfering with the operation of the rest of the equipment or system. If

necessary, consideration should be given to switching off the supplies locally to a card to

prevent inadvertent interference to the equipment or system during removing / replacing a

card.

Electronic equipment shall not use local internal batteries unless the approval of the JAL

NIGAM or their representative ‟s Representative has been obtained. Where approval is given,

batteries used inside equipment shall be of the totally sealed, leak proof type.

1.3.19.1 Interference

a) Self-Generated Interference

Equipment shall not generate any type of interference at a level, which could be

detrimental to the performance of any other equipment / component or which could

cause annoyance or discomfort to personnel.

The earthing and cabling arrangements shall be such that detrimental interference is

not generated.

b) External Interference

In the presence of interference expected in substation environments, the design of the

equipment shall be such that no damage occurs and performance is maintained to the

requirements of the individual specifications.

c) Spark Quenching

Spark quenching devices shall be fitted wherever necessary to ensure continued

satisfactory operation of contacts and prevent mal-operation of electronic devices.

d) Noise and Vibration

The acoustical noise levels and / or vibration produced by the equipment in operation

shall be as low as is reasonably practicable for the type of equipment concerned and

shall be agreed with the JAL NIGAM or their representative ‟s Representative.

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1.3.19.2 Setting-Up and Maintenance Facilities

All equipment shall be provided with sufficient easily accessible test points to facilitate

setting-up and fault location together with maintenance aids such as extension boards, jumper

leads and special maintenance tools.

Pin or terminal numbering of all cards in all crates shall be consistently uniform throughout.

Power supplies shall use the same pin positions on all cards in an equipment or system.

1.3.19.3 Loose Equipment

Special connecting leads, extension boards and any special item required for calibration or

maintenance purposes, together with the mating half of all necessary connectors shall be

supplied.

1.3.19.4 Printed Circuit Boards

Printed circuit boards shall be epoxy glass fabric boards to comply with IEC - 60321 suitable

for use in hot humid climates. Printed circuit boards may be single-sided, double-sided or

multi-layer.

Printed boards shall, in general, comply with IEC 60326. They shall not bow perceptibly

when they are mounted in their shelves or racks. Means shall be provided to prevent boards

being plugged into the wrong sockets and the plugging in / out action shall be arranged in a

positive manner.

An approved protective coat shall be applied to the printed circuit side of the board to protect

against tracking, tarnishing and general deterioration due to moisture and deposition of dust.

The coating shall not have any adverse reaction with any other material or components used

and shall be suitable for use under tropical conditions. When boards are repaired in the field it

shall be possible to apply (or 'touch up') such a finish by simple convenient means.

1.3.19.5 Component Identification

a) A component reference number shall be marked adjacent to each component. Where

this is impossible, components shall be identifiable from the layout drawings

provided.

b) The following shall be marked in all instances:

i. Fuses

The rating and the circuit identification of each fuse shall be marked adjacent

to the fuse base.

ii. Control, Protection and Indication Devices

The function of each control, protection and indication device shall be marked.

The caption and its arrangement shall be subject to the approval of the JAL

NIGAM or their representative ‟s Representative.

iii. Preset Controls

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The circuit reference and if possible, the function shall be marked adjacent to

each preset control in a position where it will be clearly visible while the

adjustment is being made.

iv. Connectors

The diagram reference number shall be marked on or adjacent to each

connector.

c) Test points shall be individually marked with the diagram reference number.

d) The polarity of any polarized devices (e.g. diodes) shall be marked.

1.3.20 Test Terminal Blocks

Test terminal blocks, if any, shall be provided for secondary injection and testing of relays. A

suitable metering block shall be provided where specified for the connection of a portable

precision instrument to be operated when required for specific plant testing purposes.

1.3.21 Tests

The following routine tests shall be carried out on the assembled switchboard / panel during

inspection at the manufacturer‟s works in addition to other tests as per applicable standards.

(i) Primary injection tests to ensure correct ratios and polarity of current and voltage

transformers and of the current operated protection relays and direct acting coils, over

their full range of settings.

(ii) Balance earth fault stability test by primary current injection. Care must be taken to

reproduce accurately the burdens of interconnecting cables. A further test to ensure

correct polarity must be made after assembly.

(iii) Tests on auxiliary relays at normal operating voltages by operation of associated

remote relays.

(iv) Correct operation of sequencing and control circuits at normal operating voltages by

operation of local control switches, and simulation of operation from remote control

positions.

(v) Carry out functionality tests, check interfacing status contacts and instrumentation.

(vi) Checking of Differential protection relay.

(vii) One minute power-frequency voltage dry withstand tests on the main circuits

(viii) One minute power-frequency voltage dry withstand tests on auxiliary circuits

(ix) Insulation resistance tests

All circuit breakers shall be subject to the following tests:

(i) Routine tests including HV pressure test, millivolt drop tests and mechanical

tests.

(ii) To ensure the operation of the dc closing coil and satisfactory closing of the

circuit breaker with the voltage of the coil down to 80% of its rated voltage,

and that mal-operation does not occur with a voltage on the coil of 120% of its

rated voltage.

(iii) Interchangeability of withdraw able identically equipped circuit breakers, and

checking of all mechanical and electrical interlocks.

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Type test figures for heat test runs performed on identical panel types shall be made

available.

All electrical equipment must be compatible with PLC and SCADA.

1.4 Motors

All motors shall comply with IEC 60034, 60072/ IS 325, 4691, 6362,4029,12065, 12075,

including standards referred to therein.

The technical parameters of main

The technical parameters of motors shall be as below :

Description Unit Particulars

Type Squirrel cage Induction motor (TEFC)

Rating kW (*)

Rated voltage kV 0.415

Type of mounting Vertical / Horizontal (As required)

Duty type Continuous (S1)

Method of starting By variable speed drive (For Blower/compressor

motors)

Direct on line- for motors upto 3.7kW

Star-Delta (Close transition type) – For motors above

3.7kW and upto 75kW

Soft Starter – For motors above 75kW

Type of system earthing Effectively earthed

Class of insulation F

Design ambient temperature C 50

Limits of temperature rise of

winding

- Determination by resistance

method C 70

- Determination by ETD

method C 80

Location Indoor

Degree of Protection IP55

Cooling designation IC411

External cable details 0.4 / 1 kV, 3C x (*) Aluminum, XLPE, armoured

Space heater for motor Required for rating 30kW and above

(*) Value to be ascertained by the Bidder after submitting design calculations subject to

approval.

The LV motors shall be of the totally enclosed fan cooled type, with degree of protection for

enclosure of IP 55 and shall be suitable for continuous operation and direct-on-line starting,

unless otherwise specified.

They shall be suitable in all respects for service in extreme climatic conditions. Main

conductor and slot insulation shall be non-hygroscopic and in accordance with Class F of IEC

60085.

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Motors shall be capable of operating continuously at rated output at any frequency between

49 and 51 Hz and at any voltage within + 10% of the nominal value. Motors shall be

designed to be operated for a period of not less than five minutes at a voltage of 20% below

the nominal value and at normal frequency without injurious overheating.

The starting current at rated voltage when started direct-on-line shall not exceed 6 times the

rated full load current. When started with soft starter it should be 2.5 to 3 times the rated full

load current. The motor characteristics shall be co-ordinated with soft starter manufacturer.

All bearings shall be fitted with oil or grease lubricators. Vertical shaft motors shall have

thrust bearings.

All terminals shall be of the stud type of adequate size for the particular duty, marked in

accordance with an approved standard and enclosed in a weatherproof box.

All terminal boxes shall be fitted with an approved sealing chamber, conduit entry or adapter

plate, as required, together with the necessary fittings to suit the type of cable specified.

The power rating of the motors shall be larger of the following:

a) 115% of the power input to the pump at duty point at a speed corresponding to a

frequency of 50 Hz.

Motors shall be capable of starting and accelerating the load with the applicable method of

starting, without exceeding permissible winding temperatures, when the supply voltage is

80% of the rated voltage.

Motors shall be capable of satisfactory operation at a supply voltage of 80% of the rated

voltage for 5 minutes, commencing from hot condition.

The locked rotor withstand time under hot conditions at 110% rated voltage shall be more

than the starting time at minimum permissible voltage by at least two seconds or 15% of the

accelerating time, whichever is greater. The locked rotor current of motors shall not exceed

600% of full load current of motor, which is inclusive of 20% tolerance.

Motors when started with the drive imposing its full starting torque under the specified

supply voltage variations shall be capable of withstanding at least two successive starts from

cold conditions and one start from hot condition without injurious heating of windings. The

motors shall also be suitable for three equally spread starts per hour under the above referred

supply conditions.

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In case of motors started by soft starters, the three phases shall be segregated by metal

barriers within both line and neutral side terminal boxes. The two terminal boxes shall be on

opposite sides.

The earthing pad shall be of non-corrodible metal, welded / brazed at two locations on

opposite sides. The pad size shall be 75x65x25 mm with two holes drilled at 40mm centers,

tapped and provided with suitable bolts and washers for connecting the earthing strip.

Motors shall have space heaters suitable for 230 V, single phase 50 Hz AC supply. These

shall be placed in easily accessible positions in the lower part of motor frame. Provision shall

be made to measure temperature of bearing by inserting hand held temperature measuring

device.

Motors shall have drain plugs so located that they will drain water, resulting from

condensation or other causes from all pockets in the motor casing.

Pockets shall be provided in the motor bearing housings for insertion of portable instrument

probes for measuring bearing temperature. One portable hand held instrument per pumping

station shall be provided for measuring motor bearing temperature. The same instrument shall

also be used to measure the pump bearing temperature.

1.4.1 Insulation

Any joints in the motor insulation such as at coil connections or between slot and winding

sections, shall have strength equivalent to that of slot sections of the coil. The insulation shall

be given tropical and fungicidal treatment for successful operation of the motor in extreme

climate. The motors shall be provided with class F insulation with temperature rise limited to

that of class B insulation.

1.4.2 Constructional Features

The motor construction shall be suitable for easy disassembly and re-assembly. The enclosure

shall be sturdy and shall permit easy removal of any part of the motor for inspection and

repair.

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

facilitate safe lifting.

The rotor bars shall not be insulated in the slot portion between the inner core laminations for

squirrel cage motors.

1.4.3 Terminal Box

Terminal boxes shall be of weather proof construction designed for outdoor service. To

eliminate entry of dust and water, gaskets of neoprene or equivalent approved shall be

provided at cover joints and between box and motor frame. It shall be suitable for bottom

entry of cables. It shall be suitable of being turned through 3600 in steps of 900.

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The terminals shall be of stud type with necessary plain washers, spring washers and check

nuts. They shall be designed for rated current carrying capacity and shall ensure ample phase

to phase and phase to earth clearances. Suitable cable glands and lugs shall be supplied to

match specified cables.

1.4.4 Accessories

Two independent earthing points shall be provided on opposite sides of the motor for bolted

connections. These earthing points shall be in addition to earthing stud provided in the

terminal box.

1.4.5 Tests

Motors shall be subject to routine tests which shall also include the following:

- insulation resistance

- Measurement of winding resistance

- high voltage test

- no load / full load tests to determine efficiency, power-factor and slip

- momentary overload test

- test for noise levels of motor

- test for vibration severity of motor

- overspeed test

- locked rotor reading of voltage, current and power input at a reduced voltage.

Type test certificates for test runs performed on identical motors (below 11 kW rating) shall

be made available. Whenever two nos. or more identical motors (above 11 kW rating) are

being offered, type tests on one of them shall be carried out, including heat run test.

1.5 Soft Starters for LV Motors

The soft starters shall comply with the requirements of IEC 60034, 60947 and IS 325

including those standards referred to therein.

1.5.1 Constructional and Performance Features

Motor soft starters shall be switched or electronic type.

Soft starter panel shall be indoor, metal clad with separate metal enclosed compartments for

a) control, metering and current transformers for differential protection, if specified

b) shorting (bypass) arrangement

c) bus bars

d) power cable terminations

e) push buttons with indicating lamps.

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Soft starter shall achieve smooth starting by torque control for gradual acceleration of the

drive thus preventing jerks and extending the life of equipment.

Starting current shall be limited to 2.5 to 3 times the rated current of the motor. The soft

starter manufacturer shall co-ordinate with motor manufacturer for this purpose.

Separate removable gland plates shall be provided for power and control cables.

Each cubicle shall be fitted with a label in the front and rear of the cubicle, indicating the

panel designation, rating and duty. Each relay, instrument, switch, fuse and other devices

shall be provided with separate labels.

Necessary wiring diagram shall be provided considering starting interlock, trip circuit,

starting and running mode signal.

It shall be possible to manually start the motor locally from the starter panel or in Auto mode

through PLC.

1.5.2 Main Bus Bars

Bus bars shall be fully insulated by encapsulation in epoxy resin /shrinkable PVC Sleeve,

with moulded caps protecting all joints. Bus bars shall be supported on insulators capable of

withstanding dynamic stresses due to short circuit. Bus bars shall be of Aluminium

conductor (Copper is not recommended in sewage corrosive atmosphere as it us oxidized.)

1.5.3 Earthing

A copper earthing bus shall be provided at the bottom and extended throughout the length of

the panel. It shall be bolted / welded to the framework. All non-current carrying metal work

of the panel shall be effectively bonded to the earth bus. Hinged doors shall be earthed

through flexible earthing braid.

1.5.4 Panel Accessories and Wiring

Panel shall be supplied completely wired internally upto equipment and terminal blocks and

ready for the external cable connections at the terminal blocks. Inter panel wiring between

compartment of the same panel shall be provided.

All auxiliary wiring shall be carried out with 1100 volts grade, single core, stranded copper

conductor with PVC insulation. The sizes of wire shall be not less than 1.5 sq. mm.

Terminal blocks shall be of stud type, 10 A rated, complete with insulated barriers. Terminal

blocks for CTs shall be provided with test links and isolating facilities.

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All spare contacts and terminals of cubicle mounted equipment and devices shall be wired to

terminal blocks.

Accuracy class for indicating instruments shall be 1.0 or better. Instruments shall be 110 mm

Push buttons shall be provided with inscription plates engraved with their functions.

Indicating lamps shall be of clustered LED type.

Space heaters of adequate capacity shall be provided inside each panel. They shall be suitable

for 230 V, 1 ph, 50 Hz supply. They shall be complete with MCB and thermostat.

Each panel shall be provided with 230 Volts, 1 phase, 50 Hz, 5 A, 3 pin receptacle with MCB

located in a convenient position. An interior illuminating lamp together with the operating

door switch and protective MCBs shall be provided.

The DC and AC auxiliary supply shall be distributed inside the panel with necessary isolating

arrangements at the point of entry and with sub-circuit MCBs as required.

1.5.5 Tests

Each unit of soft starter shall be tested at the manufacturer‟s work. Test result must satisfy all

the characteristics during starting and acceleration against their quoted values during bidding.

1.6 Capacitors and APFC Panel

Capacitors shall comply with IEC 60871 and IS 5553, 13925 including those standards

referred to therein.

The technical parameters of capacitors shall be as given below:

LV Capacitors and Control Panel

Description Unit Particulars

Capacitor Bank

Application Power factor improvement

Arrangement Automatic Power Factor Correction

(APFC)

Type of insulation Polypropylene (APP) / Mixed Dielectric

(MD)

Rated output kVAR (*)

Rated voltage V 415

Rated frequency and no. of phases Hz / - 50, 3 Phase

Capacitor bank connection Delta

Type of mounting and location Floor mounted and Indoor

Design ambient temperature C 50

Type of switching Automatic

Control supply 110V DC

No. of steps for control Nos. Minimum 8

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Description Unit Particulars

Degree of protection of enclosure IP4X

Color finish shade Light Grey Semi Glossy

Type of APFC relay Microprocessor based automatic power-

factor correction relay (maximum setting

0.99 lag)

(*) Value to be ascertained by the Bidder after submitting design calculations subject to

approval.

MV capacitors shall be provided for connection across MV motor terminals while LV

capacitors with APFC relay and a panel shall be provided for connection to LV switchboard

bus, where specified.

1.6.1 Design Criteria

MV capacitors – Capacitor rating shall be such that capacitor current is less

than 90% of the magnetizing current of the motor or for improvement of

rated motor power factor to 0.98, whichever is lesser.

LV capacitors – Rated for improvement of power factor on LV side to 0.98

1.6.2 General

The capacitor bank shall be complete with all parts that are necessary or essential for efficient

operation. Such parts shall be deemed to be within the scope of supply whether specifically

mentioned or not. It shall be complete with the required capacitors along with the supporting

post insulators, steel rack assembly, aluminium bus bars, copper connecting strips,

foundation channels, fuses, fuse clips, etc. The steel rack assembly shall be hot dip

galvanized.

The capacitor bank shall comprise of suitable number of single phase units in series parallel

combination. However, the number of parallel units in each of the series racks shall be such

that failure of one unit shall not create an over voltage on the units in parallel with it, which

will result in the failure of the parallel units. The assembly of the banks shall be such that it

provides sufficient ventilation for each unit.

Each capacitor case and the cubicle shall be earthed to a separate earth bus.

Capacitors shall be of polypropylene type. Each unit shall satisfactorily operate at 135% of

rated kVAR including factors of over voltage, harmonic currents and manufacturing

tolerance. The units shall be capable of continuously withstanding satisfactorily any over

voltage up to a maximum of 10 % above the rated voltage, excluding transients.

Each capacitor unit / bank shall be fitted with a directly connected, continuously rated, low

loss discharge device, if required, to discharge the capacitors to reduce the voltage to 50 volts

within one minute upon disconnection.

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1.6.3 Unit Protection

Each capacitor unit shall be individually protected by a HRC fuse suitably rated for load

current and interrupting capacity, so that only the faulty capacitor unit will be disconnected

without causing the bank to be disconnected. An operated fuse shall give visual indication so

that it may be detected during periodic inspection. The fuse breaking time shall co-ordinate

with the pressure built up within the unit to avoid explosion. Mounting of the individual fuse

should be internal to the capacitor case.

1.6.4 Capacitor (APFC) Control Panel for LV Application

APFC microprocessor based relay shall automatically switch ON / OFF the capacitor banks

to attain the value of „pf‟ close to the set value. Switching shall follow first in first out (FIFO)

method to ensure uniform use of all capacitor banks. At least eight steps shall be provided for

switching. Harmonic filter (inbuilt with APFC panel) shall be provided to restrict Total

Harmonic Distortion (THD) to 3% or less.

Capacitor and capacitor control shall be housed in a metal enclosed cubicle. Capacitor shall

be housed in the lower compartment and capacitor control unit at the top compartment, the

two compartments being segregated.

The cubicle shall be fabricated out of 2 mm thick cold rolled sheet steel and shall of a degree

of protection of IP 4X (for Capacitor Panel IP 4X ia applicable as cut out for fan for heat

dissipation.). The panel shall be of indoor type and shall consist of:

a) Isolating MCCB

b) Contactors with overload element

c) Relays responsive to current / voltage / kVAR / pf for automatic switching

d) Sequencing devices, timers and auxiliary relays for automatic sequential switching of

capacitor units in and out of circuit

e) Auto-manual selector switch

f) Microprocessor based Automatic Power Factor Correction (APFC) Relay

g) Push button for opening and closing the power circuit

h) Red and Green lamps for capacitors ON / OFF indication

i) Protective relays to protect the healthy capacitor units when one unit fails in a series

connection

j) Space heater and cubicle lighting

1.6.5 Tests and Test Reports

Capacitors shall be subjected to routine tests as per IS: 13925. Test for capacitor losses shall

also be carried out on one capacitor bank of each type ordered.

In addition to the above, the capacitor units shall be subjected to the following tests:

1. Load test at 110% rated voltage at an ambient of 45 to 50 C for a period of 8 hours

or more.

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2. Leak proofness test-initially after impregnation and total sealing, each capacitor shall

be heated up to 80o C to 110

o C for a few minutes. After the load test each capacitor

unit shall be carefully inspected for leakage.

Type tests shall be carried out as per IS: 13925 on capacitors above 1000V rating of identical

design. Certificates of type tests carried out in the last three years for similar capacitor units

shall be furnished.

1.7 MV and LV Cables

MV / LV Cables shall comply with the following International Standards, including those

referred to therein.

IEC 60183, 60228, 60502, 60884 and IS 7098, 5831, 8130, 1554, 10810.

The technical parameters of cables shall be as given below:

Description Unit Particulars

MV XLPE Power Cables

Rated voltage U / Uo (Um) kV 6.35/11(12)kV & 3.6/7.2 kV

Material of conductor Aluminum (stranded)

Cross-sectional area (*)

Type of insulation XLPE

Inner sheath Extruded

Outer sheath Extruded

Conductor and insulation screening Required

Material of armour Galvanized Steel (Aluminum for single

core cable)

LV Power, Control and Lighting

Cables

Rated voltage U / Uo (Um) kV 0.6 / 1 (1.2)

Material of conductor Aluminum for Power and Tinned

Copper for Control cable (stranded)

Cross-sectional area (*)

Type of insulation XLPE for power and PVC for control

cables

Inner sheath Extruded

Outer sheath Extruded

Material of armour Galvanized Steel (Aluminum for single

core cable)

Cable Protection Compound of outer sheath of all

HV/MV/LV cables shall contain suitable

chemicals for preventing attack by

rodents.

(*) Value to be ascertained by the Bidder after submitting design calculations subject to

approval.

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1.7.1 Installation

Cable installation shall be as per IS 1255/IEC standard

a) In air or buried in ground

b) Depth of laying in ground 1000 mm for directly buried HV / MV cables and 750 mm

for LV cables

c) In conduit: space factor not more than 40 % (ratio of total cable area to internal

conduit area)

d) In trays: single layer with spacing of one diameter for HV / MV and main LV cables

and touching for small LV cables

Control cables shall be 2C, 4C, 7C, 12C and 19C type. Minimum size of conductor for

control cables shall be 2.5 sq.mm. copper.

All power cables shall be sized based on continuous current capacity, maximum permissible

voltage drop of 2.5% and rated short circuit current withstand. In addition, rating factors for

variation in ground/air temperature, grouping of cables, depth of laying, number of racks, etc.

shall be considered for cable sizing.

1.7.2 Tests

All HV, and LV cables shall be subject to routine tests in accordance with the relevant Indian

Standard Specifications.

Test certificates shall be provided against each drum and/or cable length.

The tests carried out on every cable length and / or drum at manufacturer's premises shall

include following tests as applicable but not limited to:

- High Voltage dc insulation pressure test, between cores, each core to earth, metallic

sheath or armour as applicable;

- insulation resistance test;

- core continuity and identification;

- conductor resistance test

- Elongation test

- Smoke density test

- HCl gas generation test

- Anti rodent test (Presence of lead)

1.8 LV Indoor Switchboard

LV indoor switchboard and its components shall comply with the following International

Standards, including those referred to therein.

IEC 60269, 60947, 60529 and IS 4237, 8623, 1248, 722, 2705, 3156, 10118, 11353, 13947

The technical parameters of LV switchboard shall be as given below:

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Description Unit Particulars

General

Rated voltage, no. of phases and rated

frequency

V / - / Hz 415V, 3, 50Hz

System neutral earthing Effectively Earthed

Rated short duration power frequency

withstand voltage

- Power circuit kV (rms) 3.5

- Control circuit kV (rms) 1.5

Rated normal current of bus bars under design

ambient temperature of 50C and material of

busbar

A / - (*), Aluminum

Rated short-time withstand current and

time

kA (rms) /

sec

25 kA for 1 sec

Constructional Requirements

Thickness of sheet steel in mm Cold

rolled (Frame/Enclosure/Covers)

mm Frame – 2.5

Doors/Covers – 2.0

Degree of protection of enclosure IP-5X, Form-4 enclosure

Color finish shade

- Interior Glossy White

- Exterior Light Grey

Cable connection Bottom entry and exit

Circuit Breakers

Type Air

Rated current inside the cubicle under

design ambient temperature at 50C

A (*)

Rated operating sequence O–3 Min–CO-3 Min-CO

Rated short-time withstand current and

time

kA (rms)/

sec

25(*)

Min. no. of auxiliary contacts 6 NO + 6 NC after internal use by

manufacturer

Type of operating mechanism

- Normal Spring charging for closing and

tripping

- Emergency Manual and Spring charged for

closing and tripping

Auxiliary control voltage

- Closing coil / Tripping coil V 110V DC

- Spring charging motor V 110V DC

- Space heater and lighting V 230V AC

Earthing switch Required

Current and Voltage Transformers

Details of ratio, taps, burden, accuracy As per Single Line Diagram (*)

Protective Relays

Type Numerical (Microprocessor based)

Auxiliary supply V 110V DC

Details of protective relays As per Single Line Diagram

Moulded Case Circuit Breakers

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Description Unit Particulars

Type Moulded Case (microprocessor

based)

Rated current when installed within

cubicle under design ambient temperature

of 500C

A As required (*)

Rated short-time withstand current kA (rms) 25 kA

Miniature Circuit Breakers

Type Miniature

Rated current when installed within

cubicle under design ambient temperature

of 500C

A (*)

Rated short-time withstand current kA (rms) 10

Motor Starters and Contactors

Type Variable Frequency Drive/ Star-

Delta / Direct-on line

Rated current A (*)

Rated voltage of coil V 230V AC / 110V DC

Utilization category AC-3

(*) Value to be ascertained by the Bidder after submitting design calculations subject to

approval.

These cover the main switchboard and distribution boards. The distribution board shall be of

floor / wall mounting type. Entry for incoming and outgoing cables shall be from bottom. Bus

bars shall be of aluminiumr. Degree of protection of the panel shall be IP 5X.

The board shall be provided with circuits as required, ammeter with ammeter selector switch

and voltmeter with Voltmeter selector switch. Bidder shall furnish proposed single line

diagram of the board along with the Bid.

Incoming and outgoing circuit shall be protected by suitably rated ACBs/MCCBs.

The switchboard and its components shall be subjected to tests as per the applicable

standards.

The current rating of outgoing feeders of any switchboard shall not be less than 10% of that

of the incoming feeder. Deviation from this requirement shall be subject to the approval of

the JAL NIGAM or their representative ‟s Representative.

1.8.1 Bus Bars

The phase and neutral bus bars shall be of rating indicated in the corresponding single line

diagram. Bus bars shall be of aluminium and shall be provided with minimum clearances as

per standards.

All bus bars and bus taps shall be insulated with close fitting sleeve of hard, smooth, dust and

dirt free, heat shrunk PVC insulation of high dielectric strength, to provide a permanent non-

ageing and non-tracking protection, impervious to water, tropical conditions and fungi. The

insulation shall be non-inflammable and self-extinguishing type and in fast colors to indicate

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phases. The dielectric strength and properties shall hold good for the temperature range of 0

to 95 degree centigrade. If the insulating sleeve is not colored, bus bars shall be color coded

with colored PVC tape at suitable intervals.

Busbar joints, if any, shall be of the bolted type with minimum 4 bolts. Spring washers shall

be provided to ensure good contact at the joints. Bus bars shall be thoroughly cleaned at the

joints and suitable contact grease shall be applied just before making a joint.

Direct access to, or accidental contact with bus bars and primary connections shall not be

possible. All apertures and slots shall be protected by baffles to prevent accidental shorting of

bus bars due to insertion of maintenance tools.

Sequence of red, yellow and blue phases and neutral for four-pole equipment shall be left to

right and top to bottom, for horizontal and vertical layouts respectively.

1.8.2 Moulded Case Circuit Breaker (MCCB)

MCCBs shall be of the air break, quick make, quick break and trip free type and shall be

totally enclosed in a heat resistant, moulded, insulating material housing.

MCCBs shall have an ultimate short circuit capacity not less than the prospective short circuit

current at the point of installation.

MCCBs shall have a service short circuit breaking capacity equal to the ultimate short-circuit

capacity.

Each pole of MCCB shall be fitted with microprocessor based protection for over current,

earth fault and short circuit (L-S-I-G). Such a protection system shall be fully self-contained,

needing no separate power supply. The elements shall be adjustable. Adjustments shall be

made simultaneously on all poles from a common facility. MCCB shall be suitable for remote

On-Off-Trip operation. Necessary spare auxiliary contacts (minimum 2NO+2NC) shall be

provided for future use.

Motor protection circuit breaker (MPCB) shall be used for motor feeder instead of MCCBs.

1.8.3 Miniature Circuit Breaker (MCB)

Miniature circuit breakers shall be of the thermal and magnetic tripping type, and comply

with IEC 60898 and IEC 60947-2.

MCB shall be hand operated, air break, quick make, quick break type.

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Operating mechanisms shall be mechanically trip-free from the operating knob to prevent the

contacts being held closed under overload or short-circuit conditions.

Each pole shall be fitted with a bi-metallic element for overload protection and a magnetic

element for short-circuit protection. Multiple pole MCBs shall be mechanically linked such

that tripping of one pole simultaneously trips all the other poles. For motor feeders, MCB

shall have type C characteristics.

The short circuit rating shall be not less than that of the system to which they are connected

with a minimum of 10 kA.

1.8.4 Contactors and Starters

The power contactors used in the switchboard shall be of air break, single throw, triple pole,

and electromagnetic type. Contactors shall be suitable for uninterrupted duty and rated for

Class AC3 duty in accordance with IEC 60947-4.

Operating coils of all contactors shall be suitable for operation on 230 V, single phase, 50 Hz

supply.

Contactors shall be provided with at least two pairs of NO and NC auxiliary contacts.

Contactors shall not drop out at voltages down to 70 % of coil rated voltage. All motor

contactors and their associated apparatus must be designed to operate for a period of not less

than 5 minutes at a voltage of 20% below the nominal value and at normal frequency without

injurious overheating.

Contactors shall be provided with a three element, positive acting, ambient temperature

compensated, time lagged, hand reset type thermal overload relay with adjustable settings.

The hand reset button shall be flush with the front door of the control module, and shall be

suitable for resetting the overload relay with the module door closed. Relays shall be either

direct connected or CT operated. Overload relay and reset button shall be independent of the

"Start" and "Stop" push buttons. All contactors shall all be provided with single phasing

preventer (SPP).

Motor starters shall be complete with auxiliary relays, timers and necessary indications.

Starters shall be of the electrically held-in type with integral “start” and “stop” push buttons

mounted externally on the door, with integral interlocked isolators. Where required, auxiliary

switches shall be included for the operation of “red” and “green” indicating lights in remote

instrument panels.

For details of other equipment/ accessories of LV switchboard (e.g. circuit breaker, current

and voltage transformer, relay, constructional features of switchboard, earthing, annunciator,

indicating and measuring instrument, control and selector switch, indicating lamp, push

button, space heater, cubicle lighting/ receptacles, power and control cable termination,

wiring, terminal blocks, etc), refer specification of HV switchboard.

1.8.5 Tests

The following routine tests shall be carried out on the assembled switchboard / panel during

inspection at the manufacturer‟s works in addition to other tests as per applicable standards.

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(i) Primary injection tests to ensure correct ratios and polarity of current and voltage

transformers and of the current operated protection relays and direct acting coils, over

their full range of settings.

(ii) Balance earth fault stability test by primary current injection. Care must be taken to

reproduce accurately the burdens of interconnecting cables. A further test to ensure

correct polarity must be made after assembly.

(iii) Tests on auxiliary relays at normal operating voltages by operation of associated

remote relays.

(iv) Correct operation of sequencing and control circuits at normal operating voltages by

operation of local control switches, and simulation of operation from remote control

positions.

(v) Carry out functionality tests, check interfacing status contacts and instrumentation.

(vi) Checking of Differential protection relay.

(vii) One minute power-frequency voltage dry withstand tests on the main circuits

(viii) One minute power-frequency voltage dry withstand tests on auxiliary circuits

(ix) Insulation resistance tests

All circuit breakers shall be subject to the following tests:

(i) Routine tests including HV pressure test, millivolt drop tests and mechanical tests.

(ii) To ensure the operation of the dc closing coil and satisfactory closing of the circuit

breaker with the voltage of the coil down to 80% of its rated voltage, and that mal-

operation does not occur with a voltage on the coil of 120% of its rated voltage.

(iii) Interchangeability of withdrawable identically equipped circuit breakers, and

checking of all mechanical and electrical interlocks.

Type test figures for heat test runs performed on identical panel types shall be made

available.

1.9 DC Equipment

DC equipment shall comply with IEC 60896 including those standards referred to therein.

1.9.1 Requirements

Following items shall be covered in the Contract:

a) One no. 110 V Nickel Cadmium type Battery (Minimum capacity of Battery –

200AH)

b) Two nos. Float-cum-boost chargers for 110 V battery

c) DC distribution board.

All connections between battery, battery chargers and DC distribution board shall be

designed for effective segregation between positive and negative leads.

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1.9.2 110 V Battery

Battery offered shall be Nickel Cadmium (Ni-Cd) type. Nickel hydroxide and Cadmium

hydroxide shall be used for positive and negative electrode respectively. Aqueous solution of

Potassium hydroxide with small quantities of lithium hydroxide shall be used as electrolyte. It

shall be used only for ion transfer and shall not chemically changed during charging/

discharging.

The containers shall be transparent and preferably be made of toughened glass or plastic and

provided with acid level indicator.

The battery shall be rated on 5-hour basis and for the specified ambient temperature. The

battery shall have maximum recharge time of 8 hours. The batteries shall be sized for a

backup of 24 hours, incase of power failure. The ampere-hour capacity shall be selected to

cater to all the emergency loads, operation of control gear, indication lamps, annunciation

panels, emergency lighting, incoming breaker(s) spring charging currents, short time loads

etc. A margin of about 25% shall be taken to cater to the contingencies.

Terminal posts shall be designed to accommodate external bolted connection conveniently

and positively. Each terminal post shall have two bolt holes of the same diameter, preferably

at right angles to each other. The bottom hole shall be used to terminate the inter-cell

connection. The top hole shall be left for external terminal connections. Bolts, heads and nuts,

except seal nuts, shall be hexagonal and shall be lead covered. The junction between terminal

posts and cover, and between cover and container shall be so sealed as to prevent any seepage

of electrolyte.

Required quantity of electrolyte for first filling with 10% extra shall be supplied in non-

returnable containers.

Each battery shall be complete with following accessories, as applicable, that include, but are

not limited to:

a) Battery racks

b) Porcelain insulators, rubber pads, etc.

c) Set of inter-cell, inter-tier and inter-bank connectors as required for the complete

installation.

d) Electrolyte for first filling + 10% extra.

Accessories for testing and maintenance

i. One - -3, 0, +3 volts DC voltmeter with built-in discharging

resistor and suitable leads for measuring cell voltage.

ii. One - Filler hole thermometer fitted with plug and cap and having

specific gravity correction scale.

iii. Three - Pocket thermometers

iv Two - Cell lifting straps

v One set

Each of

- Terminals and cable boxes with glands for connecting

cable as required.

Spare connectors

Spare vent plugs

Spare nuts and bolts

Suitable set of spanners

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Each battery shall be mounted in a manner that permits easy accessibility to any cell. The

racks shall be suitable for fixing on flat concrete floor. The complete racks shall be suitable

for bolting end to end.

It shall be the responsibility of the Bidder to provide batteries of adequate capacities to meet

specified requirements pertaining to control, indication, annunciation, etc. and emergency

lighting. For computing battery capacity, it shall be assumed that the battery is fully charged

at the beginning of loading cycle and is discharged to a voltage of 1.2 volts per cell at the end

of the loading cycle.

The battery shall have minimal difference (approx. 0.3 V per cell) between float and boost

charging voltages.

1.9.3 Battery Charger (110 V) .

The float-cum-boost type battery charger shall comprise silicon controlled rectifiers (SCRs)

connected in a full wave bridge circuit.

Each battery charger shall be suitable for float charging the battery under normal conditions

and boost charging the battery when it has discharged during service conditions. The

changeover from float to boost mode and vice versa shall be automatic.

The rectifier transformer shall be dry type and double wound with required number of taps.

The DC output voltage during float charging shall be stabilized within + 1% of the set DC

bus voltage for AC input voltage variation of +10%, frequency variation of + 5% and DC

load variation from 0 - 100%. The voltage regulation shall be achieved by a constant voltage

regulator having fast response SCR control. The ripple content shall be within 1% of DC

output nominal voltage with battery disconnected and shall be designed to have voltage

regulation of 1%. Also in any mode of operation, the maximum harmonics in the charger

output shall not exceed 5%.The setting of the output DC bus voltage shall be adjustable

between + 10% of nominal rated voltage. There shall be provision for manual control if

automode fails. Line surge suppressers shall be provided.

For boost charging the discharged battery after a mains failure, the rectifier shall charge the

battery at high rate limited to the maximum boost charging voltage. The boost charging shall

come on only when selected for boost mode manually. In auto control, the DC output current

shall be stabilized within +2% for AC input voltage and frequency variation of + 10% and +

5% respectively. There shall be provision for manual control if auto-mode fails. Boost

charging time for charging the battery to full capacity from fully discharged condition shall

not exceed 8 hours.

In the float charging mode, the charger shall be designed for supplying:

a) The DC loads of control, indication and annunciation circuits that remain energized

during normal operation and the momentary closing and trip coil loads of circuit

breakers, vacuum contactors; and

b) The float charging current of the battery.

c) 25% margin over the above load

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Battery charging equipment complete with all accessories shall be housed in a free standing

sheet steel cubicle having degree of protection of IP 4X. Sheet steel used for construction

shall be 1.6 or 2 mm thick. The units shall be wired using 1100 V grade, PVC insulated,

stranded copper conductor cables.

Each battery charger shall be provided with accessories that include, but not limited to the

following:

a) Silicon controlled rectifiers connected in full wave bridge circuit with ripple control

devices and transient suppression network.

b) Double wound dry type transformer with taps

c) Automatic voltage regulator unit with manual / auto control switch

d) Coarse and fine control potentiometers for manual control

e) Selector switch for mode of charging i.e. float charging / boost charging

f) Off-load tap changing switch for changing the taps of the transformer

g) DC voltmeter with fuses and a three position selector switch

h) DC ammeter with shunt

i) AC ammeter with selector switch for incoming AC power

j) AC voltmeter with selector switch for incoming AC power

k) MCB for incoming AC supply along with surge suppressers

l) Switch-fuse / MCB on DC output side with kick fuses and alarm contacts

m) Voltage dropping diodes in load circuit during boost charging mode

n) DC under voltage relay and earth fault relay

o) AC / DC switching relays for alarm and indication circuits including buzzer

p) Cubicle space heater suitable for 230 V AC, 1 ph, 50 Hz supply, with MCB and

thermostat

q) 230 V AC compact fluorescent lamp fixture for internal lighting with MCB

Each battery charger shall be provided with the following alarms / indications:

a) AC and DC supply 'ON'

b) AC and DC supply fail

c) Modes of charging

d) Over voltage

e) Under voltage on DC side

f) Earth fault on DC side

g) AC / DC MCB trip

The Bidder shall include in the bid, detailed AC and DC scheme for battery charger offered.

1.9.4 110 V DC Distribution Board (DB) The distribution board shall be of floor mounting design. Entry for incoming and outgoing

cables shall be from the bottom. Bus bars shall be of aluminium or copper.

Incomers, bus coupler and outgoing circuits shall be controlled by suitably rated double pole

MCBs type suitable for DC application. Bidder shall furnish proposed single line diagram of

the board along with the Bid.

Constructional features, pre-treatment, painting and other aspects shall comply with the

specifications for LV switchboard.

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Aluminium earth busbar of suitable size shall be provided along the length of the DB at the

bottom. Two nos. earthing terminals shall be provided on the external face of the board for

connection to the earthing grid.

1.9.5 Tests The batteries, chargers and distribution boards and their components shall be subjected to

routine/ acceptance tests as per the applicable standards. For battery, following tests are also

to be carried out:

- Capacity test

- Test for voltage charging and discharging

- Ampere-hour and watt-hour efficiency test

Certificates of type tests carried out on similar equipment shall be furnished.

1.10 Variable Frequency Drives (VFD)

1.10.1 General .

AC induction motor in clear water pumping station for rural distribution shall be coupled

with a Frequency drive of rating commensurate with the rated motor. The Frequency drives

shall be of Current Source Inverter Pulse Width Modulated (CSIPWM) with

GTO/IGBT/IGCT/SGCT/DTC technologies or later version, which performs precise speed

and torque control of standard squirrel cage motors with optimum efficiency. Each drive must

have a soft starting feature and a by pass arrangement for DOL starting of motors. All

frequency dives shall be suitable for data connectivity with PLC/SCADA system and shall

have suitable communication port and protocol. The drives must be easily programmable.

The drives shall be provided with surge protection, programmable lockable code. The

Frequency drive shall have following characteristics:

Accurate open loop torque control

Torque step rise time typically less than 5 ms

Speed control inaccuracy typically 0.1% to 0.5% of nominal speed

150% overload capacity for 60 second

Total Harmonic distortion shall comply with the provisions of IEEE 519. Necessary

metering, self-diagnostic arrangement (including display and alarm facilities) shall be

provided for local/ remote monitoring.

1.10.2 Technical Parameters Main connection

Voltage : 3 phase, 415 +/- 10 % permitted tolerance

Frequency : 45 to 65 Hz, maximum rate of change 17%/s

Imbalance : Max. +/- 3% of nominal phase to phase input voltage

Fundamental Power

factor

: 0.97 (at nominal load)

Motor connection

Voltage : 3 phase, from 0 to applied incoming supply voltage, 3-phase

symmetrical

Output Frequency : 0 to 250 Hz

Frequency Resolution : 0.01 Hz

Continuous Current : 1.0 * I2N(normal use)

Short Term Overload : I2max = 1.1 * I2N

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Capacity (1min./10min)

Field Weakening point : 8 to 300 Hz

Acceleration Time : 0 to 1800 sec

Deceleration Time : 0 to 1800 sec

Efficiency : Min. 97% at nominal power level

Environment limits

Ambient temperature : 0 to 45 deg. Cent.

General Standard Control Connections or as per Process Requirement

3 programmable differential analogue inputs (1 voltage signal, 2 current signals)

7 programmable digital inputs

2 programmables analogues outputs (current signal)

3 programmable digital outputs ( from C relays)

Optional analogue and digital extension modules can be added as well as a wide range of

field bus adapters.

Protection

Over current

Short circuit at start-up

Input phase loss

Output phase loss

Motor overload

Earth fault

Overvoltage

Undervoltage

Over temperature

Motor stall

Application macros

The features a selection of built-in, pre-programmed application macros for configuration of

inputs, outputs, signal processing and other parameters. It shall have interfacing facilities to

communicate data to SCADA system. These include:

FACTORY SETTING for basic industrial applications

HAND/AUTO CONTROL for local and remote operation

PID CONTROL for closed loop processes

TORQUE CONTROL for process where torque control is required.

SEQUENTIAL CONTROL for processes where torque control is required.

USER MACRO 1 and 2 for user‟s own parameter setting

Comprehensive testing and diagnostic function

1.10.3 Tests Each unit of Variable frequency drive shall be tested at the manufacturer‟s work. Test result

must satisfy the efficiencies on various loads and at different frequency levels against their

quoted values during bidding.

1.11 Lighting System Equipment

Lighting system shall comply with the following International Standards, including those

referred to therein.

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IEC 60083, 60598, 60669, 60884, 60906 and 60947

General Requirements

Lighting system equipment shall cover lighting panels, lighting fixtures, switches, receptacles

with switches, for outdoor lighting - lighting masts, street lighting poles, etc.

Normal and emergency lighting for indoor and outdoor areas shall be provided.

Supply for emergency lighting shall be derived from 110 V DC distribution board to be

provided under this Contract. The Bidder shall provide emergency lighting in the vital

installation including pump house, switchboard room, office building, administration areas,

etc. 10% of the total normal lighting shall be emergency type.

Galvanized conduits shall be used for all exposed wiring and black enameled MS conduit

shall be JAL NIGAM or their representative d for all concealed wiring. Minimum size of

conduit shall be 20 mm / 25mm for exposed / concealed conduits respectively. Wiring inside

the pump house, switchboard room and other areas shall be concealed type.

Wires used for conduit wiring of lighting fixtures / ceiling fans and receptacles shall be

250/440V grade, PVC insulated, single core, stranded copper conductor wires of sizes not

less than 2.5 sq. mm and 4 sq. mm respectively. Wires shall conform to IS standards. Three

individual wires with proper color coding (P-N-E) shall be used for wiring and no joint in

wires between conduit is allowed. 3 core x 2.5 sq. mm. copper cable shall be used for

circuiting of peripheral lighting.

