Scope and Specifications

Section VII.
Work Requirements
Contents
Scope of Works ....................................................................................................... 92 Specification .......................................................................................................... 103 Drawings ................................................................................................................ 377 Supplimentary Information.....378
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Section VII. Work Requirements
Scope of Work
Name of Work: Comprehensive Water Supply Service Improvements for Armor Municipality, with the following components:
Sub-Head-1 Construction of Intake Well cum Pump House and Gangway; Construction of Earthen channel beyond intake well within the lake; Construction of road connecting the Gangway with the embankment; Supplying and installation and commissioning of Raw Water Pumps & Motors; Providing and erection of H.O.T/E.O.T cranes; Construction and development of Electrical Transformer yard including providing and erection of Transformers with switches, wiring etc. - on item rate contract basis. . Sub-Head-2 Construction of Water Treatment Plant of capacity 11.50 MLD at Yanamgutta in Armoor town including sludge disposal system; Construction of Cascade Aerator; Construction of CWR with Pump House and Pumping arrangement including electrical wiring work with fittings and fixtures and providing and erection of H.O.T/E.O.T cranes in Chlorine room and Clear Water Pump House, Site illumination; Construction and development of Electrical Transformer yard with switch room including providing and erection of Transformers with switches, wiring, Barbed wire fencing Chemical House, Chlorine Room including Safety devices, Administrative Building, and Staff Quarters, and Boundary wall with gate; Watchman Quarter, internal CC roads; masonry drains, Sludge sump cum Pump House, RCC Sludge conveying main and Sludge Pond etc. in WTP premises-on item rate contract basis. Sub-Head-3 Supplying, laying, jointing, testing and commissioning of Pipeline from Sri Ram Sagar Lake to WTP Raw Water Rising Main (500 mm dia. DI K-9 pipe total length of 19000 m ); Supplying, laying, jointing,Erection and construction of one structural bridge for crossing of the Raw Water Rising Main (10 m span); Laying, testing and commissioning of Clear Water Rising Main (150 mm dia to 400 mm dia. DI K-9 pipe total length 7,820 m); Supplying, laying, jointing, testing and commissioning of distribution lines of 1,51,399 m consisting of HDPE pipes ( 97.4 mm Internal dia. to 159.6 internal dia mm dia of total length of 1,48,643 m) and DI K-7 pipes (200 mm dia. to 350 mm dia. of total length 2756 m) including all valves, specials and appurtenances within the project Area. Construction of 3 (three) ELSRs including piping work, new piping works of existing GLSR at Siddala Gutta, construction of Boundary walls; internal Roads and drains; watchman Goomty at ELSR sites, Road and Waterway crossing arrangement, Repair and face-lifting of existing GLSR at Siddalagutta, transfer of existing HSCs from old network to new network and new HSC works on distribution system etc- on item rate contract basis. Milestone No: Milestone 1 Period from the date of issue of notice to proceed with the work 2 months
Physical works to be completed Collection of all drawings from the Department and submission of designs for ELSRs and WTP for approval of PHED.
Milestone 2
Construction of approach roads (100%); Civil construction works (50%) under Subhead-1 and Sub-head-2; Supplying of 60% pipes and
9 months
specials under Sub-head-3 and laying of 60% of pipelines supplied/procured.
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Milestone 3
Construction of (100%) Civil construction works Sub-head-1 and Sub-head-2; Supply of M&E equipment for WTP and Pumps& Motors for all puming installations; Supply of 100 % pipes
18 months
and specials under Sub-head-3 and laying of 80% of pipelines under Sub-head-3, Milestone 4 Completion of 100% civil work under Sub-head1, Sub-head -2 and laying of 100% pipes under Sub-head-3; Errection of M&E equipment in WTP and Pumps& Motors in all Pumping Stations. Milestone 5 Testing, Commissioning and Performance Trial run for the whole Package. 24 months 21 months
The Scope of Work

The Scope of Work for this contract under Sub-head 1 includes: A CIVIL WORKS
Construction of Intake Well cum Pump House 10 M dia. 28 M deep, about 4.5 M below the local ground, as per drawing, with port gates and its lifting arrangement, level indicators, lightening arrestors, framed; shuttered and glazed/paneled shutters, MS grills, rolling shutters etc including provision and construction of gantries for H.O.T cranes with lifting chains, mono-rail etc in the Pump House on the Intake Well. Construction of Gangway 5 M wide and 800 M long, on RCC framed structure with erected and provided MS railings; duly painted etc, as per drawing. Construction of earthen channel beyond the IW within the lake, 50 M long of trapezoidal section, as per drawing Construction of formed earth filled 4 M wide road connecting the Gangway with the embankment having boulder masonry retaining wall on either side, as per drawing. Development of Transformer yard including Barbed wire fencing with gates, internal CC roads and pavement of concrete blocks and pavers, RCC cable trenches, internal masonry drains, providing and fixing MS cable trays etc. Note: All buildings to have necessary doors; windows, ventilators etc, be colour washed with interior distemper and exterior cement based colour, requisite plumbing and sewer works
B MECHANICAL AND ELECTRICAL WORKS:

Supplying, installation and commissioning of Raw Water Pumps & Motors including electrical wiring, starters, switches etc , details of which is given in Table below
RAW WATER PUMP DETAILS:
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Pumping Station
Q 3 M / hr
TDH m
Expected Effy. %
Pump Speed R.P.M(Syn)
Motor KW
Pump Type
Quantity w+s
Raw Water Intake Pumping station (Sri Ram Sagar lake)
225
78.5
80
1500
90
VT
2+1
Providing and installation of 11 KVa outdoor type Transformers with power feeder wiring and connection work, OH Circuit Breakers, Switches etc, power cable work by providing; laying; jointing of multi-core armoured aluminum cables in appropriate cable trenches (RCC rectangular duct with MS cover plates and trays, etc Electrical wiring including fittings and fixtures for Pump House and area illumination of surrounding area, roads, gangway, transformer room and yard etc.. All electrical and mechanical equipment including pumps, motors, H.O.T/E.O.T cranes etc. should be as per detail technical specifications and vendor list that may be necessary and specified herein to make the works complete in all respect. All the electrical works for running the H.T. power supply, panel room, panels, and cable works are within the scope of this contract including power cable to be laid. The Contractor shall submit necessary calculations for sizes of individual connecting cables and get the same approved by the Engineer-in-charge. The cable trenches shall be covered with adequate covering and shall be provided with necessary insert plates, cable trays etc as required. The bidders shall arrange approval from the Chief Electrical Inspector for the operation of the electrical installation. Electrical wiring including fittings and fixtures for Pump House and area illumination of surrounding area, roads, gangway, transformer room and yard, quarters etc.. Erection of mechanical & Electrical equipment, trial run for 90 days (23.50 hours per day), testing the treated water for efficient standards and maintenance of records and imparting training to staff. is included in the scope of work under this sub-head.
Note:
1. During the trial run of 3 months, the entire expenditure shall be borne by the Bidder including cost of oil and lubricants, man power etc. but excluding cost of energy for the Raw Water Pumping station (sub-head -1). It is solely the responsibility of the successful Bidder to run the raw Water Pump House and Water Treatment Plant without any disruption or interruption during the 3 months period of Trial Run.
2.
Supply of 6 sets of completion plans and maintenance manual and brochures will be required to be provided. The bidder is required to examine carefully the site of the proposed works, each and every data of existing facilities as required and provided in the tender document.
3.
The Scope of Work for this contract under Sub-head-2 includes:

Design and Construction of 11.5 MLD capacity Water Treatment Plant with all its ancillary units namely, raw water inlet well , Cascade (fountain) aerator, venturi (Parshall) flume and RC Channel, flash mixer, chemical house, with alum solution tank and solution dosing arrangement, alum storage, pre and post chlorination arrangement, chlorine storage room with cylinder resting trunions; safety gears & devices; neutralization arrangement etc. Clari-flocculator units, Rapid gravity filter and filter house including sludge disposal arrangement and all ancillary arrangement. The construction of Water Treatment Plant will include all civil,
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mechanical and electrical works, fully automated control system including successful trial running etc. complete as detailed below:
A CIVIL WORKS
Construction of 11.5 MLD capacity Water Treatment Plant having following components, as per design: (all
works of VRCC shall be in M 30 design mix).

1. Raw Water Inlet Well 2. Fountain cascade type Aerator 3. RC Channel with Venturi Flume (Parshal Flume) 4. Flash mixer with necessary inlet and outlet arrangements. 5. Clari-flocculator with launder, moving bridge with rubber tyre wheels and steel rails, mixing and slow churning arrangement and scraping arrangement (stainless steel spindles and blades, rubber scrapers, sludge extraction arrangement etc. 6. Filter House with RG filters, with all ancillary arrangements of under drainage network, wash water drainage system, etc. Construction of elevated Back wash Tank with requisite piping work with fittings; fixtures; specials & valves etc. Construction of Chemical House, having following major components: 1. Alum Storage with unloading ramp 2. Alum dissolution trays with water sprinklers 3. Alum solution tanks having polymeric inside surface layers, with electrically operated stainless steel agitator and mixing devices, Alum solution feeder piping etc. Construction of Chlorine Room having structure to unload Chlorine gas cylinders and storing on trunion wheels, piping work up to Chlorinator including piping for water injection to the Chlorinator, Chlorine solution conveying piping neutralization arrangement, low level louvers, safety gears, construction of gantries for H.O.T/E.O.T Cranes in the Chlorine Room for handling Gas Cylinders, safety devices and neutralization arrangements etc. Construction of Pump house with framed; shuttered and glazed/paneled shutters, MS grills, rolling shutters etc including provision and construction of gantries for H.O.T cranes with lifting chains, mono-rail etc in the Pump House. Construction of Clear Water Ground Level Reservoir of 1000.KL capacity, within WTP campus Construction of Sludge sump cum pump house including construction of gantries for H.O.T/E.O.T cranes and mono-rails; construction of loading/unloading ramp and platforms, Sludge conveying RCC nain (gravity flow), Distribution box,Sludge ponds and collection well with gangway etc. Construction of Water testing and Analysis Laboratory with all machineries and equipments, glass and PVC wares, Chemicals and Reagents, in order to carry out testing on various parameters, few of which are: a) Colour b) Odour c) pH d) Turbidity e) Total and Dissolved solids f) Electrical conductivity
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g) Total hardness (CaCO3) h) Chloride i) Sulphate j) Fluoride k) Nitrates l) Calcium m) Magnesium n) Iron o) Aluminum p) Alkalinity q) Residual Chlorine r) Other metals like Manganese, Copper, Zinc etc. s) Phenolic compounds, Anionic Detergents, Mineral Oils etc. t) Other Heavy metals, pesticides etc. as per requirement Note: Many of tests are to be undertaken through electronic analyzers.
Testing of all components for water tightness including cost and conveyance of water per CI. 10 of IS 3370 (part-I) of 1965, and shall satisfy the water tightness requirements as per CL.10,12 of 3370/1965 emptying the containers after testing, cleaning, finishing etc., complete, leveling the site including disposal of surplus earth etc. The contractor has to make his own arrangements for conveyance of all mechanical and electrical materials, pipes. Specials, bolts, nuts, rubber packing to site. Double rows of 30 mm, dia. G.I. tubular hand railing fixed in C. I. Stanchions shall be provided on the edge of the walkways and platforms, duly erected; fitted ; fixed and painted etc. The Contractor shall furnish designs and get approved by the department including conducting soil investigation tests. Soil investigation shall be done to determine the SBC and the ground water table on the basis of which designs shall be submitted. The cost of the WTP quoted by the bidder shall remain unchanged irrespective of the actual SBC / Foundation Strata and ground water table. No extra claim shall be entertained on account of variations in soil strata or Ground water table.
Construction of Administrative Building with all sanitary and plumbing works & fitting and septic tank along with sewer lines with fixtures, etc. as per drawing. Construction of two storied staff quarter buildings with sanitary and plumbing works, septic tank along with sewer lines with fixtures etc. as per drawing, within WTP campus. Construction of Watchman quarter etc. as per drawing, within WTP and ELSRs & GLSR sites. Construction of internal CC road, 4 M wide, as per drawing, within WTP and ELSRs & GLSR sites Construction of masonry drains, as per drawing, within WTP and ELSRs & GLSR sites Construction of masonry Boundary wall with gates, as per drawing, around WTP and ELSRs & GLSR sites
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Development of Transformer yard including Barbed wire fencing with gates, internal CC roads and pavement of concrete blocks and pavers, RCC cable trenches, internal masonry drains, providing and fixing MS cable trays etc. within WTP campus. Construction of Clear Water Pump House, construction of gantries for H.O.T./E.O.T cranes and mono-rails, construction of loading/unloading ramps and platforms etc. within WTP campus. Note: All buildings to be colour washed with interior distemper and exterior cement based colour.
B MECHANICAL AND ELECTRICAL WORKS:

Necessary agitating and thorough mixing arrangement by installation, including providing electrical motors and coupling system. Different gauges, pneumatic and water based back washing arrangement, control valves and floats, monitors, air compressors; air driers; air blowers etc in the Filter House. Metering pumps in Chlorine room. Erection and providing H.O.T/E.O.T cranes, mono-rails etc. in Pump House and Chlorine room. Pumping arrangement for injecting Chlorine Solution and, gas leak detector in the Chlorine Room. Pumps and pumping arrangement for sludge disposal to Sludge ponds and recirculation pumps, dewatering pumps etc. Wiring and Electrical fittings & fixtures etc for the Administrative Building... Few of such are: A Electrical fixtures: MCB distribution boxes and Main Switches, Fluorescent tube light sets in reflector boxes as well as on battens (single and double), Ceiling fans and Pedestal fans, Split type AC machines, exhaust fans etc.
Electrical wiring and fittings, main switches, junction and distribution boxes etc. (excluding fans and lights) for Staff quarters and Watchmen Goomties. Providing and installation of Clear Water pumps, motors, and other appurtenances. Details of the pumps to be supplied, installed, commissioned, and run, including providing and erection of H.O.T/E.O.T. cranes, mono-rails, Details of Clear Water Pumps are given in Table below: Pumping Station Q 3 M / hr TDH m Expected Effy. % Pump Speed R.P.M(Syn) Motor KW Pump Type Quantity w+s
Clear Water Pumping Station (WTP at Yanamgutta Village)
200
50.5
80
1500
45
HSC
2+1
Providing and installation of 11 KVA outdoor type Transformers with power feeder wiring and connection work, OH Circuit Breakers, Switches etc, power cable work by providing; laying; jointing of multi-core armoured aluminum cables, etc Electrical wiring including fittings and fixtures for Pump House and area illumination of surrounding area, roads, gangway, transformer room and yard etc..
Lightening arrestors as per IS: 3070/1974 as per requirement. Note:

1. During the trial run of 3 months, the entire expenditure shall be borne by the Bidder including cost of flocculants, disinfectants, oil and lubricants, man power etc. but excluding cost of energy for Water Treatment Plant. It is solely the responsibility of the successful Bidder to run the raw Water Pump
97
House and Water Treatment Plant without any disruption or interruption during the 3 months period of Trial Run.
2.
Supply of 6 sets of completion plans and maintenance manual and brochures will be required to be provided. The bidder is required to examine carefully the site of the proposed works, each and every data of existing facilities as required and provided in the tender document.
3.
4. Soil investigation shall be done to determine the SBC and the ground water table on the basis of which design shall be submitted. The cost of the ELSRs/GLSRs/PUMP HOUSES quoted by bidder shall remain unchanged irrespective of the actual SBC/Foundation Strata and ground water table. No extra claim on account of variations in soil strata or ground water table. 5. All ELSRs and GLSRs will be constructed by using cement concrete of M30 grade.
C Automation for flow measurements

1. Off - Site Supervisory and Data Accusation (OSSADA) system for Raw water and clear water measuring, recording, Off-Site Digital Display and data Transmission to Cell Phone(SMS). 2. Automated Water Testing laboratory equipments of internationally reputed make.
3. Automated facility for display of Conductivity, Turbidity, pH value, Residual Chlorine, records of stock of different chemicals and reagents etc.