1.11.1 Lighting Panels Lighting panels shall be of wall mounting type and fabricated out of 1.6 mm. thick cold rolled

sheet steel. lncomer circuit shall be controlled by a switch disconnector with a link in the

neutral circuit. Outgoing circuits shall be controlled by single pole MCBs of minimum 10A

rating and a link in the neutral circuit. TPN MCB shall be provided for street lighting/ area

lighting purposes. Breaking capacity of MCBs shall not be less than 10 kA. Residual circuit

breakers (RCCBs) shall be used on all lighting and receptacle circuits.

It shall be possible to terminate incoming and outgoing circuits from top and bottom. Knock-

out for cable / conduit entries for all the circuits shall be provided. Separate circuits shall be

provided for control of lighting fixtures and receptacles. Each phase shall have at least one

spare circuit.

The panel shall be provided with 3 phase and neutral copper busbar adequately rated to cater

to the requirement of all the outgoing circuits. Two earthing terminals shall be provided

external to the panels for terminating the external earthing conductor.

The panel shall be internally wired using color coded, stranded copper conductor, PVC

insulated wires of 1100 V grade.

The panels shall have hinged door, gasketed all round and provided with handle lock.

Operation of incomer switch or MCBs shall be possible without opening the door.

Detailed specification of lighting panel and its accessories (e.g. busbar, MCB, indicating

instrument, indicating lamp, etc.) are described at MV and LV switchboard.

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1.11.2 Lighting Fixtures and its Accessories Lighting fixtures for illumination of outdoor and indoor areas shall be supplied. Fixtures for

outdoor installation shall be of weatherproof design with degree of protection of IP66. The

fixtures shall be suitable for operation on a nominal supply of 240 V, single phase, 50 Hz, AC

with a voltage variation of + 3 %.

Fixtures shall be complete with internal wiring, lamp, , holder, ballast, reflector, louvres /

perspex, etc. as required for their satisfactory operation. Fixtures shall be energy efficient and

ballast shall be electronic low loss type. All indoor lighting fixture for office and control

room shall be decorative type and for remaining areas it shall be industrial type.

The power factor of the luminaries shall be maintained at 0.95.

LED lamp shall be „Tri-band” color temperature of the luminaire shall be in the range of

5000 k – 6000k (CCT as per BIS).

Lighting fixture reflectors shall generally be manufactured from steel or aluminum sheet of

not less than 20 SWG thickness. Each fixture shall be complete with a four way terminal

block for connection and looping of incoming and outgoing cables. Each terminal shall be

able to accept two 2.5 mm2 copper stranded conductors. Each lighting fixture shall be

provided with an earthing terminal suitable for connecting 16 SWG copper stranded

conductor. All metal or metal enclosed parts of the housing shall be bonded and connected to

the earth terminal to ensure satisfactory earthing continuity throughout the fixture. All

reflectors and louvers shall be finished to the same standard as the fixture housing.

The enamel finish shall have a minimum thickness of 2 mils for outside surface and 1.5 mils

for inside surfaces. The finish shall be non-porous and free from blemishes, blisters, and

fading.

Size of wire chosen shall be such as to limit the voltage drop to within 3 %. Minimum area of

conductor shall be 1.5 sq mm stranded copper for lighting and 2.5 sq mm / 4 sq mm for 5A /

15A receptacle circuits respectively, and current density shall not exceed 2.5 A/sq mm.

Generally, not more than 8 to 10 lighting points shall be wired in one circuit. For calculating

connected loads of various circuits, a multiplying factor of 1.25 shall be assumed on the rated

lamp wattage for sodium vapour and fluorescent lamp fixtures to take into account the losses

in the ballast. A loading of 100 watts and 500 watts shall be assumed for each, single-phase 5

amps and 15 amps receptacles respectively. Wires belonging to different phases shall not be

run in the same conduit. However, more than one circuit on the same phase can be run in the

same conduit. For every phase wire, a separate neutral wire shall be run. Neutral wire for

different phases shall not be looped.

The following types of fixtures shall be considered for various areas. The construction

features are indicative. Equivalent or superior feature is acceptable.

General purpose flood lighting fixtures - Housing with integral control gear from die-cast

aluminum alloy, vitreous enameled, and with electrochemically brightened anodized

aluminum reflector, clear, heat resistant glass with rubber gasket secured to housing by a

ring, cast iron base and MS cradle for turning in horizontal and vertical planes and lockable

in desired position, suitable for max. 3000 W LED lamp. These fixtures shall be used for

illumination of outdoor area for providing general illumination.

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Gate post lights - Top canopy spun from aluminum sheet and vitreous enameled. Spigot shall

be made of die-cast aluminum and vitreous enameled. Fixture shall be suitable for 70 W

HPSV/MH lamp.

Fluorescent tube fixtures - Housing made from mild steel sheet and stove enameled white.

Reflector assembly made from electrochemically brightened anodized aluminum sheets

secured to housing with spring loaded triggers and suitable for 2/3 nos. 36 watt triphosphor

coated tubes. These fixtures shall be used in switchboard room and other areas. Where false

ceiling is provided, fixtures shall be suitable for recessed mounting. For non-false ceiling

office areas, decorative type fixtures shall be used.

Street lighting fixtures for the approach road shall be weather-proof, suitable for 70 W / 150

W LED lamp and shall be cut-off type. The fixtures shall be of die-cast aluminum with

electrochemically brightened anodized aluminum reflector and with transparent

polycarbonate cover. The degree of protection shall be IP66. Street lighting control

(switching ON and OFF automatically) shall be done by photo-electric sensor or by timer.

Lighting fixture used for pump house and other areas with high ceiling shall be medium/high

bay type suitable for 150/250/400 W LED lamps. These shall have housing with integral

control gear of from die-cast aluminum alloy, electrochemically brightened anodized

aluminum reflector, etc.

1200mm sweep ceiling fans shall be provided in areas such as offices, etc. as per design

requirement. Adequate ventilation arrangements shall be made for enclosed areas where

ceiling fans are not proposed to be installed or cannot be provided. Power supply for the

ceiling fans shall be derived from lighting circuits. Ceiling fans shall be complete with all

accessories. Regulators shall be electronic (triac) type.

The work shall comprise wiring in heavy gauge (minimum 16 SWG) GI conduits, fixed and

supported at intervals of 300 mm on walls, ceiling etc.; installation of light control switches

and receptacles housed in GS boxes; earthing with 16 SWG copper wire run along the

conduit and clamped to it at every 300 mm; and termination of cables/wires at lighting

panels, light control switches, receptacles, lighting fixtures etc., as required. The minimum

size of conduit shall be 20 mm. Space factor (ratio of total wire area to internal conduit area)

shall be 40 %. Concealed conduiting shall be provided to all building / office areas. For pump

house area, the Bidder shall adopt surface conduiting also.

Receptacles and Switches – It shall be weather-proof for outdoor application. For Pump-

house area and Switchgear room, industrial type receptacles with switch shall be provided.

For Office areas, it shall be decorative type. 3 phase welding receptacles shall also be

provided as per requirement.

Types of fixtures proposed by the Bidder for various areas shall be subject to JAL NIGAM or

their representative ‟s Representative approval.

The lighting poles for streetlights shall be of tubular / swaged type steel poles, circular in

construction. The steel poles shall be coated with bituminous preservative paint on the inside

as well as embedded outside surface. Exposed outside surface of the steel poles shall be

painted with one coat of red lead oxide primer. After completion of installation, two coats of

aluminum paint shall be applied. The supply of poles shall be complete with fixing bracket,

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necessary pipe reducer for fixing the fitting and also include the necessary associated pole

mounted junction boxes. 2 nos. studs shall be provided on the pole for earthing. The lighting

poles shall have an end cap with brackets for mounting HPSV/MH lamps (of suitable

wattage) in weatherproof fittings, cut-off type or semi- cut off type luminaries. The brackets

shall be welded to the pole and shall ensure an suitable overhang depending on height of the

pole.

Junction boxes with terminals shall be supplied for branching and terminating the lighting

cables, weatherproof and suitable for usage in outdoor areas. The junction boxes shall be dust

and vermin proof and shall be fabricated from 2 mm CRCA sheet steel and shall be complete

with removable cover plate with gaskets, two earthing terminals each with nut, bolt and

washer. The Bidder shall provide support arrangement (through 25 x 4 mm GI flat U clamp)

for proper fixing of the junction box to the pole.

The boxes shall be hot dipped galvanized / painted with on shop coat of red oxide zinc

chromate primer followed by a finishing coat of paint. Suitable rubber gaskets shall be

provided on the doors of the junction boxes. The junction boxes shall have a locking facility,

suitable to be opened by a common panel key for all the junction boxes. The boxes shall have

provision for mounting on the poles. Suitable knockouts for the entry for cable / conduit entry

shall be provided with terminal blocks, HRC fuses etc.

The terminal blocks shall be mounted securely on brackets welded to the back sheet of the

box. The terminals shall be 1.1kV grade, one piece construction complete with barriers,

galvanized nuts, bolts, washers and provided with identification strips of PVC. The terminals

shall be made of copper alloy and shall be of box clamp type. Double compression brass

glands shall be provided for entry / exit of the cables into the junction box.

1.11.3 Illumination Levels Lighting system shall be designed to achieve the average maintained levels of illumination as

indicated below. The Bidder shall be required to measure the actual levels and carry out

necessary modifications to accomplish specified levels. It is to be noted that the values

measured after installation will exceed those specified due to inclusion of light loss factor in

the calculation. Measurement shall be carried out after 100 burning hours.

The illumination system shall be so designed that the uniformity factor is of acceptable level

and that the glare is within limits. The ratio of maximum to minimum illumination levels

shall not exceed 20 in outdoor area.

The following values of „light loss factor‟ shall be considered for design:

a) Indoor air-conditioned area : 0.85

b) Other indoor areas : 0.85

c) Outdoor area : 0.85

The Bidder shall furnish detailed design calculations, uniformity factors, ratio of maximum to

minimum illumination levels, ratio of average to minimum illumination levels, glare values,

etc. for approval. Detailed characteristics of various types of fixtures including photometric

curves and tables shall also be furnished for review.

1.11.4 Receptacles with Switches

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Adequate number of receptacles of 6A, 16A and 32A rating with MCBs suitable for

operation on 230 V AC, 1 phase, 50 Hz supply shall be provided as detailed below:

a) Decorative and industrial type shall be proposed in relevant areas.

b) Receptacles proposed for outdoor installation shall be of weatherproof design of

degree of protection IP65.

c) Single phase receptacle shall be provided with a switch / MCB of the same current

rating, housed in the same enclosure. Three phase receptacles shall be associated with

a MCB of the same rating, housed in the same enclosure. The number, type, rating

and location of receptacle shall be subject to approval of the JAL NIGAM or their

representative‟s Representative.

1.11.5 Switches

Decorative / industrial type switches of 6A / 16A rating shall be provided for all indoor areas.

Switches shall be provided to control a group of lighting fixtures in various areas. Switches

shall be housed in galvanized steel boxes.

1.11.6 Water Coolers

General

Water cooler shall conform to IS 1475/78 with latest amendment suitable for operation on

230 volts ±10%, 50 cycle‟s single phase AC supply. It shall be supplied with hermetically

sealed type suction cooled compressor with overload protection conforming to IS 10167. It

shall have cooling capacity of 40 liters per hour with storage capacity as 80 liters. The other

technical parameters are as under:

Specifications

Sr. No. Particulars Parameter

1 Overall Dimensions of

Unit

Width 590 mm

Depth 735 mm

Height 1555 mm

Tank

Width 485 mm

Depth 455 mm

Height 485 mm

2 Details of Cabinet

Material of Construction CRCA Sheet/Coated GI

Thickness 1 mm

Surface Treatment Powder Coated

Type of finish Structural

Dimensions of SS front panel below water outlets 410mm X 465 mm

3 Details of pedestal

Material of construction Stainless steel

SS conforming AISI 304

Thickness 2.65 mm

Method of securing to the cabinet SS bolts washer and nuts

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Sr. No. Particulars Parameter

5 Rated voltage of water cooler 230 ±10 % volts

6 Details of compressor

Capacity of compressor 900 Kcal per hour

Max output of compressor motors 0.25 KW

Rated

Current 3.1 (nominal) Amps

Speed 2850 RPM

Voltage 230±10 % volts

Maximum full current of compressor 3.4 Amps

Warranty of compressor One year

Class of insulation B

Power consumption (max) during operation under

capacity rating test condition

575 watts

1.11.7 Tests Lighting panels, fixtures, receptacles and other accessories shall be subjected to routine and

acceptance tests as per the applicable standards.

1.12 Cabling System Installation

General

The scope shall cover, in addition to supply, complete installation of plant items and

accessories as indicated in various parts of the specification. Requirements / guidelines /

information / parameters / instructions, etc. specified in this section shall apply to all the

sections.

Installation work pertaining to plant items and systems such as cabling, lighting, earthing and

lightning protection systems, etc. shall comply with the applicable standards, safety codes,

etc.

Installation shall be carried out strictly in accordance with the approved drawings. Changes,

modifications, if any, required to suit site conditions, shall be carried out only with the prior

approval of the JAL NIGAM or their representative‟s Representative. All such changes shall

be incorporated in the "As built" drawings to be furnished by the Bidder.

All tools, brazing equipment, crane, scaffolding, rigging materials, ladders, consumables,

hardware, etc. required for installation shall be provided by the Bidder.

It shall be the responsibility of the Bidder to engage Specialist Engineers from his Sub-

Bidders / Manufacturers to supervise installation work for plant items such as switchboard,

motors, etc. where felt essential. Such services shall be arranged by the Bidder at no extra

cost to the JAL NIGAM or their representative.

It shall be the responsibility of the Bidder to obtain approval / clearance, if any, from local

statutory authorities, for conducting any work for completed installation.

The Bidder shall ensure that all plant under erection as well as the work area and the project

site are kept clean to the satisfaction of the JAL NIGAM or their representative. In case the

JAL NIGAM or their representative is not satisfied about the cleanliness, he will have the

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right to carry out the cleaning operations. Expenditure incurred by him in this regard will be

to the Bidder's account. Packing cases and packing material, except for spares shall be cleared

from sites.

In order to avoid hazards to personnel moving around the equipment, which is kept charged

after installation before commissioning, such equipment shall be cordoned off by suitable

barriers to prevent accidental injury.

Switchboard shall be installed on finished surfaces. Proper aligning, joining of various

vertical shipping sections, busbar connections, inter panel wiring, etc. will be the

responsibility of the Bidder.

The Bidder shall take utmost care in handling instruments, relays and other delicate

mechanisms. Wherever the instruments and relays are supplied separately, they shall be

installed only after the erection of switchboards is complete.

1.12.1 Cabling System All apparatus, connections and cable work shall be designed and arranged to minimize risk of

fire and any damage, which might be caused in the event of a fire.

Cables shall be laid directly buried in earth, on cable trays in built-up trenches, in conduits /

pipes along walls / structures / foundations / ceilings, etc. The Bidder's scope of work

includes unloading, excavation, laying, backfilling, fixing, bending and terminating the

cables. The Bidder shall supply the necessary material and accessories required for

installation and termination of the cables which shall include but not be limited to items such

as glands, lugs, terminating accessories, hardware, consumables, saddles / spacers, GI

conduits / pipes, cable identification tags, protective bricks, civil materials, etc.

1.12.2 Buried Cables Cable installation in outdoor areas shall be carried out in directly burried cable trenches.

Stabilized thermal backfilling shall be used for directly buried cables. Cabling from trenches

up to junction box / equipment, etc. shall be carried out in GI conduit / pipes of class B.

Provision of GI pipe sleeves in trench wall shall be the Bidder's responsibility. Where cables

cross roads or water / sewage pipes, the Bidder shall provide rows of 150 mm diameter GI

pipes in a concrete block for passage of cables. Bidder shall also lay spare pipes for future

use. Alternatively, Bidder shall provide concrete cable duct for road crossing. LV cables shall

be buried at a depth of minimum 750 mm while HV and MV cables shall be buried at a depth

of minimum 1000 mm. For road crossings, the pipe for the cables shall be buried at not less

than one meter depth.

Directly buried cables shall be laid on a 75 mm thick riddled and compacted earth bed. The

cables shall then be covered on top and at their side with riddled earth to a depth of about

150mm. This shall then be gently pulled down to a depth of about 100 mm above the top of

uppermost cable to provide bedding for the protective concrete cable covers, which shall be

placed centrally over the cables. The protective cable covers shall be of reinforced concrete.

The RCC covers shall have one hole at each end to tie them to each other with GI wires to

prevent displacement. The trench should be then backfilled with the excavated soil and well

rammed in successive layers of not more than 300 mm thick, with the trenches being watered

to improve consolidation, wherever necessary. To allow for subsidence, a crown of earth not

less than 50 mm in the center and tapering towards the sides of the trench should be provided.

All cables to be routed along any particular route shall be laid at one time to avoid repeated

excavation, etc. Each cable shall be tagged with numbers. The tag shall be of aluminum with

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the number punched on it and securely attached to the cable / conduits by not less than two

turns of 20 SWG GI wire. Cable tags shall be of rectangular shape for power cables and of

circular shape for control cables. Cables tags shall be provided on all cables at each end, on

both sides of wall / floor crossings, on each duct / conduit entry, at each bend/ corner and at

every thirty (30) meters in cables trench / tray racks on straight run.

Where groups of HV, LV and control cables are to be laid along the same route, suitable

metallic barriers to segregate them physically shall be JAL NIGAM or their representative.

When power cables are laid in the proximity of communication cables, minimum horizontal

and vertical separation of 300 mm shall be maintained. Power and communication cables

shall, as far as possible, cross at right angles to each other.

1.12.3 Cables in Trays Cables in trays shall be cleated individually or in a group using GI saddles. Interval for

cleating shall not exceed 1500 mm.

In case of laying on cable trays / racks, power and control cables shall be laid in separate

cable trays, the order of laying of various cables being as given below:

a) HV cables on top tiers

b) LV cables on subsequent tiers

c) Control, instrumentation and other service cables in bottom-most cable tier.

Ladder type GI cable trays and painted rack support shall be installed in cable trenches for

power cables. Perforated trays shall be used for control and instrumentation cables.

Embedded flats for fixing cable tray supports shall be provided in cable trenches to support

the cable trays during civil works. Where such flats cannot be used, the fixing of cable trays

shall be done using anchor fasteners. All cable trays shall be earthed at a regular interval.

The cable trays shall be complete with all necessary coupler plates, elbows, tees, bends,

reducers, stiffeners and other accessories and hardware. Cable trays and accessories such as

tees, elbows, reducer, etc. shall be fabricated out of minimum 2 mm thick sheet of hot dip

galvanized sheet except for trays of width 300 mm and lower for which 16 G GS sheet is

acceptable. Bends, tees, etc. shall be supplied or fabricated at site, as required. Cable tray

supports such as angles, channels, etc. shall be of galvanized steel. Galvanizing thickness

shall be not less than 85 micron.

1.12.4 Cable Pulling The cables shall be laid in built-up trenches, directly buried in ground, or on cable trays,

vertical raceways, clamped on structures / walls / ceiling, pulled through pipes and conduits,

etc. The scope of cable installation shall include excavation and backfilling (in case of buried

cable trench), laying, pulling of cables, proper dressing of cables on cable trays, racks,

vertical raceways and supply and installation of cable tags, saddles, spacers and nylon chord

for tying as required. The cost of supplying covers for cable route / joint markers, supply of

sand and cover plates are included in the scope of the Bidder.

Standard cable grips and reels shall be utilized for cable pulling. If unduly difficult pulling

occurs, the Bidder shall check the pull required and suspend pulling until further procedure

has been approved by the JAL NIGAM or their representative‟s Representative. The

maximum pull tension shall not exceed the recommended value for the cable measured by the

tension dynamometer. In general, any lubricant that does not injure the overall covering and

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does not set up undesirable conditions of electrostatic stress or electrostatic charge may be

used to assist in the pulling of insulated cables in conduit / pipes and ducts.

After pulling the cable, the Bidder shall record cable identification with date pulled neatly

with waterproof ink in linen tags / aluminum tag and shall securely attach such identification

tags. Identification tags shall be attached to each end of each cable with non-corrosive wire.

The wire must be non-ferrous material on single conductor power cable. Tags would further

be required at intervals on long runs of cables on cable trays and in pull boxes. Cable and

joint markers and RCC warning covers shall be provided wherever required.

Each cable shall be pulled into the particular conduit / pipe and shall be taken from the

particular reel designated for the run. In hand holes, pull boxes or junction boxes having any

dimension over 1000 mm, all conductors shall be cabled and / or racked in an approved

manner. Care shall be taken to avoid sharp bending or kinking cables, damaging insulation or

stressing cable beyond manufacturer's recommendations in pulling. Cable shall be protected

at all times from mechanical injury and from absorption of moisture at unprotected ends. The

bending radii for various types of cables shall not be less than 12/15 times the overall

diameter of the cable for armoured cables and 15/20 times the overall diameter of the cable

for unarmoured cables.

Cables on cable racks and in conduits / pipes shall be formed to avoid bearing against edges

of trays, racks, conduit / pipes or their supports upon entering or leaving racks or conduit /

pipes.

Cables splices shall not be used except where permitted by the JAL NIGAM or their

representative's Representative. Splices shall be made by Bidder for each type of wire or

cable in accordance with the instructions issued by cable manufacturers and the JAL NIGAM

or their representative's Representative. Before splicing, insulated cables shall have conductor

insulation stepped and bound or penciled for recommended distance back from splices to

provide a long leakage path. After splicing, insulation equal to that on the spliced conductors

shall be applied at each splice.

At cable terminal points, where the conductor and cable insulation will be terminated,

terminations shall be made in a neat, skillful and approved manner by specially trained staff.

Terminations shall be made by the Bidder for each type of wire or cable in accordance with

instructions issued by cable manufacturers and / or the JAL NIGAM or their representative's

Representative.

Control cable termination shall be made in accordance with wiring diagrams, using proper

color codes for the various control circuit.

When control cables are to be fanned out and corded together with a cord, the Bidder shall

make connections to terminal blocks, and test the equipment for proper operation before

cables are corded together. If there is any doubt about correctness of connection, the Bidder

shall make a temporary connection with sufficient length of cable so that the cable can be

switched to another terminal without splicing. After correct connections are established,

cables shall be cut to their correct lengths, connected to terminals in the specified manner,

and corded together where necessary to hold them in place in a skillful manner. Jointing of

cables shall be in accordance with relevant Standards and manufacturer's instructions.

Materials and tools required for cable jointing work shall be supplied by the Bidder. Cables

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shall be firmly clamped on either side of a „straight through joint‟ at a distance of not more

than 300 mm away from the joints. Identification tags shall be provided at each joint at all

cable terminations.

Where cables pass through floor or wall openings or other partitions, suitable bushes / pipe

sleeves of GI shall be provided by the Bidder. The Bidder shall seal the cables at the bushes /

pipe sleeves using fire resistant material.

Cable seals shall be examined to ascertain if they are intact and that cable ends are not

damaged. If the seals are found to be broken, the cable ends shall not be jointed until after

due examination and testing under supervision of the JAL NIGAM or their representative's

Representative. Before joining is commenced, insulation resistance of both sections of cables

to be jointed shall be checked by megger.

In case of motor cables, after installation and alignment of motors, the Bidder shall complete

the conduit / pipe installation, including a section of flexible conduit / pipe between motor

terminal box and trench / tray, if necessary. The Bidder shall install and connect the power,

control and heater supply cables as per equipment manufacturer‟s drawings / instructions.

The Bidder shall be responsible for correct phasing of the motor power connection and shall

interchange connections at the motor terminal box, if necessary, after each motor is test run.

Connections to recording instruments float switches, level electrodes, limit switches, pressure

switches, thermocouples, thermostats and other miscellaneous equipment shall be done as per

manufacturer's drawings and instructions.

In each cable run, some extra length shall be kept at a suitable point to enable one or two

straight-through joints to be made, should the cable develop fault at a later date.

1.12.5 Conduits / Pipes Where cable trench is not available, cables shall be laid in GI conduits / pipes routed along

walls / columns / beams / steel structures or buried in concrete slabs, etc. to suit site

conditions. GI conduits shall be Class C type. Supply and installation of GI conduits / pipes,

their accessories such as bends, tees, couplers, etc., saddles, spacers, junction / marshalling

boxes and GI hardware required for installation shall be included in the Bidder's scope.

Interval between supports shall not exceed 500mm. For multiple cables, maximum utilization

factor (ratio of total wire area to internal conduit area) shall be 50% of the conduit area.

Non-metallic conduits / pipes shall be used for single core cables of a 3 phase circuits.

1.12.6 Junction Boxes / Marshalling Boxes Junction boxes / marshalling boxes shall be hot-dip galvanized, weather proof with IP 55

degree of protection and shall be provided with cable glands for incoming and outgoing

cables. The boxes shall be fabricated from 1.6 mm thick sheet steel and galvanized. The

boxes shall be suitable for mounting on walls / columns / steel structures, etc. and shall be

supplied with mounting accessories. The front covers of the boxes shall be removable and

provided with gaskets. All the terminals shall be complete with insulated barriers, terminal

studs, washers, nuts, etc. The boxes shall be effectively earthed.

1.12.7 Fire Proof Sealing (FPS) System Fire proof sealing system shall be provided and shall consist of

a) Fire-stops / fire-seals for sealing of cable / cable tray and conduit / pipe penetrations,

both horizontal and vertical, through brick or RCC walls / floors, to prevent the spread

of fire from one area to other areas by fire-resistant barriers.

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The FPS system shall also include all the necessary accessories and equipment required for

supporting, holding in position, fixing and installation of the fire-stop.

The FPS system shall comply in all respects with the requirements of the codes and standards

mentioned herein IEC-111 and IEC-112.

1.12.7.1 Fire Stop / Seal

The FPS system adopted for cables or cable trays penetrating through walls and floor

openings, or cables passing through embedded conduits / pipes / pipe-sleeves, constitutes a

`fire stop / seal', which is meant to prevent spreading of fire between areas separated by fire-

resistant barriers.

1.12.7.2 Performance Requirements

Requirement of fire stops

i. The material, design and construction of the fire stops shall be such as to provide a

fire-rating of 120 minutes for a fire on any side and meet all requirements listed in this

specification and the relevant codes and standards.

ii. The materials used in the fire stops shall be non-hygroscopic, compatible with the

type of cables.

iii. The fire stops shall be suitable for retrofitting of cables through the penetration seal

without disturbing the sealing of the cables already existing.

1.12.7.3 Application of Fire Proof Sealing System

a) Fire stops

Fire stops shall be provided for cable penetration openings listed below

i. The passage of cables / cable trays pipe sleeves / embedded conduits through

walls / floors.

ii. Vertical raceways, if any, which carry cables between successive floors,

through openings provided in the RCC floor slab, shall be sealed by fire stops

at each floor level.

iii. Cable entry through openings in floor slabs.

Bidder shall furnish the test certificates for the fire stops after award of Contract for JAL

NIGAM or their representative ‟s Representative eview. If the certificates are not satisfactory,

all the tests shall be conducted free of cost. The offered system i.e. fire stops and fire breaks

shall be identical (or better) with the system which is successfully type tested for the

specified rating i.e. the composition density of the material, thickness of coating in case of

fire breaks and any other properties of the material / system offered shall be identical or better

than the tested system and shall be subject to JAL NIGAM or their representative approval.

1.12.7.4 Performance Tests:

a) The fire stops shall be subjected to the following type tests:

i. Fire Rating Test

ii. Hose Stream Test

b) Type tests shall be conducted on different fire stop test specimens described above as

per IEEE-634. The sizes of the fire stop test specimens shall be similar to the largest

of the sizes being used in the plant.

c) Preconditioning of fire stop test specimens

Before conducting the Fire Rating and Hose Stream tests, each test specimen shall be

preconditioned for thermal ageing, water immersion and vibration.

d) Test on Fire Stops

During the Fire Rating test, the transmission of heat through the cable penetration fire

stop shall not raise the temperature on its unexposed surface above the self ignition

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temperature of the outer cable covering, the cable penetration fire stop material, or

material in contact with the cable penetration fire stop, with a maximum temperature

limit on the unexposed surface of 2000C.

1.13 Earthing and Lightning Protection System

Earthing and lightning protection system shall comply with the following International

Standards, including those referred to therein.

ANSI / IEEE Std. 80 and 142, IEC 61024 and IS 2309, 3043.

The scope includes measurement of electrical soil resistivity (during dry season) at site,

supply of earthing conductors, earth electrode pits, lightning protection system and their

installation including associated civil work as per the specifications and approved drawings,

to the satisfaction of the JAL NIGAM or their representative ‟s Representative. The scope of

works shall also comprise designing the earthing and lightning protection systems as per the

applicable standards and specific design basis listed below:

a) Average value of soil resistivity as measured for different electrode spacing, at site.

(from 2 to 100 Meter or more in steps of 5, 10 Meter. At least 20 nos. readings shall

be taken over the plant area, each in two different directions)

b) Permissible values of step and touch potentials based on weight of human being as 70

kg and Earth fault current of 40 kA for 1 seconds

c) Gravel with surface resistivity of 3000 ohm-m

d) Depth of burial of earth conductors of 600 mm below ground level

e) Ground resistance with only electrodes of maximum 1 ohm.

f) Ground resistance of earthing grid of maximum 1 ohm

g) Corrosion allowance of at least 20 %

h) Earthing conductor material shall be minimum 20 mm diameter and 3 m long GI Pipe.

Earthing system design and calculations shall be subject to JAL NIGAM or their

representative‟s approval.

Earthing and lightning protection system shall be provided to ensure equipment safety,

personnel safety and to facilitate designed operation of protective devices during earth fault

conditions in the associated system.

The Bidder shall install bare earth conductors as required for the system and individual

equipment earthing. All the work such as cutting, bending, supporting, drilling, brazing /

soldering/welding, clamping, bolting and connections to structures, equipment frames,

terminals or other devices shall be in the Bidder‟s scope. All hardware and consumables such

as fixing cleats / clamps, anchor fasteners, lugs, bolts, nuts, washers, brazing electrodes, flux,

bituminous compound, anti-corrosive paint, etc. as required for the complete work shall be

included by the Bidder.

Tap connections (earthing leads) of more than 500 mm long, from main earthing grid to

equipment shall be embedded in the floor by the Bidder together with associated civil work

such as chipping / chasing, concreting and surfacing, etc. The concrete cover over the

conductor shall not be less than 50 mm.

The scope of installation of earth conductors in outdoor areas, buried in ground shall include

excavation in earth up to 600 mm depth and 400mm width, laying of conductor at 600 mm

depth, brazing as required of main grid conductor joints as well as riser‟s up to 500 mm

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above ground at required locations and backfilling. Backfilling material to be placed over

buried conductor shall be free from stones and other mixtures. Backfill shall be placed in

layers of 150 mm, uniformly spread along the trench and compacted. If the excavated soil is

found unsuitable for backfilling, the Bidder shall arrange for suitable material from outside.

Earthing conductors in outdoor areas shall be laid 1500mm away from buildings. The scope

of installation of earth conductors in outdoor areas buried in ground, shall include excavation

of earth up to 600 mm depth, brazing / welding of main grid conductor, joints as well as risers

of length 500 mm above ground at required locations and then backfilling.

Wherever earthing conductor crosses underground service duct and pipes, it shall be laid 300

mm below them. If the distance is less than 300 mm, the earthing conductor shall be bonded

to such service ducts / pipes.

The scope of installation of electrodes shall include installation of electrodes in constructed

earth pits, and connecting to main buried earth grids. The scope of work shall include

excavation, construction of the earth pits including all materials required for treatment (salt,

charcoal, chemicals, etc.), placing the electrode and connecting to main earth grid conductors.

The work of embedment of earthing conductor in RCC floors / walls along with provision of

earth plate inserts / pads / earth risers shall be done by the Bidder preferably before the floors

/ columns / walls are cast. The embedded conductors shall be connected to reinforcing rods

wherever necessary.

The scope of installation of earthing leads to the equipment and risers on steel structures /

walls shall include laying the conductors, brazing / cleating at specified intervals, brazing to

the main earth grids, risers, bolting at equipment terminals and coating brazed joints by

bituminous paint.

Earthing and lightning protection system conductors along their run on walls / columns, etc.

shall be cleated at an interval of 750 mm.

Main earthing conductor shall be buried below the trench at crossing points.

Metallic frames of all electrical equipment shall be earthed by two separate and distinct leads

and then connected with earthing system.

Neutral of a transformer shall be earthed to two separate earth electrode pit by two separate

earth leads.

Crane rails shall be connected to the earthing system.

An earthing mat shall be provided under the operating handle of the disconnector. Operating

handle of the disconnector and the supporting structure shall be bonded together by a flexible

connection and connected to earth grid.

Metal pipes and cable conduits shall be effectively bonded and earthed by earthing clamps

efficiently fastened to the conduit at both ends.

Neutral connection shall never be used for equipment earthing.

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A separate earth electrode shall be provided for each lightning arrester and for each lightning

conductor down comer.

Cable sheaths and screen shall be bonded to the earthing system.

Armour of multicore cables shall be bonded to earthing system at both ends, while that of

single core cables shall be earthed at source end only. The size of conductor for bonding shall

be appropriate with the system fault current.

Conduits, fixtures, junction boxes, etc. shall be bonded to the earthing system by 16 SWG

diameter copper wire looped from lighting panel earth bus onwards. Outdoor lighting poles,

junction boxes, etc. shall be earthed by 12 SWG copper wires.

Street light pole and junction box shall be earthed with 12 SWG tapped off from the 25x3

mm GI earthing conductor to be laid along the street lighting cable.

All metallic parts such as transformer, fence, gate, etc. shall be properly earthed.

Wherever earthing conductor passes through walls, galvanized steel pipe sleeves shall be

provided for the passage of earthing conductor. The pipe ends shall be sealed by the Bidder,

by suitable water-proof compound. Water stops shall be provided wherever earthing

conductor enters the building from outside below ground level.

All connections in the main earth conductors buried in earth / concrete shall be brazed type.

Connections between main earthing conductor and earth leads shall also be of brazed type.

Connection between earth leads and equipment shall be by two bolts.

Installation of lightning conductors on the roof of buildings shall include laying, anchoring,

fastening and cleating of horizontal conductors, grouting of vertical rods wherever necessary,

laying, fastening / cleating / brazing of the down comers on the walls / columns of the

building and connection to the test links to be provided above ground level.

Lightning protection system down-conductors shall not be connected to the conductors of

safety earthing system above ground level. The lightning protection system for the structures

shall be installed by forming a grid of exposed continuous earth conductors and taking down-

comers along the walls/supports of the structure and terminating the same at earth pits. A

separate earth electrode shall be provided for each lightning arrester and for each lightning

conductor downcomer. The lightning protection system earth pits shall be inter-connected to

form the safety earthing grid provided for the building / structure. The safety earthing grid

shall be connected to the mains grid of the switch yard.

The lightning protection air termination rods and / or horizontal air termination conductors

shall be fixed in a firm manner. The necessary accessories such as cleats, clamps, brazing

materials, bolts, nuts, shall be supplied by Bidder.

Air termination systems shall be connected to earthing system by down conductors. There

shall not be any sharp bends, turns and kinks in the down conductors.

All joints in the down conductors shall be of brazed type. All metallic structure within 1

meter of down conductors shall be bonded to lightning protection system.

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Every down conductor shall be provided with a „test link‟ mounted on wall / column at about

1000 mm above ground level housed in a 16 SWG GS enclosure. The test joint shall be

directly connected to the earth electrode.

The lightning protection system shall not be in direct contact with underground metallic

service ducts, cables, cable conduits and metal enclosures of electrical equipment. However,

all metal projections, railings, vents, tanks, etc. above the roof shall be bonded together to

form a part of roof grid.

Lightning protection system down conductors shall not be connected to other earthing

conductors above ground level. In addition, no intermediate earthing connection shall be

made to lightning arresters and transformer, whose earthing leads shall be directly connected

to electrode pit.

1.13.1 Earth Electrodes and Pit Treated earth pits shall comprise of treatment material such as salt and charcoal or any other

conductivity enhancing compound. Treatment material placed around the electrode shall be

finely graded, free from stones and other harmful mixtures. Backfill shall be placed in 150

mm thick uniformly spread and compacted layers. If excavated soil is found unsuitable for

backfilling, the Bidder shall arrange for a suitable soil from outside.

Earth electrodes shall be fabricated from minimum 20 mm diameter, 3m long, copper rod or

40 mm diameter, 3m long GI pipe. The minimum spacing between adjacent electrodes shall

be 6 m. Design and constructional details of electrode pit shall be subject to the JAL NIGAM

or their representative‟s Representative approval.

Electrodes shall, as far as practicable, be embedded below permanent moisture level.

Test pits with concrete covers shall be provided for periodic testing of earth resistance.

Installation of electrodes in test pits shall be suitable for watering. The necessary materials

required for installation of test pits shall be supplied and installed by Bidder. The installation

work shall also include civil works such as excavation / drilling and connection to main earth

grid. Earth electrode pit marker shall be provided.

Treated earth pits shall be treated with suitable treatment material mentioned above, if

average electrical resistivity of soil is more than 20 ohm meter.

Conductor size for connections to various equipments shall be as per the table as follows:

Equipment Conductor Size

Motors Up to 11 kW

11 kW up to 22 kW

22 kW up to 37.5 kW

37.5 kW to 90 kW

90 kW to 200 kW

Above 200 kW

8 SWG GI wire

4 SWG GI wire

25 x 3 mm GI flat

25 x 6 mm GI flat

40 x 6 mm GI flat

50 x 10 mm GI flat

PCC 50 x 6 mm GI flat

PDB 50 x 6 mm GI flat

DG and other panel 50 x 6 mm GI flat

Local control station, street light pole

and its junction box

8 SWG GI wire

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Equipment Conductor Size

All switchyard equipment 50 x 6 mm GI flat

Main earth grid 50 x 6 mm GI flat

Lighting Panel 25 x 3 mm GI flat

Indoor fixtures 14 SWG GI wire

All paint, scale etc. shall be removed before earthing connections are made.

Anchor bolts or fixing bolts shall not be used for earthing connections.

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Schedule II – Part D

Instrumentation Works

Instrumentation Specifications

1.1 General

Jal Nigam (JN) requires to have latest technology with compatible automation system

having fully automatic process control, ON LINE to monitor and control the plant

from a single location. The plant data collected through online monitoring of water

quality and flow shall be made available via the internet to various statutory bodies.

The bidder shall provide, install, test and commission all instruments (online and

laboratory) and local panels required for proper operation of the works. Details of

instruments associated with the actual waste water treatment processes are in some

instance given in the relevant sections of the specification. The bidders are advised to

diligently go through the complete tender document and quote instruments

accordingly. The bidder shall include in their bid a list of instruments / devices

showing compliance to agencies such as ISO, BIS, EPA, etc. as applicable.

The instrument proposed for each application shall be of reputed make with latest.

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1.2 Aim

Using the latest technology for online monitoring and control of various parameters

Jal Nigam hopes to achieve following aim:

Proper monitoring and correction

Generation of all faults and trends

Correct display of characteristics raw and output treated effluent

Long term historical storage of process data

Analysis and graphical plots of historical data

Prevention maintenance management

Inventory control

Maintain plant operation summaries

Improve plant efficiency and increase the plant life

Maintain records of pumping through flow meters

Maintain record of quantity of gas generated

1.3 Scope

This part covers the general requirements for the design, supply, installation,

inspection and testing of the instrumentation and automation solution proposed for

flow measurement, monitoring of water quality and control of plant.

1.3.1 Reference Standards

Unless otherwise approved, instrumentation shall comply with relevant quality

standards test procedures and codes of practice collectively referred to as Reference

Standards including those listed below in accordance with the requirements detailed

elsewhere in this specification. IEC 60381-1:1982 Analogue signals for process

control systems.

Specification for direct current signals:

IEC 60947-4-1:2000 Specification for low-voltage switchgear and Control Gear.

Contactors and motor-starters. Electromechanical contactors and motor-starters.

IEC 60947-4-2:1999 Specification for low-voltage switchgear and Control Gear.

Contactors and motor-starters. A.C. semiconductor motor controllers and starters.

IEC 60947-4-3:1999 Specification for low-voltage switchgear and Control Gear.

Contactors and motor-starters. Contactors and motor-starters. AC semiconductor

controllers and contactors for non-motor loads.

IEC 60770-1:1999 Transmitters for use in industrial-process control systems. Methods

for performance evaluation.

BS ISO 1217:1996 Displacement compressors. Acceptance tests.

ISO 2112:1990 Specification for aminoplastic moulding materials.

ISO 6817:1997 Measurement of conductive liquid flow in closed conduits. Method using

electromagnetic flow meters.

BS EN 837-1:1998 Pressure gauges. Bourdon tube pressure gauges. Dimensions,

metrology, requirements and testing.

BS EN 1057:1996 Copper and copper alloys. Seamless, round copper tubes for water and

gas in sanitary and heating applications.

BS EN 1092-1:2002 Flanges and their joints. Circular flanges for pipes, valves, fittings

and accessories, PN designated. Steel flanges.

BS EN 1563:1997 Founding. Spheroidal graphite cast iron.

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BS EN 60529:1992 Specification for degrees of protection provided by enclosures (IP

code).

BS EN 60534-1:1993 Industrial-process control valves. Industrial-process control valves.

Control valve terminology and general considerations.

BS EN 60546-1:1993 Controllers with analogue signals for use in industrial-process

control systems. Controllers with analogue signals for use in industrial-process control

systems. Methods for evaluating performance.

BS EN 60584-2:1993 Thermocouples. Tolerances.

BS EN 60654:1998 Operating conditions for industrial-process measurement and control

equipment. All relevant parts.

BS EN 60751:1996 Industrial platinum resistance thermometer sensors.

BS EN 60873:1993 Methods of evaluating the performance of electrical and pneumatic

analogue chart recorders for use in industrial-process control systems.

BS EN 61000-6:2001 Electromagnetic compatibility (EMC). Generic standards.

Emission standard for industrial environments.

BS 89:1990 Direct acting indicating analogue electrical measuring instruments and their

accessories. All parts.

BS 90:1975 Specification for direct-acting electrical recording instruments and their

accessories.

BS 476 Fire tests on building materials and structures. All parts.

BS 1042-1.4:1992 Measurement of fluid flow in closed conduits. Pressure differential

devices. Guide to the use of devices specified in Sections 1.1 and 1.2.

BS 1041-2.1:1985 Code for temperature measurement. Expansion thermometers. Guide

to selection and use of liquid-in-glass thermometers.

BS 1041-2.2:1989 Code for temperature measurement. Expansion thermometers. Guide

to selection and use of dial-type expansion thermometers.

BS 1041-3:1989 Temperature measurement. Guide to selection and use of industrial

resistance thermometers.

BS 1041-4:1992 Temperature measurement. Guide to the selection and use of

thermocouples.

BS 1042-1.4:1992 Measurement of fluid flow in closed conduits. Pressure differential

devices. Guide to the use of devices specified in Sections 1.1 and 1.2.

BS 1123-1:1987 Safety valves, gauges and fusible plugs for compressed air or inert gas

installations. Code of practice for installation.

BS 1203:2001 Hot-setting phenolic and aminoplastic wood adhesives. Classification and

test method.

BS 1553-1:1977 Specification for graphical symbols for general engineering. Piping

systems and plant.

BS 1571-2:1975 Specification for testing of positive displacement compressors and

exhausters. Methods for simplified acceptance testing for air compressors and exhausters.

BS 1646-1:1979 Symbolic representation for process measurement control functions and

instrumentation. Basic requirements.

BS 1646-2:1983 Symbolic representation for process measurement control functions and

instrumentation. Specification for additional basic requirements.

BS 1646-3:1984 Symbolic representation for process measurement control functions and

instrumentation. Specification for detailed symbols for instrument interconnection

diagrams.

BS 1646-4:1984 Symbolic representation for process measurement control functions and

instrumentation. Specification for basic symbols for process computer, interface and

shared display/control functions.

BS 1794:1952 Specification for chart ranges for temperature recording instruments.

BS 2765:1969 Specification for dimensions of temperature detecting elements and

corresponding pockets.

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BS 3680 Measurement of liquid flow in open channels. All relevant parts.

BS 3693:1992 Recommendations for design of scales and indexes on analogue indicating

instruments.

BS 4675-2:1978 Mechanical vibration in rotating machinery. Requirements for

instruments for measuring vibration severity.

BS 4999-142:1987 General requirements for rotating electrical machines. Specification

for mechanical performance: vibration.