The Scope of Work for this contract under Sub-head 3 includes:

Supplying, laying, jointing, testing and commissioning of Raw Water Rising Main of 500 mm dia DI K-9 pipe for a total length of 19000 m including all valves, specials and other appurtenances. Erection and construction of Structural Bridge for crossing of Raw Water PPumping Mainn 10 m span. Supplying, laying, jointing, testing and commissioning of clear water Rising Main of various diameters (150 mm dia to 400 mm dia DI K-9 pipe) of total length of 7,820 m, along with providing; fitting fixing valves; specials; valve chambers; thrust blocks etc..Bye pass arrangement between incoming and out going pipe lines at the foot of Reservoirs will be made. The diameters and subsequent length of the pipes are given below. Details of Clear Water Rising main pipes
Pipe Material DI/K-9 DI/K-9 DI/K-9 DI/K-9 DI/K-9
Internal diameter, in mm 400 350 300 200 150 TOTAL
Length, in M 1025 2515 310 1610 2360 7820
Supplying, laying, jointing, testing and commissioning of distribution lines of 1,51,399 m consisting of of HDPE pipes (97.40 mm Internal dia. to 159.6 internal dia. mm dia. of total length of 1, 48,643) and DI K-7 pipes (200 mm dia. to 350 mm dia. of total length 2756 m) including all valves, specials and
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appurtenances within the project Area, and a steel bridge for pipe crossing over the Nizam Sagar Canal of a span of 10 m. The details of Distribution pipe lines are given in Table, below Diameter, Type, and length of distribution pipeline
Pipe dia (in mm). and type 97.4, HDPE 124.0, HDPE 159.6, HDPE 200, DI/K-7 250, DI/K-7 300, DI/K-7 350, DI/K-7 Total
Zone No.1 36158 552 320 31 Nil Nil Nil 37061
Zone No.2 22408 3779 1205 742 336 170 Nil 28640
Zone No.3 35073 1884 305 43 Nil Nil Nil 37305
Zone No.4 39400 6944 615 439 685 93 217 48393
Total 133039 13159 2445 1255 1021 263 217 151399
Supplying, fitting, fixing and testing of specials and DI and MDPE barrael piece pipe, (pipe piece will be withdrawn to accommodate Water Meters when such Meters will be fitted under a separate contract), required for all types of Water Meters as per relevant IS codes including other necessary appurtenance. The sizes and numbers of Bulk Water meters as will be required in both feeder mains and distribution systems are given below.
Sl No
Size of meter (mm) 500 400 300 200 150 100 25 20 15
Number
1 2 3 4 5 6 7 8 9
2 1 2 4 4 21 22 48 22,600
Bulk Flow meters of different diameters are to be provided at different locations as shown in the drawing enclosed with the tender, under a separate contract, thus excluded from the scope of the contract of this Project. The bidder is required to examine carefully the site of the proposed works, each and every data of existing facilities as required and provided in the tender document. Thrust Blocks are to be provided at different points as required. Necessary provision for Air Valves and washouts at required points are also to be made.
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Transfer of 2788 existing HSCs from old network to new network of distribution system and 14254 Nos. of new HSCs, by using MDPE (Crade 80) pipes and specials, fittings etc. excluding supply and fitting & fixing of meters, which are covered in a separate contract. Construction of RCC Elevated Level Service Reservoirs (ELSRs), including all types of piping works with specials; valves flow meters etc, stairs & ladders, level indicators, pressure gauges, lightening arrestors, over-flow and washout drains, CC internal roads, masonry drains, Boundary wall with gate, watchman goomty and other works including colour washing (cement based paints) etc. the details of ELSRs are given in the Table:
New: ELSRs
Sl. Location No. Rajula Gutta (near Housing Board) Zirayath Nagar Teachers Colony
GL above MSL(M)
Capacity in KL 2026
LWL MWL above above MSL(M) MSL(M)
Stg. Ht.
Inlet Outlet Dia., Dia., mm mm
Remarks
384.61
450 KL,
400.61
405.41
16.00
150
200
2 3
376.74 379.43
450 KL, 450 KL,
392.74 395.43
397.54 400.23
16.00 16.00
150 150
300 200
Locations for new ELSRs have been considered within the premises under possession of the ULB.
Existing: GLSR
GL Sl. Location above No. MSL(M) 1 Siddala Gutta
Capacity in KL 2026 1200 KL,
LWL MWL Inlet Outlet above above Dia., Dia., MSL(M) MSL(M) mm mm 200 350
Remarks
Repair of existing 1200 KL Ground Level Service Reservoir (GLSR) at Siddala Gutta, involving chipping out old and damaged plasters and flooring, new plastering and flooring work, outside cement based painting, providing, fitting & fixing of new DI pipes and specials with valves, flow meter, valve and meter chambers etc.
Other components of Work

1. Crossing important major roads and water ways, as given in the table below, the contractor has to execute the work following the methods as mentioned in the table (locations are shown in the enclosed drawings). However, similar work may be required at few locations other than shown in the table, which will be executed by the contractor. List of i=few of important cases of Road/Waterway crossings are given in Table, below:
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Sl. No.
Location
Type of existing utility to be crossed
Type of pipeline
Method proposed
Remarks
Near WTP at Yanamgutta
Nizam Sagar Canal
500 mm (i.d.) DI/K-9 Raw Water Pumping main
By constructing one M.S. Structural bridge, 10 m span
ULB may permission competent authority
obtain from I&CA
Different locations on road from Sri Ram Sagar lake to NH 44 Near Journalist Colony, at two sites (Indira Nagar and near Balaji lodge)
Small bridges and culverts over water ways
500 mm (i.d.) DI/K-9 Raw Water Pumping main
By clamping with parapet/Railing along the existing bridges, 6 locations, each involving 3 m crossing length in each case (avg.) By clamping with parapet/Railing along the existing bridge over the canal. Total involved length is about 16 m and 18.5 m, respectively By clamping with parapet/Railing along the existing bridge over the canal. Total involved length is about 16 m.
obtain from I&CA
Nizam Sagar Canal
CW pumping main 200 mm DI/K-9 line
obtain from I&CA
Near Gutta
Rajula
Nizam Sagar Canal
CW pumping main 150 mm DI/K-9 line
obtain from I&CA
Different locations the town
in
Small bridges and culverts over water ways
CW pumping main DI/K-9 line and Different sizes of Distribution pipes Different size of CW rising main (DI/K-9), distribution pipes at various places, 20 cases
By clamping with parapet/Railing along the existing bridges, 18 such cases, about 3 m long each
ULB may obtain permission from competent authority of R&B department/Municipality ULB may obtain permission from concerned authorities of R&B department /Municipality
In different Wards
Different categories of existing Roads and alleys etc.
By open cut & fill method, 8 m to 15 m in length
In addition minor crossings are required for which no separate provision has been made in the estimates. The bidders are required to assess and incorporate the same in their rates. The bidder is required to examine carefully the site for the proposed works. The soil test reports and design of the distribution system attached with the bid documents are for guidance only. 2. Testing of Pipe and Equipment Fittings; Specials & Valves: All the pipes and equipment have to be tested both at factory and at site as per relevant Indian Standards. The testing shall be witnessed by the Engineer-in-Charge and his authorised representatives.
Note:
1. Erection of mechanical & Electrical equipment, trial run for 90 days 23.50 hours per day testing the treated water for efficient standards and maintenance of records and imparting training to staff. is included in the scope of work under this sub-head.
2.
Lightening arrestor as per IS: 3070/1974 - 1no each on ELSRs.
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3. During the trial run of 3 months, the entire expenditure shall be borne by the Bidder including cost of flocculants, disinfectants, oil and lubricants, man power etc. but excluding cost of energy for the Raw Water Pumping station (sub-head -2), Water Treatment Plant. It is solely the responsibility of the successful Bidder to run the raw Water Pump House and Water Treatment Plant without any disruption or interruption during the 3 months period of Trial Run.
4.
Supply of 6 sets of completion plans and maintenance manual and brochures will be required to be provided. The bidder is required to examine carefully the site of the proposed works, each and every data of existing facilities as required and provided in the tender document. The bidder has to check all survey data including levels and carryout soil investigation works before execution .No additional payment will be made for carrying out these works and modifications therein at the time of execution.
5.
6.