BS 5169:1992 Specification for fusion welded steel air receivers.

BS 5728-3:1997 Measurement of flow of cold potable water in closed conduits. Methods

for determining principal characteristics of single mechanical water meters (including

test equipment).

BS 6004:2000 Electric cables. PVC insulated, non-armoured cables for voltages up to

and including 450/750 V, for electric power, lighting and internal wiring.

BS 6739:1986 Code of practice for instrumentation in process control systems:

installation design and practice.

BS 7671:2001 Requirements for electrical installations. IEE Wiring Regulations.

Sixteenth edition. Instrument Society of American Standards and Recommended

Practices:

S 5.1 Instrumentation symbols and identification

S 5.4 Instrument loop diagrams

S 7.3 Quality standard for instrument air

RP 16.1 Terminology, dimensions and safety practices for indicating variable 2, 3 area

meters

RP 16.4 Nomenclature and terminology for extension-type variable-area meters

(rotameters)

RP 16.5 Installation, operation, maintenance instructions for glass tube variable area

meters (rotameters)

RP 16.6 Methods and equipment for calibration of variable area meters (rotameters)

RP 18.1 Specifications and guides for the use of general purpose enunciators

S 26 Dynamic response testing of process control instrumentation

RP 31.1 Specification, installation and calibration of turbine flow meters

S 37.1 Electrical transducer nomenclature and terminology

S 37.3 Specifications and tests for strain gauge pressure transducers

S 50.1 Compatibility of analog signals for electronic industrial process instruments

S 51.1 Process instrumentation terminology

RP 60.08 Electrical Guide for Control Centers

1.3.2 Statement of Compliance

The Selected Bidder shall provide a list of the reference standards used and shall

provide a compliance/non-compliance statement for all the online and lab instruments

proposed.

All standards which the Selected Bidder intends to use but which are not referenced

herein shall be submitted to the Independent Engineer for consent before any design

against that standard proceeds. Installation works shall comply with all relevant local

Indian Regulations including the Code of Practice for Electrical Wiring Installations –

IS 732.

1.3.3 Submissions by Selected Bidder

General

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The Selected Bidder shall make submissions to the Engineer of all design drawings

and schedules relating to instrumentation and control equipment and systems provided

under this Contract. These submissions shall include, where relevant, the following:

Functional Design Specification

The Selected Bidder shall submit a complete functional design specification (FDS) for

approval by the Engineer. This document shall serve as the primary mechanism by

which the Engineer may confirm that the Selected Bidder possesses an accurate

understanding of the system and its control requirements. The Selected Bidder is

encouraged to obtain clarifications and to suggest refinements to the control

descriptions contained in this Specification. The FDS shall comprise an overall

description of the plant, its functioning and control, and a detailed description of each

section of the control system covering modes of operation, manual overrides, set-point

and parameter selection and adjustment. The detailed description shall include a step-

by-step control description which defines the function of each piece of equipment and

each control action and interlock, including details of the program in each

programmable item. The format of the program details may be chosen by the Selected

Bidder, however it is suggested that this format be chosen to satisfy the requirements

of the software design documentation, if applicable, as described elsewhere.

The FDS shall describe the „fail-safe‟ features incorporated into the design for the

event of failure of a plant item or system, or loss of an input signal affecting a control

loop or process sequence.

The FDS shall describe control actions taken and monitoring functions which remain

available during a power failure, and any automatic controls or sequencing which take

place during system start-up and shut-down.

The FDS shall be presented in a clear and precise manner and shall include figures or

drawings where appropriate. The Selected Bidder shall submit and obtain approval of

the FDS from the Engineer before beginning the detailed control system design. The

Selected Bidder should take note of the importance of this obligation.

Drawings and Schedules

Process and instrumentation diagram which shall comply with BS 1646 (all parts) and

BS 1553-1:1977.

General arrangement drawings of field-mounted instruments showing installation

details.

General arrangement drawings of instrument and control panels, fully-dimensioned in

plan and elevation views, showing foundation and fixing details, access doors,

clearances, cable-entry positions, weight and lifting arrangement.

Layout drawings of panel fascias showing instruments, controls and details of all

labels.

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Layout drawings of panel interior showing equipment, terminal blocks and cable

ways.

Annunciator arrangement and engraving details.

Internal circuit and wiring diagrams for instrument and control panels.

Schematic control diagrams.

Instrument loop diagrams.

Instrument wiring and piping diagrams.

Interconnection wiring diagrams.

Cable block diagrams, drawings and schedules.

Instrument system and panel power distribution diagrams.

Programmable-device functional design specifications which shall include hardware

details, logic flow charts, ladder diagrams and program listings.

Schedules of inputs to and outputs from programmable controllers and telemetry

outstations.

Labelling schedules.

Comprehensive testing schedules for all off-site, on-site, pre-commissioning and

commissioning tests and take-over tests.

All other drawings necessary for the provision of ducts, openings, trenches, fixing

holes for panels and the like and for the complete understanding of the operation,

maintenance and extension of the system including any required for the Purchaser to

dismantle, repair, maintain, modify or extend the Plant during the O&M period.

Data and Calculations

Manufacturer‟s catalogues and data sheets

Calculations to support control system design

Specification for protective coatings and painting

Certificates

Manufacturer‟s works tests

Pre-installation checks

Pressure-testing schedules

Instrument loop test check sheets

Installed instrument performance tests

System tests

Statutory certificates of compliance (such as hazardous area equipment)

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Operation and Maintenance Instructions

Composite manual describing the functional and operation of each piece of

equipment.

Composite manual for testing and servicing every system and individual item.

1.4 Basic Features

Each instrumentation system shall be designed, manufactured and installed to achieve

the following basic requirements:

Basic Requirements

To maintain the highest standards of availability, reliability and accuracy and to give

clear warnings of any deterioration in performance

To suit the abilities of the staff who will:

(i) Use the systems

(ii) Service the systems

To measure, indicate, process, store and control the relevant parameters, as specified

To give clear warnings of dangerous and other abnormal conditions and to initiate plant

safety procedures, shutdowns and corrective measures as specified to assure the safety of

„operations and maintenance‟ personnel and that of the plant and to store and collate the

data, as required

To derive, present and utilize, as required, such additional data to facilitate:

(i) The most efficient operation of the plant

(ii) The routine maintenance of the plant

1.5 Design Requirements for Instrumentation And control Systems (I&C)

The instrumentation, control and automation installations shall fully comply with

design standards, regulations and the material and workmanship requirements of the

Specification. The instrumentation control and automation systems shall comply with

the relevant Indian Standards being practiced as per the industry norms. All

consumable items and spare parts shall be readily available within India.

All equipment and materials incorporated in the system shall be selected, designed

and rated to operate under the defined performance duties and specified site

conditions and to maintain a high level of operational reliability. The instrumentation

control and monitoring system equipment and materials shall have an operational life

of not less than 15 years, unless otherwise consented to by the Engineer.

Unless otherwise specified, all functions shall be transmitted electrically and all

analogue signal-transmission systems shall be in accordance with IEC 60381-1:1982

or equivalent and shall use a signal of 4mA to 20mA dc. Where possible, measuring

systems shall be designed so that any necessary power supply is taken from the

appropriate instrument panel. Transmitting devices shall have integral indicators to

monitor the output signal or connections suitable for use with a portable test meter,

and shall be capable of meeting the performance requirements specified in the

appropriate part of IEC 60770-1:1999 or equivalent. Equipment mounted in

enclosures shall be suitable for continuous operation at the maximum internal

temperature possible in service, due account being taken of internally-generated heat

and heat dissipated by other plant. All components shall be rated adequately and

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circuits shall be designed so that change of component characteristics within the

manufacturers‟ tolerances shall not affect the performance of plant. All equipment

shall be designed to operate without forced (or fan) cooling.

All measuring instruments shall have zero and span adjustment. Instruments not

mounted in panels shall be supplied complete with all brackets, stands, supporting

steelwork and weatherproof enclosures (separate from the instrument cases) necessary

for securing them in their working positions and affording complete protection at all

times including periods of servicing, adjustment, calibration and maintenance. The

installation arrangements for meters measuring conductivity, pH, dissolved oxygen,

chlorine residual and ionic concentration shall include a sample bench and other

facilities for operating portable test meters. Each installation shall incorporate a valve

and pipework for obtaining a sample representative of the fluid at the position of the

permanent meter, tundish and drain. If the measuring and sampling points are remote

from each other, the test and sample facilities shall be provided at both points. Sample

transport times shall be minimized by provision of a bypass and drain with control and

isolating valves and a local flow meter to enable the correct sample flow to be

adjusted. An automatic portable sampler shall be provided for collecting and

transporting the samples from the sampling locations to the laboratory.

1.5.1 Instrument Design Criteria

The design criteria to be applied to instrumentation system shall be as follows:

Instrumentation & Control (I&C) systems shall be selected, designed,

manufactured, installed, tested and rated to operate under the defined

performance duties and specified site conditions and to maintain a high level of

operational reliability. Instruments mounted in field and on panels shall be

suitable for continuous real time operation. All electronic components shall be

adequately rated and circuits shall be designed so that change of component

characteristics shall not affect the plant operation.

All I&C equipment shall be new, of proven design, reputed make and have data

logging facility. Unless otherwise specified, all instruments shall be tropicalized.

The outdoor equipment shall be designed to withstand tropical rain and shall be

suitable for the worst environmental operating conditions. Wherever necessary

space heaters, heat dissipaters, dust and weather proof cabinets shall be provided.

Instruments offered shall be complete with all the necessary mounting accessories

& safety features.

No custom made hybrid type IC's [Integrated Circuits] shall be used in any

circuit in instrumentation and control equipment. Any hybrid circuits or sealed

modules or devices which do not have alternative manufacturer shall be

disclosed in the Bid by Selected Bidder, so that such devices can be included as

component spares in sufficient quantity in advance and shall be deemed to be

included in the bid price.

Instruments and loggers provided shall be able to carry out continuous real time

monitoring and logging of selected water quality parameters.

All instrumentation shall be suitable for continuous real time operation and be

powered through the UPS.

As far as possible and depending upon the location and availability of wireless

services, all transmitting instruments and data loggers shall be of wireless type

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(GPRS / GSM based). In case of non-feasibility, the output of the transmitting

instruments shall be 4-20 mA / 0-10V DC linear having two wire system.

After a power failure, when power supply resumes, the instruments and

associated equipment shall start working automatically.

Unless otherwise specified, the normal working range of all indicating

instruments shall be between 25% and 80% of the full scale range.

The field instruments i.e. the instruments mounted outside the control panel shall

be mounted at a convenient height of approximately 1.2 m above grade

platform.

Unless otherwise stated, field mounted electrical and electronic instruments shall

be weatherproof to IP-65 or better.

The instruments shall be designed to work at the ambient conditions of

temperature, humidity, and contamination that may prevail at site. The

instruments shall be given enough protection against corrosion. All wetted parts

of instrument sensors shall be non – corrosive and suitable for use within

sewerage environment.

The performance of all instruments shall be unaffected for the ±10%

variation in supply voltage and ±5% variation in frequency simultaneously.

Unless otherwise specified, double compression glands shall be used for

glanding the cable in field instruments and instrument control panel.

All digital outputs shall be volt free.

All probe type analyzers should be IP68 rated.

All displays shall be of the digital type with no moving parts and should utilize

back lit liquid crystal diode LCD/ LED technology.

Instrumentation shall utilize solid state electronic technology and avoid the use

where practical of any moving parts.

Minimum maintenance requirements. The instruments selected shall be rugged

and not require any consumables / filling solutions. Systems should be able to

work with minimum power requirements.

Lockable enclosure shall be provided for all the field mounted instruments.

All the instruments and cabinets shall have tag plates / name plates permanently

attached to them.

All instruments to be used or installed within a corrosive sewerage environment

shall be Explosion Proof and Intrinsically Safe.

The data obtained from the online quality monitoring system shall be conveyed back via

suitable communications protocol, to web servers hosted by a service provider. The

service provider shall have the data storage capacity for next 15 years.

Unless otherwise specified, all continuous online monitoring instruments shall be plug

and play type.

Instrumentation system shall be provided to monitor the following parameters

Online Continuous Dissolved Oxygen Measuring System

Ultrasonic Level Measurement

Ultrasonic Differential Level Measurement

Ultrasonic Open Channel Flow Measurement at Parshall Flume

Gas Flowmeter (Thermal Mass Flow Measurement System)

Pressure Transmitter

Continuous Online Total Suspended Solids Analyzer

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Continuous Online pH Measuring System

Online Residual Chlorine Measuring System

Conductivity Meter

Ammonia Analyzer

Alkalinity Analyzer

Total Nitrogen Analyzer

Indicative BOD Analyzer

Indicative COD Analyzer

Indicative TOC Analyzer

Measurement of CO2, CH4 and H2S Gas Concentration

Electro-Magnetic Flow Meter

Online Gas Calorific Value Measurement

Total Phosphorus Nitrate Analyzer

1.6 Instrumentation

1.6.1 Online Instruments

The online measurement would be done at various locations within the plant. The

location wise instruments list is as follows:

AT ASSI NALA AND PUMPING STATION:

- Ultrasonic Flow Measurement at weir at Assi Nala ( to measure any incidences of

flow over

- Electromagnetic flow meter at on the existing rising main

AT INLET:

- Ultrasonic Differential Level Measurement at Screens

- Ultrasonic Open Channel Flow Measurement

- Ammonia Analyzer

- Total Nitrogen Analyzer

- Conductivity Meter

- Continuous Online pH Measuring System

- Continuous Online Total Suspended Solids Analyzer

- Indicative BOD Analyzer

- Indicative COD Analyzer

- Indicative TOC Analyzer

- Alkalinity Analyzer

- Total Phosphorus Analyzer

AFTER PRIMARY CLARIFIER:

- Indicative BOD Analyzer

- Indicative COD Analyzer

- Indicative TOC Analyzer

- Continuous Online Total Suspended Solids Analyzer

AT PRIMARY SLUDGE PUMP HOUSE:

- Electro-Magnetic Flow Meter at the Header

- Pressure Transmitter on Header

- Ultrasonic Level Measurement at Sump

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- Continuous Online Total Suspended Solids Analyzer

AT DIGESTORS AND GAS HOLDERS:

- Temperature Element and Temperature Transmitter

- Gas Flowmeter (Thermal Mass Flow Measurement System) for Measuring

Quantity of Gas

- Measurement of CO2, CH4 and H2S Gas Concentration

- Online Gas Calorific Value Measurement

AT AERATION UNIT:

- Online Continuous Dissolved Oxygen Measuring System

- Continuous Online pH Measuring System

- Continuous Online Total Suspended Solids Analyzer

- Nitrate Analyzer

- ORP instrument

AT RETURN SLUDGE PUMP HOUSE:

- Electro-Magnetic Flow Meter at inlet to Thickener

- Electro-Magnetic Flow Meter at inlet to Aeration Tank – Separate for each stream

- Ultrasonic Level Measurement at Sump

- Pressure Transmitter on Header

AT SECONDARY CLARIFIER / AFTER FILTER:

- Electro-Magnetic Flow Meter

- Ammonia Analyzer

- Alkalinity Analyzer

- Nitrate Analyzer

- Total Phosphorus Analyzer

- Conductivity Meter

- Continuous Online pH Measuring System

- Continuous Online Total Suspended Solids Analyzer

- Indicative BOD Analyzer

- Indicative COD Analyzer

- Indicative TOC Analyzer

- Online Residual Chlorine Measuring System

- Total Nitrogen Analyzer

- AT MPS

ELECTRO MAGNETIC FLOWMETER

LEVEL TRANSMITTER and SENSOR

The selected bidder must provide PLC/SCADA system at MPS which is integrated

through router from STP ,so that from SCADA room of STP,MPS could be supervise

and control.

Online instrument system shall have the ranges listed in “Table 1” and shall also be

in accordance with Guidelines for continuous monitoring for Effluents.

Table 1: Online Instrument Range

Sl.

No. Parameter Required Range(s)

1. Online Continuous Dissolved Oxygen Measuring 0 – 20 mg/l

370

Sl.

No. Parameter Required Range(s)

System

2. Ultrasonic Level Measurement As required at site

3. Ultrasonic Differential Level Measurement As required at site

4. Ultrasonic Open Channel Flow Measurement at

Parshall Flume 5 mtrs

5. Gas Flowmeter (Thermal Mass Flow

Measurement System)

0 – 1500 Normal

m3/hr

6. Pressure Transmitter As required at site

7. Continuous Online Total Suspended Solids

Analyzer

0 – 50 mg/l,

0 – 1000 mg/l,

0 – 5000 mg/l

8. Continuous Online pH Measuring System 0 – 12 pH

9. Online Residual Chlorine Measuring System 0 – 10 ppm

10. Conductivity Meter 0 – 1000 µS/cm

11. Ammonia Analyzer 0 – 5 mg/l,

0 – 50 mg/l

12. Alkalinity Analyzer 0 – 500 mg/l

13. Total Nitrogen Analyzer 0 – 30 mg/l,

0 – 80 mg/l

14. Indicative BOD Analyzer 0 – 50 mg/l,

0 – 500 mg/l

15. Indicative COD Analyzer 0 – 250 mg/l,

0 – 1000 mg/l

16. Indicative TOC Analyzer 0 – 1000 mg/l

17. Measurement of CO2, CH4 and H2S Gas

Concentration 0 – 100%

18. Electro-Magnetic Flow Meter As required at site

19. Online Gas Calorific Value Measurement 6000 Kcalorie/m3

20. Total Phosphorus 0 – 10 mg/l

21. Nitrate Analyzer 0 – 10 mg/l

1.7 Laboratory – Laboratory Instruments and Sampling System

The laboratory shall be housed within the administrative building and shall be

equipped with instruments, equipment, chemicals and other infrastructure that is

necessary to perform the routine analysis for the parameters as detailed in “Table 2”.

The equipment shall be supplied with all the accessories that are necessary to make

the equipment functional for analyzing parameters and generating daily reports. In

addition to these, Selected Bidder shall also provide necessary chemicals, glassware

and reagents required for sample testing in the laboratory along with calibration

standards / solutions for calibrating the instruments.

The quality of the sewage entering, passing and leaving the treatment plant shall be

monitored via online monitoring equipment as well as manual sampling systems and

tested daily, at least from the following parameters:

Table 2

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Parameters

Sl. No. Parameter

1. BOD5 or BOD3

2. pH

3. SS

4. Temp.

5. COD

6. TOC

7. Ammonia

8. Total Phosphorous

9. Acidity, Alkalinity

10. Ammonical Nitrogen

11. Total Nitrogen

12. MLSS/MLVSS

13. Dissolved Oxygen

14. SVI

15. Total Hardness, Calcium Hardness

16. Gas Analysis

17. Calorific Value Monitoring

18. Volatile Suspended Solids

19. Total Solids

20. Specific Gravity

21. Moisture Content

22. Total Coliform

23. Faecal Coliform

24. Total Dissolved Solids

25. Bacteria, Escherichia Coli

Three nos. portable samplers shall be provided to collect composite samples for

monitoring from

Inlet chamber for raw sewage

At the outlet of clarifying units

At the outlet of STP

The laboratory shall have the equipment, storage space and chemicals for all the

chemical and bacteriological routine analyses. The area of laboratory shall be

sufficient with sufficient length of working platforms and adequate no. of sinks. Area

of laboratory shall be defined by bidder as per the requirement but not less than

specified in the bid document. At least the following equipment and all required

laboratory chemicals / reagents given in Table 3 are to be provided by the Selected

Bidder within the scope of work and have to be replenished by him till the end of the

O&M Period.

All lab based test instruments results shall be stored automatically and transferred to

the PLC as well as web servers on real time basis for control and report applications.

Table 3

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Lab Instruments

Sl.

No. Description

1. Comparator test set for residual chlorine or chloroscope

2. Single / Multi parameter meter for pH, Conductivity, DO, Ammonia and

Phosphate

3. Mains operated pH meter completed with one calomel electrode and glass

electrode

4. Turbidity meter - Bench Model

5. Turbidity meter - Hand held (Portable)

6. UV / VIS Spectrophotometer

7. Water bath with 6 to 8 concentric holes and discs, electrically heated

8. Hot plates – 25cm

9. Ultrapure Water Plant

10. Conductivity with TDS meter

11. Refrigerator (280 litres capacity) double door / cooling cabinet for sample

preservation

12. Muffle furnace

13. Electronic Burettes and Dispensers

14. Magnetic stirrer

15. Analytical balance (Electronic) with weight box – Resolution up to 4 decimal

places

16. Jar-Test apparatus – 6 Stirrers

17. Centrifuge

18. Flame photometer with gas cylinder

19. Fume cupboard

20. Field Test kit for cations and anions

21. Depth Sampler

22. Total Organic Carbon Analyser

23. Sieve shaker with standard sieves and two pan balance weighing up to 200gm

samples

24. Hot Air Oven

25. Autoclave

26. Binocular microscope

27. Automatic Portable Sampler

28. Pipette Box (Stainless Steel)

20. Wooden Racks/Aluminium Racks

30. Wire Baskets

31. Cotton/ Aluminium Foils

32. Burners (Bunsen) With Pilot Lamp

33. Suction Flask (1 Litre Cap)

34. Suction Pump

35. Sampling Bottles

36. Measuring Cylinders (1000 Ml, 500 Ml, 200 Ml, 100 Ml, 50 Ml, 25 Ml)

37. Vacuum pump

38. Soxhlet extraction unit

39. Kjeldhal digestion unit

40. Weighing Balance (max 10kg)

373

Sl.

No. Description

41. Laminar Air Flow chamber

42. M. Endo Broth (dehydrated)

43. Lactose or Lauryl Tryptose broth

44. Mac Conkey broth

45. Brilliant Green Bile Lactose Broth

46. Total Plate Count Agar

47. Peptone / Triyptone Water

48. BOD Analysis: Incubator, Reagents, etc.

49. COD Analysis: COD Reactor – 15 Vials, Reagents, etc.

50. Filtration assembly for suspended solids

51. Incubator 44°C (Water/Air-Jacketed)

1.8 Online Instruments Specifications

1.8.1 Flow Measuring System

1.8.1.1 Ultrasonic Flowmeter – Open Channel

The open channel flow meter should employ ultrasonic principle to measure level and

level to flow conversion should be inbuilt in the unit. Ultrasonic flow measuring

system shall consist of flow sensor / transducer, flow computer and flow transmitter.

The flow transmitter shall be coupled with an ultrasonic level sensor for emitting and

receiving ultrasonic waves and signal conditioning & flow compounding unit. The

unit shall be suitable for installation in corrosive environment and shall be unaffected

by H2S laden atmosphere.

Flow transducers shall be rugged in construction and shall be suitable for continuous

operation. Flow transducers shall have waterproof construction and shall be suitable

for installation in underground/ above ground pipeline.

The design and application of ultrasonic level meter shall take into account the

channel construction, the material size, shape, environment, process fluid or material,

the presence of foam granules, size etc. To avoid the effects of disturbances in the

velocity profile, a straight and uninterrupted run, upstream as well as downstream

from the location of the flow sensor shall be provided in accordance with the

requirements of the flow meter manufacturer.

The flow transmitter shall be suitable for field mounting and shall accept an input

from the flow sensor. It shall process the input signal and provide isolated 4-20mA/0-

10VDC output proportional to flow rate. The flow range shall be adjustable.

Flow measurement shall not be affected by physical properties of waste water viz.,

temperature, pressure, viscosity, density etc., within given limits. The system should

have inbuilt temperature sensor for automatic compensation for changes in air

temperature to ensure measurement accuracy. Selected Bidder shall provide additional

compensating electronic circuits if required. The installation shall avoid any

degradation of performance from spurious reflections, absorption, sound velocity

variations, sensor detection area, temperature fluctuation, specific gravity changes and

condensation. For application where spurious reflections are unavoidable the control

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unit shall be provided with facilities for spurious reflection rejection. The structure

required for supporting the level sensor, platform, railings etc. shall be in the Selected

Bidder‟s scope.

Technical Specifications

Measuring Principal : Ultrasonic

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 2 Meters

Accuracy : ± 0.5% of measured value or better

Mounting

a.) Sensor : Installation in open channel (above Parshall

Flume)

b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

a.) Sensor : IP-65

b.) Transmitter / Controller : IP-66 (NEMA 4X)

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 3 SPDT contacts

Zero & Span : Field Adjustable

Operating Temperature : 0 to 50°C

Temperature Compensation : Inbuilt temperature sensors for automatic

compensation for changes in air temperature

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Sensor Cable : Integral to sensor

Cable Length : As per site requirement

1.8.1.2 Electromagnetic Flowmeter

Flow meters shall operate on the electromagnetic induction principle and shall consist

of a measuring sensor and measuring transmitter complying with ISO 6817:1997.

Measuring sensors shall have a full bore stainless steel metering tube and non-

conductive, abrasion-resistant lining to suit the fluid being metered. The lining of

material can be of polyurethane. No rubber lining will be allowed. The flow meter

shall have flanged connection. Measuring sensors shall have factory-sealed power and

signal cables. Unless otherwise specified, the cable lengths shall be sufficient to

permit termination external to the chamber, either at a junction box or at the

measuring transmitter. Remote flow indicator cum integrator shall be provided on the

control panel.

Measuring sensors installed within a chamber shall be suitable for indefinite

submersion under a head of water equal to the chamber depth or 3 meters whichever

is the greater. Measuring sensors shall be installed on a steel cradle or concrete plinth

with upstream and downstream straight pipe lengths not less than those recommended

375

by the manufacturer. When fitted in lined non-metallic or internally-coated pipe work,

measuring sensors shall have an earthing electrode or corrosion-resistant earthing

rings. To ensure full electromagnetic compatibility the flow tube flanges and

transmitter housing shall be connected earth.

Measuring sensors shall be bonded by tinned copper braid links at each end to the

adjacent pipe work to ensure a good connection between the body and the metered

liquid. Measuring sensors installed in a catholic protected pipeline shall have isolation

and bonding in accordance with the recommendations of the manufacturer. The

measuring transmitter shall provide a precise current input to the field winding of the

measuring sensor and shall convert the resultant signal from the electrodes to

analogue and pulse outputs in accordance with IEC 60381-1:1982. The signal

processing facilities of the converter shall ensure that the output signals are unaffected

by interfering voltages, stratified flow, changes in fluid electrical conductivity within

the limit stated, non-homogeneity of the fluid and the presence of ferrous particles.

The zero and output signals shall be unaffected by partly-fouled electrodes.

The following measuring transmitter features shall be provided as a minimum;

additional requirements may be stated elsewhere in the Specification:-

Measuring Transmitter Features:

Pulsed D.C. field excitation

Scaled pulse output for integration counter drive

Capability of bi-directional measurement with differing forward and reverse ranges and

with local and remote indication of flow reversal

Contact operation at a programmable measured value

Integral display of flow and integrated quantity

Galvanic isolation between each output circuit and between the electrode circuit and

output circuit

Output circuit isolation from earth within the instrument but suitable for earthing at any

point in the external circuit

Key entry for basic parameters

Commissioning and re-scaling to require no special programming knowledge

Adjustable low flow cut-off

Self-diagnosis

Continuously adjustable velocity and flow range settings

Terminals accommodated in a compartment separate from electronic components

Outputs including: analogue - 4-20mA

Pulse - two programmable outputs

Alarms - two outputs programmable for high/low

Flow, polarity, forward/reverse, instrument fault, liquid sensing fault condition including

partially empty pipe

Technical Specifications

Measuring Principal : Electromagnetic

Type : Pulsed DC

376

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Metering Tube : SS 304

Sensor Housing : SS 304 fully welded

Connection / Junction Box : SS 304

Lining Material : PTFE/Polyurethane

Range : As per site requirement

Accuracy : ± 0.5% of flow rate at maximum mean velocity

of

1.5 to 3.0 m/sec

Electrode Type : Flush or bullet nose as recommended by

the

Manufacturer

Earthing Ring/Electrode Material: Type 316 stainless steel

Protection Category

a.) Sensor : IP-68

b.) Transmitter / Controller : IP-65

Transmitter / Controller Type : Microprocessor Based

Display : Indicating and totalizing

a.) Indicator : Digital 16-character display

b.) Totalizer : Digital 16-character display

Mounting : Pipe, wall, panel

Diagnostic : Inbuilt

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA / 0-10VDC output based on

the

flow rate

Zero & Span : Field Adjustable

Turndown Ratio : Minimum of 10 to 1 when flow velocity

at minimum

flow is at least 0.3 metres per second

Zero Stability Feature : Required to eliminate the need to stop

flow to

check zero alignment

Pressure Loss : Very Low

Removable Electrodes : Required

Flange Material : Carbon steel, Epoxy Coated

Empty Pipe Detection : Inbuilt

Operating Temperature : 0 to 50°C

Temperature Compensation : Inbuilt temperature sensors for automatic

compensation for changes in air temperature

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

1.8.2 Level Measuring System

1.8.2.1 Ultrasonic Level Meters

Ultrasonic level measuring devices applied for liquid level measurement shall

comprise of level sensor / transducer, level transmitter, digital level indicator / remote

377

indicator, control unit and any other items required to complete the level measuring

system.

The transducer shall be suitable for flange or bracket mounting as required. To reduce

the effect of sewage turbulence in wet wells / tanks, averaging facility should be

provided in the transmitter unit for providing steady readings.

The design and application of the ultrasonic level measuring system shall take into

account the vessel / sump / wet well / channel construction, the material, size, shape,

environment, process fluid or material, the presence of foam, granules, size etc.

In case of ultrasonic level sensor, the installation shall avoid any degradation of

instrument performance due to spurious reflections, absorption, sound velocity

variations, sensor detection area, temperature fluctuations, specific gravity changes

and condensation. For applications where spurious reflections are unavoidable the

control unit shall be provided with facilities for spurious reflection rejection. If

turbulence exists, shielding, stilling tubes or other measures shall be provided to avoid

effects on the measurement.

Technical Specifications

Measuring Principal : Ultrasonic

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : As required at site

Accuracy : ± 0.25% of measured value or better

Resolution : 2mm or 0.2 percent of range, whichever is

greater

Blanking Distance : As short as 0.3 meters

Beam Angle : 12 degrees or less

Temperature compensation : Integral

Mounting

a.) Sensor : Flange or bracket

b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

a.) Sensor : IP-68

b.) Transmitter / Controller : IP-66 (NEMA 4X)

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 3 SPDT contacts

Zero & Span : Field Adjustable

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Sensor Cable : Integral to sensor

Cable Length : As per site requirement

378

1.8.3 Ultrasonic Differential Level Measurement

The ultrasonic type differential level measuring system shall consist of ultrasonic type

level sensors on upstream and downstream of screens, differential level computer /

transmitter and indicator. The flow computer / transmitter shall be microprocessor based

and shall have facility for programming (i.e. adjustment of set points) while the sensor

shall be capable of adjustable datum setting facilities.

The differential level control shall be done by two ultrasonic sensors, one before and one

after the screen to sense the differential level through the screen and give a signal to the

control to start the screens operation as soon as a preset differential level is reached. After

receiving the level signal the control shall start and operate the screen as long as the preset

level difference appears.

Technical Specifications

Measuring Principal : Ultrasonic

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : As required at site

Accuracy : ± 0.25% of measured value or better

Resolution : 2mm or 0.2 percent of range, whichever is

greater

Blanking Distance : As short as 0.3 meters

Beam Angle : 12 degrees or less

Temperature compensation : Inbuilt

Mounting

a.) Sensor : Flange or bracket

b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

a.) Sensor : IP-68

b.) Transmitter / Controller : IP-66 (NEMA 4X)

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 3 SPDT contacts

Zero & Span : Field Adjustable

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Sensor Cable : Integral to sensor

Cable Length : As per site requirement

1.8.4 Pressure Measuring System – Pressure Transmitter

Pressure measuring system shall measure pressure and transmit signal proportional to

pressure. The system shall consist of a combined pressure transducer and transmitter,

digital panel indicator, connecting pipe work, diaphragm seal and valves. Pressure

measuring system shall be rugged in construction and shall be capable for with

379

standing surge pressures likely to occur in the monitored system. Pressure transmitters

shall have over range protection up to 1.5 times the maximum line pressure and shall

be capable of withstanding full line pressure on any side with the other side vented to

atmosphere without damage or effect on the calibration. No plastic material shall be

used in their construction. Internal parts shall be of stainless steel, bronze or approved

corrosion-resistant material. Where necessary, a special diaphragm shall be used to

segregate the corrosive fluid media. In ammonia applications, the diaphragm shall be

in stainless steel. In chlorine applications, the diaphragm shall be in silver or tantalum.

In Sulphur dioxide applications, the diaphragm shall be in tantalum.

The zero and span of a pressure transmitter shall not change by more than ±0.1% of

the span per °C change in ambient temperature. After application for 10 minutes of

pressure at 130% of maximum pressure, the change in zero and span shall not exceed

±0.1% of the span. Pressure transmitters shall be protected to BS EN 60529:1992, IP

65 standard or higher. For transmitters installed in locations liable to flooding or

underwater applications, they shall be to IP 68 standard and shall operate up to a

maximum submergence of 20 meters of water.

Technical Specifications

Parts : Transmitter and communicator

Type : Electronic variable capacitance; two-wire

transmitter

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : As required at site

Accuracy : ± 0.25% of span or better

Humidity : 0 to 100% relative humidity

Damping : Fluid or electronic type with adjustment

Indicator : LCD with LED backlighting

Materials : Wetted parts including process flanges and drain

/

vent valves, Type 316 stainless steel otherwise

specified

Wetted O-Rings : Glass filled TFE, graphite filled PTFE,

or Viton, unless

otherwise specified

Fill Fluid : Silicone

Output : 4 – 20mA DC output proportional to the

pressure

range

Mounting : Pipe or wall as specified. Provide stainless steel

brackets with stainless steel bolts

Housing : Modular with separate compartments for

electronics and field wiring termination. Epoxy

coated aluminium, unless otherwise specified

380

Power Supply : 230 V AC ± 10%, 50 Hz

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

1.8.5 Dissolved Oxygen Measuring System - DO Analyzer

DO Analyzers shall be installed to continually record the dissolved oxygen level at

every grid within each aeration basin. The primary sensing device used for the

dissolved oxygen level measurement, shall be a sensing probe mounted within the

aeration basin and connected to a controller for displaying and transmitting the results

Technical Specifications

Measuring Principal : Optical

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 0 to 20.0 ppm, 0 to 20.0 mg/L

Accuracy : ± 0.5% or better

Repeatability : ±0.5% of span

Sensitivity : ±0.5% of span

Pressure Limit : 4 - 6 bar

Temperature Indication : Inbuilt

Calibration Method : Air Calibration: One point, 100% water

saturated air;

Sample Calibration: Comparison to standard

instrument, or comparison to Winkler Titration

method

Cleaning : Air Blast Unit. Probe should be able to function

with

cleaning unit attached to it

Mounting

a.) Sensor : Inside aeration basin at each grid

b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

a.) Sensor : IP-68 for Sensor

b.) Transmitter / Controller : IP-66 (NEMA 4X)

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 2 SPDT contacts

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Sensor Cable : Integral to sensor

Cable Length : As per site requirement

381

1.8.6 Total Suspended Solids Measuring System - TSS Analyzer

Technical Specifications

Measuring Principal : Optical

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 0 – 50 mg/l, 0 - 1000 mg/l, 0 – 5000 mg/l

Accuracy : <5% of reading or better

Pressure Limit : 6 bar

Flow Rate : Maximum 3m per second

Temperature Indication : Inbuilt

Calibration Method : Single point or two point

Cleaning : Inbuilt

Mounting

a.) Sensor : Inside pipe / channel / tank

b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

a.) Sensor : IP-68 for Sensor

b.) Transmitter / Controller : IP-66 (NEMA 4X)

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 2 SPDT contacts

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Sensor Cable : Integral to sensor

Cable Length : As per site requirement

1.8.7 pH Measuring System – pH Analyzer

Technical Specifications

Measuring Principal : Combination / Differential Electrode

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 0 - 12 pH

Accuracy : ±0.02 pH or better

Repeatability : ±0.05 pH

Sensitivity : ±0.01 pH

Pressure Limit : 4 - 6 bar

Flow Rate : Maximum 3m per second

Temperature Indication : Inbuilt

Temperature Compensation : Inbuilt automatic temperature compensation

Temperature Accuracy : ±0.5 °C

Calibration Method : Two point automatic, one point automatic, two

382

point manual, one point manual

Mounting

a.) Sensor : Inside pipe / channel / tank

b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

For Transmitter / Controller : IP-66 (NEMA 4X)

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 2 SPDT contacts

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Sensor Cable : Integral to sensor

Cable Length : As per site requirement

1.8.8 Residual Chlorine Measuring System – Residual Chlorine Analyzer

Technical Specifications

Measuring Principal : Amperometric or DPD Colorimetric

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 0 – 10 ppm

Accuracy : ±3% of the reference test or better

Resolution : 0.001 ppm

Repeatability : 30 ppb or 3%, whichever is greater

pH : Automatic

Temperature Compensation : Inbuilt temperature sensor

Temperature Indication : Inbuilt

Pressure Limit : 0.5 bar

Flow Rate : Maximum 50 L/hour

Calibration Method : 1-point or 2-point calibration

Mounting : Wall, Panel

Protection Category

a.) Sensor : IP-65

b.) Transmitter / Controller : IP-66 (NEMA 4X)

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 2 SPDT contacts

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Sensor Cable : Integral to sensor

Cable Length : As per site requirement

383

1.8.9 Conductivity Measurement – Conductivity Analyzer

Technical Specifications

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 0 - 1000 µS/cm

Accuracy : ±0.5% or better

Temperature Compensation : Inbuilt

Temperature Indication : Inbuilt

Pressure Limit : 6.9 bar

Flow Rate : Maximum 3m per second

Mounting

a.) Sensor : Inside pipe / channel / tank

b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

For Transmitter / Controller : IP-66 (NEMA 4X)

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 2 SPDT contacts

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Sensor Cable : Integral to sensor

Cable Length : As per site requirement

1.8.10 Ammonia Measurement – Ammonia Analyzer

Technical Specifications

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 0 – 5 mg/l, 0 - 50 mg/l

Accuracy : 3% ±1mg/l or better

Repeatability : 2% ±1mg/l or better

Flow Rate : Maximum 20 L/h

Cleaning : Automatic

Mounting

a.) Analyzer : Wall, Panel

b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

a.) Analyzer : IP-55 or better

b.) Transmitter / Controller : IP-66 or better

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

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Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 2 SPDT contacts

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Cable Length : As per site requirement

1.8.11 Alkalinity Measurement – Alkalinity Analyzer

Technical Specifications

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 0 – 500 mg/l

Accuracy : ±5% of reading or ±1.0 mg/L, whichever is

greater

Repeatability : ±3% of reading or ±0.6 mg/L, whichever is

greater

Pressure Limit : 2 bar

Flow Rate : Maximum 2 L/m

Mounting : Wall, Panel

Protection Category : IP-66 (NEMA 4X)

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 2 SPDT contacts

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

1.8.12 Total Nitrogen Measurement – Total Nitrogen Analyzer

Technical Specifications

Measuring Principle : UV Absorption

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 0 – 30 mg/l, 0 - 80 mg/l

Accuracy : ± 3% of mean + 0.5 mg/l

Resolution : 0.1 mg/L

Pressure Limit : 0.5 bar

Cleaning : Automatic

Mounting

a.) Sensor : Inside pipe / channel / tank

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b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

a.) Sensor : IP-68

b.) Transmitter / Controller : IP-66 (NEMA 4X)

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 2 SPDT contacts

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Sensor Cable : Integral to sensor

Cable Length : As per site requirement

1.8.13 BOD Measurement – Indicative BOD Analyzer

Technical Specifications

Measuring Principle : UV Absorption

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 0 – 50 mg/l, 0 - 500 mg/l

Accuracy : ± 5% or better

Compensation : 550 nm

Sample pH : 4.5 to 9 pH

Pressure Limit : 0.5 bar

Cleaning : Automatic

Mounting

a.) Sensor : Inside pipe / channel / tank

b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

a.) Sensor : IP-68

b.) Transmitter / Controller : IP-66 (NEMA 4X)

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 2 SPDT contacts

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Sensor Cable : Integral to sensor

Cable Length : As per site requirement

1.8.14 COD Measurement – Indicative COD Analyzer

Technical Specifications

Measuring Principle : UV Absorption

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Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 0 – 250 mg/l, 0 - 1000 mg/l

Accuracy : ± 5% or better

Compensation : 550 nm

Sample pH : 4.5 to 9 pH

Pressure Limit : 0.5 bar

Cleaning : Automatic

Mounting

a.) Sensor : Inside pipe / channel / tank

b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

a.) Sensor : IP-55 or better

b.) Transmitter / Controller : IP-55 or better

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 2 SPDT contacts

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Sensor Cable : Integral to sensor

Cable Length : As per site requirement

1.8.15 TOC Measurement – Indicative TOC Analyzer

Technical Specifications

Measuring Principle : UV Absorption / UV Pursulphate

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 0 - 1000 mg/l

Accuracy : ± 5% or better

Compensation : 550 nm

Sample pH : 4.5 to 9 pH

Pressure Limit : 0.5 bar

Mounting

a.) Sensor : Inside pipe / channel / tank

b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

a.) Sensor : IP-55 or better

b.) Transmitter / Controller : IP-55 or better

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

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Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 2 SPDT contacts

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Sensor Cable : Integral to sensor

Cable Length : As per site requirement

1.8.16 Total Phosphorus Measurement – Phosphorus Analyzer

Technical Specifications

Measuring Principle : Photometric

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 0 - 10 mg/l

Accuracy : 2% of the measured value + 0.05 mg/L or better

Repeatability : 2% of the measured value + 0.05 mg/L

Flow Rate : Maximum 20 L/h

Sample pH : 5 to 9 pH

Pressure Limit : 0.05 bar

Mounting

a.) Analyzer : Wall, Panel

b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

a.) Analyzer : IP-55 or better

b.) Transmitter / Controller : IP-55 or better

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 2 SPDT contacts

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Cable Length : As per site requirement

1.8.17 Nitrate Measurement – Nitrate Analyzer

Technical Specifications

Measuring Principle : UV Absorption

Application : H2S laden atmosphere and other poisonous

gases,

Corrosive Waste Water Environment

Safety : Explosion Proof or Intrinsically Safe

Range : 0 – 30 mg/l, 0 - 80 mg/l

Accuracy : ± 5% or better

Resolution : 0.1 mg/L

Pressure Limit : 0.5 bar

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Mounting

a.) Sensor : Inside pipe / channel / tank

b.) Transmitter / Controller : Wall, Panel, Pole

Protection Category

a.) Sensor : IP-68

b.) Transmitter / Controller : IP-66 (NEMA 4X)

Transmitter / Controller Type : Microprocessor Based

Diagnostic : Inbuilt

Display : LCD with LED backlighting

Power Supply : 230 V AC ± 10%, 50 Hz

Analog Output : Isolated 4 – 20mA

Relay Contacts : Minimum of 2 SPDT contacts

Operating Temperature : 0 to 50°C

Communication Protocol : Open Protocol like MODBUS, PROFIBUS, etc.

Sensor Cable : Integral to sensor

Cable Length : As per site requirement

1.9 Surge Protection Devices

Surge protection devices (SPDs) shall be suitable for withstanding the surge arising

out of high energy static discharge / lighting strikes and protect the instrument to

which it is connected against damage. SPDs shall provide protection through the use

of quick acting semiconductors like Tranzorb, zener diodes, varistors and an

automatic disconnect and reset circuit. SPDs shall be passive and shall require

negligible power for operation. During the occurrence of a surge it shall clamp on the

allowable voltage and pass the excess voltage to the ground. The SPD shall be self-

resetting to minimize the down time of the measurement loop.

SPDs shall be provided to protect devices transmitting and receiving analogue and

digital signals derived from field devices located outdoors.

The surge protection device shall be rated for surge rating of 10kA.

1.10 Cabinets for Field Instruments

Wall mounted cabinets shall be provided for enclosing transducer unit and associated

accessories which are mounted outside the main control panel. The cabinet shall be of

die-cast aluminium; field provided not less than IP-65 protection and shall be

lockable. The cabinet shall have facilities for earthing. A steel plate shall be provided

inside the cabinet for mounting instrument and accessories.

1.11 Panel Details

1.11.1 Cabinet / Enclosure for Instruments

Enclosures shall be any form of board, cabinet, panel, desk, box or case used to

protect, contain or group instrumentation, telemetry or control equipment. Cabinets

shall be fabricated from cold rolled steel with powder coating sheet of minimum 2

mm thick and shall be suitable for wall mounting or pedestal mounting as required. A

steel plate/pipe, as per the requirement, shall be provided in the cabinet for mounting

the instrument and accessories. The cabinet shall be properly painted from inside and

outside and shall have built in locking facility. The cabinet shall also be earthed

properly. All equipment in or on enclosures shall be arranged logically and, as far as

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possible, symmetrically, with projections kept to a minimum. Each enclosure shall be

designed on ergonomic principles and shall permit in-situ and safe access for any

normal adjustment, maintenance and servicing. The tops of plant-mounted enclosures

shall be sloped downwards from front to rear.

The minimum degree of protection shall be IP 54 for indoor locations and enclosures

for use outside buildings or in places where splashing may occur shall have a

minimum rating of protection to BS EN 60529:1992, IP 65 and have tops which

project sufficiently to protect the vertical faces of the enclosure and any component

mounted thereon from splashing, inclement weather and direct sunlight. Also, when

enclosures for use outside buildings are located where exposure to direct sunlight will

give rise to high top-panel surface temperatures such that the internal temperature

rises above the manufacturer‟s recommendation (normally 40°C), the enclosure shall

include a sun shield fitted to the top of the enclosure and should have sufficient air

ventilation for heat dissipation.

Fixing arrangements for surface-mounting enclosures shall be external to the

enclosure and shall ensure that the rear face of the enclosure is not in contact with the

surface to which it is fixed. Enclosures shall have hinged access doors, fitted with

recessed lockable handles. Doors shall be of rigid construction and provided with

close-fitting flexible seals in recesses to prevent the ingress of liquids, moisture, dust

and vermin. Hinges shall be of the lift-off pattern and one hinge shall engage before

the other for ease of fitting. Wherever necessary, removable access covers secured by

quick-release fasteners shall be provided to ensure ease of maintenance for all

installed apparatus. Mounting plates, brackets and racks shall be provided for all other

internal equipment which shall be hinged or otherwise arranged with quick-release

fasteners or captive screws to give quick and easy access to equipment, securing

screws, terminals and wiring.

Enclosures for two or more devices with electrical circuits shall have gland plates and

terminal blocks as specified elsewhere. Each enclosure shall be designed for the safe

testing and servicing of equipment with the power on. Each part which may be live

under any circumstances shall be so covered or shielded as to prevent inadvertent

contact.

1.11.2 Panel Design and Construction

Unless otherwise specified, all instrument panels, instrument cubicles, control panels,

control consoles and desks, associated equipment and terminal racks, telemetry and

electronic equipment racks and the like shall be free-standing, floor-mounted units

and shall conform to the requirements of this part and will hereafter be referred to as

panels. The design and dimensions of control consoles and desks shall be determined

according to their intended function but shall be in accordance with the requirements

of the Specification drawings. The height shall not exceed 1400mm above the

finished floor level.

Unless otherwise specified or shown in the Specification drawings, the height of

panels shall be not greater than 2130mm overall (excluding lifting devices) above

finished floor level. Front-of-panel instruments and controls shall be mounted so that

the height of their centers above the floor shall be generally between 1800mm and

900mm for indicators, 1400mm and 900mm for recorders and process controllers,

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2000mm and 750mm for alarm facias and signal lamps and 1500mm and 750mm for

manual controls. Controls, switches and push-buttons shall be positioned below or

adjacent to any associated reading instrument. Panels for use in locations such as

pumping stations and machinery rooms shall have anti-vibration mountings. The

clearance between the extremities of apparatus mounted on the internal walls shall

allow safe and unobstructed access to all terminals and to parts requiring

maintenance. Panel layout drawings shall normally include a list of all instruments,

accessories and components contained therein. If the drawings have insufficient space

for the list, a separate schedule of instruments, accessories and components shall be

provided and the panel drawing shall contain a cross reference to the contents list and

an indication of the panel location of each item on the list.

1.11.3 Panels - Major

Panels shall be constructed generally as specified in the preceding clause and as

shown in the Specification drawings. Panel material shall be prime-quality, cold-

rolled and annealed mild steel or zinc-coated mild steel sheet, suitably braced and

stiffened as necessary with flat bar or angle to form a rigid structure.

Panel fronts shall be flat and free from bow or ripple. Exterior corners and edges shall

be rounded or welded and ground to give a smooth overall appearance. Flanged edges

shall be straight and smooth. Materials shall be chosen with due regard to the panel

size, number of cut-outs, instrument weight and position of centre of gravity and

method of fabrication, with the following:

minimum thicknesses except where otherwise shown in the Specification

drawings

instrument bearing surfaces, gland plates and pneumatic distribution plates: 3mm

internal mounting plates: 3mm

doors, covers and filler panels: 2mm

No design involving the use of externally-visible assembly or fixing bolts and screws

nor any design resulting in dust or water-collecting crevices will be accepted.

Stiffeners and supporting frameworks shall be provided where necessary inside

panels. Framework shall be hinged or fixed, suitable for the installation of

instruments, components and internal equipment for which it is provided and located

to give easy access to adjacent equipment.

When a panel is constructed in sections, the sections shall be designed for ease of

assembly during installation and, in any case, shall not exceed 2m in length. All

necessary nuts, bolts, washers and the like shall be supplied and included in the same

shipment as the relevant sections. Sections exceeding 1m in length shall be provided

with double doors. Unless otherwise shown in the Specification drawings, each panel

shall be mounted on a self-draining base frame fabricated from 150mm deep, steel

channel section which shall be drilled or provided with clamps for bolting to the floor.

The base frame shall be set back from the panel front face to give a toe space of not

less than 25mm. The outside of the base frame shall be covered with an approved

kicking strip.

Ceiling and other filler panels shall be fabricated from sheet steel and adequately

stiffened. Each section shall have 50mm returned edges along all four sides and shall

391

be braced to the main steelwork of the panel. A chequer-plate floor shall be provided

inside and above the level of the base frame, having openings suitable for the bottom

entry of cables when applicable. Sufficient removable undrilled gland plates, in

sections convenient for handling, shall be fitted close to the appropriate terminal

blocks and not less than 230mm above the panel floor or not less than 230mm below

the panel top. The gland plates shall have removable side covers giving access to both

sides of the gland plate and ensuring vermin-proof and dust-proof construction. Gland

plates of a surface-mounted enclosure may form a part of the base or top. Panels

containing pneumatic or other instruments using a fluid as the transmission medium

shall have distribution plates with bulkhead unions for the termination of internal and

external pipework.

All doors shall open outwards and all doors in one panel assembly shall use the same

lock and key combination. Panel design shall ensure adequate ventilation and air

circulation without permitting the entry of vermin or dust. Panels installed in control

rooms or other clean condition areas shall have louvres to allow air circulation.

Temporary closures shall be provided to prevent the entry of dust and vermin during

transit and installation. After commissioning has been completed, all entries except

air-circulation louvres shall be sealed.

No equipment other than front-of-panel items shall be mounted on panel wall

surfaces. If electrical and non-electrical instruments are mounted in the same panel,

the panel shall be subdivided internally to separate the electrical and non-electrical

sections. All connections shall be arranged to ensure that no accidental damage to

cabling or electrical components can occur in the event of failure of any non-electrical

component or connection. Provision shall be made for safe and easy handling during

transit and installation. If lifting eyes are provided, they shall be reversible and panel

tops shall be reinforced where necessary.

Where equipment is specified to be installed at a future date, space shall be allocated,

and cutouts with removable masking plates, brackets, supports, wiring, terminals and

piping and the like shall be provided. Panels shall be finish-coated at the place of

manufacture before commencing the installation of apparatus and other fittings.

1.11.4 Panels - Minor

Panels for installation on the Plant which contain relatively few items of equipment,

or where so specified elsewhere, shall be classed as minor panels and shall be

constructed generally as specified in the preceding clause and comply with this

Clause. Panels shall be fabricated from sheet steel or other approved material less than

2.5mm thick suitably braced to form a robust and rigid structure. Exterior corners and

edges shall be rounded to give a smooth overall appearance and assembly bolts,

screws or rivets shall not be visible on the front face.

The design shall be such as to ensure adequate ventilation and air circulation where

required, without permitting the entry of vermin. Openings for cables shall be made

vermin-proof. Doors shall be hinged and shall be provided with close-fitting flexible

seals in recesses to prevent the ingress of liquids, moisture, dust and vermin. Unless

otherwise specified, panels shall be suitable for floor mounting and shall not exceed

2130mm in height. Where surface mounted panels are provided, the fixing shall

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prevent the ingress of moisture and the rear of the enclosure shall be not less than

10mm from the wall.

Lifting eyebolts shall be removed, issued to the Purchaser and subsequently replaced

with bolts after installation. Panels shall be extensible, and symmetrically arranged as

far as possible with projections kept to a minimum. Where two or more panels are

fitted together, they shall form a flush-fronted continuous panel of uniform height.

Front door and top cover dimensions shall match. Instruments, relays, and control

devices shall be mounted at a height not more than 2000mm and not less than 300mm

from floor level.

The arrangement of equipment within each enclosure shall be such as to permit easy

access for installation and maintenance. No instruments, relays or other components

shall be mounted on rear access doors or removable covers.

1.11.5 Panels - Composite

In situations where space limitations preclude the use of separate instrumentation,

control and automation (ICA) and switchgear panels and, at the sole discretion of the

Engineer, ICA equipment may be combined within a single enclosure subject to the

following conditions:

Enclosure

The observance of all other clauses herein relating to enclosures, mounting boards and

minor panels.

The written assurance of each supplier of ICA equipment that the proximity of the

switchgear will have no detrimental effect on the life or performance of any ICA

component

The total segregation of ICA equipment and switchgear including the glanding and

termination facilities.

The absence of any voltage exceeding 250V ac or 50V dc from any compartment

containing ICA equipment.

The use of the full height of the panel (excluding the busbar chamber and cable space)

for any ICA equipment compartment.

1.11.6 Panels - Glass Reinforced Plastic (GRP)

Any panel required to be installed outside buildings shall, unless otherwise approved

by the Engineer, be manufactured from double-skin, resin-bonded fibreglass, with a

totally encapsulated infill of rigid weatherproof and „boil proof‟ plywood to BS

1203:2001 between the two skins to provide a rigid and vandal-proof enclosure. The

environmental rating shall be IP 65 or better.

For any application in a non-temperate climate or where so specified elsewhere, the

roof section shall be sloping and have a totally-encapsulated infill of end-grain balsa

instead of plywood. Box-section steel shall be encapsulated into door edges and door

frames. Door locks, handles and hinges shall be of a high tensile strength, non-

corroding alloy with stainless steel pins and through fixing bolts. Large plane surfaces

shall have adequate reinforcing to ensure rigidity.

The doors shall be complete with latching handles and locks. All door catches and

locks shall latch onto steel-reinforced surfaces. Threaded studs shall be incorporated

393

into the design of the panel for the mounting of sub frames within the panel. Any

panel drilled to provide fixings for internal equipment will not be accepted. Each

cubicle shall be provided with a floor or deck with a removable gland plate for cable

entry.

The laminate material shall have flame-retardant characteristics in compliance with

BS 476 Class 2, and shall retain „stability, integrity and insulation‟ for 30 minutes.

Colour-impregnated gel coats backed by coloured resin shall be used to ensure

maintenance free and „colour-fast‟ finishes. The external finish colour shall be

advised by the Engineer and the internal finish colour shall be white. The fronts of

externally-visible instruments and windows shall be of glass. An air-gap of 100mm

shall be provided between the top surface of the panel and its protective canopy. All

internal equipment shall be mounted on supports built into the fiberglass structure.

Fixing bolts through the skin will not be accepted.

1.11.7 Panel Protection

Adequate facilities for isolation and protection by miniature circuit breaker or fuse for

each instrumentation and control circuit and sub-circuit shall be provided and shall be

so arranged that any interruption causes minimum disruption of plant, operates the

appropriate alarm and cannot result in any unsafe operating condition. All fuses shall

be of the cartridge pattern and main fuses shall be of the high rupturing capacity type.

Fuse and solid-link carriers and bases shall be of plastic-moulded insulating material

as per best industry practices. Ceramic materials will not be accepted. Live

connections shall be efficiently shrouded and it shall be possible to change fuses with

power on without danger of contact with live metal. The fuses shall be rated to give

maximum protection to the equipment in circuit and the rating shall be permanently

inscribed on the fuse label and on the fuse carrier.

Unless necessary for the protection of particular equipment, miniature circuit breakers

used for individual circuits in a panel or control desk shall not trip on over-voltage or

under-voltage. Bases for solid links shall not be interchangeable with those for fuses.

Fuses and links in the same circuit shall be mounted opposite each other in separate

adjacent rows and shall not alternate in the same row. At least 10% and not less than

two unallocated miniature circuit breakers or fuses and links shall be provided in each

panel distribution board. Miniature circuit breakers and fuses of similar size and

rating shall be of the same make and type. At least 10%, and not less than two, spare

fuses and links of each rating shall be provided and fitted in clips inside the panel.

Each instrument requiring a power supply shall be individually wired and protected so

that, in the event of a failure in one circuit, the remainder is unaffected. Power supply

circuits shall be of sufficient rating that any protective device may operate without

reducing the voltage at the terminals of any other component to an unacceptable level.

Remote alarms shall be operated on failure of the electrical supply to a panel or to any

internal sub-circuit. Clearly identifiable, switched socket outlets of 15A minimum

rating to comply with IS 4615, supplied at the main cabinet operating voltages shall

be fitted within the panel at the rate of one for each operating voltage per meter of

panel length; for a panel whose length is less than one meter, one switched socket

outlet for each main operating voltage shall be provided. Suitable socket outlets for

portable tools and hand lamps shall be provided as specified elsewhere.

394

1.11.8 Panel Isolation

Clearly-labelled isolating circuit breakers shall be provided for each incoming power

supply. Switches shall be of the quick make-and-break type with spring-loaded

contacts that close fully without requiring full operation of the handle. The handle and

cover shall be interlocked so that the handle cannot be operated when the cover is

open and the cover cannot be opened unless the switch is in the „off‟ position. The

„on‟ and „off‟ positions of each switch shall be indicated clearly.

Circuit breakers for panel power supplies shall be mounted near an access point and in

positions where they may be operated easily from a standing position. Plug-in

isolating links or devices of an approved type shall be provided in any circuit that may

still be alive when the power supply isolators are in the „off‟ position, as, for example,

in circuits controlling equipment whose power supply is independent of the panel.

Such links or devices shall be properly screened and, if not incorporated in or adjacent

to their associated outgoing terminals, shall be labelled with suitable warning notices.

Any item of panel equipment to which panel internal wiring is connected with a plug

and socket instead of terminals shall be wired in flexible cable of adequate rating

between the „free‟ plug and a socket mounted adjacent to the device. The power

supply connector shall be a socket.

1.11.9 Panel Terminal Blocks

External wiring for panel power supplies shall be terminated on the appropriate

isolator. Signal cables from strain gauges, analyzers, resistance thermometers, re-

transmitting slide wires and thermocouples may be terminated at their appropriate

instruments. A terminal block shall be provided as the interface between the

corresponding conductors of each internal and external wire and each internal and

external connection except those listed above. The terminal blocks shall be mounted

vertically where possible and not nearer than 230mm to the floor or less than 230mm

from an incoming cable gland.

Terminal block rows shall be spaced apart by not less than 150mm and arranged to

permit convenient access to wires and terminals and to enable ferrule numbers to be

read without difficulty. Other circuits shall be grouped on the terminal blocks

according to the classification given in the clause for „Panel internal wiring‟ which

shall be clearly marked along the corresponding section of each terminal board.

Groups of different voltages on the same board shall be separated by insulated

barriers.

All connections shall be made from the front of terminal blocks and no live metal

shall be exposed at the back. All terminal blocks shall be of the type which clamps the

wire securely and without damage between two plates by means of a captive screw

and which permits removal of any terminal without disturbance to adjacent terminals.

Pinch-screw type terminal blocks will not be accepted. Terminal mouldings shall be

in melamine to ISO 2112:1990, polyamide or equivalent. Terminal rails shall be hot-

dip galvanized. Current bars between the two connection points of each terminal

block shall be of copper or brass with tin/lead alloy plating. All steel parts shall be

zinc-plated and passivated with a yellow chromate layer.

Terminal blocks for input and output analogue signals and for circuits containing volt-

free contacts internal or external to the cabinet shall be of the Klippon type SAKC or

395

equivalent which permit the connection of a test milliammeter or continuity meter

without disconnecting any wiring. Terminal blocks for power supplies for equipment

external to the panel shall permit the isolation of the item of external equipment

without affecting the operation of any other circuit within or outside the panel.

No more than one core of external cables or one internal wire shall be connected to

any terminal. If terminal blocks are used as common points for two or more circuits,

individual terminals with the appropriate number of permanent cross-connections

shall be provided. The lengths of exposed cable cores shall be sufficient to reach any

terminal in the appropriate row or rows. The cores shall be formed into a neat loom

and a separate loom shall be provided for each cable. Identification ferrules as

specified in the clause for „Panel wiring identification and termination‟ shall be fitted

on each core of all external cables and on each internal wire. The size of the terminals

shall be appropriate to the size and rating of the cable cores which will be connected

to them but shall not be smaller than Klippon type SAK2.5 or equivalent unless

otherwise agreed with the Engineer.

Each row of terminal blocks shall contain at least 25% spare terminals over the

number required for terminating all cores of external cables in that row. Unless

otherwise specified or shown in the Specification drawings, each external cable shall

contain at least 20% spare circuits, with a minimum of one spare circuit. Terminal

blocks shall be numbered consecutively in a sequence different from that used for

identifying wiring. The terminal numbers, voltage grouping and terminal board layout

shall correspond precisely with wiring diagrams so that quick and accurate

identification of wiring can be made. All the terminal boards shall be provided with

covers of transparent insulating material that does not sustain combustion and shall be

sectionalized where possible to give access to groups of terminals without uncovering

all boards. Terminals which may be live when the panel is isolated from its main

supplies shall be suitably labelled to minimize the risk of accidental contact.

1.11.10 Panel Internal Wiring

Panel circuits shall be segregated into the following categories:-

Group 1: Power control and very-high-level signal wiring (above 50V):

AC power supplies

DC power supplies

DC current signals above 50mA (such as CT circuits)

AC voltage and control signals above 50V (such as PT circuits)

Group 2: High-level signal wiring (6V to 50V dc):

Signals from conventional electronic transmitters and controllers (such as 4mA to 20mA)

Circuits to alarm enunciators and other solid-state devices (excluding those in categories

2.1, 2.5, 3.1, 3.2 and 3.3)

Digital signals

Emergency shut-down and tripping circuits

On / Off control circuits

Intrinsically safe circuits

Speech-frequency circuits

Group 3: Low-level signal wiring (5V dc and below):

Signals from thermocouples

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Signals from resistance thermometers and re-transmitting slide-wires

Signals from analytical equipment and strain gauges

For Group 3 wiring, internal connections to the instruments shall be made by one of

the following methods:

The twisted, screened conductors of the external cable shall be led direct to their

appropriate instruments via ducting systems installed for this purpose during construction

of the panel.

The conductors of the external cables shall be terminated on terminals segregated from

all other categories and the connections to the appropriate instruments shall be made

using twisted pairs with individual screening installed for this purpose during

construction of the panel.

Internal wiring for all circuits in Group 2 except those sharing a common connection

shall be multi-stranded, twisted pair, 0.75mm² minimum copper conductors with

HPDE or PVC insulated cable of adequate grade and rating in accordance with BS

6004:2000. Wiring for circuits in other Groups or sharing a common connection shall

be run in stranded, 1.0mm² minimum copper conductors with 250V grade, PVC-

insulated cable of adequate grade and rating. Wiring sheath colours shall be black for

ac circuits, and grey for dc circuits (excluding thermocouple circuits) and blue for

Group 2.6 circuits. Circuits supplied at 240V, between 240V and 110V dc shall also

be physically segregated from each other and from other circuits. Access to wiring

and components of circuits having voltages exceeding 240V shall not be possible

unless and until the circuit has been isolated.

Separate ducts, trunking, cable looms, tray work and the like shall be provided within

the panel for each category with at least 150mm between parallel paths of Group 1

and those of any other Group. Intrinsically-safe circuits and their terminals shall be

segregated from other circuits and terminals. All wiring shall be neatly and securely

fixed by insulated cleats, bunched and secured by approved plastic strapping or run in

approved insulated wiring trunking or non-corrodible flexible tubing. Not more than

75% of the capacity of trunking, ducts, looming, or tubing shall be used. Insulated

earth wiring shall be so arranged that access to any equipment or connection point or

the removal of any item of equipment is unimpeded. Wiring for future equipment

shall be secured and terminated on terminal blocks. Lacing for wiring looms shall be

of rot-proof cord or plastic strips. Inter-section wiring in multi-section cabinets shall

be via a terminal block in each section.

1.11.11 Panel Wiring Identification And Termination

Identification ferrules shall be fitted at both ends of each wire. The numbers or letters

used shall correspond with the appropriate wiring diagram. The ferrules shall be of

plastic insulating material with permanent black characters on a colour-coded

background for numbers and on a white background for letters, unaffected by oil or

water. They shall be so arranged that they can be read logically from left to right

when viewed normally. The system of wire identification shall be such that wires in

the same circuit on opposite sides of a terminal shall have the same reference, and this

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system shall be continued through all external cabling. Terminal ferrules (spade,

tongue, crimped connections) shall be provided on each conductor.

1.11.12 Panel Earthing

A continuous copper earth bar of not less than 25mm % 6mm cross section shall run

the full length of each panel and shall be securely fixed and bonded electrically to the

main frame. The cable gland-plates and the earth bar shall be provided with suitable

brass terminals of not less than 6mm diameter for connecting the metal cladding or

armouring of all incoming and outgoing cables to the station earthing system.

A second continuous copper earth bar of not less than 25mm % 6mm cross section,

electrically isolated from the steelwork of the panel and metal cladding and armouring

of cables, shall be provided for earthing the signal earth connection of each

instrumentation and control device and the screen(s) of each instrument cable not

earthed elsewhere to the station instrumentation earth plate. The earth bar shall have

sufficient brass terminals as specified above for each instrumentation and control

device and the screen of every shielded cable plus 25% spare terminals. In multi-

section panels, each earth bar shall be electrically bonded to the corresponding bars in

the adjacent section(s). Instrumentation and instrument cable screen earthing shall

comply with BS 6739: 1986, Section 10, unless otherwise stated in this clause.

1.11.13 Panel Heating

Each panel shall have one or more thermostatically-controlled tubular or ribbed panel

heaters to prevent condensation and assist ventilation and which shall be adequate for

ambient temperatures down to 5°C. The heater rating shall not exceed 0.2W/mm and

the surface temperature of any part which could be contacted accidentally shall not

exceed 60°C. Heaters shall be so situated that no deterioration can be caused to any

equipment or wiring in the panel. The heating circuits shall be switched and fused

independently of the instrumentation and control equipment and manually controlled

by an enclosed switch mounted in an accessible position within the panel.

Thermostats shall be mounted remote from the heaters and other sources of heat and

shall be fully adjustable over a range of not less than 0°C to 50°C.

Thermostats shall cut out each heater when the internal temperature of the panel

exceeds a preset value; differential thermostats shall be used to maintain the panel

internal temperature at a pre-set value above the external ambient temperature. If the

permanent power supply is not available at the time of installation of the panel and

condensation is detected, a temporary power supply shall be connected to the panel of

sufficient rating to operate the heaters.

1.11.14 Panel Lighting

Each panel shall be adequately illuminated internally, as evenly and as free from

dazzle as possible, by fixed fluorescent lighting controlled from totally-enclosed light

switches and by totally-enclosed door-operated switches positioned so as not to

interfere with access. There shall also be one installed inspection lamp per three

meters of panel length or part thereof with adequate flexible connection cable to reach

any point in the panel. The control switch for an inspection lamp shall form part of the

lamp assembly. Lighting circuits shall be fused independently of any instrumentation

and control circuit and designed to allow lamps to be replaced safely and shall be fed

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from a distribution board and circuit breaker connected on the live side of the main

panel ac supply circuit breaker.

1.11.15 Panel Ventilation

Each panel shall be provided with ventilation fans as required to ensure that

equipment within the panel is maintained within manufacturer‟s recommendations,

with due regard to the environment in which the panel will be mounted. Fans shall be

controlled by a suitably labeled enclosed switch mounted internally in an accessible

position. Fans shall be mounted with their axes horizontal and shall be arranged to

draw clean air into the panel. Air entries shall have filters which can be renewed from

outside the panel and shall be designed to prevent the entry of rain, spray, injurious

fluids, sand or dust.

1.11.16 Panel Piping and Tubing

Panels containing equipment using a supply of compressed air shall have a common

air pressure-reducing station with duplicate pressure-reducing valves and filters. The

pressure reducing station shall also include isolating valves upstream and downstream

of each filter/reducing-valve set, pressure-relief valve, pressure indicator and low-

pressure alarm unit for the low-pressure header and a pressure indicator for the high-

pressure pipework. The pressure-reducing station components shall be mounted in a

clear space inside the panel, supported on a suitable framework between the lower

horizontal row of instruments and the main low-pressure header.

All piping, fittings and valves downstream of the pressure-reducing station shall be of

brass, copper or plastic. PTFE tape shall not be used downstream of the main filters.

The low-pressure header shall be brass and shall be near the panel floor with drain

valves and tundishes piped to a drain. Branch air headers shall be of brass (15mm

diameter minimum) and shall run vertically from the header to the instrument. The

low pressure header and each branch shall have a 6mm minimum, non-ferrous shut-

off valve for each instrument requiring an air supply and a compression coupling for

each air-purge connection. At least 10% spare connections for possible future

instruments shall be provided in each panel section. Any header dismantled before

shipment shall have brass unions or flanges at each panel-section junction.

Panel-mounted instruments shall be piped to bulkhead fittings on a gland plate during

assembly at the manufacturer‟s works. Piping shall be colour-coded in accordance

with Recommended Practice ISA−RP 7.2 issued by the Instrument Society of

America and shall be segregated from wiring so that any leakage is harmless. Each

panel-mounted pressure gauge shall have a stainless steel flush-mounted shut-off and

fine-regulating valve mounted vertically below. A drip tray shall be provided below

each row of gauges. Exhaust and de-pressurizing pipework shall be routed out of the

panel.

1.11.17 Panel Labels

Labels shall be provided for every panel to describe the duty or otherwise identify the

panel and its sections and every instrument, component and item of equipment

mounted internally and externally. Where applicable, front-of-panel labels shall be as

shown in the Specification drawings. Wording shall be clear, concise and

unambiguous and shall be subject to review by the Engineer before manufacture.

Each label shall be permanently secured to the surface near the item to which it refers.

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Externally-fitted labels shall be of perspex or other approved transparent plastic, with

letters and numbers rear-engraved and filled with black. The rear surface of each

perspex label shall be finished with a coat of paint of the same colour as the panel

external finish. Instrument duty labels fitted externally shall be below the item to

which they refer. Embossed tape or similar adhesive labels will not be approved.

Laminated materials or rear-engraved and filled plastic shall be used for internally-

fitted labels, which shall be white with engraved black letters. Labels conforming to

the requirements of the preceding paragraphs or other approved means shall be

provided:

Labels

To describe or identify circuits or circuit components

To identify DC polarity

To warn or remind about dangerous or potentially-dangerous circumstances

Wherever elsewhere specified

Unless otherwise specified, all engraving shall be in plain block letters, 4mm high.

The minimum practicable number of different sizes shall be used. Manufacturers‟

nameplates shall not be fitted on panel external surfaces.

1.11.18 Panel Finish

For control and instrument panels, desks and cubicles a hard, smooth, durable finish,

free of blemishes, shall be provided. Before painting, all external welds and any rough

areas shall be smoothed, and all surfaces shall be thoroughly cleaned and free from

scale, contaminates, corrosion or grease. If rust-proof or Zintec steel has not been

used in the construction, the panel shall be treated with a passivating agent such as

phosphoric acid. All internal surfaces shall have a minimum of three coats of paint of

which the first shall be an approved antirusting priming coat and the final coat shall

be opaque gloss white enamel. All external surfaces shall have not less than five coats

of paint of which the first shall be an approved etchpriming coat, and the second and

third suitable undercoats, all of which shall be rubbed smooth when dry before

application of the next coat. The undercoats shall be easily distinguished in shade or

colour from the priming and finishing coats. The two final coats shall be of stove

enamel paint, gloss or semi-matt finish, to a colour and finish to be advised by the

Engineer. Stoving shall be carried out in accordance with the recommendation of the

paint manufacturer. The overall dry film thickness (DFT) shall be between 85 and 120

microns. Nuts, bolts, washers and other fixing devices which may have to be removed

for transit or maintenance purposes shall be galvanized or otherwise finished to an

approved standard. A 500ml tin of matching touch-up paint shall be provided and

packed with each panel. The colour of glass reinforced plastic panels shall be to the

approval of the Engineer.

1.12 Recording Equipment

1.12.1 Chart Recorders

Chart recorders shall be microprocessor-controlled or have auto-balancing

potentiometric movements and conform with BS 90:1975 where applicable and shall

be able to pass each test specified in BS EN 60873:1993 or equivalent standard.

Recording instruments shall have an accuracy of +/-0.5% full-scale deflection or

better. The operating temperature range shall be 0°C to 50°C. The recorder shall be

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equipped with indicating scales and pointers for each measured variable. The pen and

a reasonable length of chart shall be visible without opening the case. Strip-chart

recorders shall be electrically driven and have monthly or fanfold charts of not less

than 100mm width which shall advance at a minimum of three selectable rates,

including 20mm per hour.

Recorder inks and inking systems shall be suitable for use both in highly-humid

conditions and in air-conditioning. Inks of differing colours shall be used for

recording two or more quantities on the same chart. Each recorder chassis shall be

easily withdrawable from its housing for chart changing without interrupting its

circuits. Recorder scales and charts shall be in accordance with BS 1794:1952 and BS

3693:1992 or equivalent as applicable. Single-pen recorders used for more than one

measurement shall have rotary-switch selectors with plates engraved to show the

density of the selected measurement.

1.12.2 Electrical Indicators and Integrators

Indicators for use with analogue signal-transmission systems shall comply with BS

89:1990 or equivalent and have an accuracy class index of 1.0. Indicator movements

shall be critically damped (dead-beat). Indicators for use on more than one circuit

shall have rotary switches to select the circuit, with engraved plates to show the

circuit selected. Indicators shall have circular scales or shall be of the vertical

edgewise type and shall be designed to avoid parallax error. Scales shall be clearly

marked in SI units and shall comply with BS 3693:1992 or equivalent. All

instruments mounted on one panel or board, or in adjacent groupings, shall have

similar styles of figures and letters. Dials shall be white with black scales and lettering

not subject to fading.

The material for scales shall be such that no peeling or discolouration will take place

with age under any environmental conditions. Major scale marks and numerals shall

be of the same size and thickness and shall be separated by not more than twenty-five

minor marks. Pointers shall taper to the width of the scale marks. Integrators shall be

of the multi-digit cyclometer type. Integrators operating in conjunction with an

electromagnetic or ultrasonic flow meter shall use the pulse output from the flow

transmitter. Any integrator operating from a device without a pulse output shall have

an integral or separate current-to-pulse converter with sufficient adjustment of the

pulse rate to avoid the use of any multiplying factor except in integer power of 10.

Each integrator shall incorporate an adjustable limiter whereby any input below a pre-

set value is inoperative. Unless otherwise specified, integrators shall have a minimum

of eight digits with a decimal point where applicable.

1.12.3 Alarm System

Alarms shall be initiated by the opening or closing of volt-free contacts which shall

remain unchanged throughout the periods in which the alarm conditions exit. Alarm

circuits shall be capable of conversion from open-healthy to open-alarm or vice versa

by a simple modification after installation requiring no additional parts or special

equipment.

Each alarm shall initiate the operation of both visual and audible devices. The sound

intensity of each audible device shall be suitable for the maximum sound level of its

environment.

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Audible devices in the same room or area shall have distinguishable sounds and

adjustable sound levels.

1.12.4 Matrix Type Alarm Annunciators

The alarm annunciator shall be microprocessor based, modular, split type unit with

alarm windows mounted on the front door and electronic modules inside the panel.

The weather protection class for alarm annunciator shall be IP-54 of IS 13947, Part-I.

Each alarm shall initiate a visible and audible indication of the specified condition.

Unless otherwise specified, alarm indicators shall be grouped together in annunciator

units each having at least 20% spare ways. Alarm indicator lamps (Cluster LED type)

shall have transparent screens engraved with legends approved by the Project

Implementation Unit of JAL NIGAM (PIU). The legend area of each indication shall

not exceed 40mm high and 75mm wide.

When any alarm condition occurs, a condition device common to an alarm

annunciator system shall sound and the appropriate indicator shall flash on an off. The

flashing rate shall not be less than 2 Hz and shall not exceed 5 Hz. On pressing an

accept pushbutton, the audible device shall be silenced and the flashing light shall

become steady. The alarm indicator shall remain illuminated until the alarm condition

ceases and a reset pushbutton has been operated.

The operation or acceptance of one alarm shall not inhibit the operation of the audible

device or the flashing of the appropriate alarm indicator if a further alarm condition

occurs.

At unmanned locations alarms operated on two or more annunciators shall require

acceptance at each annuciator.

Alarms shall be accepted automatically and the appropriate audible device silenced

after an adjustable period of 1 to 5 minutes.

An integral „test‟ pushbutton shall be provided to illuminate each lamp in the

appropriate group and to operate the audible device but shall not cause a spurious

alarm condition on any other annunciator.

Alarm circuitry shall be arranged so that spurious or transient alarm states persisting

for less than 0.5 seconds do not initiate any action.

Alarm annunciator / indicator legends or labels shall be arranged with three lines of

text as follows:

Top Line: Location; example: Sludge Blanket Level

Middle line: parameter; LEVEL

Bottom line: status. HIGH

1.12.5 Push-Buttons and Indicator Lights

Push-buttons in control circuits shall have shrouds, guards or other suitable means for

preventing inadvertent operation. Status-indicator lights shall be of the high-intensity

LED type. Indicator lights shall be of a design which allows easy LED replacement

from the front. Indicator lights shall be easily visible above the ambient light level

402

when viewed from within an included angle of 120 degrees. LEDs shall be chosen to

ensure clear discrimination between the energized and de-energized states and to

ensure an average working life of not less than 3000 hours. A „lamp-test‟ push-button

shall be provided for each group of indicator lights. The colours of push-buttons and

indicator lights on instrument panels shall be as follows:

INDICATOR LIGHTS ON INSTRUMENT PANELS

Duty Push button - Signal lamp

Start or on (energize) - Green

Stop or off (de-energize) - Red

Open valve - Black*

Close valve - Black*

Accept - Black

Lamp test - Black

Reset - Black

Motor running (energized) - Red

Motor stopped (de-energized) - Green

Valve open - Red

Valve closed - Green

Urgent alarm - Red

Non-urgent alarm - Yellow

Plant healthy or ready for use - White

*Panel-mounted push-buttons for valve operation shall be

coloured black, unless otherwise agreed with the Engineer,

with the duty clearly defined by legend on an associated label.

1.12.6 Analogue Signal Transmission

Unless otherwise specified, analogue signal-transmission systems shall be in

accordance with BS EN 60546-1:1993 and shall use a signal of 4mA to 20mA DC.

Transmitting devices shall have integral indicators to monitor the output signal or

connections suitable for use with a portable test meter. Transmitters shall be capable

of meeting the performance requirements laid down in the appropriate part of IEC

60770-1:1999.

1.12.7 Analogue Process Controllers

Analogue controllers shall use solid-state components and shall have outputs

containing three terms with negligible interaction. The controller fascia shall have

measured value, set value and output indication, manual set-value and output controls,

auto/manual switch for control mode and remote-local transfer switch for set-value

control. Manual control stations shall have measured-value and set-value indication,

local/remote switch and control available lamp indicator. Each controller shall have

the means to restrict its output signal to a predetermined, fully adjustable band so that

the regulating device is not moved to unsafe positions. The adjustment of these safe

operating limits shall be by means of accessible, clearly marked, internal components.

A continuously adjustable proportional band of not less than 5 to 500% shall be

403

provided. Integral and derivative action times shall be adjustable over ranges which

shall not be narrower than 6 seconds to 25 minutes and 0-to 10 minutes respectively.

If the integral or derivative action times' adjustments are in steps, the ratio of

successive steps shall not exceed 2. The controls used to set the P, I and D values may

be at the front of the instrument or mounted internally in an accessible position.

Each controller shall be designed so that in the event of failure, it shall be possible to

plug a portable manual station into the controller case and to control the regulating

device manually. Controller design shall ensure automatic procedure-less, bump less

transfer whenever the instrument is switched from "auto" to "manual" or vice versa.

Controller action shall be adjustable from direct to reverse and vice versa by the

operation of an internal switch. Analogue process controllers shall be capable of

meeting the performance requirements laid down in the appropriate part of BS EN

60546-1:1993.

1.13 SCADA System

1.13.1 General

The purpose of this document is to briefly describe the proposed Automation system

(SCADA System) for UPJN. The SCADA shall monitor complete parameters of Plant

including Mechanical Equipment (Pumps, Motors, Valves, etc.) Process Instruments

and Power Network. The System should be such that it has feature as per generic

requirements to enable the system for seamless integration with other SCADA

System.

The SCADA System shall collect data of various Process instruments, Mechanical

Equipment, MFM and I/Os through Communication Network . The System

Architecture has been provided for reference purpose.

The System shall collect data through PLC under scope of supply. The field

instruments (continuous monitoring online analysers) can transfer data to Control

centre directly through GPRS (Mentioned in Annexure - 1A) other equipment (pumps,

motors, valves, etc.) data will report to remote PLC and PLC will report to Control

centre through Fibre cable.(Annexure - 1B). The fibre cable will be laid across all

location in Ring (Annexure - 1C) so that we can get redundant communication.

1.13.2 Basic Requirements for the Control System

This section summarizes the basic requirements for the control system, including the

system‟s components, its open communication capabilities, its combined DCS

functionality, and its scalable architecture.

1.13.3 System Components

The control system shall consist of a modular controller (including control, I/O, and

communications functions), a peer to peer architecture, comprehensive process

automation software (including configuration, documentation, operator interface,

historian, and simulation software) and software modules that facilitate open systems

connections.

The system shall include a full complement of modular supporting equipment

(including mounting racks, power supplies, termination strips, equipment enclosures,

404

prefabricated cables, furniture, etc.), all of which shall be designed to simplify

construction and the overall engineering effort.

1.13.4 Open Communications The control system shall be open to enable easy integration with OPC (OLE for Process

Control) [where OLE stands for Object Linking and Embedding (OLE)] server so as to collect

the data from the remote housing station.

The control system shall include features traditionally associated with both a

programmable logic controller (such as logic processing, modular rugged hardware,

and remote I/O architectures) and a distributed control system (such as continuous and

complex control, advanced operator interfaces, sophisticated redundancy). These

capabilities must seamlessly reside in one control system, without the use of special

gateways or interfaces.

1.13.5 Scope of Work

The solution should meet the functionality as per requirements for connectivity of

PLC, IP Camera (Optional) etc. with Control Centre. The scope of supplies for the

SCADA project shall be as detailed below and given in the System Architecture

attached herewith (Refer Annexure-1A).

1.13.5.1 Scope of Supply

Supply of Control Centre Hardware and Software for SCADA System

Networking Equipments (Router, Firewall etc.) for Control Centre.

Interface / Integration of PLC Units with SCADA System.

Integration of Field instruments Hardware with Control Centre.

Testing, Erection & Commissioning of supplied system.

Training as per detailed Offer.

1.13.6 Hardware Details

This chapter contains a detailed configuration description of Automation System.

The building sub-systems are:

SCADA cum Communication Server

User Interface subsystem like WS

Video Projection System (Optional)

IP Camera (Optional)

Local Area Network subsystem like LAN switch, Router, Firewall

12 C Single Mode Fibre cable

RTU/PLC,

Peripheral subsystem

Each subsystem is built from hardware common components. All subsystems and

hardware components are described below:

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1.13.6.1 Subsystem Description

This section lists and describes the subsystems (associated hardware components) at

each location.

SCADA CUM COMMUNICATION SERVER, WEB SERVER, ISR SERVER

Qty Hardware Component Remarks

1 SCADA cum Communication

Server

The interfaces for each server are connected to

Ethernet networks to collect data from field.

1 WEB server Interface with Internet to remote client

1 ISR server Databases server with Oracle/SQL for Alarm and

MIS Report

USER INTERFACE SUBSYSTEM

Qty Hardware Component Remarks

2 Workstation Console

The console is provided with 2 TFT Monitor

The interface is connected to the Ethernet

networks.

1 Remote access terminal LAPTOP connected through a serial link and a

modem.

LOCAL AREA NETWORK SUBSYSTEM

Qty Hardware Component Remarks

1 LAN Switch Ethernet switch 14 ports (10/100 Base TX)+2

Fibre Port

6 Remote Location LAN switch Ethernet switch 14 ports (10/100 Base TX)+2

Fibre Port

1 Router 2 LAN+2 WAN, all are 10/100 with 2 V.35 Port

2 Firewall 4LAN+2 WAN, all Wan are 10/100Mbps and

LAN are 10/100/1000 Mbps

Lot 12C Single Mode Fibre

armored cable

For Connectivity

1.13.6.2 Peripheral Subsystem

PRINTERS Qty Hardware Component Remarks

1 Laser Printer(Colour) Each laser printer is connected to Ethernet

network.

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UPS

Qty Hardware Component Remarks

1 10 KVA UPS for Control

room Hardware

The UPS is designed for 10 KVA with two hours

backup.

2 3 KVA UPS at all Remote

location

The UPS is designed for 2 KVA with two hours

backup.

IP Camera (Optional)

Qty Hardware Component Remarks

1 IP Camera Each Camera is connected to Ethernet network

for Remote location surveillance

Video Projection System (Optional)

Qty Hardware Component Remarks

1 Rear Projection one cube with

controller

Each VPS is connected to Ethernet network.

1.13.7 Hardware Components Description This section describes the common hardware components.

1.13.7.1 Communication cum SCADA Server, Web Server, ISR Server

Characteristics*

Intel® Xeon® Quad-Core Processor E5606 2.13 GHz, 8MB L3 Cache 1

Integrated Two Broadcom dual-port Gigabit Ethernet with TOE enabled 1

8GB Memory (4x2GB), 1333MHz, DDR3 RAM 1

2nd Intel® Xeon® Quad-Core Processor E5606 2.13 GHz, 8MB L3

Cache 1

300GB 15K RPM,6Gbps SAS 3.5 Hot Plug Hard Drive " With RAID5 3

DVD+/-RW ROM, SATA, Internal for Ms 2008 R2 1

High Output Power Supply, Redundant, 460W 1

Power Cord, GType, 230V (Nepal, Sri Lanka, India) 2

2U Cable Management Arm 1

2U Sliding Rail 1

Windows Server 2008 1

* The system (hardware, software, accessories, etc.) being provided during

installationwould be of latest configuration.

1.13.7.2 Workstation Console Dual Monitor

Characteristics*

Motherboard Intel® Xeon® Dual-Core Processor W3503 (2.40 GHz, 4 MB

cache, 1066 MHz memory)

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Video Card ATI FirePro 2270 (512 MB )

RAM Memory 4GB (2x2GB) DDR3 SDRAM Memory, 1333MHz,ECC 1

HDD 500 GB SATA (7200 RPM) HDD

Input Power

Supply 220 to 240 VAC (+/- 10%), 50 Hz (+/- 2 Hz)

Power Cord Indian Style

CD Drive 16X DVD + /-RW Combo Drive

Keyboard USB Entry Keyboard

Mouse USB Optical Scroll Mouse (2 buttons) with Mouse Mat

LAN(Ethernet

port)

Dual Broadcom RJ45 10/100/1000 BASE on board Ethernet

NIC

I/O Cards One serial RS-232 port, 4 USB port and one parallel port

Indicator & Switch Power on/off x 1, HDD x 1. Power on/off x 1, System reset x 1

*The system (hardware, software, accessories, etc.) being provided during

installation would be of latest configuration.