In addition to the above provision has been also been made for pipe support structures for crossing minor cross drainages. In addition some small drains are required to be negotiated for which no separate provision has been made in the estimates. The bidders are required to assess and incorporate the same in their rates. (iv) Supplying, laying, jointing, testing and commissioning of distribution lines for 4 zones within Armoor area with necessary HDPE and DI-K7 pipes and fittings with specials, valves etc. has been included within the scope of works under this sub-head.. The bidder is required to examine carefully the site for the proposed works. The soil test reports and design of the distribution system available with the employer may be referred. However, after award of contract actual soil tests shall be done to determine the SBC and the ground water table on the basis of which designs shall be submitted for GLSRs; ELSRs and Pump Houses. The cost of the PHs, GLSRs, ELSRs and all types of Pipelines quoted by the bidder shall remain unchanged irrespective of the actual SBC / Foundation Strata and ground water table. No extra claim shall be entertained on account of variations in soil strata or Ground water table. Testing of Pipe and Equipment: All the pipes and equipments have to be tested both at factory and at site as per relevant Indian Standards. The testing shall be witnessed by the Engineer-in-Charge and his authorized representatives. The bidder has to check all survey data including levels and carryout soil investigation works before execution .No additional payment will be made for carrying out these works and modifications therein at the time of execution. Issue of Materials by the Employer (ULB) Water meter both bulk meters and domestic meters for House Service Connection (HSC) shall be procured separately (under sepaerate contract) and supplied to the Contractor free of charge, for installation in the works. Supplying, fitting, fixing and jointing of all relevant specials shall however remain under the scope of the present contract. Materials in excess of consumption shall have to be returned to the stores of the employer in good condition. Failure shall result in recovery in terms of cost of the goods supplied as per the prevailing market rate or rate at which procured which ever is more+over heads.
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SPECIFICATIONS INDEX
Sl.No 1 Section No. VII A Specification General Specification of Workmanship and Materials for Civil Work Division 1 Division 2 Division 3 Division 4 Division 5 Division 6 Division 7 Division 8 Division 9 Division 10 Division 11 Division 12 2 VII B General Specifications Site work Earth work Masonry Plastering & Pointing Concrete Materials required for pipeline work Laying and Jointing of pipelines Ductile Iron Pipes for Water supply HDPE pipe lines House service connection Material Tree Plantation Strategy Technical Specifications for Civil Works ( ELSRs, CW sumps/GLSRs) 3 4 5 6 7 8 VII C VII D VII E VII F VII G VII H Annexure-I Technical Specification for Equipment Technical Specification for Electro Mechanical Works Technical Specification for Electric Motors Technical Specification for Electric Motors, controls of WTP Specifications for transformers and feeder lines General conditions for Erection & Commissioning Environmental Management Plan (EMP)-Pre-construction phase Annexure-II Environmental Management Plan (EMP) Construction phase Appendix I List of Pumpsets Drawings etc., to be furnished by the Successful Tenderer List Of Tools / Electrical Equipment to be provided By Contractor List of Spare parts to be provided by the Contractor Water Quality Data Soil Investigation Reports Salient Features of Labour Laws Salient Features of some of the major laws that are applicable for protection of Environment
Appendix-II Appendix-III Appendix-IV Appendix-V Appendix-VI Appendix-VII
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SECTION VII A GENERAL SPECIFICATIONS OF WORKMANSHIP AND MATERIALS FOR CIVIL WORK 1. 1.1 GENERAL General Materials
1.1.1 All materials used in the permanent works shall be of the best quality of the kind and to the approval of the Engineer-in-Charge. Any material not covered by these Specifications, shall comply with the relevant latest Indian Standard Specifications (Referred to as IS as revised or modified up to the date one month prior to Tender date). British or American Standard Specifications shall be referred to in case any particular specification is not available in any of the aforesaid Specifications. 1.1.2 Samples of materials to be supplied and used, by the Contractor in the works shall be to the prior approval of the Engineer-in-Charge. For this purpose the Contractor shall furnish in advance representative samples in quantities and in the manner as directed by the Engineer-in-Charge for his approval. Materials brought to the Site, which in the opinion of the Engineer-in-Charge do not conform to the approved sample, shall, if so directed by him, be removed by the Contractor from the Site and replaced by the materials of approved quality. Sourcing of all the material such as metal, sand and quarry dust shall be sourced from approved quarries and the contractor shall provide relevant approval details to the Engineer-in-Charge, upon request. 1.1.3 In spite of approval of the Engineer-in-Charge of any materials brought to the site, he may subsequently reject the same if in his opinion the materials has since deteriorated due to long or defective storage or for any reason whatsoever and is thereby considered unfit for use in the permanent works. Any material thus rejected shall be immediately removed from the Site at Contractor's cost and expense. 1.1.4 All materials brought to the Site shall be properly stored and guarded in the manner as directed by the Engineer-in-Charge and to his satisfaction. 1.1.5 The Engineer may carry out test of materials as he may decide. The Contractor shall, at his cost and expenses, for this purpose supply requisite materials and render such assistance to the Engineer-in-Charge as he may require. 104
1.2
Workmanship All works are to be carried out in proper workman like manner. Items of works not
covered by these Specifications or by other tender documents shall be carried out as per best practice according to the direction of the Engineer-in-Charge and to his satisfaction. The relevant IS Specifications and in case of necessity British or American Standard Specifications shall be taken as guide for the purpose. 1.3 Works Included The rates for all items, unless specifically stated otherwise in the Contract, must cover the cost of all materials, labour, tools, machinery, plant, pumps, explosives, scaffolding, staging strong props, bamboos, ropes, templates, pegs and all appliances and operations whatsoever necessary for efficient execution of work. 1.4 Ground Conditions The Contractor shall visit the site and ascertain local conditions, traffic restrictions, obstructions in the area and allow for extra expenses likely to be incurred due to any limitations whatsoever. 1.5 Setting Out and Leveling The Contractor is to set and level the works, and will be responsible for the accuracy for the same. He is to provide all instruments and proper qualified staff required for checking the Contractor's work. 1.6 Safety The Contractor shall take adequate and necessary precautions ensuring complete safety including occupational health safety as well as site safety preventing accidents. (i)The specific aspects shall include but not limited to: (a) barricading the site all the time to prevent access to public to the construction site; (b) ensuring all workers are provided with and use Personal Protective Equipment including helmet, gloves and gumboots at work locations, nose musk at dust producing areas, safety belt during work at height; (c) H and S Training for all site personnel; (d) documented procedures to be followed for all site activities; and (e) documentation of work-related accidents; (ii) Ensure that qualified first-aid be provided at all times (at working sites and 105
camp). First Aid box shall be easily accessible throughout the site; (iii) Provide H and S orientation training to all new workers; (iv) Use fall protection equipment when working at heights; (v) Maintain work areas to minimize slipping and tripping hazards; (vi) For night work, provision of proper illumination for the work space, while controlling glare so as not to blind workers and passing motorists; (vii) Ensure the visibility of workers through their use of high visibility vests when working in or walking through heavy equipment operating areas; viii) Ensure moving equipment is outfitted with audible back-up alarms; and (ix) Disallow worker exposure to noise level greater than 80 dBA for a duration of more than 8 hours per day without hearing protection. The use of hearing protection shall be enforced actively. 1.7 Keeping Works Free from Water
The Contractor shall provide and maintain at his own cost, electrically or other power driven pumps and other plant and equipment to keep site, excavated foundation pits and trenches free from surface as well as subsoil / leakage water from Primary Grid of any other source thereof and continue to do so during construction and afterwards to the complete satisfaction of the Engineer-in-Charge till the site is handed over. Method of dewatering shall need approval of the Engineer-in-Charge but no payment whatsoever is allowed on this count. The pumped water shall be drained to the nearest storm water drainage without causing inconvenience to public (such as flooding of roads, private properties, inundations, creation of cess pools). The pumped water shall not be discharged into the fresh water bodies which are used for drinking or bathing purposes. 1.8 Earthwork Debris Disposal 1.8.1 The Contractor shall clear all rubbish, vegetation, roots, soda etc., and dispose
them with proper leveling in the area indicated to the satisfaction of Engineer-in-Charge. The mitigation measures shall include : a) Manage debris/waste according to the following preference of hierarchy: reuse, recycling and disposal to designated areas as per ULB b) Avoid stockpiling of excess excavated soils without causing disturbances/difficulties for public movment; c) Dispose oil and lubricants waste as per Hazardous Waste (Management and Handling) Rules 1989; 106
1.8.2
After the work is completed, the Contractor shall clear the area surrounding the
buildings, of all hutments and excess stores and remnants of building materials such as brick bats, left over construction material etc. to the satisfaction of the Engineer-in-Charge. 1.9 Bench Marks and Ground water Gauges The Contractor shall protect surveyor's bench marks and ground water gauges, zero line marks and base line marks from damage of movement during work. 1.10 Inspection The Contractor shall inspect the Site of works and ascertain site condition and the nature of soil to be excavated. 1.11 Contractor's Staff The Contractor must provide at all times efficient staff of trustworthy, skillful and experienced assistance capable of carrying out the work in accordance with the drawings and specification and to correct levels. The cost this establishment should be included in his rates. 1.12 Method of Measurement Unless otherwise specified, the method of measurement for building works shall be as per IS: 1200. 1.13 Specifications Referred to
1.13.1 The specification contained herein is not exhaustive and for such items of works which may arise and which are not covered by these specifications, the provisions in the relevant Indian Standard (Latest Edition) shall apply. 1.13.2 A list of some Indian Standards is given herein. 1.13.3 Wherever reference to the Indian Standard mentioned below or otherwise appears in the specification, it shall be taken as reference to the latest version of the Standard: General IS Building Cement Sand Aggregates Code No. IS:1200 IS:269 IS:1242 IS:383 IS:515 107 Description Method of measurement of A Civil Engineering works. Ordinary, Rapid Hardening and Low Heat Portland Cement. Sand for Plaster Aggregates-Coarse and fine, from Natural source for Concrete. Aggregates for use in mass
General IS
Code No.