1.13.7.3 Remote Access Terminal (1no.)

Characteristics*

LAPTOP*

Processor 2nd generation Intel® Core™ i3-2350M processor (2.30 GHz,

1333, 3M cache)

Operating System Genuine Windows® 7 Professional SP1 32bit (English) for

India

Display 14.0" HD WLED Anti-Glare (1366x768)

Memory2 2GB2 DDR3 SDRAM at 1333MHz

Hard Drive 320GB 5400RPM SATA Hard Drive

Video Card Intel® HD Graphics/ Intel® HD Graphics 3000( It depends on

processor selected)

*The system (hardware, software, accessories, etc.) being provided during

installation would be of latest configuration.

1.13.7.4 LAN Switch

Characteristics*

Specification Managed Industrial Ethernet switch

Ethernet Standards

IEEE 802.3 for 10BaseT

IEEE 802.3u for 100BaseT(X) and 100BaseFX

IEEE 802.3x for Flow Control

Design Standard

FCC Part 15, CISPR (EN55022) class A, Shock- IEC60068-2-

27, Vibration-IEC60068-2-6, EN61000-4-2 (ESD), EN61000-

4-3 (RS), EN61000-4-4 (EFT), EN61000-4-5 (Surge),

EN61000-4-6 (CS), EN61000-4-8, EN61000-4-11 standards

Input Voltage 9.6-60 VDC

Operating

Temperature: 0 to 60°C

Ambient Relative

Humidity: 5% to 95% Non-condensing

408

Overload Current

Protection Present

Mounting DIN Rail Mounting

No. of Ports 12 Nos. (10 CU + 2 FO)

Interface

Ethernet ports 10 no. RJ45 Ports with 10/100BaseT(X) auto negotiation speed,

Full/Half duplex mode, and auto MDI/MDI-X connection

Fiber Port Two 10/ 100BaseFX port SC Type Single-Mode, 1310 nm

Supports Ring, and Self Healing

* The system (hardware, software, accessories, etc.) being provided during

installation would be of latest configuration.

1.13.7.5 Color Laser Printer

Characteristics*

Print speed Up to 12 & 8 ppm

Print quality Up to 600x600 dpi with HP ImageREt 3600

(A4 Size, ready) 26/32 sec

Print speed footnote

Exact speed varies depending on the system

configuration, software application, driver and document

complexity.

Memory, standard 128 MB, expandable to 384 MB

Processor speed 600 MHz

Duty cycle (monthly, A4) Up to 30000 pages

Connectivity, standard Hi-Speed USB 2.0 port; built-in Fast Ethernet

10/100Base-TX

Print technology In-line colour laser printing technology

Print languages HP PCL 6, HP PCL 5c, HP Postscript level 3 emulation

Paper trays, standard 2

Paper handling input,

standard 150-sheet input tray

Paper handling output,

standard 150-sheet face-down output bin

Power

Input voltage 115 to 127 VAC (+/- 10%), 60 Hz (+/- 2

Hz), 12 A; 220 to 240 VAC (+/- 10%), 50 Hz (+/- 2 Hz),

6 A

Power consumption 445 watts maximum (active), 18 watts maximum (ready),

6.7 watts maximum (sleep), 0.48 watts maximum (off)

Media sizes supported

Tray 1: A4, A5, A6, B5 (JIS), 10 x 15 cm, 16K,

envelopes (ISO DL, ISO C5, ISO B5), post cards

(Standard #10, JIS Single, JIS Double); Tray 2 : A4, A5,

A6, B5 (JIS), 10 x 15 cm, 16K, envelopes (ISO DL, ISO

C5, ISO B5), post cards (JIS Single, JIS Double)

Media sizes, custom Tray 1: 76 x 127 to 216 x 356 mm; Tray 2 : 100 x 148 to

216 x 356 mm

Media weight, supported

Tray 1: 60 to 176 g/m² (up to 220 g/m² with HP laser

glossy photo papers); tray 2, optional tray 3: 60 to 163

g/m² (up to 176 g/m² with postcards, up to 220 g/m² with

HP laser glossy photo papers)

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Recommended operating 15 to 27° C

Operating humidity

range 20 to 70% RH

* The system (hardware, software, accessories, etc.) being provided during

installation would be of latest configuration.

1.13.7.6 UPS (1 No.)

Characteristics

Technology Micro processor based IGBT, High Frequency Switching

Sinusoidal multiple PWM

Rating 10 KVA

Input 230 V AC, +10%, -15%

Output 230 V AC

Battery Sealed Maintenance Free Batteries, CSB / Panasonic /

Global & Yuasa or eqvt

Backup Hours 120 Minutes

1.13.7.7 UPS (6 NO.)

Characteristics

Technology Micro processor based IGBT, High Frequency Switching

Sinusoidal multiple PWM

Rating 3 KVA

Input 230 V AC, +10%, -15%

Output 230 V AC

Battery Sealed Maintenance Free Batteries, CSB / Panasonic /

Global & Yuasa or eqvt

Backup Hours 120 Minutes

1.13.7.8 Router (2 No.)

Characteristics*

Memory RISC @ 533 MHz

Flash Memory:256M Bytes

SDRAM: 256M Bytes

Interface 2 x 10/100/1000 Mbps Ethernet Port

2 Serial Ports (V.35)

2 X 10/100 Mbps WAN Interface

1 Console port

1 Auxiliary port

Performance

Throughput 300 Kpps (64-byte packets)

Routing table size 30000 entries

Network Management IMC - Intelligent Management Center; command-line

interface; Web browser; SNMP Manager; Telnet;

RMON1; FTP; IEEE 802.3 Ethernet MIB

Operating Temperature 0° to 40° C (32° to 104° F) (Relative Humidity: 5% to

90% non-condensing)

Non Operating

Temperature

-40° to 70° C (Relative Humidity: 5% to 90% non-

condensing)

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Power 100-120/200-240 VAC

*The system (hardware, software, accessories, etc.) being provided during

installation would be of latest configuration.

1.13.7.9 IP Camera (6 No.) - Optional

Characteristics*

Camera

Sensor 1/2.7” HD progressive scan CMOS

Lens C/CS mount lens (lens not included)

Auto Iris Type DC drive

Illumination (low light

sensitvity)

• Color: 0.2 lux at F1.2

• B/W: 0.05 lux at F1.2

Synchronization Internal

White Balance ATW/AWB (range: 3200 to 10000°K)

Dynamic Range

• Color: 100 dB

• B/W: 110 dB

Auto Electronic Shutter 1/30 to 1/25000 sec.

Electronic Shutter Auto

S/N Ratio 50 dB (Gamma, Aperture, AGC OFF; DNR ON)

ICR Control Auto (light sensor control) or DI control

DNR Built-in DNR

WDR Level 1-8/Off

AGC control 2X, 4X, 8X, 16X, 32X, 64X

Flickerless Control Indoor/Outdoor mode

Black Level Control High/Medium/Low

Auto Exposure Level ±5

Image Rotation Flip, Mirror, and 180° rotation

Image Setting Manual tuning with saturation, sharpness, and contrast

• Video

Video Compression H.264 (ISO/IEC 14496-10) or MJPEG

Video Outputs Ethernet

Video Streams

Up to 3 video streams (2 x H.264 and 1 x MJPEG)

• Stream 1: H.264, 1280 x 800 resolution (max.)

• Stream 2: H.264, 720 x 480 resolution (max.)

• Stream 3: MJPEG, 720 x 480 resolution (max.)

Note Streams 2 and 3 must be at the same resolution

Video Resolution and FPS

(frames per second) Not less than 20 FPS in NTSC or PAL

• Network

Protocols

TCP, UDP, HTTP, SMTP, FTP, Telnet, NTP, DNS,

DHCP, UPnP, RTP, RTSP, ICMP, IGMPv3, QoS,

SNMPv1/v2c/v3, DDNS, Modbus/TCP, 802.1X,

SSH/SSL

Ethernet 1 10/100BaseT(X) Ethernet port, RJ45 connector

• Serial Interface

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RS-485 1 half-duplex RS-485

• GPIO

Digital Input

1, max. 8 mA

• High: +13 V to +30 V

• Low: -30 V to +3 V

Relay Output 1, max. 24 VDC @ 1A

• LED Indicators

STAT Indicates if the system is booted properly or not

Network 10 Mbps or 100 Mbps

Power Power on/off

• Local Storage

SD Socket Standard SD socket (SDHC)

• Power Requirements

Input

• Redundant power inputs

• 12/24 VDC, 24 VAC, or Power-over-Ethernet (IEEE

802.3af)

• Physical Characteristics

Camera Body Housing Metal, IP30 protection

Installation Wall mounting, pole mounting, corner mounting

Note Optional external housing and mounting accessories

may be required.

• Security

Password User level password protection

Filtering By IP address

Authentication 802.1X

Encryption HTTPS, SSH

• Alarms

Intelligent Video Camera tamper, virtual fence, alert zone, missing object,

unattended object

Note IVA functions are optional except for camera tamper.

Video Motion Detection 3 independently configurable motion areas

Scheduling Daily repeat timing schedule

Imaging JPEG snapshots for pre/trigger/post alarm images

Video Recording Event recording and stored in the SD card

Email/FTP Messaging Automatic transfer of stored images via email or FTP as

event-triggered actions

Custom Alarms HTTP event servers for setting customized alarm

actions

Pre-alarm Buffer 24 MB video buffer for JPEG snapshot images

• Environmental Limits

Operating Temperature Standard Models: 0 to 60°C (32 to 140°F)

Wide Temp. Models: -40 to 75°C (-40 to 167°F)

Storage Temperature -40 to 85°C (-40 to 185°F)

Ambient Relative Humidity 5 to 95% (non-condensing)

• Standards and Certifications

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Safety UL 60950-1

Hazardous Location UL/cUL Class I Division 2 Groups A/B/C/D (Pending),

ATEX Zone 2 Ex nCnAnL IIC T4 (Pending)

EMI FCC Part 15, CISPR (EN 55022) class A

EN 61000-4-2 (ESD), Level 3,

EN 61000-4-3 (RS), Level 3,

EN 61000-4-4 (EFT), Level 3,

EN 61000-4-5 (Surge), Level 3,

EN 61000-4-6 (CS), Level 3,

EN 61000-4-8,

EN 61000-4-11

Traffic Control NEMA TS2

Rail Traffic EN 50121-4

Shock IEC 60068-2-27

Freefall IEC 60068-2-32

Vibration IEC 60068-2-6

*The system (hardware, software, accessories, etc.) being provided during

installation would be of latest configuration.

1.13.7.10 Video Projection System (1 No.) – Optional Characteristics*

Resolution SXGA+

Individual Cube Size 67" Diagonal

Image Size (mm) 1361 x 1021

Display Technology DLP, single chip

Native Resolution 1400 x 1050 pixels

Aspect Ratio 4:03

Screen to screen gap Rear access:

Adjustable up to 0.2 mm

DMD 0.95” DMD 12 deg.

Light Source LED - 1R1G1B - 12 sq mm each

Brightness 650 Lumens

Luminance (Nits or cd/m2) Based on screen used, lamp mode and screen size

Brightness Uniformity Greater than 90%

Screen Type Fresnel/ Lenticular/Black Bead/Cross Prism (XPS)

Full Viewing Angle 180 degrees

Colors 16.7 million

Color Temperature Range 3200K to 9300K

Color Temperature Range 3200K to 9300K

LED Life (typical) > 60,000 Hours

Inputs RGBHV on BNC, Dsub -15,

DVI-DX2, Composite video, (NTSC/PAL/SECAM)

Component video HDTV, RS232C

Outputs Video/DVI

Control RS-232/IR, RS 422/IP

Voltage AC100-240V @ 50/60 Hz

Power Consumption ‹ 350 W

Operating Temperature 10-35°C

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Operating Humidity 10%~90%

Storage -20 to 60°C

*The system (hardware, software, accessories, etc.) being provided during installation

would be of latest configuration.

1.13.7.11 12C Single Mode Fibre Cable

Characteristics

Configuration MULTITUBE DOUBLE SHEATH ARMOURED

CABLE

Nos. of Core 12

Maximum Tensile Loading 1361 x 1021

Installation 2700N

Long Term Installed 900N

Operating Temperature -30°C to +60°C

Normal Dia 14.8 mm

Nominal weight 200 KG/KM

Mode Single Mode

Single mode Fiber: (G.652.B)

1.13.7.12 Server Panel The equipment can be of any Standard make which can comply with the following

standards:

Type SERVER RACK 42U/600W/1000D

Specification

Captive Front Panel Hardware, Pkt of 20

Castors (Plain)

ServerRack , 19"/42U

consisting of High quality extruded Aluminium vertical profiles 4

Nos.Top and Bottom steel end

frames with bottom Panel having gland plate for cable entry, Top

cover with FHU provision, Side

Panels with latches and venting slots at bottom 1/3 area and 2 pairs of

19" Mounting Angles

Dimension: 2150 x 600W x 1000D Powder Coated BLACK

Front CRCA steel single door with Perforation

Rear CRCA steel single door with Perforation

Component Shelf, Universal, 19"W/575mmD, Load cc 50 kg.

Top Mounting, Fan Housing Unit with 4 fans 230 V / 90CFM

Rotary Keyboard Tray with slides

Castors (with brake)

Earth Continuity straps (kit)

1.13.7.13 PLC (1 No.) The equipment should be of Reputable make which can comply with the followings

standard:

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1. Powerful Integrated Controller

The controller shall consist of a family of intelligent integrated modules, with each

performing a dedicated function. It shall have an integrated redundant interface for the I/O

modules as well as redundant interface for the Human machine interface.

Additionally the controller should be able to able to communicate to its redundant pair

directly preferably on a Passive backplane.

2. Modular Architecture

The modular approach shall enable a very small system to be installed with expansion to a

very large system without changing the basic hardware or disrupting the architecture. A

minimum of the following module types must be available: control modules, I/O modules,

communications modules, computer modules, and power supply modules.

3. Controller Packaging

For installation flexibility and high reliability, controller hardware must be designed to

withstand harsh conditions within industrial environments, such as heat, humidity, shock,

vibration, and electrical surge and discharge.

A. Module Hardware

Module hardware must meet the following requirements:

The modules shall be identical in appearance.

All the module shall be housed in a powder coated metal case rack to prevent physical

damage from handling or dust.

All control and I/O modules shall be rated for operation within the following ranges:

0-50 Deg C and 5-95% relative humidity, non-condensing.

I/O and power modules shall have circuitry to protect the system from electrical surge

and discharge.

The modules shall comply with the following specifications:

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International Electro-technical Commission (IEC)

IEC 60751 (1983-01) Industrial platinum resistance thermometer sensors

IEC 61000-4-2 (2001-04) Electromagnetic compatibility (EMC)- Part 4-2

IEC 61000-4-3 (2002-03) Electromagnetic compatibility (EMC) - Part 4-3

IEC 61000-4-4 (1995-01) Electromagnetic compatibility (EMC) - Part 4

IEC 61158 (2000-08): Field-bus standard for use in industrial control systems - Part

2:

IEC 61131-3 (1993-03) for Programmable controllers - Part 3

The modules shall comply with the following shock and vibration standards:

Vibration: IEC 68-2-6, Fc: 10-50 Hz, 2g

B. Module Racks

The modules shall be grouped together in racks to form the control system. The racks

shall provide the communications mechanism to fully integrate the modules and

facilitate intercommunications between racks. A rack should hold approximately ten

individual modules, with each slot identical and able to accept any module. Modules

should be connected to the backplane using high quality, gold-plated, industry-grade

pin connectors.

It shall be possible to remove and reinsert the modules under power with no damage to

the rack or modules and without removing any external wiring or cables. The rack and

modules shall provide a physical keying mechanism to prevent incorrect module

insertion during system operation.

To simplify installation and maintenance, the module racks and modules shall

be designed for front access only. All user functions, including diagnostics,

field wiring, cable connections, switches and status indications, shall be

available from the front of the rack.

C. Power Supply

Redundant Power supplies shall be available for card rack mounting to form as

an integral part of the system. The module rack must provide two individual

power supply buses that to be driven by two independent power sources for high

availability placed in the rack in current sharing mode. Each module shall be

capable of using power from any of the two buses.

D. Enclosures

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The racks shall be mounted in an industrial enclosure with a front & rear -access

design, with all frequently accessed items (such as modules, connectors, status

indicators, switches, and termination assemblies) located in the front of the

enclosure. For maximum flexibility, the enclosures shall be modular, with the

ability to be stacked, joined side to side, or joined back to back. To provide the

degree of environmental security required, enclosures shall be available in

sealed and vented versions. Enclosure shall be

i) for Indoor IP 44 and ii) for Outdoor IP 65

4. Control Module

A control module shall provide process control functions. The control module should

be used with dedicated I/O modules to read and control field signals. The module

shall also be capable of operation independent of I/O modules, “supervising”

operation of other control modules. In addition, the control module shall be capable of

executing on a 5 millisecond resolution input-to-output when required by the

application.

A. Hardware

The control module shall consist of a single-slot module with a dedicated

microprocessor. Memory should be battery-backed RAM so that the module

retains its configuration and state information to optionally and automatically

restart after a power failure without requiring its database to be downloaded.

The minimum memory required is 16MB.

During a hot start, all variables can be selected as retain or non retentive.

B. Software

The control system must support a full complement of process control functions.

It shall be possible to define these functions using a mix of function blocks,

ladder logic diagrams, sequential function charts, and textual programming.

Each of the four languages and their interaction within a configuration shall be

based on the IEC 61131-3 standard. The languages shall be completely

interchangeable and interactive, with a single control module‟s database capable

of including any combination of the four languages.

5. Input / Output Devices

Input/output Modules shall be intelligent I/O modules. Each module should be able to

communicate with the CPU in a dedicated fashion without requirement of any

additional interfacing hardware so as to reduce the common cause of the Failure. Each

module should have its own microprocessor to execute its input/output function,

maintain ownership of its configured data, and perform module diagnostics.

All process I/O shall be electrically isolated from both computer common and

communications common. Isolation shall meet be min 1500 VAC requirements.

Modules shall automatically determine their physical address and report this

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information to the controller. No range jumpers or user- configurable physical address

jumpers should be necessary.

All configurable data shall be set via software, with no hardware jumpers used.

Configurable data should include Channel tag.

All the I/O modules shall have max 8 channels for the Analog and 16 channels

for the Digital modules. Special modules like Counter inputs shall monitor dry

contact pulses with an input resolution of one HZ minimum.

A. Field Termination for I/O Modules

Each I/O module‟s field signals shall be wired into the system such that an I/O

module can be removed at any time without disturbing the field wiring.

The field wiring should be separate from the I/O module(s). The extension from

the module(s) shall be accomplished via a marshalled I/O cable assembly. This

assembly should be a multi-conductor cable that attaches to the module rack

(and the back of the I/O module) on one end and a finished termination end.

The marshalled termination assemblies shall be DIN rail-mounted PCB-based

fixtures that include terminal blocks and two receptacles for accepting the

interconnect cable plug. These receptacles must be female to eliminate the

possibility of power from the terminal block being exposed on pins.

1.14 System Communications

The communication networks in the system shall provide redundant, high-speed,

secure controller information exchange via Ethernet TCP/IP. Communication between

individual modules shall be via redundant, local, independent buses that allow

complete integration of the family of modules.

1.14.1 Module Communication Bus

All the communication to the I/Os in the DCS shall use a deterministic. This protocol

must be compliant to IEC61158, and open. It shall be possible to connect a minimum

of 100 nodes on a single network

The bus must be redundant. Minimum data transmission rate is 10 Mbps.

Communication on the expanded network shall be accomplished in a manner

identical to that of local communication bus. The extension shall be transparent to

the user, and no extra software configuration effort shall be required.

1.14.2 Configuration Software

The configuration software shall be portable. It shall run on a personal computer of

the most current technology under Windows.

The software shall execute in the off-line mode when the computer is not attached to

any controller hardware, allowing controller databases to be created, edited, and

documented. When the computer is attached to the controller hardware via the

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networked or direct-connected PCs, the networked workstations, or by running in the

industrial computer module, an on-line mode of operation shall be available to allow

use of all off-line functions plus on-line troubleshooting tools. This software shall be

able to be used to configure continuous, batch, and safety protection control strategy

configurations from a single user console.

1.14.2.1 IEC 61131-3

The configuration software shall allow controller databases to be created using the

following standard languages defined by the specification IEC 61131-3: function

blocks, ladder logic, sequential function charts, and structured text.

1.14.3 Graphical Configuration and Documentation

Controller configuration should provide graphical configuration methods, with

functions entered into a database using a point and click object-oriented routine. The

resulting database should be its own documentation because of the graphical

appearance. Furthermore, the graphical database must be transferable directly to the

controller as it exists, including all graphical information, with no compile routine

necessary before transferring the database to the controller. The graphically

configured database shall be stored and executed in the controller, and the controller-

resident database shall be viewable graphically on-line and uploadable to a PC or

workstation without the need for storing the “source” database off-line.

A. On-Line Tools

The configuration software shall provide on-line tools that assist in troubleshooting

control schemes. These tools must include on-line display of variables, the ability to

force values and states, support for on-line database changes, and on-line real-time

trending.

It should be possible to display variables‟ values and the status of ladder logic and

SFC elements while viewing an on-line controller database. The ladder logic and

SFC element states shall be indicated using colors.

The configuration software shall provide the ability to write values, states, and modes

to independent variables and elements in the controller. It shall also provide the

ability to force non-independent variables and elements to a predetermined value,

state, or mode.

During troubleshooting, the user shall have the ability to stop the controller and

single-step its execution. This will provide a way to clearly understand complex

configuration schemes and highly interactive logic that might need to be examined.

B. Prebuilt Library of Functions

The configuration software shall include a predefined library of control schemes. The

library must include at least:

Single PID loop with alarm

Single PID loop with external setpoint and alarm

Ratio control loop with alarm

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Cascade loop with alarm

Primary control loop with alarm etc.

Separate, optional libraries should be available for specialized applications.

The configuration software shall also allow commonly used functions created by the

user to be added to a library for future use.

C. On-Line Help

On-line help screens in the configuration software shall be available to assist while

creating a database. The help screens shall include descriptions of every

configuration element (e.g. each function block and ladder logic element).

D. System Architecture

A system architecture graphic depicting the hardware within the control system. This

graphic should give status information for the modules in the system by using colors

to indicate general health of the modules.

1.14.4 Windows Based Operator Software

The industrial-grade PC-based operator interface software shall be able to run on a

personal computer of the most current technology under Windows. The software

shall provide all standard operator functions, including process monitoring, alarm

management, real-time and historical trends, reports, plus provide process graphic

displays, an integrated historian, Internet enabler, batch manager and control

simulator.

1.14.5 Reliability

The system must be designed for maximum reliability and minimal downtime. This

should be achieved through a fault-tolerant design with minimal common cause

failures and state-of-the-art redundancy schemes.

1.14.5.1 Controller

The controller must have a fault-tolerant design, with redundancy in the same model

A. Standard Fault Tolerance

The module communication bus and each I/O communication bus must be redundant.

If one side of a redundant bus should fail, communications should continue,

uninterrupted, on the remaining side of the bus.

The module rack shall provide two separate power supply modules, with each module

capable of drawing power from any of the two.

B. Redundancy

Complete 1:1 redundancy needs to be quoted. The redundant control modules that

share a single set of I/O, identical, standard hardware must be used for all redundancy

schemes with option of duplication of control modules and I/O modules.

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It must be possible to replace a failed component on-line, without removing power.

Process control shall continue to be executed in the non-failed unit.

When a module is replaced, the new module must automatically initialize, receive the

current database from the primary module, and pick up in synchronous execution as a

secondary module in the redundant relationship. This should take place without user

action for any of the steps.

1.14.6 Operator Interface

Window based operator interfaces need to be supplied such that the failure of one

component, card, or module does not cause the operator to lose any portion of the

process window.

1.14.7 System Architecture

The system should be capable of Remote I/O modules architecture at various remote

locations near to the major equipment sensors to reduce the commissioning. There

will be two remote I/O module stations. Please refer the Annexure 1 & 2 of the

system architecture.

1.14.8 Features Required in SCADA System

The system will be based on latest version of SCADA system. The main SCADA

system will be redundant. Based on application, servers are to be distributed with

redundancy. For Cyber Security it is proposed that Security Solutions Shall be

provided and separate DMZ zone be made so that outside intrusion can be minimised.

Network monitoring system shall also be provided for monitoring of Network devices.

SCADA system will have many extra features and the proposed system should

support multiple PLC/ RTU Protocol like Modbus, Profibus, DNP (Serial/TCPIP),

OPC etc.

1.15 Detailed Specification of SCADA System Components

1.15.1 Data Acquisition

The SCADA system shall perform data acquisition from PLC and field Equipments.

PLC is to be located at each location of the plant. PLC communications with

Control Centre shall utilize the Open protocol like Modbus, Profibus.

1.15.2 Data Exchange

The SCADA systems shall be able to exchange various types of data with the other

application software using ActiveX Data Objects (ADO) or Dynamic Data Exchange

(DDE).

1.15.3 Data Processing

a) Analog data

Analog data processing shall be performed according to the requirements listed

below.

- Conversion to Engineering Units

- Reasonability Limits Checking

- Limit Monitoring

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b) Digital/Status Input Data

The following status input data types shall be accommodated as a minimum:

Two-state points: The following pairs of state names shall be provided:

(1) Open/Closed

(2) Tripped/Closed

(3) Alarm/Normal

(4) On/Off

(5) Auto/Manual

(6) Remote/Local

c) Calculated Data

It shall be possible to define the calculations on real-time data and historical data,

periodically and on request. The results shall be incorporated into the database as

calculated data available for display & report generation.

The user shall be able to define calculated analog values using database points as the

arguments and mathematical functions as the operations. Functions such as addition,

subtraction, multiplication, division, maximum value, minimum value, average,

count, square root, exponentiation, trigonometric functions, logarithms and other

statistical functions shall be provided.

The SCADA system shall be capable of analysing the open/closed status of

switching devices, such as Motor, PUMP etc. The configuration shall be updated

whenever a switching device status change is detected.

1.15.4 Quality Codes

Quality codes indicate the presence of one or more factors that affect the validity of a

data value. All quality codes that apply to a data value shall be maintained in the

database for that data value. At least following quality codes shall be supported:

- Telemetry failure

- Delete from scan

- Limit violated

- Manually replaced

- Alarm inhibit

- Abnormal data

1.15.5 Sequence-Of-Events Recording

The Sequence-of-events (SOE) data is listing of status change events with time

stamp. SOE data shall be collected by the SCADA system from PLCs. The

description of each event shall include the database description name, device state, the

date, and the time (to the nearest millisecond) of each event.

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1.15.6 Supervisory Control

An authorized user of an SCADA system shall be able to control the operation of field

devices connected to PLCs. A control action shall require a confirmation of selection

prior to execution of control command.

The user shall be able to select and operate any controllable switching device.

Controllable switching devices will be of like, Pump, Motor.

1.15.7 Information Storage and Retrieval

Information Storage and Retrieval (ISR) system shall collect and store analog data

(telemetered and calculated) periodically at every 5 minute (configurable) and status

data by exception. Associated quality codes shall be included. It shall be possible to

perform calculations on the stored data, and the results of these calculations shall be

collected and stored. Other information such as alarms, events, SOE and reports shall

also be stored. The data shall be stored on hard disc with date tag on daily basis for

easy retrieval. Subsequently, the data shall be retrieved for analysis, display, trending,

and report generation.

1.15.8 Extensive Use of Standard

The SCADA Software should be such that it uses an extensive use of standards,

achieved by a corporate commitment to comply with all standards that are

recognized on the SCADA market, and in particular:

- Intel (or compatible) based hardware;

- Operating system options of WNT 4.0, Windows 2000 or Windows 2003;

- Uses Microsoft Foundation Class (MFC) Object Oriented Database;

- Developed with Microsoft Developer‟s Studio;

- Installed using Microsoft Install Shield utilities;

- Component Based Architecture;

- Interfaced using Active X controls (OCX);

- TCP/IP for Local and Wide Area Networks (LAN & WAN) ;

- Web-enabled Operator Consoles;

- Control Center Application Programming Interface (CCAPI) Initiatives

1.15.9 System Sizing & Extensibility

The hardware and software openness of SCADA allows the customer to smoothly

upgrade the proposed system with great facilities. Common upgrading needs include

(but not limited to) the following items:

- Additional measurement points (analog and digital);

- Additional protocol-compliant IEDs;

- Additional protocol-compliant PLCs;

- Additional operator consoles;

- Additional printers;

- Connection to other SCADA centers

1.15.10 SCADA Interfaces

User interface and gateway services communicate with SCADA over the following

interfaces:

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- OLE Automation Control Interface - OLE Automation provides the easiest

programming interface to SCADA. OLE automation client services may be built

using Visual Basic or C++. The service may direct SCADA to add, delete, or

modify SCADA objects, may issue controls, and may retrieve measurement data.

The OLE Automation interface may be distributed across CPUs, such that a

service on one server uses SCADA running on another server;

- Publisher/Subscriber Control Interface - The publisher / subscriber interface

allows for high performance data update and automatic refresh. This interface is

based on TCP/IP sockets, and may run on the same server or between servers.

This may be used directly from C++ or using custom OLE controls in Visual

Basic;

- Custom ITelemetrySink Interface – The custom ITelemetrySink interface is

used by gateway services for high performance data transfer. This interface works

between two processes on the same server. This interface supports C++

programming.

1.16 Graphical User Interface (Gui)

The GUI shall operate within a window environment The system shall use displays

which mimic the existing control panels so that the operators working in conventional

control room environment are comfortable while working on the new system. Selected

Bidder shall develop control panel display generally similar to the one existing in

conventional control room.

The GUI shall allow the personnel to monitor and control the equipment through the

control panel displays and Tabular displays. The control panel displays shall be

dynamically updated for measurands, device positions, annunciations. To have better

visibility of control panels, it shall be possible to iconise each control panel separately.

Operator shall select that icon to zoom/view that panel display & carry out operations

such as alarm annunciation accept/reset, device close/open operations etc.

1.16.1 Trending

Trend displays shall enable the user to select real-time and historical data for trending on

graphical displays and for tabular displays. It shall be possible to take print of these trends.

1.16.2 Alarms

Alarms are conditions that require user notification when detected. Audio, visual alarm

shall be generated for all such conditions. It shall be possible to accept & reset all trip

& non-trip alarm annunciation appearing on control panel facia from control panel

display itself. Alarm annunciation on control panel shall have following characteristics:

Condition Facia Sound

Alarm initiation by

relay contact Flashing Glow On

Accept PB pressed Steady Glow Off

Reset

Off (if relay contact is reset)

Steady Glow (if relay contact is not

reset)

Off

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Other alarm conditions shall be acknowledged from respective alarm list displays. Other

alarm conditions shall include, but not be limited to the following:

(a) Telemetered or calculated value limit violations

(b) Un-commanded changes of a power system device state

(c) Data source communication errors resulting in loss of data

(d) SCADA hardware and software element failures.

The standard products for advanced alarm management shall also be provided.

Regardless of the alarm management technique used, all alarm messages shall be

recorded with time & date tag on auxiliary memory for review and printing on demand

by the user.

Displays shall highlight alarm condition using a combination of colour, intensity,

inverse video and blinking. Alarm messages shall be a single line of text describing the

alarm that has occurred with date & time of occurrence.

1.16.3 Events

Events are conditions or actions that shall be recorded by the SCADA system but do not

require user action. Events shall be recorded in the form of an event message. The event

message format shall be similar to the alarm message format. Events shall include but

not limited to followings:

Values returning to normal from a limit violation state

Device status change on manual operation.

1.16.4 Hardcopy Printing of Display

A means shall be provided to produce a copy of a display. The display printout shall be

initiated from user friendly push buttons/pull down menus. The options for printing mode

shall include at least selection for orientation, background colour, page size, colour or black

& white print and print preview. It shall also be possible to print selected portions of display

and direct printing on any of the connected printer.

1.16.5 Report Generation

The user shall be able to schedule periodic reports generation, direct a report to a display,

print a report, and archive a report. Hardcopy report formats shall be handed over to

Selected Bidder for generation of report formats in the system. It shall also be possible to

define and generate the additional user configurable reports. The generation and printing of

any report shall not effect normal scanning of data from PLC. The report scheduling display

shall enable entry of the following parameters, with default values provided where

appropriate:

(a) Report name

(b) Report destination (printer or archiving device)

(c) Time the system should produce the report.

1.17 SCADA System Access Security

A mechanism for defining and controlling user access to the SCADA system shall be

provided.

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1.17.1 Alarm Summary Displays

Displays that list or summarize all unacknowledged and acknowledged alarms shall

be provided. The user shall be able to select between viewing alarms in

chronological and reverse chronological order. The default shall be most recent

alarms. The summary shall separate acknowledged and unacknowledged alarms. To

facilitate identification of unacknowledged messages the time field shall blink or

entire row shall blink. It shall be possible to sort alarms by user defined text, date,

time.

1.17.2 Event Summary Displays

Event summary displays shall list the most recent events. The user shall be able to

select between viewing events in chronological and reverse chronological order.

The user shall be provided with a convenient and efficient means of selecting an

event summary display. It shall be possible to sort events by user defined text, date,

time.

1.17.3 Operating Information Summaries

The operating information summaries defined below shall be provided. Summary

items will be listed in reverse chronological order with the most recent item shown

on the first page. The user shall have the ability to sort summary items by device.

1.17.4 Abnormal Summary

The summary display shall list devices and values that are found to be abnormal,

i.e., are not in their normal state. Telemetered, calculated, and manually entered

status and data values shall be included.

1.17.5 Out-Of-Scan Summary

The out-of-scan summary display shall list device status and data values that are not

currently being processed by the system.

1.17.6 Alarm Inhibit Summary

This display shall list devices and data values for which the user has suspended

alarm processing.

1.17.7 Tag Summary

This display shall list and describe all active device tags.

1.17.8 Help Displays

Help displays shall be provided to aid the user in interpreting displayed information

and to guide the user through a data entry or control procedure.

1.17.9 Alarm Beeper Services

The Alarm Beeper service audibly notifies the operator of recent alarms by

playing a wave file. Wave files can be used to distinguish between Alarm

priorities. All the Windows‟ .wav files or customised .wav files can be used

1.17.10 Alarm Pager Services

The Alarm Pager service allows the user to configure the system to issue various

pages in response to specified alarms.

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1.18 Quality Assurance Plan

To ensure total conformation of the application to the user requirement and to make

sure that S/W package development is of high quality, proper quality control activities

shall be performed and documented throughout the development. For this, the bidder

shall give a S/W quality assurance plan to establish system of controls and make the

S/W development activity less intangible and more manageable throughout life cycle of

S/W development viz. Review and acceptance of Requirement Analysis, Design,

Development, Testing, Implementation, User training, Maintenance, etc.

The Vendor shall be ISO 9001:2000 certified and shall ensure that all the activities

including documentation comply with the standards.

1.19 Time Schedule

Time is the essence of the work under this contract. The total turnkey work shall be

completed in 18 months and handed over, from the issue of award of contract, to the

owner.

The bidder shall workout a detailed bar chart for each activity separately indicating the

start & finish dates of each activity along with the resources that he plans to deploy in

each case and submit the same immediately after the award of contract.

1.20 Project Management

Progress of the project will be monitored by Project Management Team (PMT) which

will be steered by group of IT personnel, Site O&M persons.

1.20.1 Progress Review

The above team will monitor the progress on monthly basis and submit the

exceptional report to Owner‟s representative highlighting the achievements and

hurdles in achieving the targets with suggestions to solve these hurdles.

1.20.2 Warranty

The warranty shall be valid for a period of One (1) year from the date of installation /

Commissioning of the System.

Supplier shall ensure the warranty of supplied system for 1 Year after issuance of

Operational Acceptance by User and any defect/ repair shall be handled by

supplier‟s Engineer.

1.20.3 Preventive Maintenance

Time for regular preventive maintenance with a frequency of not less than once per

quarter will be required during the Warranty period. This should include general

checkup of various parameters, running diagnostics etc. to avoid any possible failure

or deterioration in response time.

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1.20.4 Documentation

The following documents shall be required for smooth functioning of the system:

DOCUMENT NAME NO.OF COPIES IN ONE

SET

Installation Manual 2

System Administration and Maintenance Manual 2

User Manual 2

Technical Manual 2

Test Document(FAT &SAT) 1

1.20.5 Training Of Owners Engineers The Selected Bidder is required to provide in depth training to Owners engineers (10

Nos.) for 1 month at his facilities on all aspects of the system being supplied. Training

module shall be mutually discussed and finalized to cover Owner‟s personnel to

operate, append, modify and troubleshoot the System effectively. All the

documentation and write up material for trainees shall be provided by the Selected

Bidder.

The vendor should conduct this training at his premises, before testing of the

package start. The Bidder should devise an exhaustive training program.

1.20.6 Annual Maintenance Contract Supplier will support and provide services to ensure smooth functionality of the

supplied System for 15 Years under Annual Maintenance Contract. Any System

problems arising during AMC Period shall be handled and rectified by supplier‟s

engineer.

1.21 Project Schedule

The tentative Project schedule is 12 months from LOA.

1.22 Testing / Inspection

1.22.1 Test on Complete Control System

On completion, the functioning of the complete system shall be tested to

demonstrate its correct operation in accordance with the Specification.

For control system testing, the Selected Bidder may provide temporary means to

simulate operating conditions, but the system will not be finally accepted until

correct operation has been demonstrated to the satisfaction of the Engineer when all

the pumps are operating.

The system shall be shown to operate correctly whatever the selection of duty and

standby equipment may be.

Conditions to be tested shall include:

Normal automatic operation.

Normal manual operation

Emergency manual operation

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1.22.2 Commissioning Tests Correct operation of controllers shall be verified by observing that the final control

element moves in the proper direction to correct the process variable as compared to

the set point.

All logic sequences shall be verified to operate in accordance with the

specifications.

All defects and malfunctions disclosed by test shall be corrected immediately. New

parts and materials shall be used as required and approved and tests shall be

repeated.

A report certifying completion of validation of each instrument system indicating

calibration values, verification that the system performs as per requirements and any

provisional settings made to devices shall be provided. A format for commissioning

checklist to be provided for approval before performing the commissioning tests.

1.22.3 Final Operational Testing and Acceptance

Upon completion of instrument calibration and system validation, all systems shall

be tested under process conditions.

The testing shall include, but not limited to all specified operational modes, taking

process variables to their limits (simulated or process) to verify all alarms, failures,

interlocks and operational interlocks between systems and/ or mechanical

equipment.

Any defects or malfunctions shall be immediately corrected using approved

methods and materials and the tests shall then be repeated.

Upon completion of final operational testing, a report shall be submitted, indicating

that the total control system provided meets all the functional requirements specified

herein. This report shall be made in the format approved by the Engineer. The

Engineer shall certify this report and it shall constitute final acceptance of the

control system.

1.23 Commissioning

After completion of installation works the Selected Bidder shall arrange to carry out

following checks/tests in the presence of JAL NIGAM representative / Engineer – in

– charge.

1.23.1 Test on Control Panels and Switchboards

1.23.1.1 Mechanical Completion Test

i) Check name plate details of every associated equipment according to

specification

ii) Check for physical damage

iii) Check for tightness of all bolts, clamps and connecting terminals

iv) Check earthing

v) Switch developments

vi) Each wire shall be traced by continuity tests and it should be made sure that

the wiring is as per relevant drawings. All interconnections between

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panels/equipment shall be similarly checked.

vii) All the wires should be maggered to earth

1.23.1.2 Commissioning Tests

i) Checks on relays, functioning of relays, simulation of fault for testing

ii) Checks on motors

iii) Setting of relays, other alarm, tripping devices and interlocks as per scheme

iv) Phase angle checks, measurement of magnitude and phase angle of current

transformer secondary currents and potential transformer secondary voltage

v) Functional checking of all power and control circuits e.g. closing, tripping,

control, interlock, supervision and arm circuits including proper functioning of

the components equipment. If inter locks are provided with other equipment, it

shall be thoroughly tested.

1.23.2 Test of Relays

1.23.2.1 Mechanical Completion Checks

i) Check name plate details according to specification

ii) Check for any physical damage

iii) Check internal wiring

iv) Megger all terminals to body

v) Megger AC to DC terminals

1.23.2.2 Commissioning Checks

i) Check operating characteristics over the entire range by secondary injection

ii) Check minimum pick up voltage

iii) Check operation of electrical / Mechanical targets

iv) Relay settings to be checked by injecting different values of current

v) Setting of relays as per discrimination chart

1.23.2.3 Miscellaneous

Mechanical completion checks and commissioning tests on items not covered above,

shall be carried out by the Selected Bidder as per the instructions of JAL NIGAM

representative / Engineer - in – charge.

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1.24 ANNEXURES ANNEXURE – 1A

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ANNEXURE – 1B

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ANNEXURE – 1C

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Schedule II – Part E

General Painting and Protection Requirements

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General Painting and Protection Requirements 1.1 General

The preparation, application and conditions for work shall comply with the

recommendations of BS 5493 and BS 6150 or if the protection is of a special nature,

in accordance with the manufacturer's directions.

Paints, primers and undercoats shall be obtained from the same manufacturer and

except where a definite time is specified between mixing and application, shall be

ready mixed for use. They shall be compatible with one another.

Paints shall be delivered in sealed containers bearing the manufacturer's name, batch

number, etc. and shall carry a label giving details of quality and instructions for use.

No site painting shall be carried out unless the surface to be painted is dry, the air

temperature above 4oC and the relative humidity less than 85% or as otherwise

specified by the paint manufacturer, whichever is minimum. The Employer‟s

Representative shall approve the methods for removing all dirt, oil, grease, etc, before

Site painting commences.

Test plates carrying finishes from the actual coating used may be required by the

Employer‟s Representative for inspection and test purposes.

To facilitate inspection, no consecutive coats of paint shall be of the same shade

except in the case of white.

Priming to two mating surfaces shall be applied prior to assembly.

All items of Plant shall be delivered to Site with the shop paint finish applied unless

specified otherwise. A further coat of final finish paint shall be applied at Site, of

sufficient thickness to produce a uniform colour and appearance. Such painting shall

be carried out within one month of successful acceptance trials for the Plant.

All paint thicknesses shall be checked using an Elkometer or equivalent instrument,

supplied by the Selected Bidder, for each layer of paint, to the reasonable satisfaction

of the Employer‟s Representative.

All coatings applied to any part of the plant in contact with water to be used for

drinking, washing or cooking shall be non-toxic, non-carcinogenic, shall not impart

taste, odour, colour or turbidity to the water or foster microbial growth. No

manufacturer‟s name-plate identification, vented filler plugs in gearboxes or grease

nipples shall be painted over. Lead based paints shall not be used.

The Selected Bidder shall liaise closely with the paint manufacturer who shall

provide full facilities for him to inspect and check the preparation and painting during

all stages. The Selected Bidder shall report on his inspections to the Engineer.

The Selected Bidder shall ensure that all coatings are free from defects and adequate

in all respects for the purpose intended.

1.1.1 Painting System Failure

The painting system shall be deemed to have failed if:-

After painting, damage has been caused by handling, impact, abrasion or welding;

Any portion of the paint film separates from any other or the parent metal;

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After painting the total dry-film thickness is less than that specified.

Failure shall not include:-

Loss of gloss;

Variation of shade, not affecting the anti-corrosive properties of the system.

1.2 Colour Coding and Labelling of Pipes and Equipment

All pipes and equipment shall be colour coded to a schedule to be agreed with the

Employer‟s Representative before any site painting starts, or earlier if necessary to

suit manufacturing procedures.

Valves and fittings shall be painted in the same colour as of the pipe of which they

form a part. Where a pipe enters or leaves a piece of equipment the pipe colour shall

extend up to but not including the flange attached to the equipment.

All pipelines shall be identified by stick-on 90 micron thick vinyl film labels showing

the name of the material to be carried by the pipeline and an arrow indicating the

direction of flow. Letters of titles shall be pre-spaced on carrier tape and the complete

title protected by one piece removable liners. Titles shall be at intervals not less than 8

m, but shall in any case be provided in every space through which the pipe passes.

Locations of labels shall be subject to prior approval by the Employer‟s

Representative. Lettering sizes shall be between 16 mm and 75 mm in height

depending on the size of the pipe.

Pipes smaller than 22 mm outside diameter shall be labelled by the use of tags instead

of labels. Tags shall be made of brass no smaller than 65 mm x 16 mm by 1.5 mm

thick, with lettering etched and filled with black enamel.

Titles shall also be provided on all equipment in locations and in sizes to be approved

by the Employer‟s Representative.

1.3 Cleaning and Preparing at Place of Manufacture

The Selected Bidder shall be responsible for the cleaning and preparation for painting,

priming or otherwise protecting as specified of all parts of the Plant at the place of

manufacture prior to packing.

1.3.1 Cleaning

Parts shall be cleaned prior to testing at the manufacturer's works. Parts subject to

hydraulic test shall be tested before any surface treatment. After test all surfaces shall

be thoroughly cleaned and dried out if necessary by washing with an approved

dewatering fluid prior to surface treatment.

1.3.2 Preparation

Bright Parts: Bright parts and bearing surfaces shall be thoroughly polished and

protected from corrosion by the application of rust preventive lacquer or high melting-

point grease, as approved by the Employer‟s Representative, before the parts are

packed. A sufficient quantity of the correct solvent for removal of the protective

compounds shall be supplied and packed with each particular part.

Embedded Parts: Embedded parts or those parts of an assembly which will be

embedded in concrete shall be thoroughly de-scaled and cleaned to the satisfaction of

the Employer‟s Representative and before being packed shall be protected by a

cement wash or other approved method. No cast iron or steel work shall be bitumen or

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tar coated where it is to be cast into the concrete and provision shall be made for

cleaning off any portions so coated.

Grit or Shot Blasted Parts: Grit or shot blasting shall be carried out in accordance with

B.S. 7079 to a standard between `First Quality' and `Second Quality' given in Table 1

after which the maximum amplitude of the surface shall not exceed 0.1 mm.

Cast Iron and Steel Pipework: All ungalvanised steel pipework including pump

suspension mains, bearing spiders and tunnel tubes shall be prepared internally and

externally by grit or shot blasting as specified above and the surfaces primed as

specified within four hours of blasting.

1.4 Painting and Finishing at Place of Manufacture

This Clause governs the methods for the protective coatings to be applied to structural

steel, metalwork and ironwork as corrosion protection systems. The systems designed

as specified here shall be applied as specified under Protective Coatings. Protective

coating specified elsewhere for particular works such as pipes and cladding shall

firstly be designed in accordance with particular requirements specified elsewhere and

secondly in accordance with any requirements herein which are not overridden

elsewhere. This specification makes reference to the following standard:

B.S.5493 "code of practice for the protective coating of iron and steel against

corrosion"

The Selected Bidder shall design each protective coating system and shall submit

details of each system to the Employer‟s Representative for approval. Submissions

shall where possible be in the format of which examples are given at the end of this

section with such additional information and samples as the Selected Bidder may

provide or the Employer‟s Representative may require to enable the system to be

assessed.

Protective coating shall be designed in accordance with B.S. 5493 to have a long life,

generally of at least 10 years to first maintenance. Protection systems shall be chosen

to be easily maintained in the future and to allow non-specialist on-site re-coating

where necessary using single part paints.

For the purposes of system design the general environment shall be as specified in

B.S. 5493 Table 3 Part 2 `Exterior exposed polluted inland'. Bulkhead gates and

stoplogs shall be assumed to be exposed to a Table 3 Part 8 `Non-saline water'

environment unless otherwise approved by the Employer‟s Representative.

Interior spaces shall be considered to be dry in administration areas open to

continuous access and damp or immersed in other spaces. The protective coating of

components or structures which are continuously or infrequently immersed shall be

designed for the more onerous of these two conditions relevant to the protection

system used.

All exterior exposed items to be coated shall have a final coat of good appearance of a

colour and type as approved by the Employer‟s Representative.

Protective coating systems shall generally fall into one of the following basic systems;

1.4.1 Protective Coatings

Galvanising;

Galvanising plus painting;

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Multi-coat painting; Bitumen enamel;

Others as proposed by the Selected Bidder and approved by the employer‟s

representative.

The Selected Bidder shall submit to the Employer‟s Representative details of his

proposals for the corrosion protection of each of the items requiring such protection,

which will generally fall into the above categories, as follows:

Trash screens, flooring, ladders, access covers and frames, step irons and other

components which are inaccessible but subject to abrasion/damage;

Structural steelwork (including crane beams, monorails, crane structures and chassis),

bulkhead gates, stoplogs, grappling beams, steel tanks and other large items readily

accessible for maintenance;

Valves and other corrosion-susceptible items which may be buried and are not covered by

the provisions of other specifications :

Other components not covered by the above for which the Selected Bidder may propose a

system which he considers to be more suitable for the duty;

Electrical switchgear, transformers, control panels etc.

All painting material shall be applied in strict accordance with the paint manufacturer's

instructions.

Plant supplied to site with final coating applied:

Cubicles, cabinets etc. other than those specified in elsewhere in bid document.

Before any steel work is painted, the steel must be thoroughly cleaned and an

approved anti-rusting priming coat applied so that the possibility of rusting or

corrosion taking place is negligible. All surfaces should have not less than two stoved

undercoats and two top coats or air drying paint. The undercoats shall be easily

distinguishable in shade or colour from the priming and finishing coats. The two final

coats shall be in a colour and finish to be advised by the Employer‟s Representative.

The inside surfaces of any cubicles, cabinets etc. where condensation is liable to

occur, shall be coated with an approved anti-condensation composition. The Selected

Bidder shall ensure that all component sections of a switch board wherever

manufactured shall have a finish of uniform texture and an exact colour match.

Chromium Plated Parts: Where chromium plating is specified or offered by the

manufacturer it shall comply with the requirements of B.S. 1224 including the

following provisions. No blistering of any surfaces will be tolerated. The finished

appearance shall be bright. Where the base metal is steel, plating shall be applied in

accordance with Table 2. Other base metals shall be plated in accordance with Tables

3, 4, 5 as appropriate. For all base metals the service condition number 2 shall be

used.

Small bore pipes, valves and fittings etc., which are sited in architecturally finished

areas of the station and selected by the Employer‟s Representative shall be chromium

plated. Damage to chromium plating shall be made good before Taking Over.

Galvanized Parts: All materials to be galvanized shall be shown on the approved

drawings or specified. All punching, cutting, drilling, screw tapping and the removal

of burrs shall be completed before the galvanizing process begins. Parts to be

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galvanized shall be shot blasted as specified above. Such parts shall be galvanized not

more than four hours after commencement of shot blasting.

All galvanizing shall be done by the hot dip-process. No alternative process may be

used without the approval of the Employer‟s Representative. No components shall be

galvanized which are likely to come into subsequent contact with oil.

The zinc coating shall be uniform, clean smooth and as free from spangle as possible.

In the case of component parts the zinc coating shall weigh not less than 610 g/sq.m

of area covered and shall not be less than 0.090 mm in thickness.

Where hot-dip galvanizing is not practicable bolts and nuts shall be sherardised,

which shall conform to BS: 4921. The Employer‟s Representative may select for test

as many components to be weighed after pickling, and before and after galvanizing as

he may think fit.

All galvanized parts shall be protected from injury to the zinc coating due to

differential serration and abrasion during the periods of transit, storage and erection.

Damaged areas of the coating shall be touched up with an approved zinc-dust paint or

other approved flake metallic compound.

Cast Iron and Steel Pipework: (Internal surfaces)

The internal surfaces shall have an approved coating.

Where a bitumen based coating is used, it shall be in accordance with Type 2 of B.S.

4147.

Prior to lining, the pipe shall be grit blasted and primed with an approved primer. The

lining shall be in accordance with B.S. 534. After installation, the internal lining shall

be made good and satisfactorily tested with required detector.

The coating shall be suitable for use in contact with drinking water. The type of

coating shall be entered in Schedule L provided and the Employer‟s Representative

reserves the right to call for test plates of the paint. The manufacturer shall at the time

of ordering carry out the `Taste and smell test' (Appendix E of B.S.4147) and `Effects

on water test' (Appendix C of B.S. 3416) and forward 3 copies of the test results to the

Employer‟s Representative for approval.

Where pipes are to be welded after the protective coatings have been applied, the pipe

surfaces shall be primed and all other coating stopped of the weld preparation. Collars

and fillings shall be primed but no other coating applied.

The manufacturer shall supply a sufficient quantity of suitable materials to repair

damage occurring during delivery to site and to provide a flush finished internal lining

at welded joints. He shall supply sufficient coating to fill in the recesses at internal

welds over the previously primed areas. The costs of these materials shall be included

in the unit rates for the supply of the pipes and specials.

The coating shall be applied in accordance with the manufacturer's instructions and

with Appendices J and K of B.S. 3416.

Machinery- (Internal surfaces) e.g. pumps, valves, strainers, rising and suspension

mains of wet well pumps:

As for cast iron and steel pipework (Internal surfaces).

Cast iron and steel parts (External surfaces) immersed in Water:

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All ungalvanised metal parts which will be immersed in water shall be cleaned by grit

blasting and within four hours of blasting given a coating similar to that specified for

internal surfaces.

Cast iron and steel (External surfaces) in manholes and areas of high humidity:

Ungalvanised metal parts exposed in manholes or areas of high humidity shall be

cleaned by grit blasting and given two coats of a black bituminous solution.

Plant forwarded to site for final finishing.

Cast Iron and Steel Parts (External surfaces) outside buildings:

All ungalvanised metal parts which will be exposed to the outside atmosphere shall be

cleaned by grit blasting and provided with two coats of an approved primer.

Cast Iron and Steel Parts inside buildings:

All exposed metal surfaces which will not be immersed in water or exposed in areas

described above shall be rubbed down, cleaned by grit blasting and within four hours

of blasting given one coat of an approved primer before packing.

1.5 Painting at Site

Immediately on arrival at the site, all items of plant shall be examined for damage to

the paint coat applied at the manufacturer‟s works, and any damaged portions shall be

cleaned down to the bare metal, all rust removed, and the paint coat made good with

similar paint.

Steel and cast iron parts received at site shall be provided with adequate number of

further coats of coal tar epoxy polyamine coating to a total dry film thickness of 275

microns including the primer coats. All sharp edges, nuts, bolts and other items

difficult to be painted shall receive a brush coat of specified paint before application

of each coat of epoxy based coal tar paint giving a total dry film thickness of at least

275 microns. In the case of fabricated steelwork this work shall be done after

assembly.

Before painting is commenced the Selected Bidder shall submit for the approval of

the Employer‟s Representative, full details of the paints he proposes to use together

with colour charts for the gloss finishes.

After erection, such items which are not finish painted shall be finish painted, items

finish painted at the Manufacturer‟s works shall be touched up for any damaged paint

work.

1.5.1 Painting System Requirements

The painting work shall conform to the following requirements:

The surface preparation shall be carried out generally in accordance with IS: 1477 Part I

and IS: 6005.

After surface preparation, two coats of primer-red oxide zinc chromate with modified

phenolic alkyd base conforming to IS: 2074 shall be applied. Dry film thickness of each

coat shall be 25 microns.

For finish painting, after application of primer as in (b) above, two coats of synthetic

enamel conforming to IS: 2932 shall be applied. Dry film thickness of each coat shall be

25 microns.

Colours shall be selected as per IS: 5

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No painting shall be carried out unless the item has been inspected and accepted by

Employer‟s representatives at the Manufacturer‟s works.

The dry paint film thickness shall be measured by Elcometer or other instruments

approved by the Employer. In order to obtain the dry film thickness (DFT) specified,

the Selected Bidder shall ensure that the coverage rate given by the paint

manufacturer will enable this thickness to be obtained. Strength of adhesion shall be

measured with an adhesion tester and this value shall not be less than 10 kg/cm2.

Painted fabricated steel Work which is to be stored prior to erection shall be kept clear

of the ground and shall be laid out or stacked in an orderly manner that will ensure

that no. poles of water or dirt can accumulate on the surface. Suitable packings shall

be laid between the stacked Materials. Where cover is provided, it shall be ventilated.

1.5.2 Painting System

The painting procedure shall be submitted in the following format:

Surface Preparation

Reference Standard

Conditions of Work

Type of Materials

Tests and inspection methods and sequence, thickness (DFT)

Colour in final coat

Total thickness of coats (DFT)

Other necessary data and information

The following items in the plant are required to be painted;

Outer surfaces of pumps, valves, pipes, fittings, motors etc., not exposed to treated water

Steelwork exposed to weather, such as outer surface of surge vessel, valves, pipes etc.

Internal Plant and pipework, cranes, exhaust fans, fire extinguishers and miscellaneous

steelwork not exposed to weather

Steelwork exposed to weather, such as platforms, ladders, hand railing, etc.

Steelwork exposed to humid weather and requiring hard maintenance and repairs

Buried steelwork

Buried pipes and fittings prior to application of wrapping

Other equipment, as per requirement of employer.

All buried steel pipes and fittings shall be coated and unwrapped with hot or cold

applied, self-adhesive, polyethylene in accordance with AWWA C214 or equivalent

Standard.

Cast iron or mild steel parts to be built into concrete shall remain unpainted.

Immediately before it is cast in-situ, it shall be made perfectly free from dirt, scale,

loose rust, paint, oil lime wash or any other coating.

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No blast cleaning or painting shall be applied to corrosion resistant Materials such as

stainless steels. Ni-resist cast iron, bronze and other metals used for seals, bearings,

lighting fitting etc.

Machined surfaces such as gear teeth shall be coated with a thick layer of grease.

Other mechanical surfaces such as shaft ends or other bright parts shall be coated with

two coats of an anti-rust solution which can be removed easily when required.

Permanently bolted mechanical interfaces such as flanges shall be coated with a thin

coat of anti-rust compound before assembly.

All primers, under coats and finishes shall be applied by brush or airless spray, except

where otherwise specified.

Consecutive coats shall be in distinct but appropriate shades. All paints shall be

supplied from the store to the painters, ready for application, and addition of thinners

or any other Material shall be prohibited. Any instruction given by the paint

manufacturer shall be strictly followed.

All painting shall be carried out by the qualified, experienced & competent painters

under supervision. Paint shall be applied to the dry surface which has been prepared

in compliance with the approved procedure.

The Plant and equipment shall be inspected and reviewed at the various stages of the

coating application both at the manufacturer‟s Works and at the Site of the Works.

Samples may be taken from the paints as delivered and submitted to such tests as are

deemed necessary. The completed paint systems shall be tested by instruments to

ensure that the protection is of adequate thickness and is free from pinholes and the

direct measurement of adhesion shall be checked by the removal of a small section of

the coating. The Selected Bidder shall supply all instruments and apparatus required

for carrying out such tests required by the Employer.

1.6 Fusion-bonded Epoxy Powder Coatings

All fabricated steel pipework and other Plant where specified, shall have a lining and

coating, not less than 250 microns thick, of 100% solids, thermosetting fusion-

bonded, dry power epoxy coating. All grit and dust shall be removed and coating shall

be started before formation of visible oxidation of the surface. The metal shall be pre-

heated to a temperature recommended by the manufacturer and the epoxy powder

applied by immersion in a fluidized bed, after which excess powder shall be removed.

The powder shall be allowed to flow out completely before curing. The thickness of

the coating, including any repaired areas, shall be checked with a calibrated tester.

Spark testing, for pinholes, voids, contamination, cracks and damaged areas, shall use

a high-voltage spark generator. Repairs due to coating imperfections or damage shall

be done using a brush-applied compatible two-pack liquid epoxy compound. The area

to be repaired shall be cleaned to remove dirt, grease, scale and damaged coating,

which shall be feathered. Pinhole surface preparation is not required other than

removal of detrimental contaminants which could impair the adhesion of the repair

material. The surface coating shall be applied by an approved applicator. GRP covers

and guards shall be pigmented to give the finished colour without painting.

1.7 Waterworks Finish

A high standard of finish, defined as "Waterworks finish" is required for all Plant as

detailed below.

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1.7.1 Welding and flame cutting

A smooth neat finish, by careful grinding if necessary is required on all exterior

welding and flame cutting. All plates and bars used in fabrication shall have smooth

surfaces with no pitting or deep slag inclusions.

1.7.2 Castings

Casting surfaces shall be smooth and free from surface blowholes. Stock castings

shall be specially selected with this in mind. All castings shall be shot blasted before

machining.

1.7.3 Covers

All covers shall be firmly fixed. Weld mesh shall sit square in its frame. Where panels

are placed next to each other the patterns shall line up.

1.7.4 Flanges and beadings

All bolt holes shall be spot faced parallel with the mating face for good seating of nuts

and bolt heads. Surplus jointing shall be removed from mating faces and peripheries.

1.7.5 Items to be chromium plated

Name plates, instruction plates, rotation arrows, indicators and pointers, small bore

pipework, oil level gauges and fittings, small valves (including air valves), plugs and

grease nipples, which are sited in architecturally finished areas of the station and as

selected by the Employer‟s Representative, shall be chromium plated. Damage to

chromium plating shall be made good. All pipes and fittings etc. shall be fitted in a

straight, neat symmetrical manner so as to present a pleasing appearance.

1.7.6 External screws, Bolt Heads, nuts and washers

These shall be chromium plated, sherardised or made in stainless steel.

1.7.7 Gauges

All indicating gauges fitted to any machine assembly shall be of similar appearance

and grouped together to present a pleasing aspect. They shall all have chromium

plated cases, bezels, cocks and fittings

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Schedule III

Inspection, Testing And Commissioning Requirements

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1.1 Inspection and Testing During Manufacture

1.1.1 General

(a) All inspection and testing shall be carried out in accordance with the Specification

and in absence of Specification relevant Indian Standard or internationally approved

equivalent standard. After award of contract, Selected Bidder shall furnish a QA plan

for approval by Engineer / Independent Engineer. QA plan shall include testing for

incoming supply of raw materials and bought out items, stage inspections and tests on

finished products at manufacturer‟s works / appropriate testing station. QA plan shall

clearly indicate tests which are intended to be witnessed by the Selected Bidder alone

and those by both Selected Bidder and Engineer / Independent Engineer.

(b) Inspection and tests schedule shall be as follows;

1) Manufacture tests

2) Acceptance inspection / Quantity checking

3) Install /site inspection

4) Site acceptance test

5) Tests on Completion

6) Process Wet Tests (by Raw Sewage & tertiary treated sewage )

7) Operation Test (Tests After Completion)

(c) The Selected Bidder shall carry out at the place of manufacture tests of the Plant

/Equipment at any part of the Works.

(d) The Engineer / Independent Engineer and/or duly authorised and designated

representative(s) shall be entitled to attend the aforesaid inspection and/or tests.

(e) Selected Bidder shall provide test procedure, pre-factory test results, and calculation

sheet and provide all of test result with necessary document including its data and

photo to show Engineer / Independent Engineer that test is carried out in proper

condition and the its test results.

(f) The procedure for the testing and inspection to be carried out during or following the

manufacture of the materials to ensure the quality and workmanship of the materials

and to further ensure that they conform to the Contract in whatever place they are

specified shall be as described below.

(i) The Selected Bidder shall give the Engineer at least 21 clear days notice in

writing of the date and the place at which any plant or equipment will be ready

for inspection/testing as provided in the Contract. The Engineer / Independent

Engineer or his duly authorised representative shall thereupon at his discretion

notify the Selected Bidder of his intention either to release such part of the plant

and equipment upon receipt of works tests certificates or of his intention to

inspect. The Engineer / Independent Engineer shall then give notice in writing

to the Selected Bidder, and attend at the place so named the said plant and

equipment which will be ready for inspection and/or testing. As and when any

plant shall have passed the tests referred to in this section, the Engineer /

Independent Engineer shall issue to the Selected Bidder a notification to that

effect.

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(ii) The Selected Bidder shall forward to the Engineer / Independent Engineer 6

duly certified copies of the test certificates and characteristics performance

curves for all equipment.

(iii) If the Engineer(s) / Independent Engineer fails to attend the inspection and/or

test, or if it is agreed between the parties that the Engineer(s) / Independent

Engineer shall not do so, then the Selected Bidder may proceed with the

inspection and/or test in the absence of the Engineer / Independent Engineer and

provide the Owner with a certified report of the results thereof as per (ii) above.

(iv) If any materials or any part of the works fails to pass any inspection / test, the

Selected Bidder shall rectify or replace such materials or part of the works and

shall repeat the inspection and/or test upon giving a notice as per (i) above. Any

fault or shortcoming found during any inspection or test shall be rectified to the

satisfaction of the Engineer / Independent Engineer before proceeding with

further inspection of that item. Any circuit previously tested, which may have

been affected by the rectification work, shall be re-tested.

(v) Where the plant and equipment is a composite unit of several individual pieces

manufactured in different places, it shall be assembled and tested as one

complete working unit, at the maker‟s works.

(vi) Neither the execution of an inspection test of materials or any part of the works,

nor the attendance by the Engineer(s) / Independent Engineer, nor the issue of

any test certificate pursuant to (iii) above shall relieve the Selected Bidder from

his responsibilities under the Contract.

(vii) The test equipment, meters, instruments etc., used for testing shall be calibrated

at recognised test laboratories at regular intervals and valid certificates shall be

made available to the Engineer / Independent Engineer at the time of testing.

The calibrating instrument used as standards shall be traceable to

National/International standards. Calibration certificates or test instruments

shall be produced from a recognised/Laboratory for the Engineer‟s consent in

advance of testing and if necessary instruments shall be recalibrated or

substituted before the commencement of the test.

(viii) Tests shall also be carried out such that due consideration is given to the Site

conditions under which the equipment is required to function. The test

certificates shall give all details of such tests.

(ix) The Selected Bidder shall establish and submit a detailed procedure for the

inspection of materials or any part of the works to the Engineer / Engineer‟s

representative for approval within the date indicated in the Programme Details.

The detailed procedure shall indicate or specify, without limitation, the

following :

Applicable code, standard, and regulations.

Fabrication sequence flow chart indicating tests and inspection points.

Detailed tests and inspection method, indicating the measuring apparatus to

be used, items to be measured, calculation formula, etc.

Acceptance criteria.

Test report forms and required code certificates and data records.

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Method of sampling, if any sampling test to be conducted.

Selected Bidder‟s or Engineer‟s / Independent Engineer‟s witness points.

(x) The Selected Bidder shall not pack for shipment any part of the Plant until he

has obtained from the Engineer / Independent Engineer or his authorised

representative his written approval to the release of such part for shipment after

any tests required by the Contract have been completed to the Engineer‟s /

Independent Engineer / Owners satisfaction.

(xi) The following Inspection and Testing procedures shall be carried out for the

equipment as applicable.

The detailed procedure shall indicate or specify, without limitation, the

following:

Visual Inspection.

Dimension Checking

Dynamic balancing for all rotating parts

Hydrostatic / Leak testing for all pressure parts, Pneumatic Leak Test

wherever applicable

Operation check

Liquid penetrant tests or magnetic particle tests for all machined surfaces of

pressure parts.

(g) The Selected Bidder shall maintain proper identification of all materials used, along

with reports for all internal / stage inspection work carried out, based on the specific

job requirement and or based on the datasheets / drawings / specifications.

(h) The expenses incurred during inspection shall include, but not be limited to all

travelling, boarding, lodging, local; travelling and out of pocket expenses.

(i) For inspections of major equipments such as pumps, blowers etc at manufacturer‟s

sites within India, the Selected Bidder shall incur all the expenses of the Engineer /

Independent Engineer. All the expenses with respect to the aforementioned

inspection(s) shall be for maximum Ten inspection trips comprising of two members

from the Employer per trip.

(j) However, cost of all the inspection shall be borne by the Selected Bidder and will not

be reimbursed when material or any part of the facilities is not ready at the time

specified by the Selected Bidder for inspection or when re-inspection is necessitated

by prior rejection.

(k) Witnessed testing will normally be waived on standard types of equipment such as

small motors, individual standardised instruments, small mass produced components

used in the manufacture of Plant items, small bore pipework and fittings, minor

installation materials and low voltage cable. In order to remove doubt this shall not

relieve the Selected Bidder of his obligation under the Contract to ensure that all Plant

is tested at the manufacturer's works prior to delivery to Site.

(l) As a guide to the Selected Bidder the Engineer / Engineer‟s representative reserves

the right to witness testing of the following but not limited to the following Plant

items:

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a) Electrical:

(1) Transformers

(2) 33 LV & 11 kV Metal enclosed switchboards & Switchgears.

(3) 415 V Metal enclosed switchgears (PCC)/ MCC

(4) 415 V Power capacitor and control panel

(5) Battery, battery charger and DC Distribution Board

(6) Variable Frequency Drives

(7) Non Segregated Bus Duct

(8) Power & control cables

(9) Lighting System

b) Mechanical:

(1) SBR mechanism/Clarifier and thickener bridges, drives, and sludge/scum

mechanisms

(2) Chemical dosing systems complete

(3) Mixers, pumps and blowers including their motors rated at greater than 25

kW

(4) Valve and penstock actuators

(5) Valves and non return valves greater than 300 mm diameter

(6) Pipes more than 200 mm diameter

(7) Sluice Gates

(8) Weir Gates

(9) Coarse Screens and Fine Screens

(10) Dewatering Centrifuge / Belt Press Filter and associated plant

(11) Fine Bubble Diffuser systems

(12) Chlorination system and Gas Scrubbers

(13) Process Air Blowers

(14) Vertical turbine Pumps

(15) Horizontal & Submersible Pumps

(16) Membranes

(17) Gas safety devices/control valves

(18) Flame arrester and trap assembly

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(19) Flares

(20) EOT Cranes and Hoists

c) Instrumentation and Control:

(1) Flow meter and Process Instruments

(2) Programmable Logic Controller

(3) SCADA / HMI System

(4) Uninterruptible Power Supply System

(5) Wireless GPRS gateway testing

(6) FAT & SAT for complete ICA system

(m) All destructively tested samples shall be replaced with new.

(n) The Engineer / Independent Engineer reserve the right to be present during the testing

and inspection of all Plant items.

Materials, Plant and Equipment

The Selected Bidder shall place orders for the material and the equipment only after

approval of the Engineer. The Selected Bidder shall submit the detailed drawings and

the procedure of submission, review and revision shall be as specified herein below.

The Selected Bidder shall inform the Engineer / Independent Engineer about the

likely dates of manufacturing, testing, and dispatching of any material and equipment

to be incorporated into the Permanent Works. The Selected Bidder shall notify the

Engineer / Independent Engineer for inspection and testing, at least twenty-eight (28)

days prior to packing and shipping and shall supply the manufacturer's test results and

quality control certificates. The Engineer / Independent Engineer will decide whether

he or his representative (Engineer) will inspect and test the material / equipment or

whether he will approve it on the basis of the manufacture‟s certificate.

The following inspection and test categories shall be applied prior to delivery of the

equipment, of various categories as indicated in the technical specifications for each

type of the equipment:

Category A: -The drawings have to be approved by the Engineer before manufacture

and testing. The material has to be inspected by the Engineer or a third party

inspecting agency approved by the Engineer / Independent Engineer at the

manufacturer‟s premise before packing and dispatching. The inspection charges of the

agency will be borne by the Engineer / Independent Engineer. The Selected Bidder

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shall provide the necessary equipment and facilities for tests and the cost thereof shall

be borne by the Selected Bidder.

Category B: - The drawings of the equipment have to be submitted and approved by

the Engineer prior to manufacture. The material has to be tested by the manufacturer

and the manufacturer‟s test certificates are to be submitted and approved by the

Engineer before dispatching of the equipment. Notwithstanding the above, the

Engineer / Independent Engineer, after examination of the test certificates, reserves

the right to instruct the Selected Bidder for retesting, if required, in the presence of the

Selected Bidder‟s representative.

Category C: - Samples of the materials and/or equipment shall be submitted to the

Engineer for pre-construction review and approval in accordance with the provisions

of conditions of the contract. Following approval by the Engineer / Independent

Engineer, the material may be manufactured as per the approved standards and

delivered to the Site.

For material/equipment under Category “A” and “B”, the Engineer / Independent

Engineer will provide an authorization for packing and shipping after inspection.

The testing and approval for dispatching shall not absolve the Selected Bidder from

his obligations for satisfactory performance of the plant.

1.2 Factory Acceptance Test (FAT) Document

Fifty six (56) days prior to commencement of inspection of each Plant item /

equipment the Selected Bidder shall supply a Factory Acceptance Test (FAT)

Document for approval. This shall comprise four copies of the following:

- Unpriced copy of the Selected Bidders order for the Plant item / equipment

concerned:

- Details of the inspection and test procedures to be carried out.

- Pre-factory test results and its photos.

The FAT Plan shall provide comprehensive details of the tests to be carried out, the

purpose of each test, the equipment to be used in carrying out the test and the methods

to be adopted in carrying out the tests. The FAT shall provide space within the

documentation for results of the tests to be added and for each test and for the FAT as

a whole to be signed off by the Selected Bidder and the Engineer.

On completion of the tests the Selected Bidder shall provide four copies of all test

certificates, curves etc. for the inspected Plant item.

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1.3 Inspection and Testing Programme

The Selected Bidder shall submit to the Engineer / Engineer representative not later

than 56 days prior to the commencement of the first inspection and test during

manufacture a programme detailing the inspection dates for all Plant. Usually 2-3

engineer from JAL NIGAM would go for the inspection . Those items of Plant that

the Engineer has specifically identified for witness testing test shall be highlighted in

the programme.

The Contractor shall make all necessary arrangements for to and fro travels of the Employer's

Engineers I Officers & Consultant for pre-delivery inspection of major equipment in India or

Abroad. The entire travelling cost including ticketing, boarding, lodging, local travel, visa

charges, insurances and other miscellaneous cost, of the members of the Employer's team

shall be borne by the Contractor as per RBI Guidelines (for overseas visit) and no claim,

whatsoever on this ground, shall be entertained by the Engineer-in-Charge. The Contractor

shall keep a provision in the program for 4 weeks' notice for inspection in India and 12

weeks' notice for testing/inspection overseas.

The Selected Bidder shall keep the Engineer / Engineer‟s representative informed of any

changes to the programme.

The Engineer / Engineer representative shall not be requested to inspect an item of

Plant until the Selected Bidder has satisfied himself that the equipment meets all

requirements of the Engineer / Independent Engineer‟s Requirements.

The Selected Bidder shall inform the Engineer / Independent Engineer in writing at

least 21 days in advance regarding readiness for carrying out inspection of

equipment/material etc. at manufacturer's works or at places of inspection. The

programme for inspection shall be finalised by the Engineer after the receipt of the

above. In case inspection cannot be carried out due to non-readiness of

equipment/material etc. a subsequent date shall be finalised for carrying out the

inspection in which event all expenses incurred by the Corporation for such visits

shall be recovered from the Selected Bidder. In case equipment/material etc. is found

not to comply with the specification, dates for re-inspection shall be finalised and

expenses incurred by the Corporation for such visits shall also be recovered from the

Selected Bidder. Selected Bidder's Representatives shall essentially be present during

all inspections. The following information shall be given in the inspection call letter

mentioned above:

(a) Name of manufacturer/supplier;

(b) Address of place where inspection is to be carried out;

(c) Proposed date/s and equipment to be inspected;

(d) Name/s of contact personnel at manufacturer's/ supplier/s works with

their telephone and fax numbers.

(e) Name of Selected Bidder's Representative who will be present during

the inspection.

(f) Confirmation that internal testing has been completed.

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1.4 Tests at Manufacturer's Premises – Mechanical Equipment

1.4.1 Sewage / Sludge Pumps

Bidders shall complete the Schedule of Particulars and Guarantees and shall state

therein, inter alia, the guaranteed efficiencies of the pumps and motors offered, and

the overall guaranteed rates of energy consumption of the complete pump sets at the

duties specified.

The Selected Bidder‟s guarantees given when bidding in respect both of performance

and efficiency shall be binding and considered part of the contract.

1.4.2 Motors

(a) Routine TestsAll routine tests shall be carried out on all motors as per the latest

edition of IS 325.

1.4.3 Valve

(a) During testing there shall be no visible evidence of structural damage to any of the

valve component.

(b) Motorized valves shall be tested with their actuators, with a differential head

equivalent to their maximum working pressure, to prove that the actuators are capable

of opening and closing the valves under maximum unbalanced head condition within

the specified opening or closing period.

(c) Hydrostatically tested shall be as per relevant IS/BS standard for each type of valve.

1.4.4 Pipe-work

Testing of pipes and fitting shall be carried out in accordance with relevant Indian

Standard and internationally approved standard. Pipes, fittings and expansion bellows

shall be hydrostatically tested for 1.5 times the rated pressure.

The following test shall be carried out for pipelines:

(1) Pressure test

(2) Leakage test

(3) Colour check for welding pipeline

(4) Welding beat check

1.4.5 Compressors and Blowers

Tests shall be carried out in accordance with the relevant international standard. All

compressors and blowers shall be tested with their ancillaries to confirm design

performance particularly in respect of flow and pressure. The test shall demonstrate

that vibration and noise are within the specified limits and that the pressure relief

valve operates correctly.

Air receiver shall be tested in accordance with the relevant section of B.S. 5169.

All pressure vessels shall be inspected and hydro water tightness tested.

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1.4.6 Process Plant Items

All process plant items shall be tested to ensure they meet the Engineer / Independent

Engineer‟s Requirements for quality of workmanship, construction, and performance.

1.4.7 Crane & Hoists

Hoists and lifting equipment shall be assembled and tested at the place of manufacture

in accordance with IS 3938.

Each and every rotating part/assembly/sub-assembly shall be dynamically balanced as

per grade G16 of ISO 1940/1 - 1986.

1.4.8 Sluice Gates

(a) Seat Clearance Check

With the gate fully closed, the clearance between seating faces when checked with the

thickness gauge, shall not exceed 0.1 mm.

(b) Movement Tests

Each gate shall be shop operated three times from the fully open position to the fully

closed position and return to fully open, under no flow conditions to demonstrate that

the assembly is workable.

(c) Leakage Tests

With the gate in closed position design pressure shall be applied for a period not lesser

than 5 minutes to the unseating side of the sluice gate and the leakage shall not exceed

the maximum leakage permissible as per IS 13349.

(d) Hydrostatic Tests.

Finally a differential of one and a half times the design pressure shall be applied to the

unseating side of the gate. Under these tests no part shall show any deflection of

deformation.

1.4.9 Medium Screens

(a) All screens shall be checked for overall dimensions, clearance between the bars /

aperture size and its material as well as painting works.

(b) Conveyor shall be checked for dimensions and physical conditions, belt joint portion,

travelling accuracy of belt, motors and its power consumption, performance of safety

device.

(c) At least one screen of each type shall be tested for efficiency and operation by

employing screenings. For the screen having depth of channel more than 3 metres,

testing with reduced depth is acceptable.

1.4.10 Fine Bubble Diffusers

(a) Clean water Standard Oxygen Transfer Efficiency (SOTE) tests shall be

performed for each different diffuser grid geometry/arrangement proposed in

the design. These tests shall be performed by the diffuser Manufacturer at the

Manufacturer‘s testing facility or an equivalent facility appropriately equipped

with an adequately sized testing tank and other required appurtenances. The

testing shall be performed in full compliance with the latest version of the

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applicable standard testing protocol. These tests shall be witnessed by Engineer

per procedures set forth for witnessing elsewhere in this document.

(b) All diffusers including 5 % spares shall be thoroughly inspected by Selected

Bidder for physical damage to the membrane or any other part of the diffuser

and results of the inspection shall be reported to Engineer.

1.5 Miscellaneous Pump-sets (Drainage, Filtrate and Domestic Pump sets)

All the pump-sets other than sludge pumps shall be tested for performance as per IS

5120.

1.6 Manufacturer's Works Acceptance Tests on Electrical Equipment

The following equipment / items shall be subjected to inspection, routine

/acceptance tests as per latest edition of relevant Indian / International standards in

the presence of Engineer / Independent Engineer/ his Engineer

(a) Transformers

(b) 33 KV & 11 kV Metal enclosed switchboards & Switchgears.

(c) 415 V metal enclosed switchgears (PCC) /MCC

(d) 415 V Power capacitor and control panel

(e) Diesel Standby Generator with AMF Control Panel and Synchronizing panel

(f) Battery, battery charger and DC Distribution Board

(g) Variable Frequency Drives

(h) Non Segregated Bus Duct

(i) Power & control cables

(j) Cable carrier system

(k) Lighting system

(l) Earthing and lightning protection systems

Copies of test Certificates for the type tests and Special tests not later than 5 years

conducted as per relevant Indian / International Standards for all the equipment /items

of above shall be furnished for the perusal of Engineer / Independent Engineer / his

Engineer. If type tests and special tests have not been conducted on any of these

items, the same shall be carried out in the presence of owner/ Engineer at no extra

cost.

1.7 Manufacturer's Works Acceptance Tests on Instrumentation, PLC, SCADA and

Associated Equipment

A. Instrumentation:

(a) Inspection, Testing and Setting to Work:

(i) General

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Each item of plant shall be subjected to the manufacturer‟s own tests which shall be

certified.

Each item of plant and its installation shall be subject to inspection and testing at the

place of manufacture.

The Selected Bidder shall be responsible for the provision of all necessary test

equipment. The Selected Bidder shall demonstrate to the Engineer, the correct

operation of any item of plant and the Engineer may witness any test. Tests which, in

the opinion of the Engineer, were failed or not performed correctly shall be repeated.

Calibration tests for field instruments and analytical instruments should be conducted

on site after installation and the same should be witnessed by the Engineer.

Before any test is made, the Selected Bidder shall submit to the Engineer a full list of

test equipment & test procedures (method statements) to be used. Each item of test

equipment shall have a standard of accuracy better than that stated by the

manufacturer of the item to be tested. The Selected Bidder shall provide evidence of

the condition and performance of any item of test equipment, in the form of test

certificates issued by an appropriate authority independent of the Selected Bidder and

manufacturer, or as otherwise directed by the Engineer. Test equipment shall be

checked frequently during the period of the tests.

The Selected Bidder‟s staff responsible for supervising and carrying out tests shall be

fully conversant with the various items of equipment of other manufacturers and if

necessary the Selected Bidder shall arrange for his personnel to attend suitable

training courses on his own expense.

Any fault or shortcoming found during any inspection or test shall be rectified to the

satisfaction of the Engineer before proceeding with further inspection or testing of

that item. Any circuit previously tested, which may have been affected by the

rectification work, shall be re-tested.

(b) Preliminary Inspection and Testing at the Place of Manufacture

(i) Field-mounted instruments

After the successful completion of the manufacturer‟s own inspection and testing of

instruments supplied under the Contract, similar tests shall be carried out in the

presence of the Engineer and the Selected Bidder. Such tests shall include a

demonstration that an increase or decrease of the measured value at several points

over the full range of the instrument produces a corresponding increase or decrease in

the instrument output signal. These tests shall include checks on the specified

accuracy of the instrument at all points.

(ii) Instrument panels, enclosures and mounting boards

The manufacturer shall not present instrument panels, enclosures and mounting

boards (assemblies) for inspection and testing until the manufacturer‟s own tests and

inspection has been completed. A preliminary inspection and test of these assemblies

may then be witnessed by the Engineer. The Selected Bidder shall give not less than 7

days‟ notice in writing that he has completed.

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His tests and inspection and is ready for the witnessed tests and inspection. Where this

notice period is different in the Conditions of Contract this shall take precedent.

The witnessed inspection and testing shall include the following:

a. A visual inspection of the panel assembly to show that the design, construction and

finish are satisfactory and in accordance with the Specification;

b. A check that equipment is securely mounted, accessible for removal or calibration

without damage to or undue disturbance of other components, wiring or piping;

c. That all engraving and labels are correctly positioned, fixed and designated in

accordance with the Specification;

d. Panel power-distribution circuits have the correct breaker/fuse rating coordination and

designation;

e. Power-isolation facilities meet the Specification;

f. The main incoming supply voltage, frequency and/or pneumatic supply pressure is

within the required limits, these being checked at the beginning and end of the test

and the results recorded on test certificates;

g. The output of all power supply units again at the beginning and end of the testing with

results being recorded;

h. The power supply voltage or air pressure of all component instruments of the

assembly(s), these voltages/pressures being recorded on the test certificate;

i. The insulation resistance of all circuits except sensitive electronic equipment which is

liable to damage by application of the test voltage, such circuits being disconnected

before making the insulation resistance tests and these tests being carried out in

accordance with IEE Wiring Regulations;

j. That the clean earth bar is isolated from main frame of the panel.

Internal lighting and anti-condensation heaters and associated thermostats, isolators,

limit switches and wiring shall be checked for compliance with the Specification.

Spare capacity within the panel(s) shall be checked to see that it complies with the

Specification. This shall include future equipment space, spare terminals, space in

wiring trunkings and provision for additional cable entry.

(c) Functional Testing at the Place of Manufacture

(i) General requirements

Once the preliminary inspection and testing is complete to the satisfaction of the

Engineer, functional testing shall commence. The purpose of the functional tests are

to demonstrate that instrument panels enclosures and mounting boards (assemblies)

conform with requirements of the Specification.

Not less than 30 days before the commencement of functional tests, the Selected

Bidder shall submit to the Engineer, for approval, two copies of comprehensive test

procedural documents detailing each test to be carried out. The document shall

include results forms on which the results of each test will be entered. The forms shall

include spaces for numerical values, where necessary, and witness signatures.

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All applicable drawings and data shall be provided at the place of inspection by the

Selected Bidder.

The Selected Bidder shall provide all test instruments and equipment necessary to test

the assemblies in their entirety.

The following is a typical list of the equipment required:

• Switch boxes;

• Indicator light boxes;

• Analogue signal sources;

• Dummy loads;

• Meters;

• Simulators;

• Desk-top computers;

• Programmers for DCS or outstations;

• Insulation test equipment

B. Programmable Logic Controller (PLC) and SCADA

The Selected Bidder shall carry out specified tests as follows in addition to any tests

stated or implied by the foregoing sections of this clause.

The tests shall be carried out on the fully assembled control panel containing the PLC

and associated equipment in order to demonstrate correct functional operation of the

hardware and software systems.

(ii) Factory Acceptance Test (FAT)

The Selected Bidder shall conduct a full programme of tests of the PLC & SCADA

system at the Selected Bidder‟s testing facility in the presence of the Engineer to

verify that all features of the system have been provided, are operating correctly and

are in full compliance with the Specification. Unless otherwise specified or agreed by

the Engineer, the entire PLC & SCADA system shall be assembled and tested

together as an integrated system, including all master station equipment, all operators‟

consoles, all outstations and telemetry equipment all instrumentation panels and

uninterruptible power supplies included in this Specification. The scheduled date for

the factory acceptance test shall be as agreed by the Selected Bidder and the Engineer

at least four weeks before the test.FAT shall be conducted with a hardwired

simulation panel connected to the PLC based SCADA system. Selected Bidder shall

note the importance of the requirement. No software based simulation testing shall be

accepted or allowed.

Not less than one month before the scheduled factory acceptance test, the Selected

Bidder shall submit to the Engineer for approval two copies of a comprehensive

manual detailing each test to be conducted. The manual shall include a results form on

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which the results of each test will be entered, including spaces for numerical values

where appropriate and witness signatures.

Not less than 7 days before the scheduled factory acceptance test, the Selected Bidder

shall give written notification to the Engineer that a complete dry-run of the factory

acceptance test has been performed successfully and that, in the opinion of the

Selected Bidder, the system exhibits stable operation and is ready for the formal

factory acceptance test.

The factory acceptance test will be considered successfully completed only when the

system has successfully passed all factory tests. The system shall not be delivered to

Site until the successful completion of the factory acceptance test is certified by the

Engineer or unless otherwise approved by the Engineer. Delay in the delivery of the

system due to failure of the factory acceptance test shall not constitute an unavoidable

delay. If the system fails the factory acceptance test, the test shall be extended or

rescheduled at the discretion of the Engineer.

All hardware to be used in the testing of the system shall have passed an agreed

preliminary hardware performance test to ensure known hardware operability before

software testing begins.

After successful completion of the factory acceptance test, no software changes shall

be made to the system without written authorisation by the Engineer. Any changes to

the system which effect the system software documentation, such as input scale

modifications or changes to the control logic, shall be entered into the system

documentation before delivery of the system to Site.

(iii) FACTORY ACCEPTANCE TEST PROCEDURES

(d) General

The scope of the tests shall include the proving of every aspect of hardware and

software operation and functions as detailed below.

(e) Hardware tests

(a) Verify the correct inventory of hardware including cables and printed circuit

boards;

(b) Demonstrate that all spare-memory, disk-capacity and system-expansion

requirements have been met;

(c) Demonstrate all hardware and software diagnostics;

(d) Verify all power supply voltages are within tolerance;

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(e) Verify proper earth connections and isolation of instrumentation earth for all

equipment;

(f) Demonstrate operation of test simulation and indication equipment and its

Suitability for adequate functional testing of all system functions.