Concrete-Plain
IS:456
IS:3370 Brickwork IS:1077 IS:1235 IS:1443 Plaster and Painting Steel (Revised) Iron Work 2. 2.1 IS:1661
IS:800
Description concrete, natural and manufactured. Code of Practice for Plain and Reinforced Concrete for General Building Construction Code of Practice for Concrete Structures for the Storage of Liquids Common Burnt Clay Building Bricks, Paving Flooring Tiles, Cement Concrete, Floor Finish Cement Concrete, Flooring Tiles Laying and finishing Cement and Cement Lime Plaster finishes on walls and ceilings Code of Practice for use of Structural Steel in General Building Construction
Earth Work in Excavation & Fillings General
Applicable provisions of Earth work in excavation & fillings shall govern work under this section. 2.2 Excavation for Foundation, Trenches, Pit etc.
The excavation work shall be carried out in all kinds of Soil including Sand in workman link manner without endangering the safety of the nearby structures or works without causing any hindrance to other activities in the area. The existence of old buildings, boundary walls, hutment, sewer lines, water lines, if any very close to the area of excavation should be given careful consideration while designing carrying out the excavation work. The excavation shall be done in such method as would technically be appropriate and befitting the site conditions subject to the approval of the Engineer-in-Charge. All foundation trenches shall be excavated to the full width and depths shown on the approved drawing or to such ordered to the Contractor. The Contractor shall not undertake any earth work without having obtained prior approval from the Engineer-in-Charge to the methods he proposes to employ in order to execute the work in the most efficient manner. He shall not modify such methods without the approval of the Engineer-in-Charge. This approval, however, shall not in any make the 108
Engineer-in-Charge responsible for any consequent loss or damage. 2.2.1 Should any excavation be taken down the specified levels, the Contractor shall fill
in such excavation at his own cost with concrete as specified for foundations, well rammed in position until it is brought up to the specified level. 2.2.2 The Contractor shall notify when the excavation is completed and no concrete or
masonry shall be laid until the soil for each individual footing, rafts etc. is approved. 2.2.3 The Contractor shall keep the site clear of water at all times. To this end he shall
provide arrangements for bailing and pumping or any special arrangements as required within his quoted prices. 2.2.4 All foundation pits shall be refilled to the finished ground level (formation level) with approved materials, which shall be suitably consolidated in layers to the satisfaction of the Engineer-in-Charge. 2.2.5 Nothing extra will be paid for bailing out water collecting in excavation due to rains,
ordinary springs, leakage from existing primary grid etc., or any other reason. 2.2.6 For the work of excavation the Tenderer shall include in his quotation the shoring,
sheeting, bracing and sheet pilling (if required). The quotation shall also include the cost of compaction of foundation sub-base, removal and storage of excavated materials and back-filling. 2.3 Back Filling
The space around the foundations in trenches or sites shall be cleared of all trash and loose debris and filled with approved excavated earth, all clods being broken up to the finished G.I. Filling shall be done in 200mm layers, each layer to be property moistened and well rammed. Excavated materials,which is surplus or which is consolidated unsuitable for back filling is to be disposed of in spoil dumps as directed by the Engineer-in-Charge. 3. 3.1 3.1.1 section. Concrete General Applicable provisions of Conditions of Concrete shall govern work under this
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3.1.2
All concrete work, plain or reinforced shall be carried out strictly in accordance
with this specification and any working drawing or instructions given from time to time to the Contractor.
3.1.3
The Contractors states shall allow for wastages in all materials as well as for all
tests of materials and concrete. 3.1.4 No concrete shall be cast in the absence of the Engineer-in-Charge or any other
person duly authorized by him. The Contractors Engineer shall personally check that both the form work and reinforcement have been correctly placed and fixed, and shall satisfy himself that all work preparatory to the casting is completely ready, before informing the Engineer-in-Charge for final inspection and approval and for which purpose at least 24 hours notice shall be given by the Contractor. 3.1.5 The Indian Standards wherever referred to herein shall be the latest addition of
such standards. 3.2 Cement
Cement shall conform to IS: 269. Cement tests shall have to be carried out at Contractors expense as and when directed. Cement which has or practically set shall not be used under any circumstances. 3.3 Aggregates
The fine and coarse aggregates shall conform to all provisions and test methods of IS: 383 and / or IS: 515. Samples of aggregates, proposed to be used in the work shall be submitted free of charge in sufficient quantities to the Engineer-in-Charge with sieve analysis and other physical and chemical analysis data for his approval. Approved samples will be preserved by him for future reference. This approval will not in any way relieve the Contractor of his responsibility of producing of specified qualities. 3.3.1 Coarse Aggregates
Coarse aggregates for use in reinforced and other plain cement concrete works shall be crushed black granite trap stone obtained from approved source and shall consist of uncoated, hard, strong dense and durable pieces of crushed stone, and be free from undesirable matters, viz. Disintegrated stones soft, friable, thin, elongated or laminated pieces, dirt, salt, alkali, vegetable matter or other deleterious substances. The aggregates shall be thoroughly washed with water and cleaned before use to the satisfaction of the 110
Engineer-in-Charge at no extra cost of the Employer. The maximum size of coarse aggregates shall be as follows unless specified otherwise with very narrow space: 12 mm. Elsewhere. Reinforced Concrete Plain Concrete Thin R. C. C. Members Mat/Lean Concrete : 20/40 mm : : 20 mm 20 mm.
(The actual size to be agreed by the Engineer-in-Charge) Grading of coarse aggregates for a particular size shall generally conform to relevant I. S. Codes and shall be such as to produce a dense concrete of the specified proportions and or strength and consistency that will work readily in position without segregation. 3.3.2 Fine Aggregates Sand shall be clear River sand brought from approved source and consist of siliceous material, having hard, strong, durable uncoated particles, free from undesirable matters viz. dust lumps, soft or flaky particles or other deleterious substances. The amount of undesirable shall not exceed the percentage limits by weights as specified in relevant IS Codes. Washing of aggregates by approved means shall be carried out, if desired by the Engineer-in-Charge, at no extra cost to the Employer. Coarse and fine sand shall be well graded within the limits by weight as specified in relevant IS Code. Fineness Modulus shall not vary by more than plus or minus 0.20 from that of the approved sample. Fineness Modulus for sand should not be less than 2.5. 3.4 3.4.1 Reinforcement The Contractor shall prepare and furnish to the Engineer-in-Charge, Bar Bending
Schedules in considerations of the approved drawings for all R. C. C. works for review and checking by the Engineer-in-Charge before taking up the work. 3.4.2 The mild steel reinforcement shall conform to IS: 432 & the tor-steel reinforcement
shall conform to IS: 1788. All steel for reinforcement shall be free from loose, oil, grease, paint or other harmful matters immediately before placing the concrete.
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3.4.3 The Reinforcement shall be bent to the shapes shown on the approved drawings prior to placing and all bars must be bent cold. The Steel shall be placed in such a way that it is rigidly held in position while concrete is being cast. The correct clearance from the form shall be maintained by either precast mortar blocks or by metal supporting chairs to
be supplied by the Contractor free of charge. The intersection of roads crossing one another shall be bound together with soft pliable wires (No. 16 to 18. S.W.G), at every intersection so that reinforcement will not be displaced in the process of depositing concrete. The loops of binding wire should be tightened by pliers. 3.4.4 The work of reinforcement shall also be inclusive of stirrups distribution bars,
binders, initial straightening and removing of loose rust, if necessary, cutting to requisite length, hooking and bending to correct shape, placing in proper position including supplying and binding with block annealed wire as stated in clause 3.4.3 above. 3.4.5 Welding of reinforcement shall be done according to the IS specifications where
binding wire will not be sufficient without any extra payment to the Contractor. 3.5 Water The Water shall be clean and free from acid, alkali, oil or injurious amounts of deleterious materials. As far as possible, the water be of such quality that it is potable. If any chemical analysis of water is necessary and ordered, the same shall be carried out at an approved laboratory at the Contractors cost and expenses. 3.6 3.6.1 Concrete Proportioning The concrete proportions shall be as indicated on the approved drawings and shall
conform to IS: 456 & IS: 3370. The quality and character of concrete shall be governed by IS: 383. It should be sampled and analyzed as per IS: 1199. The concrete should stand the test specified in IS: 516. 3.6.2 The minimum cover of main reinforcement shall be 25 mm or the diameter of the
bar whichever is greater. Cover to any reinforcement of R. C. C. piles shall be minimum 65 mm, in case in-situ and 50 mm, in case of precast piles. Suitable spacer blocks shall be provided at intervals not exceeding 1.2 m. throughout the length of the pile.
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3.6.3
The work ability shall be measured by slump. Slump for different grades of
concrete shall not exceed following unless specifically permitted by the Engineer-inCharge. i) For M 15 concrete 3.75 cm.
ii) For M 20 concrete 2.50 cm. ii) For M 30 concrete 2.50 cm. 3.6.4 All concrete works shall be thoroughly compacted and fully worked around the
reinforcement, around embedded fixtures and into corners of the form work. The Concrete shall be thoroughly and shall be efficiently vibrated during laying. The use of mechanical vibrators shall comply with IS: 2608, IS: 2506 and IS: 456. Whenever vibration has to be applied externally, the design of form work and deposition of vibration shall receive special consideration to ensure efficient compaction and to avoid surface blemishes. 3.6.5 Test for Water Tightness of Structures / Pipes All liquid retaining structures including underground reservoir, and different units of water treatment plant like inlet chambers, flocculator, clarifier, filter etc. shall be deemed to be satisfactory water tightness test as per relevant clause of IS:3370. Approved corrective measures, if necessary, shall be undertaken by the Contractor at his own expenses. This water tightness test is mandatory for all type of water retaining structure and no security deposit shall be released without satisfactory water tightness test results. As regards the pipe lines, the tests shall be performed for the Hydrostatic Pressure of 10 Kg./Sq. cm in case of Mild Steel and 2 Kg./Sq. cm. for P.S.C./R.C.C. respectively. The tests shall be carried out as per relevant IS Codes and pipes shall be considered satisfactory if the tests results satisfy the requirements of the relevant clauses of the Codes. The Contractor shall give all these Hydraulic Tests by making his own arrangements for water supply and filling and disposing the water after the tests. The Contractor shall rectify the defects noticed and carry out the tests again and repeat the testing operation till successful result is obtained and accepted by the Engineer. The rates Quoted for the work shall be considered as inclusive of cost of all Labour, materials and equipment required to give successful tests for Water tightness.
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3.7 3.7.1
Workmanship All Concreting work shall be carried out according to the IS: 456 and IS: 3370. It
should, however, be noted that for every 15 Cum of concrete placed or for every one days volume of concrete whichever is lower, a minimum of 3 (three) Cubes shall be cast for test purpose, and tested at the Contractors cost and expenses at a Laboratory as approved by the Authority. The number of test cubes may, however, be altered at discretion of the Engineer-in-Charge. It is compulsory to test 3 (three) cubes in each case. 3.7.2 Structural Concrete Design mix Concrete shall be on all concrete works except in case of Mud-mat concrete/ lean concrete where nominal mix concrete will be allowed. Design mix Concrete will be used in Reinforced Concrete Structures shall be in Grade or M20 or richer. The mix shall be designed to produce to produce the grade of concrete having required workability and a Characteristic Strength not less than appropriate values given in Clause 5.1 or IS:456/1978. For mix design, procedure given in Indian Standard. Recommendation or any other standard procedure shall be adopted. As long as the quality of materials does not change a mix design done earlier may be considered adequate for later work. Batching mixing, sampling and Strength Test of concrete shall be carried out in compliance with the relevant clause of IS: 456/2000 and all other relevant Indian Standards recommended therein. The mix design by the Contractor shall be used for works only after obtaining written approval of the Engineer-in-Charge. Mix design shall be entirely the responsibility of the Contractor and any approval by the Engineer-in-Charge shall not relieve him of his responsibility in respect thereof. The Contractor shall prepare all the Calculations. Tabulations, Graphs etc. pertaining to Mix design / Test result and supply copies of such Calculations, tabulations, Graphs etc. required by the Engineer-in-Charge. The minimum Cement content in each grade of Concrete shall be as given below: Grade of Concrete Minimum Cement Content per cum of finished Concrete (Kg.)
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Grade of Concrete M 15 M 20 M 25 M 30
Cement Content (Kg.) 310 330 350 400
On proportioning concrete, the quantity of both cement and aggregate shall be determined by weight, where the weight of cement is determined on the basis of weight per bag a reasonable number of bags be weighed periodically to check the net weight or should be either weighed or measured by volume in calibrated tanks. All measuring equipment shall be maintained in a clean serviceable condition and shall periodically checked for accuracy. The grading of coarse and fine aggregates shall be checked frequently and frequency of testing shall be determined by the Engineer-in-Charge. Where weight batching is not possible or practicable, the quantities of coarse and fine aggregates may be determined by volume but cement in any case shall be weighed by weight only. If fine aggregate and volume batching is adopted, allowance shall be made for bulking. The bulking shall be determined in accordance with IS: 2386 (Part-III). The Water-Cement Ratio shall be maintained to its correct value. Surface moisture content of aggregate shall be determined as per IS: 2386 (Part-III) and the amount of water to be added shall be adjusted accordingly to maintain the correct Water-cement Ration. During the progress of work in order to ensure correct strength of concrete proper control should be exercised by the Contractor as specified in Specifications mentioned in the Clause. 3.7.1 Test strength of every sample shall be determined in accordance with the
recommendations of IS: 456-1978. If one out of ten consecutive test cubes shows a deficiency in strength upto a maximum limit of 10%, the concrete will be deemed satisfactory. If two of the test cubes out of ten show a deficiency in strength upto a limit of 10%, the concrete shall be deemed to be less satisfactory and a reduction of 1% will be made on the cost of such concrete. If three out of ten test cubes show deficiency in strength upto a limit of 10%, a reduction of 5% will be made on the cost of such concrete. If more than three rest cubes show a deficiency in strength upto a limit of 10% a reduction 115
of 10% will be made on the cost of such concrete. If more than five shows a deficiency in strength upto a limit of 10%, the concrete shall be rejected. Such rejected concrete work shall have to be dismantled and replaced to the satisfaction of the Engineer-in-Charge by the Contractor free of cost to the Employer. No payment for the dismantled concrete, the relevant from work and reinforcement, embedded fixtures etc. wasted 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 deficiency in strength of one test cubes exceeds the 10% limit, a reduction of 5% will be made on the cost of such concrete. if the deficiency in strength to two out of ten test cubes exceeds the 10% limit, a reduction of 10% will be made on the cost of such concrete. If the deficiency in strength of two out of ten test cubes exceeds the 10% limit, a reduction of 10% will be made on the cost of such concrete. If the deficiency in strength of three out of ten test cubes exceeds the 10% limit, a deduction of 20% on the cost of such concrete will be made. With permission of the Engineer-in-Charge for any above mentioned grades of concrete, if the quantity of water has to be increased in special cases, cement shall also be increased proportionally to keep the ratio of water to cement same as adopted in trial mix design for each grade of concrete. No extra payment for additional cement will be made. 3.8 Precast Concrete Precast Concrete items shall conform to relevant IS Specifications. Precast items shall be suitably marked with the date of casting identification marks and shall show the right way up as may be required. The arrangements to be made by the Contractor for Site manufacture and handling of precast items shall be done to the approval of the EngineerIn-Charge. Each precast unit shall be cast in one operation and no construction joints shall be permitted. No damaged or defective units shall be built into the works and units shall be so stored that they are not over stressed. Precast units shall be provided in places as shown in the approved drawings. The precast units shall be cast at site strictly following the Specifications of Precast Concrete work. Proper care shall be taken to ensure that the units are obtained from the moulds without any damage. Before erecting in position the position the units shall be cured adequately by keeping units immersed in water. 116