(f) Software tests

(a) Demonstrate the editing of all system parameters including set-points, timers and

the like;

(b) Demonstrate system configuration capabilities including the addition and deletion

of input and output points, outstations, and all data base parameters;

(c) Demonstrate the addition, deletion and modification of mimic displays and report

formats;

(g) Functional tests

The functional tests shall verify proper operation of every specified system function

as an integrated system. These tests shall be conducted in conjunction with functional

tests of instrumentation and control panels as specified elsewhere. All failures or

discrepancies found shall be documented in the test manual.

Following a failure of any functional test, should software or hardware modifications

be required it shall be the decision of the Engineer whether the factory acceptance test

is to continue, re-start or be aborted. If testing is allowed to continue, any changes

which are required shall be described in a system modification document, signed by

both Selected Bidder and Engineer and be incorporated into the final factory

acceptance test documentation. The failed test shall be re-conducted and the Engineer

may require the retest of functions which may be affected by the modification.

The functional tests shall include, as a minimum, the following:

(a) Demonstration that the system meets the requirements of the Specification for

response time and speed of screen update

(b) Verification of the accuracy of all analogue input points in the system. The

procedure shall include applying the appropriate signal to each analogue input at

a minimum of three points within the range of the input, checking for expected

numerical results, and verifying appropriate update of related mimic displays.

Proper sensing and action by the system to high and low out-of-range inputs shall

also be verified

(c) Verification of the proper logic sense, pulse accumulation and rate computation

where appropriate, of all digital inputs and verifying appropriate update of related

mimic displays;

(e) Verification of all control and sequencing operations and proper operation of all

digital and analogue outputs. The procedure shall include simulation of all related

process variables for both normal and abnormal conditions, including instrument

and component failure, and demonstration of fail-safe response of the system.

System outputs shall be indicated with appropriate lamps and indicators;

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(f) Simulation of outstation communications errors and failures and demonstration of

error detection and handling, failure detection and handling, and appropriate

changes to control actions as designed and specified;

(g) Verification of fault detection and diagnostics by inducing a sufficient variety of

fault conditions in the system to ensure that detection processes and fail-safe

operation are adequately tested;

(h) Demonstration of proper operation of all mimic displays, help pages, reports,

operator procedures and historical data accumulation;

(j) Demonstration of proper operation of all outstations following a simulated master

station central processor failure;

(k) Demonstration of proper operation of all equipment during both a system wide or

isolated power failure, and following power restoration. The procedure shall

include the demonstration of battery backup of both master station and outstation

for the full length of time specified, and proper operation of power fail, low

voltage warning and all associated alarms.

(h) Reliability test

After successful completion of the functional tests a 48-hour continuous run of the

system shall be performed. The test shall be passed if no system function is lost or no

hardware or software failure occurs. Hardware failure is defined for this test as the

loss of a major component such as the computer, an outstation, a VDU or a peripheral

device. Non-repetitive mechanical failures of loggers, push-buttons and the like are

excluded.

During this test, the system shall be exercised with simulated inputs and conditions in

a manner which approximates the on-site operational environment. Unstructured

testing by the Engineer shall be included during this test. Upon any system failure

during this period, it shall be the decision of the Engineer whether the reliability test is

to continue or be aborted. If testing is allowed to continue any changes to the system

which are required shall be described in a system-modification document, signed by

both Selected Bidder and Engineer and the document shall be incorporated into the

final factory acceptance test documentation.

(i) Factory acceptance test documentation

As a minimum, the following information shall be included in the factory Acceptance

test manual for each test:

• Test identification number;

• Test name and description;

• List of all equipment to be tested including any special test equipment required;

• Description of the test procedure broken down into logical steps;

• Description of the expected system response verifying the completion of each

logical step;

• Space for recording the results of the test and the time and date of the test;

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• Space for signatures of the Selected Bidder and the Engineer.

In addition, the Selected Bidder shall provide a method for recording and tracing all

problems, discrepancies, queries and suggestions regarding the system and software,

and for formalised control of any modifications to the system.

(iii) Pre-commissioning tests

The Selected Bidder shall perform pre-commissioning, or preliminary, testing of the

SCADA system in accordance with that specified for instrumentation. The purpose of

pre-commissioning tests is to confirm readiness of the system for commissioning.

The scope of pre-commissioning tests shall be generally as specified for factory

acceptance tests but real field inputs and final control elements shall be used wherever

practical to provide inputs to the system and to confirm proper outputs.

Where this is impractical, simulation signals shall be injected as near as possible to

their ultimate sources so as to include in the tests as much of the cabling system as

possible.

Each process system shall be set to work under manual control and the system tested

to confirm proper operation. After proper operation of manual control mode has be

verified, tests of automatic controls of each process system shall be conducted

wherever practical.

(iv) Commissioning

(j) Site Acceptance Tests (SAT)

The Selected Bidder shall submit all relevant draft operating manuals for the PLC &

SCADA System to the Engineer for approval prior to commissioning tests.

Any faults or failures of the system detected during the previous tests shall be noted

and corrected to the satisfaction of the Engineer before commissioning is allowed to

commence.

As part of commissioning, the PLC & SCADA system shall be tested for availability

for a continuous period of 30 days. During this period, the system will perform the

normal functions according to the procedures described in the SAT documentation

approved by the Engineer.

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The system shall have passed the SAT if all major components have been free from

fault or failure and exhibit full error-free functionality for 100 % of the total duration

of the test, unless otherwise agreed by the Engineer. Major components include all

master station equipment, outstations, communications facilities and instrument panel

components, excluding push-buttons, switches and lamps and any equipment not

supplied by the Selected Bidder.

During SAT, no modifications to the system shall be made by the Selected Bidder

without the written approval of the Engineer. Erroneous functioning which requires

software modifications or re-configuration to correct, other than set-point or

parameter changes, shall constitute a failure of the availability test. Any changes to

the system which are required and approved shall be described in a system-

modification document, signed by both Selected Bidder and Engineer and the

document shall be incorporated into the final test documentation. The test shall be

restarted after corrections have been made.

1.8 Manufacturer's Works Acceptance Tests on Uninterruptible Power Supplies

The Selected Bidder shall carry out further specified tests as follows in addition

to any tests stated or implied by the foregoing sections of this clause.

The tests shall be carried out on the fully assembled unit utilising the batteries

that are to be supplied with the unit.

The Selected Bidder shall demonstrate the following:

(1) Change-over from full load with mains present to full load on battery supply

(2) Carry out a discharge test on the system at full load and for the specified duty

bridging time period.

(3) Carry out recharge test after operation for the specified duty bridging time at full

load. The UPS shall supply the full load during the recharge cycle.

1.9 Inspection at Site

During erection of the Plant the Engineer will inspect the installation from time to

time in the presence of the Selected Bidder's Supervisor to establish conformity with

the requirements of the Specification. Any deviations found shall be corrected as

instructed by the Engineer.

1.10 Plant protection on Site

Factory finished plant shall be adequately protected both before and during

installation against damage to finished surfaces, fitted components, and the ingress of

dust. It may be necessary for structural finishing operations to be carried out in the

vicinity of installed plant before it is taken over and the Selected Bidder shall take this

into consideration in complying with the requirement of this clause.

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1.11 Civil Inspection (Water Leakage Test)

1.11.1 Anaerobic Digester Tank

(a) Gas Leakage test of tanks

This test shall be conducted after water retention test before drain the water from the

digester.

The test procedure shall include but not necessarily be limited to the following;

a) Install blind flanges at all open pipes, and inject air at 700 mmAq into the

upper area of Anaerobic Digester tank.

b) Check and write down water level at Anaerobic Digester tank again before

starting the air leakage test.

c) Install differential pressure type level gauge and add air pressure up to

1,500mmAq and close the air feeding valve.

d) Observe the air pressure level gauge for 1.5 hrs,

e) If air pressure drop is observed, and then start air compressor at 700mmAq

again to find out air leakage location by soap.

f) Repair and retest until no air pressure drop checked by the Engineer.

(b) Operation test for safety valve

a) Set Gas safety valves for 520 mmAq and then inject air into the upper area of

sludge digestion tank.

b) Verify the action of safety valve open at 520 mmAq to control gas pressure in the

sludge digestion tank.

1.11.2 Digested Sludge and Biogas Storage Tank

The Digested Sludge and Biogas as Storage Tank shall consist of concrete Digested

sludge storage tank and M.S. Gas bell.

The Gas bell shall move up and down depending on generation of Biogas and

cogeneration operation.

The Digested Sludge and Biogas Storage Tank shall provide with a safety pressure

relief valves, flame arrester and trap assembly, vacuum contort valve.

(a) Water retention test of tanks (Refer to Part 7 – Particular Civil and Structural

Works Requirements of the Bid Document).

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(b) Gas Leakage test of tanks

This test shall be conducted after water retention test before drain the water from the

digester.

The test procedure shall include but not necessarily be limited to the following;

a) Install blind flanges at all open pipes, and inject air at 700 mmAq into the

upper area of sludge digestion tank.

b) Check and writ down water level at sludge digestion tank Sludge and Gas

Storage tank again before starting the air leakage test.

c) Install differential pressure type level gauge and add air pressure up to

1,500mmAq and close the air feeding valve.

d) Observe the air pressure level gauge for 1.5 hrs,

e) If air pressure drop is observed, and then start air compressor at 700mmAq

again to find out air leakage location by soap.

f) Repair and retest until no air pressure drop checked by the Engineer.

(c) Operation test for safety valve

a) Set Gas safety valves for 520 mmAq and then inject air into the upper area of

Digested Sludge and Biogas Storage tank.

b) Verify the action of safety valve open at 520 mmAq to control gas pressure in

Digested Sludge and Biogas Storage tank.

1.11.3 Field Control Inspection

Selected Bidder shall be conduct periodic field control inspection to prevent any field

accident. The Engineer shall joint field inspect or conduct unannounced inspections.

1.11.4 Inspection after Erection

After the erection of any item of Plant and its associated equipment has been completed,

it shall be offered to the Engineer for inspection in its static state prior to

commissioning the item.

Completion of erection and procedure prior to setting to work.

The mechanical completion of plant under erection shall be deemed to occur if all the

units/systems of the Works are structurally and mechanically complete as noted below:

All rotary, static, structural equipment, piping, electrical/instrumentation and other

equipment under the scope of the Contract have been erected, installed and grouted and

are as per the specifications.

All systems have been washed/flushed/drained/boxed up where necessary.

All system testing including pressure, vacuum and nondestructive tests, no load tests

and such other tests are completed with safety valves/relief valves set to operating

conditions installed in position.

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All panels, local control desks erected with power/control cable terminations with all

continuity checks, insulation checks and other installation checks are carried out.

Prior to pre-commissioning checks, the Selected Bidder shall erect the entire Plant and

ensure readiness of civil works to the satisfaction of Engineer / Independent Engineer,

so that the Works are physically ready to undergo pre-commissioning checks. Pre-

commissioning checks will include checks like no-load running of machinery, checks

on instruments and electrical including calibration and loop checks, functional checks,

inter-lock checks etc.

At the stage of mechanical completion of erection, the Selected Bidder shall ensure that

all the physical, aesthetic and workmanship aspects are totally complete and the Plant is

fit and sound to undergo pre-commissioning checks.

The following documentation shall be completed before the Selected Bidder notifies

Mechanical Completion of Erection to the Engineer / Independent Engineer

a) All shop inspection records compiled and bound in 4 (four) copies.

b) All erection and commissioning procedures duly approved.

c) All instruction manuals in draft form - with each sheet bearing a stamp to

indicate "DRAFT FOR REVIEW ONLY" submitted in 4 (four) copies.

Upon achieving mechanical completion, the Selected Bidder shall notify the

Engineer / Independent Engineer of such completion of section/units/systems and

readiness for inspection for acceptance of mechanical completion of erection. The

Engineer / Independent Engineer/ Engineer shall proceed with inspection of such

sections/units/systems within 10 days of such notice.

Consequent to inspection, the Engineer / Independent Engineer will inform the

Selected Bidder a list of deficiencies for rectification and the Selected Bidder shall

complete the rectification work within a jointly agreed period prior to start of pre-

commissioning tests. The erection period allowed by the Selected Bidder shall

include all activities of mechanical completion as noted above.

1.12 Site Acceptance Test Document

Fifty six (56) days prior to commencement of Tests on Completion the Selected

Bidder shall supply a Site Acceptance Test (SAT) Document for approval. This shall

comprise four copies of the details of the inspection and test procedures to be carried

out in testing the Works.

The SAT Plan shall provide comprehensive details of the tests to be carried out, the

purpose of each test, the equipment to be used in carrying out the test and the methods

to be adopted in carrying out the tests. The SAT shall provide space within the

documentation for results of the tests to be added and for each test and for the SAT as

a whole to be signed off by the Selected Bidder and the Engineer.

The SAT shall categorise tests as follows:

a) Dry tests

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Dry tests are those tests carried out without process fluid being present.

b) Wet tests which can be further sub-divided into

(1) Hydraulic tests

Hydraulic wet tests are those tests carried out with potable water in

order to prove the hydraulic capability of the Works.

(2) Process tests /System tests

Process wet tests are those tests carried out with raw Sewage as the

feed stock to prove the process capability of the Works.

The Selected Bidder shall make his own arrangements for water supply, chemical,

electric power, fuel, instrument and labour during hydraulic wet tests.

1.13 Tests on Completion

14.30.1General

Prior to the commencement of Tests On Completion the Selected Bidder shall submit

for approval the following:

(1) Site Acceptance Test Documents

(2) As-Built Drawings

(3) Operation and Maintenance Manuals

(4) Site test results / data sheet and photo

Tests on Completion shall not be commenced until the aforementioned documents are

approved.

The initial charges of oil, grease, electrolyte, generator fuel / oil, chemical, disposal of

cake, etc. necessary for Tests on Completion shall be provided by the Selected Bidder.

Raw Sewage and electricity required for Tests on Completion will be provided by the

Engineer / Independent Engineer free of charge. If necessary, Selected Bidder shall

create design loading conditions for testing purposes by testing fewer than the total

number of installed units of process tanks or equipment at a time. In such cases,

multiple tests shall be conducted to ensure that all installed units are tested. In the event

that raw sewage/influent wastewater is not available at the plant, the Selected Bidder

shall defer testing until such time as sewage becomes available for treatment as

described elsewhere in these Bid Documents. The Selected Bidder shall provide

adequate notice (this notice period shall be determined by the normal lead time for

locally purchased chemicals plus at least 28 days) of his chemical requirements prior to

commencement of the Tests on Completion involving their use.

The cost of chemicals used for the Tests on Completion shall be met by the Selected

Bidder.

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a) Manual Commissioning Tests

Manual Commissioning Tests shall be such preliminary trials, tests and retests on

individual items of Plant or complete systems as are required by the Engineer in

order to demonstrate that the Plant as a whole is ready to undergo the Manual

Operation Tests and that these will take place with a minimum of interruption.

The Manual Commissioning Tests shall demonstrate not only the items of Plant

under normal operation, but also their response to abnormal and emergency

conditions.

The Engineer will notify to the Selected Bidder which items of Plant will be tested

and the extent to which they will be tested in order to fulfill the requirements of

the Specification.

Leakage tests at 1.5 maximum working pressure shall be carried out on all erected

pipe work prior to the Manual Commissioning Tests.

Pump curves shall be available for the Manual Commissioning Tests and all

instruments essential for the tests shall have been calibrated.

b) Manual Operation Tests

When the Manual Commissioning Tests have been completed so that the items of

Plant have been demonstrated to the satisfaction of the Engineer / Independent

Engineer Representative, the Selected Bidder shall commence the Manual

Operation Tests.

These tests shall demonstrate the correct operation of the whole Plant whilst using

the minimum quantity of automatic control and monitoring equipment. Such

equipment shall be at least that required both for the maintenance of safety and for

the normal mode of operation of the Plant.

The Plant will be required to demonstrate satisfactory operation at all design flow

rates.

The tests shall be of seven consecutive days' duration; if the supply of water

should fail or other matters interfere outside the Selected Bidder's control, the tests

may be of such number of broken days as the Engineer considers is the equivalent.

The exact date of commencement shall be subject to the approval of the Engineer

and shall be dependent on the following conditions having been met

(1) All relevant items of Plant in approved working order

(2) All items of Plant correctly identified with labels

c) Automatic Commissioning Tests

The Automatic Commissioning Tests shall be such preliminary trials, tests and

retests on individual items of Plant or complete system as are required by the

Engineer in order to demonstrate that the Plant as a whole is ready to undergo the

Tests of Completion and that these will take place with a minimum of

interruption.

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At least one week before the commencement of these tests, the Engineer will

notify the Selected Bidder which items of Plant will be tested and the extent to

which they will be tested in order to fulfill the requirements of the specification.

(1) All pipe work shall be hydrostatically tested at site to a pressure equal to 1.5

times the maximum working pressure likely to be encountered in the system.

(2) The Selected Bidder shall carry out all tests on the Plant and shall supply four

copies of all test results to the Engineer.

(3) All tests shall be to the approval of the Engineer who may require them to be

repeated, prolonged or modified as may be necessary to ensure that any or all

items of Plant conform to the Contract.

(4) The Engineer shall be permitted to inspect all Plant which is undergoing tests

and may himself conduct tests.

Where it is necessary for the Engineer to make arrangements for the supply of water,

chemicals, power, etc., for any testing, the Selected Bidder shall not commence the

tests until after these arrangements have been made on or after a date agreed by the

Engineer and the Selected Bidder shall make no claim for delay to such testing on this

account except as provided for under Clauses 44 of the General Conditions of contract.

If any item of plant fails during or after testing to achieve its intended duty or

otherwise proves defective, it shall be modified or altered as necessary and re-tested

and re-inspected as required by the Engineer.

Vibration/noise level tests shall be carried out at site which will form basis for

acceptance of the equipment. If the Selected Bidder is not in a position to meet the

requirements given below as per ISO 10816 – 1995, the equipment may either be

rejected or the Selected Bidder shall carry out all necessary modifications to keep

vibrations within the acceptable limits specified.

Equipment Noise Level

(dBA at 1.86 m from

equipment)

Velocity of

vibration

(mm/sec)

All rotating equipment not having

reciprocating parts with motor kW

less than or equal to 15 kW

85 1.12

All rotating equipment not having

reciprocating parts with motor kW

more than 15 kW and less than

or equal to 75 kW

85 1.8

All rotating equipment not having

reciprocating parts with motor kW

greater than 75 kW

85 2.8

All equipment having reciprocating

parts viz. compressors, dosing pumps

85 -

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sampling pumps

The Selected Bidder shall have a minimum of two commissioning engineers, one for

process and plant and the other for electrical/instrumentation works on site during all

tests in order to both demonstrate the Plant and to correct any faults which may occur.

1.14 Dry Test Requirements

As a minimum requirement the following dry tests shall be carried out as a general

requirement:

(1) A general inspection to check for correct assembly and quality of

workmanship

(2) A check on the presence of lubricant, cooling medium, electrolyte, etc.

(3) A check on adequacy and security of Plant fixing arrangements.

(4) A general check to ensure that all covers, access ladders, water proofing,

guard railings etc are in place.

(5) A check on damp-proofing, rust-proofing and vermin-proofing and

particularly the sealing of apertures between building structures, chambers

etc and the outside.

a) Civil and Building Works

As a minimum requirement the following dry tests shall be carried out on the civil

engineering and building works:

- Check for the presence of foreign bodies in pipe work and structures.

b) Mechanical Works

As a minimum requirement the following dry tests shall be carried out on the

mechanical systems:

- Carry out preliminary running checks as far is permitted by circumstances in

order to ensure smooth operation of Plant.

c) Electrical Works

As a minimum requirement the following dry tests shall be carried out on the

electrical systems:

(1) Check phasing and polarity.

(2) Carry out point to point check on all cables.

(3) Check on security of cable terminations.

(4) Check on completeness and adequacy of earthing systems.

(5) Check setting on protection relays, sizes of fuses and motor overload

settings.

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(6) Carry out checks on cabling systems in accordance with the requirements of

the relevant standards.

(7) Check operation of main circuit breakers by secondary injection methods.

(8) Check rotational direction of Plant.

(9) Check instrument loop integrity, functionality and calibration.

(10)Check operation of standby generator installation and mains / generator

changeover procedures; a 4 hour load test (using the normal load of the

Works) shall be carried out on the generator when the load is available.

(11) Check plant functionality.

(12) Check functionality of the central MMI and its power supply.

1.15 Process Plant Item / Equipment

All process plant items / equipment shall be tested to ensure they meet the Engineer /

Independent Engineer‟s Requirements for quality of workmanship, construction and

performance.

1.16 Hydraulic Wet Test Requirements

Hydraulic wet tests shall be carried out on completion of dry tests.

Clear Water shall be used for hydraulic wet tests. The purpose of the tests is to prove

the hydraulic performance of the Works. In order to demonstrate this, the Selected

Bidder shall ensure that each part of the Works is hydraulically loaded to its rated

throughput for a period of at least four hours.

In order to ensure a sufficient supply of water to carry out these tests the Selected

Bidder shall provide all required facilities, including but not limited to any temporary

facilities that may be required for storage and recycle of Clear Water or facilities for

the disposal of the water off Site in an approved manner.

The following tests inter alia shall be carried out:

(1) Pressure testing of all piped systems laid direct in ground in accordance

with the relevant standards.

(2) Fill all structures and check for leaks.

(3) Filling of all storage vessels to check for leaks and distortion.

(4) Running of all pumped systems in order to check for.

i) Correct functionality.

ii) Absence of leaks.

iii) Correct running temperatures.

iv) Smoothness of running and the absence of undue vibration or stress.

v) Check drive running currents.

(5) Carry out calibration of instruments where appropriate.

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(6) Carry out valve operation, diversions etc. to fully hydraulically load each

process element (or where there is a requirement to withstand an over

load), overload each process element.

(7) Demonstrate correct functionality of electrical, control and

instrumentation systems.

The Selected Bidder shall simulate the conditions that will prevail when operating as

a process in order to demonstrate the correct functionality of process control loops

etc.

During these tests a check on the performance of Plant shall be made to compare its

site performance with the factory test data and to identify any constraints on

performance due to site conditions.

1.17 Safety Audit

After satisfactory completion of hydraulic wet tests and prior to introduction of

process fluid to the plant a safety audit shall be carried out to ensure compliance with

the necessary requirement for safety and for operation of Plant. The safety audit shall

be documented. The safety audit document shall be approved by the Engineer prior to

commencement of Plant commissioning.

1.18 Process Wet Tests (with Raw Sewage)

On approval by the Engineer / Independent Engineer the Selected Bidder shall carry

out process wet tests.

Raw Sewage shall be used as the main feed stock for process wet tests. These tests

shall be carried out to demonstrate the process performance of the Works. In order to

demonstrate this, the Selected Bidder shall ensure that each part of the Works is

loaded to its rated throughput (including a period of overload if required in order to

demonstrate compliance with the Engineer / Independent Engineer‟s / Owners‟s

Requirements) for a continuous stable operating period of not less than 48 hours. If

necessary, Selected Bidder shall create design loading conditions for testing purposes

by testing fewer than the total number of installed units of process tanks or equipment

at a time. In such cases, multiple tests shall be conducted to ensure that all installed

units are tested.

The Selected Bidder shall provide all required facilities for the disposal off Site in an

approved manner.

The following tests inter alia shall be carried out:

(1) Check for leaks on vessels, structures, pumps and pipe work.

(2) Running of all pumped systems in order to check for.

Correct functionality.

Absence of leaks.

Correct running temperatures.

Smoothness of running and the absence of undue vibration or stress.

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Check drive running currents where the solution pumped is different from

that pumped during hydraulic wet tests.

(3) Carry out calibration of instruments.

(4) Carry out valve operation, diversions etc. to fully hydraulically load each process

element (or where there is a requirement to withstand an over load), overload each

process element.

(5) Demonstrate correct functionality of electrical, control and instrumentation

systems not checked during dry or hydraulic wet tests or which may have changed

as a result of the different operating conditions now prevailing.

On completion of the tests on the various parts of the works the Selected Bidder shall run

the plant as a whole in order to demonstrate the full functionality and preliminary

performance of the Works at various throughput rates for a continuous period of not less

than 15 days.

During the various process tests the Selected Bidder shall take samples and carry out

Sewage quality analysis at not greater than one-hour intervals in order to demonstrate to

the Engineer that the Works is functioning in accordance with the requirement of the

performance guaranteed. Each sample shall comprise two 1 litre (minimum) quantities

and shall be labelled to identify the contents, where taken and time and date. The flow

recorded at the time of sampling shall also be indicated in the log book or record. One

sample shall be used by the Selected Bidder for his analysis; the other shall be handed

over to the Engineer / Independent Engineer / Owner.

The Engineer reserves the right to take additional samples and to carry out his own tests

or to check the samples taken by the Selected Bidder.

The Engineer shall be given reasonable access to the premises where analysis is taking

place in order to check on working practices and the procedures being adopted.

1.19 Performance Guarantee (PG) Test (Tests after Completion)

(a) General

On successful completion of “Test on Completion” the Selected Bidder shall carry

out the Performance Guarantee out over a period of 30 days. Any failure to perform

during the 90 days period shall restart the „30 day clock‟. If any part of the Facilities

fails to pass the test in the 90 days period the test shall be deemed as a failure and the

Selected Bidder shall carry out any necessary remedial work to the satisfaction of the

owner before the owner restarts the test. All expenses shall be borne by the Selected

Bidder. These tests shall be used to prove the operation of the Works and the

performance guaranteed of the works at varying flows and with varying raw sewage

quality.

1) The capacity of the whole plant and the quality of treated sewage produced

2) Guaranteed Power Consumption.

3) Tests shall be conducted by accredited representatives of the Selected Bidder

and the owner and/or owner‟s representative. Selected Bidder‟s

representatives shall witness all phases of the test and record the data jointly

with the Owner‟s representatives.

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4) The responsibility of conducting the test will be with the Selected Bidder

5) The timing of the tests shall be determined by the Independent Engineer who

shall give notice to the Selected Bidder.

6) All the instruments required for the PG test should have been calibrated by the

Selected Bidder prior to the start of the PG test, by the standard methods

acceptable to owner / owner‟s consultant. Wherever this is not possible, valid

calibration certificates by an independent agency shall be submitted by the

Selected Bidder.

7) All necessary tools and instruments required for PG test shall be arranged by

the Selected Bidder.

8) The Selected Bidder shall take samples in the presence of the owner and carry

out water quality analysis as specified in the contract in order to demonstrate

to the owner / consultant that the Plant is functioning in accordance with the

owner‟s requirements. Each sample shall comprise two 1 litre (minimum)

quantities and shall be labeled to identify the contents, where taken and time

and date. The flow recorded at the time of sampling shall also be indicated in

the log book or record. One sample shall be used by the Selected Bidder for

his analysis and the other shall be handed over to the Owner.

9) The owner reserves the right to take additional samples and to carry out his

own tests or to check the samples taken by the Selected Bidder.

10) If lab facility does not exist for any test, the same shall be arranged by the

Selected Bidder or the sample shall be tested for the same by a laboratory

approved by owner.

11) The owner shall be given reasonable access to the premises where analysis is

taking place in order to check on working practices and the procedures being

adopted.

12) Commissioning & PG test Record:

The Selected Bidder shall maintain two copies of Commissioning Record and

PG test Reports for documentation of following information on daily basis.

Print outs of data logs from SCADA system.

Water quality for samples collected (for parameters listed under

Functional Guarantee).

Electricity consumption.

Sludge Characteristics

13) Log sheets required for noting down readings / results of various tests shall be

prepared during formal approval of PG test procedure.

14) During PG test, the Selected Bidder shall run all the components of the plants

as a whole in order to demonstrate the full Functionality and performance of

the Facilities for a continuous period of not less than 30 days in accordance

with contract provision.

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15) The Functional Guarantee Tests would be carried out over a period of 30 days.

Any failure to perform during the 30 days period shall restart the „30 day

clock‟. If any part of the Facilities fails to pass the test in the 90 days period

the test shall be deemed as a failure and the Selected Bidder shall carry out

any necessary remedial work to the satisfaction of the owner before the owner

restarts the test. All expenses shall be borne by the Selected Bidder.

16) During the performance test all equipments, instruments, materials, tools,

tackles, chemicals and all other consumable, utilities, manpower, sludge

disposal shall be provided by the Selected Bidder at his own cost except for

the power cost.

17) The Selected Bidder will not be held responsible for interruptions to the

sewage treatment process as a result of Grid power failures (unless as a result

of a Plant failure interruptions in the raw Sewage supply etc. which are out of

his control. However, the Selected Bidder shall be required to demonstrate

that the Works can cope with these inevitable interruptions in an orderly

fashion and recover to a normal operational state with the minimum of

manual intervention.\

18) All consumables except power needed for operation of the works shall be

provided by the Selected Bidder.

19) The Selected Bidder shall provide all facilities and equipment not supplied

under the contract and which are deemed necessary for the Selected Bidder to

carry out and monitor the Tests after Completion.

(b) Methodology of the Tests:

1) During PG test, the Selected Bidder shall run all the components of the plants

as a whole in order to demonstrate the full functionality and performance of

the facilities for a continuous period of not less than 30 days in accordance

with Selected Bidder agreement.

2) Any failure to perform during the 30 days period shall restart the „30 day

clock‟. If any part of the Facilities fails to pass the test in the 30 days period

the test shall be deemed as a failure and the Selected Bidder shall carry out

any necessary remedial work to the satisfaction of the owner before the owner

restarts the test. All expenses shall be borne by the Selected Bidder.

3) All the instruments and interlocks provided with requisite controls and alarms

shall be checked during the test periods.

4) The results of the Tests shall be compared and evaluated by the Engineer /

and Selected Bidder.

(c) Sampling and Analysis

Sampling and analysis shall be performed to measure the parameters indicated

technical specifications

All costs associated with the taking and analysis of samples shall be met by the

Selected Bidder. If lab facility does not exist for any test, the same shall be arranged by

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the Selected Bidder or the sample shall be tested for the same by a laboratory approved

by owner and shall be performed in strict compliance with appropriate analytical

methods published in Indian Standards, or in “Standard Methods for the Examination of

Water and Wastewater” published by the American Public Health Association, or as

published by the US Environmental Protection Agency. The Selected Bidder shall

submit to the Engineer a comprehensive report of the above sampling and analysis,

including details of each analytical test as well as a summary of all the data and results

in a spreadsheet.

475

Environment Health & Safety

476

1.1 GENERAL

This Project should avoid, minimize, and control adverse impacts to human health,

safety, and the environment. The Selected Bidder shall follow all the related

Environmental Laws and Rules including the following:

a) Air (Prevention and Control of Pollution) Act, 1981 amended 1987

b) Water (Prevention and Control of Pollution) Act, 1974 amended 1988

c) Water (Prevention and Control of Pollution) Rules, 1975

d) The Environment (Protection) Act, 1986, amended 1991

e) Environmental (Protection) Rules, 1986 (Amendments in 1999, 2001, 2002, 2002,

2002, 2003, 2004)

f) Hazardous Waste (Management and Handling) Rules, 1989 amended 2000 and 2003

g) Manufacture Storage and Import of Hazardous Chemicals Rules, 1989 amended 2000

h) Chemical Accidents (Emergency Planning, Preparedness and Response) Rules, 1996

i) Batteries (Management and Handling) Rules, 2001.

j) Public Liability Insurance Act, 1991 amended 1992

k) Public Liability Insurance Rules, 1991 amended 1993

l) Factories Act, 1948

m) The Petroleum Act, 1934

n) The Petroleum Rules, 2002

o) The Motor Vehicle Act, 1988

p) The Central Motor Vehicle Rules, 1989

Selected Bidder shall obtain all the necessary permission from Central/ State Pollution

Control Boards and other regulatory agencies.

1.2 AIR EMISSIONS AND AMBIENT AIR QUALITY

Construction activities may generate emission of fugitive dust caused by a

combination of on-site excavation and movement of earth materials, contact of

construction machinery with bare soil, and exposure of bare soil and soil piles to

wind. A secondary source of emissions may include exhaust from diesel engines of

earth moving equipment etc. Techniques to consider for the reduction and control of

air emissions from construction sites may include:

• Minimizing dust from material handling sources, such as conveyors and bins, by

using covers and/or control equipment (water suppression, bag house, or cyclone)

• Minimizing dust from open area sources, including storage piles, by using control

measures such as installing enclosures and covers, and increasing the moisture content

• Dust suppression techniques should be implemented, such as applying water or non-

toxic chemicals to minimize dust from vehicle movements

During transportation, material should be covered by tauplin sheets to avoid fugitive

emission

• Managing emissions from mobile sources methods as given below:

477

Energy use efficiency

Application of emissions control techniques etc.

• Avoiding open burning of solid

Air emissions and potential for significant impacts to ambient air quality, should

prevent or minimize impacts by ensuring that Emissions do not result in pollutant

concentrations that reach or exceed relevant National Ambient Air Quality Standards.

1.3 NOISE AND VIBRATION

During construction activities, noise and vibration may be caused by the operation of

pile drivers, earth moving and excavation equipment, concrete mixers, cranes and the

transportation of equipment, materials and people. The Ambient Air Quality

Standards in respect of Noise is as following:

Area Code Category of Area / Zone Limits in dB(A) Leq*

Day Time Night Time

A Industrial area 75 70

B Commercial area 65 55

C Residential area 55 45

D Silence Zone 50 40

Note:- 1. Day time shall mean from 6.00 a.m. to 10.00 p.m.

2. Night time shall mean from 10.00 p.m. to 6.00 a.m.

3. Silence zone is an area comprising not less than 100 metres around

hospitals, educational institutions, courts, religious places or any other area

which is declared as such by the competent authority

4. Mixed categories of areas may be declared as one of the four above

mentioned categories by the competent authority.

* dB(A) Leq denotes the time weighted average of the level

Some recommended noise reduction and control strategies to be considered in areas

close to community areas include:

• Using noise control devices where necsseary, using sound proof enclosures for noise

generating equipment and machinery

• Avoiding or minimizing project transportation through community areas

• No employee should be exposed to a noise level greater than 85 dB(A) for a duration

of more than 8 hours per day without hearing protection. In addition, no unprotected

ear should be exposed to a peak sound pressure level (instantaneous) of more than 140

dB(C).

• The use of hearing protection should be enforced actively when the equivalent sound

level over 8 hours reaches 85 dB(A), the peak sound levels reach 140 dB(C), or the

average maximum sound level reaches 110dB(A). Hearing protective devices

provided should be capable of reducing sound levels at the ear to at least 85 dB(A).

• Although hearing protection is preferred for any period of noise exposure in excess of

85 dB(A), an equivalent level of protection can be obtained, but less easily managed,

by limiting the duration of noise exposure.

• For every 3 dB(A) increase in sound levels, the „allowed‟ exposure period or duration

should be reduced by 50 percent.

478

• Prior to the issuance of hearing protective devices as the final control mechanism, use

of acoustic insulating materials, isolation of the noise source, and other engineering

controls should be investigated and implemented, where feasible

• Periodic medical hearing checks should be performed on workers exposed to high

noise levels

1.4 SOIL EROSION

Soil erosion may be caused by exposure of soil surfaces to rain and wind during site

clearing, earth moving, and excavation activities. The mobilization and transport of

soil particles may, in turn, result in sedimentation of surface drainage networks, which

may result in impacts to the quality of natural water systems and ultimately the

biological systems that use these waters.

Recommended soil erosion and water system management approaches include:

Sediment mobilization and transport

• Reducing or preventing erosion by:

Scheduling to avoid heavy rainfall periods (i.e., during the dry season) to the

extent practical

Contouring and minimizing length and steepness of slopes

Mulching to stabilize exposed areas

Re-vegetating areas promptly

• Reducing or preventing off-site sediment transport through appropriate measures and

modifying or suspending activities during extreme rainfall and high winds to the

extent practical.

1.5 RUN OFF

• All necessary measures to be adopted to allow flow of run off from the site to nearby

by water body resulting in increased TDS of receiving water body. Such measures

may include silt fencing, provision proper storm water drains etc.

1.6 SOLID WASTE

Non-hazardous solid waste generated at construction sites includes excess fill

materials from grading and excavation activities, scrap wood and metals, and mall

concrete spills. Other non-hazardous solid wastes include office, kitchen, and

dormitory wastes when these types of operations are part of construction project

activities. Hazardous solid waste includes contaminated soils, which could potentially

be encountered on-site due to previous land use activities, or small amounts of

machinery maintenance materials, such as oily rags, used oil filters, and used oil, as

well as spill cleanup materials from oil and fuel spills. Techniques for preventing and

controlling non-hazardous and hazardous construction site solid waste can include the

following best work practices:

479

• Establishing waste management priorities at the outset of activities based on an

understanding of potential Environmental, Health, and Safety (EHS) risks and impacts

and considering waste generation and its consequences

• Establishing a waste management hierarchy that considers prevention, reduction,

reuse, recovery, recycling, removal and finally disposal of wastes.

• Avoiding or minimizing the generation waste materials, as far as practicable

• Where waste generation cannot be avoided but has been minimized, recovering and

reusing waste

1.7 WASTEWATER DISCHARGES

Construction activities may include the generation of sanitary wastewater discharges

in varying quantities depending on the number of workers involved. Adequate

portable or permanent sanitation facilities serving all workers should be provided at

all construction sites.

The quality of treated process wastewater, wastewater from utility operations or storm

water discharged should be established as set by Central Pollution Control Boards.

1.8 ENVIRONMENTAL MANAGEMENT PLAN

Selected Bidder shall prepare an Environmental Management Plan for pollution

abatement during, pre and post construction phase. This plan shall be approved by

Independent Engineer and shall be based on the standard practice and World Bank

guidelines. This Plan should identify the Potential Environmental Impacts at the

various project stages, Mitigation Measures and should also identify the agency

responsible for its implementation. This Plan should also include the environmental

monitoring plan.

1.9 Monitoring

To monitor the extent of environmental impact for proposed project, the periodic

monitoring of the ambient environmental quality will be done. The overall monitoring

requirement for the different environmental components is presented in table below:

Air Quality Monitoring

O&M Phase Operation & Maintenance period

Parameter SPM, SO2, NOx, CO and Pb

Sampling Method Use method specified by CPCB for analysis

Standards Air (Prevention and Control of Pollution) Rules, CPCB, 1994

Frequency Once before start of O&M phase

Duration As per rule / procedure

Location DG Sets.

Implementation Selected Bidder through approved monitoring agencies

Supervision Implementing agency

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Water quality Monitoring

O&M phase Operation & Maintenance period

Parameter As agreed by client / as per applicable standards

Sampling Method Grab sample collected from source and analysis as per Standard

Methods for Examination of water and Waste water

Standards Indian standards for Inland Surface Water (IS; 2296, 1982) / for

Drinking water (IS; 10500,1991) or as per contract specifications.

Frequency Twice a year (pre monsoon and post monsoon seasons)

Duration Grab sampling

Location Treated water reservoir / raw water sump.

Implementation Selected Bidder through approved monitoring agencies

Supervision Implementing agency

Noise Operation & Maintenance period

Frequency Once in a year.

Duration Reading to be taken at 15 seconds interval for 15 minutes every

hour and then averaged

Location Blower, Centrifuge & pump houses

Measures

Incase of noise levels causing disturbance to the receptors,

management measures as suggested in the EMP shall be carried

out.

Implementation Selected Bidder through approved monitoring agencies

Supervision Implementing agency

Apart form the above mentioned monitoring requirements, any major accidents

/spillage during bulk transport of hazardous materials. Depending on the type of

spillages / accidents the parameters to be monitored will be decided as per applicable

rules.

Environmental Compliance Report: A progress report will be submitted as prescribed,

to know status of the implementation of the EMP for its compliance.

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Health and Safety section

GENERAL

During installation, construction and maintenance the Selected Bidder shall follow all the

Safety Policy and Plant Safety rules of the country and World Bank including of the Uttar

Pradesh Factory Rules 1950 and Factories Act, 1948.

The drawings developed as part of detailed design during construction, operation and

maintenance shall be approved by the Independent Engineer. However, in any case

manufacturer / Selected Bidder will be wholly responsible for Safety, operation, performance

and all other related activity of the plant.

The Selected Bidder shall ensure at all times that his workers do not lie down or sleep under

or around any machine, equipment, vessel, vehicle or structures in his work area.

HEALTH AND SAFETY PLAN

A project specific health and safety plan shall be developed by the Selected Bidder and

submitted to Independent Engineer for approval. This health and safety plan shall be

reference document for implementation, control and monitoring of health and safety aspects

of the project by the main Selected Bidder, Independent Engineer and other parties

concerned.

Project health and safety plan shall describe how the project specific health and safety

objectives and targets shall be achieved. It shall define the road map for achieving the

standards that an organization lays down for itself so that efforts can be coordinated,

synergized and monitored.

Health and safety plan shall explain the means of establishing a positive health and safety

culture at the project site. Health and safety plan shall identify and enumerate the control

measures to mitigate the risks to the project completion arising out of health and safety issues

so that the project is allowed to proceed without interruption and executed as per schedule.

Salient aspects that may be covered in the project health and safety plan shall be:

a) Project specific health and safety objectives, targets and programmes in line with

health and safety policy

b) Hazard identification and risk assessment

c) Meeting legal and other requirements

d) Health and safety organization

e) Resources, roles, responsibility and authority

f) General health and safety rules

g) Health and safety requirements to be followed by sub-Selected Bidders

h) Operation control procedure

i) Activities requiring work permit system and its procedure

j) Management of traffic safety inside the project

k) Access control of employees

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l) Safety of visitors

m) Management of critical activities such as work at height, material handling and

working with plant and machinery

n) Ensuring the competency and awareness of the workmen

o) Fire prevention and fire fighting plan

p) First Aid

q) Hand Tools, Electrical Safety, Welding

r) Confined Space, Scaffolding, Ladders, Formwork, Demolition, Dumping, Piling and

Stacking, Fabrication, Erection & Rigging, Excavation and other related works

s) Use of compressed gas cylinders

t) Plant equipment

u) Emergency preparedness and response plan

v) Traffic management plan

w) Training matrix, Health and safety performance monitoring measures such as

Inspection, Audit

x) Personal Protective Equipment Matrix

y) Incident reporting and investigation procedure

z) Checklist and formats

The risk control measures identified shall meet the provisions of Building and other

Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996 and

other legislations. Provisions of various safety related standards shall also be referred to while

identifying the control measures for ensuring compliance of the same.

SAFETY ORGANISATION

Selected Bidder at site shall organize a Safety Group headed by a Safety Officer who shall be

responsible for providing, supervising and monitoring safe working conditions at all times for

their workers. The Safety Officer shall be experienced in maintaining safe conditions for

workers at site and shall be responsible for and shall have authority to enforce safe conditions

for the workers.

Selected Bidder shall have a declared Safety Policy in accordance with the Environmental,

Health, and Safety (EHS) Guidelines of the World Bank and shall get the same approved by

the Independent Engineer. The approved Safety Policy shall be displayed prominently in the

Selected Bidder‟s site office. Selected Bidder shall take active interest and participate in the

development and operation of safety programs at site. His responsibility does not cease with

establishment of Safety Group and approval of its various activities. He shall demonstrate his

involvement by regular participation in safety meetings, review of safety records and taking

corrective action where required, introduction of safety promoting bulletins, posters,

suggestions and awards and by setting example by strictly observing safety rules.

Selected Bidder shall remove all waste material and debris from and around the work area

and properly clean up the area at the end of each day before leaving the work site. Selected

Bidder shall take all necessary precautions not only for safe working of his own workmen but

also deploy all precautions to ensure safety of structures, equipment and workmen of other

agencies in and around his work site. The Selected Bidder shall ensure that his workmen do

not trespass into prohibited areas. Independent Engineer shall have the right to inspect at any

time, all items of machinery or equipment brought to site by the Selected Bidder, his agents

483

or workmen and to prohibit the use on the site of any item, which in the opinion of the

Independent Engineer is or may be detrimental to the safety of the site. The exercise of such

right or the omission to exercise it in any particular case shall not absolve the Selected Bidder

or his agents or workmen of their responsibility of adhering to the safe working practices.

Selected Bidder shall execute the work in a manner causing the least possible interference

with the business of the Independent Engineer, or with the work of any other Selected Bidder

who may be engaged on the premises and shall at all times co‐operate with the other Selected

Bidders working at site. Selected Bidder shall obtain work permit from the Independent

Engineer before starting any work at site. The work permits are issued to prevent the Selected

Bidder from working in un‐authorized areas and shall be valid for specific area for a

stipulated period.