3.9 3.9.1
Form Work The Form Work shall conform to IS: 456. Whenever necessary, shuttering must be
provided. The work shall also include providing all necessary staging, centering, form work and moulds for placing concrete. Shuttering may be of approved dressed timber true to line, not less than 37 mm. thick. Surface to be in contact with concrete are to be planed smooth. Alternatively, sufficiently rigid plywood shuttering or steel shuttering may be used. In every case, joints of the shuttering are to be such as to prevent the loss of liquid from the concrete. In timber shuttering the joints shall, therefore, be either long & grooved or the joints must be perfectly close and lined with draft paper polythene films or other types of approved materials. In case of plywood or steel shuttering also the joints are to be similarly lined. All shuttering and framing must be adequately stayed and braced to the satisfaction of the Engineer-in-Charge for properly supporting the concrete, during concreting and the period of hardening. It shall be so constructed that it may be removed without shock or vibration to the concrete. No through bolts are allowed for holding the shuttering in water retaining structure. 3.9.2 Cleaning, Treatment and Removal 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 chippings, shavings, saw dust etc. shall be scrupulously removed from the interior of the forms before the concrete is poured. Form work shall not be used/reused, if declared unit or unserviceable by the Engineer-in-Charge. If directed by the Engineer-in-Charge, compressed air jet/or water jet shall be kept handy along with wire brushes, brooms etc. for the purpose of cleaning. Before shuttering is placed in position, the form surface in contact with the concrete shall be treated with approved non-staining oil or composition. Care shall be taken that the oil or composition. Care shall be taken that the oil or composition does not come in contact with reinforcing steel or existing concrete surface. They shall not be allowed to accumulate at the bottom of the shuttering. Forms shall be truck in accordance with the relevant clause of IS: 456 or as directed by the Engineer-in-Charge. The Contractor shall record on the drawings or in other approved manner, the date in 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 recorded checked 117
and countersigned by the Engineer-in-Charge. The Contractor shall be responsible for the safe removal of the form work, but the Engineer-in-Charge may delay the time of removal if he considers it necessary. Any work showing signs of damage through premature removal of form work or loading shall be entirely reconstructed without any extra cost to the Employer. 3.10 Protection and Curing of Concrete Newly placed concrete shall be protected by approved means; from rain, sun and wind and extreme temperature. Concrete placed below the ground level shall be protected from failing earth during and after placing. Concrete placed in ground containing deleterious substance shall be kept free from contact with such ground or, with water draining from such ground during placing of concrete and for a period of at least 3 (three) days or as otherwise directed by the Engineer-in-Charge. the ground water around newly poured concrete shall be kept to an approved level by pumping or other approved means of drainage at the cost of the Contractor. Adequate steps shall be taken to prevent flotation or flooding. Steps, as approved by the Engineer-in-Charge, shall be taken to project immature concrete from damage by debris, excessive loading, vibration, abrasion, mixing with earth or other deleterious materials, etc. that may impair the strength and durability of the concrete. As soon as the concrete has hardened sufficiently for the surfaced to be marked it should be covered with hessian, canvas, or similar materials and kept continuously wet for at least 7 (seven) days after final setting. This period may be extended at the direction of the Engineer-in-Charge, upto 14 (fourteen) days. Concrete slabs and floors shall be cured by flooding with water of minimum 25 mm. depth for the period mentioned above. Approved curing compounds may be used in lieu of moist curing with the permission of the Engineer-in-Charge. Such compound shall be applied to all exposed surface of the concrete as soon as possible after the concrete has set. No extra payment is allowed on such count. 3.11 Concrete Finish The Concrete surface on removal of form work shall be such that no finish in necessary, If, however, the surfaces is not satisfactory the Contractor shall, if so instructed, remove unwanted, projecting parts by chipping and smoothening the surface with cement rendering at his own expenses. The shutter marks shall invariably be removed by rubbing with carborandum stone. The Contractor shall therefore take all 118
precaution for avoiding the shutter marks. 3.12 Construction Joints These shall be in according with IS: 337 or as directed. 3.13 Expansion Joints Expansion joints shall be provided at position as directed and the spacing shall not exceed the limits specified in IS:456. These shall comply strictly with the details shown on approved Construction drawings. Reinforcement shall not extend across any expansion joint and the break between the two sections must be complete. 3.14 Details of typical expansion joints and construction joints should comply with the
suggestive arrangements shown in IS:3370 (Part-I), Clause 8.1 (a)(2), Figure 2 (for expansion joints) and Clause 8.1(a) Figure 1, Clause 8.1 (b) Figure 4 (for construction joints). 3.15 P.V.C. Water Stops The materials shall be durable and tough and as per approval of the Engineer-inCharge. The minimum thickness of PVC sealing strips shall be 6 mm. and the minimum width 225 mm. actual shape and size shall be as per drawings. The materials should be of good quality polyvinyl chloride highly resistant to abrasion and corrosion as well as to chemicals likely to come in contact with during use. The physical properties will generally be as follows: Specific Gravity 1.3 to 1.35 Shore Hardness 60 A to 80 A Tensile Strength 100 to 150 Kg. /Cm2 Minimum Safe Continuous Temperature 75 C Ultimate Elongation Not less than 275% Water Absorption Not more than 5% by weight in a 7 day tests. 3.16 Rubber Water Stops The materials must be very durable and tough and as per approval of the Engineerin-Charge. The ribs shall be sufficient to ensure proper bonding with concrete. The width shall be minimum 225 mm. and thickness minimum 6 mm. The rubber water stop must be used in long lengths to avoid splicing as far as practicable. Ends shall have at least 200 mm. overlaps and vulcanized. The materials shall be natural rubber and be resistant to corrosion tear and also to attacks from acid, alkalis and chemicals normally encountered in service. The physical properties will generally be as follows: The Contractor shall provide 119
0
constant and strict supervision of all the items of construction during progress of work, including the proportioning and mixing of the concrete and bending and placing of reinforcement. Adequate notice shall be given before any important operation such as concreting or stripping of form work. Specific Gravity Shore hardness Tensile Strength Maximum safe continuous temperature Ultimate elongation Water Absorption 3.17 Not less than 350% Not more than 350% by weight in a 7 day test. 1.1 to 1.15 65 A to 75 A 250 to 300 Kg/Cm2 750C
Contractor's Supervision
At every stage of the contract and execution of work, intimate involvement and purposeful supervision of the Contractor is essential, and the contractor can not absolve or excused from holding the responsibility on any matter arising out of improper quality of work due to negligence in supervision. 3.18 Laying Cement Concrete Foundations and Under Floors
Before laying the concrete, the bottom and sides of the trench upto the proposed height of the concrete shall be moistened. The concrete shall be laid and not thrown, in layers not exceeding 150 mm. in depth and shall be tamped / vibrated immediately after laying. 3.19 Chases, Holes, Recesses and Inserts
All chases, holes and recess for foundation or other bolts, various services and other requirements must be formed as shown on the approved drawings or as directed during the execution of the work, without any extra charge. The Contractor shall fix all necessary inserts or fixtures in the concrete for support of hangers etc., for pipes and cables, ceiling clamps for lights and fans or for duct etc. If any of the inserts are to be supplied by other agencies, no extra payment will be made to the Contractor for placing the inserts in position. The approximate nos. of MS inserts required for fixing of cable tray/hangers in 400. The load carrying capacity of inserts per sq. m. may be taken as 100 kg.
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4.