Activities requiring permit to work shall be decided before starting the construction and shall

be suitably documented in the project health and safety plan. Some of the activities which

may require permit to work are:

a) Excavation

b) Entry into confined spaces

c) Electrical work

d) Opening manholes, covers and grills

e) Hot work

f) Work on plant, machinery and other power driven equipment.

g) Working at height

h) Working at night

The project team may establish a permit to work system for any other hazardous activity

which they feel need to be controlled administratively for safe execution.

RESPONSIBILITIES OF THE SELECTED BIDDER‘S SAFETY OFFICER

He is responsible and accountable for:

a) Preventing injury to personnel, damage to plant and equipment and fire.

b) Instituting ways to improve existing work methods from safety point of view.

c) Legal and contractual requirements affecting safety, health, and welfare of his

workmen

d) Provision and use of protective clothing and equipment and use of fire fighting

equipment

e) Suitability of new and hired equipment from a safety viewpoint

f) Identifying potential hazards.

g) Changes in safety requirements and fire precautions

h) Carrying out site surveys to see that only safe work methods are in operation, health

and safety requirements are being observed and welfare and first aid facilities are

adequate and properly maintained.

i) Determining the cause of an accident or dangerous occurrence and recommend means

of preventing recurrence.

j) Supervising the recording and analysis of information on injuries, damage and

production loss. Assess accident trends and review overall safety performance.

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k) Assisting with training of employees at all levels. Organizing periodic demonstration

of practicing safe working conditions by experienced safety instructors.

l) Taking part in discussions on injury, damage and loss control.

m) Keeping up‐do‐date with recommended codes of practice and safety literature.

Circulating information applicable to each level of employees.

n) Fostering within the company an understanding that injury prevention and damage

control are an integral part of business and operational efficiency.

o) Attending job progress meetings where safety is an item on the agenda. Report on job

safety performance.

The Safety Officer shall inspect and ensure the following:

a) All electrical equipment‟s are securely earthed.

b) Standard access platforms and ladders are provided for inspection, operation and

maintenance of equipment.

c) The equipment are periodically inspected for their condition, maintained properly and

operated by trained personnel at design speeds and loads.

OVER-EXERTION

Over-exertion, and ergonomic injuries and illnesses, such as repetitive motion, over-exertion,

and manual handling, are among the most common causes of injuries in construction sites.

Recommendations for their prevention and control include:

• Training of workers in lifting and materials handling techniques in construction

projects, including the placement of weight limits above which mechanical assists or

two-person lifts are necessary

• Planning work site layout to minimize the need for manual transfer of heavy loads

• Selecting tools that reduce force requirements and holding times, and which promote

improved postures, including, where applicable, user adjustable work stations

• Implementing administrative controls into work processes, such as job rotations and

rest or stretch breaks

SLIPS AND FALLS

Slips and falls on the same elevation associated with poor housekeeping, such as excessive

waste debris, loose construction materials, liquid spills, and uncontrolled use of electrical

cords and ropes on the ground, are also among the most frequent cause of lost time accidents

at construction sites.

Recommended methods for the prevention of slips and falls from, or on, the same elevation

include:

• Implementing good house-keeping practices, such as the sorting and placing loose

construction materials or demolition debris in established areas away from foot paths

• Cleaning up excessive waste debris and liquid spills regularly

• Locating electrical cords and ropes in common areas and marked corridors

• Use of slip retardant footwear

485

WORKING AT HEIGHTS

Wherever possible, steel staging or platform shall be erected. Staging with toe guards shall be

provided with simple safety rails or ropes at waist height throughout its length on all open

sides. Staging supports shall be All Purpose Scaffolding (APS) steel tubes scaffolding, safety

secured and supported on firm level footings or slung from overhead beams. Wherever it is

not possible to put up staging and/or use of safety belts, safety nets shall be slung beneath the

place of work for safety.

When working over open process vessels or tanks, safety belts and safety nets shall always be

used whether or not staging and scaffolding is provided.

Safe access to all points of works shall be provided in the form of suitable ladders and

stairways etc. Area around the work place shall be barricaded suitably or fenced off to avoid

injuries to personnel passing by. Suitable warning boards and signs shall be put up.

Training and use of temporary fall prevention devices, such as rails or other barriers able to

support a weight of 90.7 Kgs, when working at heights equal or greater than two meters or at

any height if the risk includes falling into operating machinery, into water or other liquid, into

hazardous substances, or through an opening in a work

surface

Written permission of the Independent Engineer shall be obtained before undertaking work

on roofs.

Training and use of personal fall arrest systems, such as full body harnesses and energy

absorbing lanyards able to support 2268 Kgs (also described in this section in Working at

Heights above), as well as fall rescue procedures to deal with workers whose fall has been

successfully arrested. The tie in point of the fall arresting system should also be able to

support 2268 Kgs.

Use of control zones and safety monitoring systems to warn workers of their proximity to fall

hazard zones, as well as

SELECTED BIDDER‘S BARRICADES

Selected Bidder shall erect and maintain barricades required in connection with his operation

to guard or protect.

a) Excavations

b) Hoisting areas

c) Areas adjudged hazardous

d) Existing property subject to damage by Selected Bidder‟s operations

Selected Bidder‟s employees and these of his sub-Selected Bidders shall become acquainted

with Owner‟s barricading practice and shall respect the provisions thereof.

STUCK BY OBJECTS

486

Construction activities may pose significant hazards related to the potential fall of materials

or tools, as well as ejection of solid particles from abrasive or other types of tools which can

result in injury to the head, eyes, and extremities.

Techniques for the prevention and control of these hazards include:

• Conducting cutting, chipping or chiseling with proper guards and anchoring as

applicable

• Maintaining clear traffic ways to avoid driving of heavy equipment over loose scrap

• Use of temporary fall protection measures in scaffolds and out edges of elevated work

surfaces, such as hand rails and toe boards to prevent materials from being dislodged

• Wearing appropriate PPE, such as safety glasses with side shields, face shields, hard

hats, and safety shoes

MOVING MACHINERY

Vehicle traffic and use of lifting equipment in the movement of machinery and materials on a

construction site may pose temporary hazards, such as physical contact, spills, dust,

emissions, and noise. Heavy equipment operators have limited fields of view close to their

equipment and may not see pedestrians close to the vehicle. Center-articulated vehicles create

a significant impact or crush hazard zone on the outboard side of a turn while moving.

Techniques for the prevention and control of these impacts include:

• Planning and segregating the location of vehicle traffic, machine operation, and

walking areas, and controlling vehicle traffic through the use of one-way traffic

routes, establishment of speed limits, and on-site trained flag-people wearing high-

visibility vests or outer clothing covering to direct traffic

• Ensuring the visibility of personnel through their use of high visibility vests when

working in or walking through heavy equipment operating areas, and training of

workers to verify eye contact with equipment operators before approaching the

operating vehicle

• Ensuring moving equipment is outfitted with audible back-up alarms

• Using inspected and well-maintained lifting devices that are appropriate for the load,

such as cranes, and securing loads when lifting them to higher job-site elevations.

DUST

• Dust suppression techniques should be implemented, such as applying water or non-

toxic chemicals to minimize dust from vehicle movements

• PPE, such as dusk masks, should be used where dust levels are excessive

SCAFFOLDING

Suitable scaffolding should be provide for workmen for all works that safely be done from

the ground or from solid construction except such short period work as can be done safely

from ladders. When a ladder is used an extra worker shall engaged for holding the ladder and

if the ladder is used for carrying materials as well, suitable footholds and handholds shall be

provided on the ladder.

487

Scaffolding or staging more than 4 meters above the ground or floor, swing suspended from

an overhead support or erected with stationary support shall have a guard rail properly

attached, bolted, braced and otherwise rewarded at least 3 ft. high above the floor or platform

of such scaffolding or staging and extending along the entire length of the outside and ends

thereof with only such openings as may be necessary for the delivery of materials. Such

scaffolding or staging shall be so fastened as to prevent it from swaying from the building or

structure.

Safe – means of access shall be provided to all working platforms and other working places,

every ladder should be securely fixed. No portable single ladder shall be over 9 meters in

length while the width between side rails in rung ladder shall in no case be less than 30 cms

for ladder up to and including 3 meters in length. For longer ladder this width should be

increased at least 5 mm for each additional foot of length. Uniform steps spacing shall not

exceed 30 cms. Adequate precautions shall be taken to prevent danger from electrical

equipment. No materials on any of the site of work shall be so stacked or placed to cause

danger from electrical equipment. No materials on any of the site of work shall be so stacked

or placed to cause danger or inconvenience to any person or public. The Selected Bidder shall

also provide all necessary fencing and light to protect the defense of every suit, action or

other proceedings of law that may be brought by any person for injury sustained owing to

neglect to the above precautions and pay any damages and costs which may be awarded in

any such suit or action or proceedings to any such person or which may with the consent of

the Selected Bidder be paid to compromise any claim by any such person.

EXCAVATION AND TRENCHING

All trenches 1.2 meters or more in depth, shall at all times be supplied with at least one ladder

for each 50 meters length or fraction thereof. Ladder shall be extended from bottom of the

trench to at least 1 meter above the surface of the ground. The sides of the trenches which are

1.5 meters in depth shall be stepped back to give suitable slope or securely held by timber

bracing, so as to avoid the danger of sides to collapse. The excavated materials shall not be

placed within 1.5 meters of the edge of the trench or half of the trench width whichever is

more. Cutting shall be done from top to bottom. Under no circumstances undermining or

undercutting shall be done.

LIFTING GEAR

The Selected Bidder shall submit a valid Test Certificate to the Independent Engineer, from

approved certifying authorities for all of his lifting gear and hoists, slings, chains, wire ropes,

hooks, chainpulley blocks, winches, hoists and cranes etc. before commencing work.

These certificates shall be available at site in the Selected Bidder‟s office for inspection as

and when required.

PRESSURE AND LEAK TESTING

Pressure and leak testing of equipment shall be carried out hydraulically. However, in special

cases where pneumatic testing is specified, written approval shall be obtained from the

Independent Engineer before starting work. Under no circumstance gases other than nitrogen,

carbon dioxide, air or steam shall be used for testing.

488

In case nitrogen or carbon dioxide is used for testing, the equipment shall be adequately

ventilated and gas tested to ensure oxygen content of 21% before permitting a worker to enter

the equipment.

WORKS INSIDE AN EQUIPMENT OR DRAINAGE SYSTEM

All equipment and associated piping shall be isolated, completely drained, purged and well

ventilated before entry of a worker. The atmosphere inside the vessel or equipment shall be

tested to ensure absence of toxic and flammable gases.

Toxic and flammable liquids and gases in the equipment shall be safely disposed of as per the

Statutory requirements to the satisfaction of the Independent Engineer.

Workers carrying out drainage, purging and testing operations shall wear gas masks and other

Protective gear appropriate to the material being handled. While a worker has entered

equipment, treatment facility or a drainage system, another worker shall be present outside at

all times to assist the worker inside in the event of an emergency.

ELECTRICAL

All power supply and distribution boards shall have canopy for protection and all the

distribution boards shall be earthed securely.

All supply points shall have proper plug and socket.

The Selected Bidder shall check tightness of connection of cable terminations and joints

before starting the work.

WELDING

Only qualified welders shall be employed at the work site. The Selected Bidder shall organise

the qualifying test at site for his welders and the Independent Engineer shall approve the

welders. All welders shall have to undergo qualifying test and only on passing the test, they

shall be allowed to work at site. For all welding work at site, generator sets shall be used

instead of AC transformer sets. AC Transformer sets are banned for welding jobs inside

vessels (both open and closed top type).

The Selected Bidder shall get his welding sets certified by the SPM and/or DCPL before

starting work. These certificates shall have to be renewed every two months. A copy of the

certificates shall be displayed on respective welding sets.

Only cables in good condition and insulated holders shall be used. The length of supply cable

to welding site shall not exceed 8 metres and the welding set body shall be properly earthed.

A charged fire extinguisher of CO2 type shall be carried with each welding set. The Selected

Bidder shall keep Halon or equivalent type fire extinguishers near hot jobs like cutting oil

lines.

489

The welder shall not use a building structure, pipeline or railway track etc. as a return path of

the current. Adequately rated circuit breaker shall be provided in the power circuit for human

protection on all power supply points.

HOT WORK

Before starting any hot work like gas cutting, welding and grinding etc., the Selected Bidder

shall obtain hot work permit from the Independent Engineer. The permit shall be renewed on

day‐to‐day basis.

The Selected Bidder shall ensure purging of piping and equipment to make it totally safe

before carrying out any hot work.

Smoking is strictly prohibited in work areas inside the plant premises.

No combustible material shall be stored on or near any source of heat like hot pipes, welding

or gas. Before leaving the place of work or the Selected Bidder‟s sheds, the Selected Bidder‟s

workmen shall ensure that no material or item that could start a fire is left at site. Special

attention shall be paid to collection and disposal of oil soaked cotton waste or rags. On no

account are these to be dropped into corners, pushed below equipment or left hanging on

pipes.

Gas cylinders shall be used in a safe manner. These shall not be dropped from heights or

dragged on the floor. Trolley with rubber rimmed wheels shall be used for transporting gas

cylinders within the site. Acetylene cylinders shall be kept in upright position. Oxygen

cylinders shall not be kept near inflammable materials like oil etc.

Tarpaulins shall not be used in the vicinity of welding and gas cutting jobs.

The Selected Bidder‟s supervisor of the rank of a foreman or equivalent shall examine the

arrangements made for hot work before commencement of work and shall satisfy him that all

reasonable safety precautions have been taken.

The Selected Bidder shall return the hot work permit after completion of welding work.

ACCIDENTS

In case of injury or serious illness of a worker, Independent Engineer shall be notified

immediately. All accidents shall be recorded by filling in the „Accident Report‟ form, which

shall be kept in easy accessible location in the site office of the Selected Bidder. Any „Near

Miss‟ incident shall also be reported by the Selected Bidder and recorded.

TRAFFIC SAFETY

Adoption of best transport safety practices across all aspects of project operations with the

goal of preventing traffic accidents and minimizing injuries suffered by project personnel and

the public. Measures should include:

Emphasizing safety aspects among drivers

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Improving driving skills and requiring licensing of drivers

Adopting limits for trip duration and arranging driver rosters to avoid overtiredness

Avoiding dangerous routes and times of day to reduce the risk of accidents

Regular maintenance of vehicles and use of manufacturer approved parts to minimize

potentially serious accidents caused by equipment malfunction or premature failure.

Minimizing pedestrian interaction with construction vehicles

Employing safe traffic control measures, including road signs and flag persons to warn of

dangerous conditions

DISEASE PREVENTION

Increased incidence of communicable and vector-borne diseases attributable to construction

activities represents a potentially serious health threat to project personnel and residents of

local communities. Recommendations for the prevention and control of communicable and

vector-borne diseases are as following:

• Undertaking health awareness and education initiatives, for example, by

implementing an information strategy to reinforce person-to-person counseling

addressing systemic factors that can influence individual behavior as well as

promoting individual protection, and protecting others from infection, by encouraging

condom use

• Training health workers in disease treatment

• Conducting immunization programs for workers in local communities to improve

health and guard against infection

• Providing health services

Vector-Borne Diseases

Reducing the impact of vector-borne disease on the long-term health of workers is

best accomplished through implementation of diverse interventions aimed at

eliminating the factors that lead to disease. Selected Bidder can implement an

integrated control strategy for mosquito and other arthropod-borne diseases that might

involve:

Prevention of larval and adult propagation through sanitary improvements and

elimination of breeding habitats close to human settlements

Elimination of unusable impounded water

Increase in water velocity in natural and artificial channels

Considering the application of residual insecticide to dormitory walls

Implementation of integrated vector control programs

Promoting use of repellents, clothing, netting, and other barriers to prevent

insect bites

Educating project personnel and area residents on risks, prevention, and

available treatment

Monitoring communities during high-risk seasons to detect and treat cases

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ILLUMINATION

Work area light intensity should be adequate for the general purpose of the location as

following:

Minimum Limits For Workplace

Illumination Intensity

Location / Activity Light

Intensity

Outdoor non working areas 20 lux

Workspace with occasional visual tasks only (corridors, stairways,

lobby, elevator, auditorium, etc.)

100 lux

Medium precision work (simple assembly, rough machine works,

welding, packing, etc.)

200 lux

Precision work (reading, moderately difficult assembly, sorting,

checking, medium bench and machine works, etc.), offices.

500 lux

Simple orientation and temporary visits (machine storage, garage,

warehouse)

50 lux

FIRE PREVENTION

Fire prevention addresses the identification of fire risks and ignition sources, and

measures needed to limit fast fire and smoke development. Necessary measures to be

adopted to prevent fire.

PERSONAL PROTECTIVE EQUIPMENT

Personal Protective Equipment (PPE) provides additional protection to workers

exposed to workplace hazards in conjunction with other facility controls and safety

systems.

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PPE is considered to be a last resort that is above and beyond the other facility

controls and provides the worker with an extra level of personal protection.

INSURANCE

All the Selected Bidder‟s workmen shall be covered under the Employees State

Insurance Scheme, Medi Claim Policy or any other scheme which may be specified

by the Statutory Authorities from time to time.

CONFINED SPACE

A confined space is defined as a wholly or partially enclosed space not designed or

intended for human occupancy and in which a hazardous atmosphere could develop as

a result of the contents, location or construction of the confined space or due to work

done in or around the confined space. A “permit-required” confined space is one that

also contains physical or atmospheric hazards that could trap or engulf the person.

Confined spaces can occur in enclosed or open structures or locations. Serious injury

or fatality can result from inadequate preparation to enter a confined space or in

attempting a rescue from a confined space. Recommended management approaches

include:

• Engineering measures should be implemented to eliminate, to the degree feasible, the

existence and adverse character of confined spaces.

• Permit-required confined spaces should be provided with permanent safety measures

for venting, monitoring, and rescue operations, to the extent possible. The area

adjoining an access to a confined space should provide ample room for emergency

and rescue operations.

• Access hatches should accommodate 90% of the worker population with adjustments

for tools and protective clothing.

• Prior to entry into a permit-required confined space:

o Process or feed lines into the space should be disconnected or drained, and

blanked and locked-out.

o Mechanical equipment in the space should be disconnected, de-energized,

locked-out, and braced, as appropriate.

o The atmosphere within the confined space should be tested to assure the

oxygen content is between 19.5 percent and 23 percent, and that the presence

of any flammable gas or vapor does not exceed 25 percent of its respective

Lower Explosive Limit (LEL).

o If the atmospheric conditions are not met, the confined space should be

ventilated until the target safe atmosphere is achieved, or entry is only to be

undertaken with appropriate and additional PPE.

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• Safety precautions should include Self Contained Breathing Apparatus (SCBA), life

lines, and safety watch workers stationed outside the confined space, with rescue and

first aid equipment readily available.

REVIEW MEETING

The Independent Engineer shall conduct fortnightly Safety Review Meeting to review the

safety conditions practiced at work areas by the Selected Bidder.

WORK AFTER NORMAL WORKING HOURS

Extra care shall be taken for jobs to be carried out after normal working hours with due

revalidated work permit and supervised by the Selected Bidder‟s site in‐charge. The

site‐incharge shall make available his residential address and telephone number to the

Independent Engineer so that he can be contacted in case of an emergency.

Proper lighting shall be ensured at the workplace for any work carried out after the normal

working hours.

CONVEYANCE FOR EMERGENCY

The Selected Bidder shall ensure that conveyance and person with driving license is available

at site at all times of work execution so that in case of an accident, the victim can be rushed to

nearest medical Centre.

EMERGENCY PROCEDURES

The Selected Bidder shall familiarize himself with the emergency procedures, which apply to

plants and areas in which his men are working.

First Aid Box shall be kept in the Selected Bidder‟s site office. The Selected Bidder‟s

site‐in‐charge and his key supervisors shall be trained in administering first aid, preliminary

treatment for electrical shocks, fall from height and burns etc.

When an emergency condition exists or on hearing the „Stop Work Alarm‟ every supervisor

shall ensure:

a) All work is stopped at once.

b) All equipment is shutdown.

c) All men are evacuated to a pre‐determined assembly point.

d) A roll call is taken and every man is accounted for.

e) No one shall be permitted to return to work until notification has been received from a

responsible authorized agency that it is safe to do so.

OPERATION AND MAINTENANCE

The Selected Bidder should follow all procedures pertaining to safety and EMS in day to day

running of the plant. The Selected Bidder shall be responsible for safety of his staff during O

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& M of the Plant and shall procure, provide and maintain all safety equipment necessary for

satisfactory O & M such as gasmasks, gloves, boots, mats etc.,

In addition to these the Selected Bidder shall also the below listed Indian Standards on safety

in construction:

IS 3696(Part 1):1987 Safety code of scaffolds and ladders: Part 1 Scaffolds

IS 3696(Part 2):1991 Safety code of scaffolds and ladders: Part 2 Ladders

IS 3764:1992 Code of safety for excavation work (first revision)

IS 4014(Part 2):1967 Code of practice for steel tubular scaffolding: Part 2 Safety

regulations for scaffolding

IS 4081:1986 Safety code for blasting and related drilling operations (First

Revision)

IS 4130:1991 Safety code for demolition of buildings (second revision)

IS 4138:1977 Safety code for working in compressed air (first revision)

IS 4756:1978 Safety code for tunneling work (first revision)

IS 4912:1978 Safety requirements for floor and wall openings, railings and

toe boards (first revision)

IS 5121:1969 Safety code for piling and other deep foundations

IS 5916:1970 Safety code for construction involving use of hot bituminous

materials

IS 7293:1974 Safety code for working with construction machinery

IS 7969:1975 Safety code for handling and storage of building materials

IS 8989:1978 Safety code for erection of concrete framed structures

IS 10067:1982 Material constants in building works

IS 10291:1982 Safety code for dress divers in civil engineering works

IS 13415:1992 Code of safety for protective barriers in and around

IS 13416(Part 1):1992 Recommendations for preventive measures against hazards

at workplaces: Part 1 Falling material hazards prevention

IS 13416(Part 2):1992 Recommendations for preventive measures against hazards

at workplaces: Part 2 Fall prevention

IS 13416(Part 3):1994 Recommendations for preventive measures against hazards

at workplaces: Part 3 Disposal of debris

IS 13416(Part 4):1994 Recommendations for preventive measures against hazards

at workplaces: Part 4 Timber structure

IS 13416(Part 5):1994 Recommendations for preventive measures against hazards

at workplaces: Part 5 Fire protection

IS 13430:1992 Code of practice for safety during additional construction and

alteration to existing buildings

IS 15883 (Part 5)] Construction Project Management - Guidelines:

Part 5 Health and Safety Management

495

Annexure-1

APPENDIX TO CONDITION OF CONTRACT

SALIENT FEATURES OF SOME MAJOR LABOUR LAWS APPLICABLE TO

ESTABLISHMENTS ENGAGED IN BUILDING AND OTHER CONSTRUCTION

WORK.

a) Workmen Compensation Act 1923: - The Act provides for compensation in case of injury

by accident arising out of and during the course of employment.

b) Payment of Gratuity Act 1972: - Gratuity is payable to an employee under the Act on

satisfaction of certain conditions on separation if an employee has completed the

prescribed minimum years (say, five years) of service or more or on death the rate of

prescribed minimum days‟(say, 15 days) wages for every completed year of service. The

Act is applicable to all establishments employing the prescribed minimum number (say,

10) or more employees.

c) Employees P.F. and Miscellaneous Provision Act 1952: The Act Provides for monthly

contributions by the Employer plus workers at the rate prescribed (say, 10% or 8.33%).

The benefits payable under the Act are:

i. Pension or family pension on retirement or death as the case may be.

ii. Deposit linked insurance on the death in harness of the worker.

iii. Payment of P.F. accumulation on retirement/death etc.

d) Maternity Benefit Act 1951: - The Act provides for leave and some other benefits to

women employees in case of confinement or miscarriage etc.

e) Contract Labour (Regulation & Abolition) Act 1970: - The Act provides for certain

welfare measures to be provided by the Contractor to contract labour and in case the

Contractor fails to provide, the same are required to be provided, by the Principal

Employer by Law. The principal Employer is required to take Certificate of Registration

and the Contractor is required to take license from the designated Officer. The Act is

applicable to the establishments or Contractor of Principal Employer if they employ

prescribed minimum (say 20) or more contract labour.

f) Minimum Wages Act 1948: - The Employer is to pay not less than the Minimum Wages

fixed by appropriate Government as per provisions of the Act if the employment is a

scheduled employment. Construction of buildings, roads, runways is scheduled

employment.

g) Payment of Wages Act 1936: - It lays down as to by what date the wages are to be paid,

when it will be paid and what deductions can be made from the wages of the workers.

h) Equal Remuneration Act 1979: - The Act provides for payment of equal wages for work of

equal nature to male and female workers and for not making discrimination against female

employees in the matters of transfers, training and promotions etc.

i) Payment of Bonus Act 1965: - The Act is applicable to all establishments employing

prescribed minimum (say, 20) or more workmen. The Act provides for payments of annual

496

bonus within the prescribed range of percentage of wages to employees drawing up to the

prescribed amount of wages, calculated in the prescribed manner. The Act does not apply

to certain establishments. The newly set-up establishments are exempted for five years in

certain circumstances. States may have different number of employment size.

j) Industrial Disputes Act 1947: - The Act lays down the machinery and procedure for

resolution of industrial disputes, in what situations a strike or lock-out becomes illegal and

what are the requirements for laying off or retrenching the employees or closing down the

establishment.

k) Industrial Employment (Standing Orders) Act 1946: - It is applicable to all establishments

employing prescribed minimum (say, 100, or 50). The Act provides for laying down rules

governing the conditions of employment by the Employer on matters provided in the Act

and get these certified by the designated Authority.

l) Trade Unions Act 1926: - The Act lays down the procedure for registration of trade unions

of workmen and Employers. The Trade Unions registered under the Act have been given

certain immunities from civil and criminal liabilities.

m) Child Labour (Prohibition & Regulation) Act 1986: - The Act prohibits employment of

children below 14 years of age in certain occupations and processes and provides for

regulations of employment of children in all other occupations and processes. Employment

of child labour is prohibited in building and construction industry.

n) Inter-State Migrant Workmen‟s (Regulation of Employment & Conditions of Service) Act

1979: - The Act is applicable to an establishment which employs prescribed minimum

(say, five) or more inter-state migrant workmen through an intermediary (who has

recruited workmen in one state for employment in the establishment situated in another

state). The Inter-State migrant workmen, in an establishment to which this Act becomes

applicable, are required to be provided certain facilities such as Housing, Medical-Aid,

Travelling expenses from home up to the establishment and back etc.

o) The Building and Other Construction workers (Regulation of Employment and Conditions

of Service) Act 1996 and the Cess Act of 1996: - All the establishments who carry on any

building or other construction work and employs the prescribed minimum (say, 10) or

more workers are covered under this Act. All such establishments are required to pay cess

at the rate not exceeding 2% of the cost of construction as may be modified by the

Government. The Employer of the establishment is required to provide safety measures at

the building or construction work and other welfare measures, such as canteens, first-aid

facilities, ambulance, housing accommodations for workers near the work place etc. The

Employer to whom the Act applies has to obtain a registration certificate from the

Registering Officer appointed by the Government.

p) Factories Act 1948: - The Act lays down the procedure for approval of plans before setting

up a factory, health and safety provisions, welfare provisions, working hours, annual

earned leave and rendering information regarding accidents or dangerous occurrences to

designated authorities. It is applicable to premises employing the prescribed minimum

497

(say, 10) persons or more with aid of power or another prescribed minimum (say, 20) or

more persons without the aid of power engaged in manufacturing process.

q) Arbitration and Conciliation Act, 1996: - The Act lays down the procedure for

appointment of Arbitrator, Arbitration and conciliation, Jurisdiction of Arbitral Tribunals,

Recourse against Arbitral award appeals.

General Manager Signature of contractor

498

Annexure-2

APPENDIX TO CONDITION OF CONTRACT

SAFETY CODE

1. Suitable scaffolds should be provided for workmen for all works that cannot safely be

done from the ground, or from solid construction except such short period work as can be

done safely from ladders. When a ladder is used, an extra mazdoor shall be engaged for

holding the ladder and if the ladder is used for carrying materials as well suitable

footholds and hand-hold shall be provided on the ladder and the ladder shall be given an

inclination not steeper than ¼ to 1(¼ horizontal and 1 vertical.)

2. Scaffolding of staging more than 3.6 m (12ft.) above the ground or floor, swung or

suspended from an overhead support or erected with stationary support shall have a

guard rail properly attached or bolted, braced and otherwise secured at least 90 cm. (3ft.)

high above the floor or platform of such scaffolding or staging and extending along the

entire length of the outside and ends there of with only such opening as may be necessary

for the delivery of materials. Such scaffolding or staging shall be so fastened as to

prevent it from swaying from the building or structure.

3. Working platforms, gangways and stairways should be so constructed that they should

not sag unduly or unequally, and if the height of the platform or the gangway or the

stairway is more than 3.6 m (12ft.) above ground level or floor level, they should be

closely boarded, should have adequate width and should be suitably fastened as

described in (2) above.

4. Every opening in the floor of a building or in a working platform shall be provided with

suitable means to prevent the fall of person or materials by providing suitable fencing or

railing whose minimum height shall be 90 cm. (3ft.)

5. Safe means of access shall be provided to all working platforms and other working

places. Every ladder shall be securely fixed. Uniform step spacing of not more than 30

cm shall be kept. Adequate precautions shall be taken to prevent danger from electrical

equipment. No materials on any of the sites or work shall be so stacked or placed as to

cause danger or inconvenience to any person or the public. The contractor shall provide

all necessary fencing and lights to protect the public from accident and shall be bound to

bear the expenses of defence of every suit, action or other proceedings at law that may be

brought by any person for injury sustained owing to neglect of the above precautions and

to pay any damages and cost which may be awarded in any such suit; action or

proceedings to any such person or which may, with the consent of the contractor, be paid

to compensate any claim by any such person.

6. (a) Excavation and Trenching - All trenches 1.2 m. (4ft.) or more in depth, shall at all

times be supplied with at least one ladder for each 30 m. (100 ft.) in length or fraction

thereof, Ladder shall extend from bottom of the trench to at least 90 cm. (3ft.) above the

surface of the ground. The side of the trenches which are 1.5 m. (5ft.) or more in depth

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shall be stepped back to give suitable slope or securely held by timber bracing, so as to

avoid the danger of sides collapsing. The excavated materials shall not be placed within

1.5 m. (5ft.) of the edges of the trench or half of the depth of the trench whichever is

more. Cutting shall be done from top to bottom. Under no circumstances, undermining or

undercutting shall be done.

(b) Safety Measures for digging bore holes:-

(i). If the bore well is successful, it should be safely capped to avoid caving and

collapse of the bore well. The failed and the abandoned ones should be

completely refilled to avoid caving and collapse;

(ii). during drilling, Sign boards should be erected near the site with the address of the

drilling contractor and the Engineer in-charge of the work;

(iii). Suitable fencing should be erected around the well during the drilling and after

the installation of the rig on the point of drilling, flags shall be put 50m around

the point of drilling to avoid entry of people;

(iv). After drilling the bore well, a cement platform (0.50m x 0.50m x 1.20m) 0.60m

above ground level and 0.60m below ground level should be constructed around

the well casing;

(v). After the completion of the bore well, the contractor should cap the bore well

properly by welding steel plate, cover the bore well with the drilled wet soil and

fix thorny shrubs over the soil. This should be done even while repairing the

pump;

(vi). After the bore well is drilled the entire site should be brought to the ground level.

7. Demolition - Before any demolition work is commenced and also during the progress of

the work,

i. All roads and open areas adjacent to the work site shall either be closed or

suitably protected.

ii. No electric cable or apparatus which is liable to be a source of danger or a cable

or apparatus used by the operator shall remain electrically charged.

iii. All practical steps shall be taken to prevent danger to persons employed from risk

of fire or explosion or flooding. No floor, roof or other part of the building shall

be so overloaded with debris or materials as to render it unsafe.

8. All necessary personal safety equipment as considered adequate by the Engineer-in-

Charge should be kept available for the use of the person employed on the site and

maintained in a condition suitable for immediate use, and the contractor should take

adequate steps to ensure proper use of equipment by those concerned:- The following

safety equipment shall invariably be provided.

500

i. Workers employed on mixing asphaltic materials, cement and lime mortars shall

be provided with protective footwear and protective goggles.

ii. Those engaged in white washing and mixing or stacking of cement bags or any

material which is injurious to the eyes, shall be provided with protective goggles.

iii. Those engaged in welding works shall be provided with welder‟s protective eye

shields.

iv. Stone breaker shall be provided with protective goggles and protective clothing

and seated at sufficiently safe intervals.

v. When workers are employed in sewers and manholes, which are in active use, the

contractors shall ensure that the manhole covers are opened and ventilated at least

for an hour before the workers are allowed to get into the manholes, and the

manholes so opened shall be cordoned off with suitable railing and provided with

warning signals or boards to prevent accident to the public. In addition, the

contractor shall ensure that the following safety measure are adhered to :-

(a) Entry for workers into the line shall not be allowed except under supervision

of the JE or any other higher officer.

(b) At least 5 to 6 manholes upstream and downstream should be kept open for at

least 2 to 3 hours before any man is allowed to enter into the manhole for

working inside.

(c) Before entry, presence of Toxic gases should be tested by inserting wet lead

acetate paper which changes colour in the presence of such gases and gives

indication of their presence.

(d) Presence of Oxygen should be verified by lowering a detector lamp into the

manhole. In case, no Oxygen is found inside the sewer line, workers should be

sent only with Oxygen kit.

(e) Safety belt with rope should be provided to the workers. While working inside

the manholes, such rope should be handled by two men standing outside to

enable him to be pulled out during emergency.

(f) The area should be barricaded or cordoned of by suitable means to avoid

mishaps of any kind. Proper warning signs should be displayed for the safety

of the public whenever cleaning works are undertaken during night or day.

(g) No smoking or open flames shall be allowed near the blocked manhole being

cleaned.

(h) The malba obtained on account of cleaning of blocked manholes and sewer

lines should be immediately removed to avoid accidents on account of slippery

nature of the malba.

501

(i) Workers should not be allowed to work inside the manhole continuously. He

should be given rest intermittently. The Engineer-in-Charge may decide the

time up to which a worker may be allowed to work continuously inside the

manhole.

(j) Gas masks with Oxygen Cylinder should be kept at site for use in emergency.

(k) Air-blowers should be used for flow of fresh air through the manholes.

Whenever called for, portable air blowers are recommended for ventilating the

manholes. The Motors for these shall be vapour proof and of totally enclosed

type. Non sparking gas engines also could be used but they should be placed at

least 2 metres away from the opening and on the leeward side protected from

wind so that they will not be a source of friction on any inflammable gas that

might be present.

(l) The workers engaged for cleaning the manholes/sewers should be properly

trained before allowing to work in the manhole.

(m) The workers shall be provided with Gumboots or non sparking shoes bump

helmets and gloves non sparking tools safety lights and gas masks and portable

air blowers (when necessary). They must be supplied with barrier cream for

anointing the limbs before working inside the sewer lines.

(n) Workmen descending a manhole shall try each ladder stop or rung carefully

before putting his full weight on it to guard against insecure fastening due to

corrosion of the rung fixed to manhole well.

(o) If a man has received a physical injury, he should be brought out of the sewer

immediately and adequate medical aid should be provided to him.

(p) The extent to which these precautions are to be taken depend on individual

situation but the decision of the Engineer-in-Charge regarding the steps to be

taken in this regard in an individual case will be final.

vi. The Contractor shall not employ men and women below the age of 18 years on

the work of painting with products containing lead in any form. Wherever men

above the age of 18 are employed on the work of lead painting, the following

precaution should be taken:-

(a) No paint containing lead or lead products shall be used except in the form of

paste or readymade paint.

(b) Suitable face masks should be supplied for use by the workers when paint is

applied in the form of spray or a surface having lead paint is dry rubbed and

scrapped.

(c) Overalls shall be supplied by the contractors to the workmen and adequate

facilities shall be provided to enable the working painters to wash during and

on the cessation of work.

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9. Safety Measures for laying of pipe lines and sewers:

9.1 Measures as provided in Manual on water supply and Manual on sewerage shall be

complied with strictly along with safety measures to be followed as per

Nigam/LSGED orders issued from time to time. Some important measures are given

below:

9.2 Proper barricading of trenches shall be done and caution boards and red flags shall be

displayed along with lighting arrangements and watchmen during night and

9.3 Watchmen shall be deployed during construction for diversion of traffic and necessary

permission shall be taken before excavation of trenches from local

administration/traffic police/Nagar Nigam/PWD/BSNL/POER CORPORATION etc.

9.4 Mouth of pipe or sewer shall be properly capped with end caps or steel plates to avoid

entry of soil/mud/water, before leaving the site at the end of days work and as for as

possible no trench shall be left open at the end of days work or shall be left

unguarded.

9.5 Open timbering should be done as per norms if the trench is more than 1.5 meter deep

and close timbering should be done when more than 3.0 meter deep.

9.6 Excavated earth should be kept at sufficiently safe distance from the sides of trench not

less than 60 cm away.

9.7 Special care should be taken during rains against collapse of trench or settlement of

soil which may take place and may pose danger to life and property.

9.8 If any trench which is more than 1.5 meter deep and within 3.0 meter adjacent to any

structure or building, then close timbering should be done.

9.9 Detailed safety measures issued by Chief Engineer (Ganga) vide letter no 463/Ganga-

06/2001 dated 31.5.2001 should be complied with.(annexed)

10. When the work is done near any place where there is risk of drowning, all necessary

equipments should be provided and kept ready for use and all necessary steps taken for

prompt rescue of any person in danger and adequate provision, should be made for

prompt first aid treatment of all injuries likely to be obtained during the course of the

work.

11. Use of hoisting machines and tackle including their attachments, anchorage and supports

shall conform to the following standards or conditions :-

(i) (a) These shall be of good mechanical construction, sound materials and adequate

strength and free from patent defects and shall be kept repaired and in good working

order.

(b) Every rope used in hoisting or lowering materials or as a means of suspension

shall be of durable quality and adequate strength, and free from patent defects.

(ii) Every crane driver or hoisting appliance operator, shall be properly qualified

503

(iii) In case of every hoisting machine and of every chain ring hook, shackle swivel and

pulley block used in hoisting or as means of suspension, the safe working load shall

be ascertained by adequate means. Every hoisting machine and all gear referred to

above shall be plainly marked with the safe working load. No part of any machine or

any gear referred to above in this paragraph shall be loaded beyond the safe working

load except for the purpose of testing.

12. Motors, gearing, transmission, electric wiring and other dangerous parts of hoisting

appliances should be provided with efficient safeguards. Hoisting appliances should be

provided with such means as will reduce to the minimum the risk of accidental descent

of the load. Adequate precautions should be taken to reduce to the minimum the risk of

any part of a suspended load becoming accidentally displaced. When workers are

employed on electrical installations which are already energized, insulating mats,

wearing apparel, such as gloves, sleeves and boots as may be necessary should be

provided. The worker should not wear any rings, watches and carry keys or other

materials which are good conductors of electricity.

13. All scaffolds, ladders and other safety devices mentioned or described herein shall be

maintained in safe condition and no scaffold, ladder or equipment shall be altered or

removed while it is in use. Adequate washing facilities should be provided at or near

places of work.

14. These safety provisions should be brought to the notice of all concerned and the person

responsible for compliance of the safety code shall be named therein by the contractor.

15. To ensure effective enforcement of the rules and regulations relating to safety precautions

the arrangements made by the contractor shall be open to inspection by the Labour

Officer or Engineer-in-Charge of the department or their representatives.

16. Notwithstanding the above clauses from (1) to (15), there is nothing in these to exempt

the contractor from the operations of any other Act or Rule in force in the Republic of

India.

General Manager

U.P.Jal Nigam

Certificate: I hereby certify that I have read/been explained contents of safety code above

and shall be abide by above rules fully and shall take all responsibility arising out of any

lapses on the part of my men and labour/workers and shall bear all costs and expenses, claims

what so ever etc. following any mishappening.

Signature

of contractor

504

Annexure-3

(DRAFT)

BANK GUARANTEE FOR ADVANCE MOBILISATION LOAN

The Project Manager,

Ganga Pollution Prevention Unit,

U.P. Jal Nigam,

Varanasi

Name of the work …………………………………………………………………..

WHEREAS M/s …………………………………………………..and having its registered

office at ………………………………………………………………….. (hereinafter called”

the Contractor / Bidder”) has undertaken, in pursuance of Work Order No.

……………………………………… to execute the work …………………………………

from …………………………………………………called “the Contract”).

AND WHEREAS it has been stipulated by you in the said contract that the contractor/

Bidder shall furnish you with a Bank Guarantee by a recognized Bank for the sum

specified therein as security for compliance with his obligations in accordance with the

contract for getting mobilization advance from you.

AND WHEREAS we have agreed to give the Contractor/bidder such a Bank Guarantee.

NOW THEREFORE, We , …………………………………………………………………

hereby affirm that we are the Guarantor and responsible to you on behalf of the

Contractor/bidder, up to a total of amount of Guarantee i.e ……………… (Rupees -

……………………………….)

We, ……………………………………………….. undertake to pay you upon your written

demand and without cavil and argument, any sum or sums within the limits of Rs.

…………………….. (Rupees

………………………………………………………………………. only) as aforesaid

without your heeding to prove or to show the grounds or reason for your demand for the sum

specified therein.

We hereby waive the necessity of your demanding the said debt from the Contractor/bidder

before presenting us with the demand.

We further agree that no change or addition to or other modifications of the terms of the

contract or of few works to be performed there under or any of the contract documents

which may be made between you and the Contractor/bidder shall in any way release us from

any ability under this guarantee, and we hereby waive notice of any such change, addition

or modification.

This guarantee is valid up to ---------------

505

The bank guarantee can be en-cashed by you at our branch ___________ (at our branch at the

city/place of work).

We--------------------------------------------- lastly undertake not to revoke

this guarantee during its currency except with the previous consent of the Authority in

writing.

Notwithstanding any contained hereinabove.

a) Our liability under this Bank Guarantee shall not exceed Rs---------------- (Rupees

Thirty --------------------------------------------------------------------------- only.)

b) This Bank Guarantee shall be valid up to --------------(60 days beyond date of

completion)

c) We are liable to pay the guaranteed amount or any part thereof under this Bank

Guarantee only and only if you serve upon us a written claim on or before ----------------

The -------------------------------------------- has here unto set his hand at ________ the

day of ---------------2016

SIGNATURE AND SEAL OF THE GUARANTOR

506

ANNEXURE—4

A FORM OF BANK GUARANTEE FOR SECURITY DEPOSIT

(SPECIMEN)

Name of Employer.__________________________________________________

Address of Employer:_________________________________________________

WHEREAS (Name & Address of Contractor/bidder ______________________dated

_______________________________________________Herein after called “the

contractor/bidder”) has undertaken, in pursuance of contract no._______________

dated ____________________ to execute (Name of Contract & Brief description of works

__________________________called “the contract”)

AND WHEREAS it has been stipulated by you in the said contract that the Contractor/

Bidder shall furnish you with a Bank Guarantee by a recognized bank for this sum specified

therein as security for compliance with his obligations in accordance with the contract.

AND WHEREAS we have agreed to give the Contractor/ bidder such a Bank

Guarantee__________________________________________________________

__________________________________we undertake to pay you upon your written

demand and without cavil or argument, any sum or sums within the limits of amount of

guarantee ___________________________as aforesaid without your heeding to prove or to

show the grounds or reason for your demand for the sum specified therein.

We hereby waive the necessity of your demanding the said debt from the Contractor/ bidder

before presenting us with the demand.

We further agree that no change or addition to or other modifications of the terms of the

contract or of few works to be performed there under or any of the contract documents which

may be made between you and the Contractor/ bidder shall in any way release us from any

ability under this guarantee, and we hereby waive notice of any such change, addition or

modification.

This guarantee is valid until the date --- months from the date_________________ month

after the issuing of the maintenance certificate.

(Guarantee period shall be minimum for ------------months.

The bank guarantee can be encashed by you at our local branch at----------------------- .

SIGNATURE & SEAL OF THE GUARANTOR____________________________

Name the Bank_____________________________________________________

Address __________________________________________________________

Date _________________

507

Engineer-in Charge Contractor