Brick Work
4.1 Applicable provisions of Conditions of Concrete shall govern work under this section. 4.2 The Contractor shall build the whole of brick work, shown on the approved drawings with first class bricks conforming to IS: 1077 and IS: 2212 in cement mortar as described. All brickworks, unless otherwise specifically mentioned, should be of 1st Class brick of approved quality. 4.3 Unless otherwise specified, the proportions of cement-sand mortar for various
classes of load tests shall be carried out in accordance with IS:456, if required brick work shall be as given below: Type of Work a) Ordinary brick work with Thickness 250 mm. above for building superstructure b) Brickwork in pillars and foundation c) Half brick or brick-on-edge portion wall with H.B. netting in every alternative 3rd layer d) Brickwork in water retaining structures 1 1 : : 4 1 1 : : 6 4 Cement : Sand
The cement and sand shall be thoroughly mixed dry in specified proportions. Water shall then be added just sufficient to make a stiff and workable paste. The mortar shall be used within half an hour of mixing. 4.4 The Contractor shall build all brickwork uniformly, no one portion being raised more
than 1 meter above another at a time. The joints shall not exceed 12 mm. in thickness and should extend the full thickness of the brickwork. All joints shall be properly raked and the surface washed down. 4.5 All the bricks shall be kept fully immersed in water at least for a minimum period of
six hours till they are completely soaked and only thoroughly soaked bricks shall be used in the work. 4.6 The Contractor shall keep wet all brickwork for at least 10 (ten) days after laying.
The surface of unfinished work shall be cleaned and thoroughly wetted before joining new work to it. 4.7 Before supplying the bricks, quality and grade of the bricks must be approved by
the Engineer on the representative sample. 121

5. 5.1
Plastering, Painting and Surface Treatment Cement Plaster The plastering work shall be governed by IS: 1661. Unless otherwise specified
5.1.1
cement plaster shall be composed of 1 part of cement and 6 parts of sand. For ceiling plaster, the composition shall be 1 part of cement and 4 parts of sand. The thickness of ceiling plaster shall be 6 mm. The thickness of plaster to the fair faces of brickwork shall be 19 mm. The thickness mentioned shall be minimum thickness. The Contractor shall allow in his rate for any rubbing out due to inequalities of brickwork. Except underground reservoir and unless otherwise specified by the Engineer, cement plaster shall be applied on all inner and outer surfaces except floors of all structures. 5.1.2 The rate shall also include for forming of any moulding drip course etc., and for
extra thickness due to corbelling of brick work in parapet or at any other place. If required all internal angles shall be rounded off as per drawing or as directed by the Engineer-inCharge without any extra charges. 5.1.3 Cement and sand shall be measured and mixed dry thoroughly to a uniform colour on a platform specially constructed for the purpose. Care should be taken to see that no foreign matters get mixed with the mixture. Only enough water shall be mixed to make the mixture workable. The mix shall then be turned over and again to a uniform colour and texture. No. more cement mortar shall be mixed at a time than cannot be used within thirty (30) minutes of mixing. 5.1.4 Surface to be plastered are to be brushed clean, wetted for 24 hours before the
plaster is put in and the joints of the brick work raked out 12 mm. deep minimum. The concrete faces to be plastered shall be chipped, roughened and soaked with water for achieving required bond with the plaster without any extra cost. 5.1.5 The surface of the plaster shall be finished absolutely in one plane. All unevenness shall be rubbed down by the Contractor with corboandum stones at his cost and expenses. Care shall be taken to see that no mark remains at the junction of plastering done at different times. If necessary, the junctions shall be rubbed with corborandum stones to eliminate such undesirable marks. The Contractor may be required to use normal sprinkling of thin cement slurry on the surface for satisfactory finishing of the plastering work for which no extra payment shall be made. 5.1.6 122 Plaster shall be protected and cured by keeping it thoroughly wet with sprinkling of
water for 10 (ten) days continuously.
5.1.7
The cost of plastering work shall also include the cost of necessary scaffolding,
staging etc. as would be required for the work. 6. Surface Finishing
6.1 General The cost of all the items of work under this section should include the cost of necessary scaffolding, staging, preparing sub base, removing stains from the floor, skirting, wood work, glass etc. caused through execution of the work. 6.2 6.2.1 White Washing White washing shall be done with 5(five) parts of stone lime and 1 (one) part of
shell lime with necessary gum (about 2 Kg. per Cum of lime) using a small quantity of blue as per direction of Engineer-in-Charge. The lime shall be brought to the site un-slaked and shall be slaked at site with an excess of water and allowed to remain under water for (two) days. To the mixture fresh water may be added to bring the consistency to that of a thin cream. When thoroughly mixed, the mix is to be strained through coarse cloth. The surface of the wall is to be brushed thoroughly cleaned before the white washing is applied. Each coat of white wash has to be laid on with brushes. Each coat of White Wash means one continues strike of brush with the prepared wash from top downwards. Another similar strike bottom upward over first strike followed by another similar strike from right to left and another from left to right over the right application of brush before it dries. Each coat must be perfectly uniform when finished and free from brush mark etc. 6.2.2 Three coats of white wash will mean a minimum of 3 (three) coats to produce on
opaque white surface to the entire satisfaction of the Engineer-in-Charge. If the surface is blotchy or otherwise unsatisfactory, more numbers of coats shall be applied till the desired effect is produced to the satisfaction of the Engineer-in-Charge without any additional cost. 6.3 6.3.1 Snowcem or Similar Decorative Cement Finish Whether specified or unspecified, all external surface shall be finished with two
coats of 'Snowcem' or similar decorative weather-proof "Weather coat" cement finish of approved colour, shade and manufacture. The surface to be finished is to be previously cleaned to remove loose dust or dirt by use of stiff wire brush. All inequalities to be rubbed down and defects rectified. The surface to be wetted well with water and the surface water is to be allowed to run off. The 'Snowcem' or equivalent to be mixed will be strictly as per manufacturer's specification. Such mixed 'Showcem' or equivalent to be applied to the 123
surface with a good quality brush. The first coat should be well brushed into the surface to form a good bond. Second coat should be applied carefully to give a good finished appearance may be applied by brushing or spraying. Each 'Snowcem' or equivalent application shall be wetted at the end of the day with a fine water spray. For the external surfaces of the Pump House, Chemical House, Annexe Building, the quality and colour scheme shall be as per direction of the E.I.C. 6.3.2 Plastic (Acrylic) Emulsion Paint: All internal surfaces of the Control Rooms of the
Pump House, Control Rooms of the Filter House and Annexe Building, Laboratory shall get plastic (acrylic) emulsion paint. On the plastered surfaces a cement priming coat is required before application of plastic emulsion. Plastic emulsion paint of approved brand and manufacturer and of the required shade shall be used. The paint will be applied in the usual manner with brush and roller. The paint dries by evaporation of the water content and as soon as the water has evaporated the films gets hard and the next coat be applied. The time for drying varies from one hour on absorbent surfaces to 2 to 3 hours on nonabsorbent surfaces. The thinning of emulsion is to be done with water and not with turpentine. Thinning with water will be particularly required for the undercoat which is applied on the absorbent surface. The quantity of thinner to be added shall be as per manufacturer's instruction. The surface on finishing shall present a flat, velvety, smooth finish. If necessary more coats shall be applied till the surface present a uniform appearance. 6.4 Painting to Steel Works
6.4.1 Any shop coat of paint shall not be considered as a coat of paint for the purpose of specification. 6.4.2 Ready mixed synthetic enamel paint of 'Jenson & Nicholoson' 'British Paints',
'Shalimar Paints' or similar other approved make and approved colour and shade shall only be used. The primer shall be red oxide zinc chromate primer (IS: 2074) or any other anticorrosive primer as approved and directed by the Engineer-in-Charge. The Contractor shall furnish the details of paints to the Engineer-in-Charge for approval of paints before commencement of painting work. 6.4.3 The surface to be painted shall be properly cleaned, de-rusted, all loose scales removed and smoothened with emery papers. Then a coat of anticorrosive priming shall be evenly applied. After this has dried up, two successive coats of best quality ready mixed synthetic enamel paint shall be given to the entire satisfaction of the Engineer-in124
Charge. Brushes of approved size and make shall only be used for application of paint and use of cloth is definitely prohibited. 6.5 Painting to Internal Walls
Whether or not specified, entire internal surfaces of Pump House, Filter House, Chemical House (except alum godown) and Annexe Building (except mentioned in Clause 6.3.2, page E-20) shall be given two coats of washable synthetic ready-mix wall paint of approved make, colour and shade on a coat of approved primer. The surfaces are to be prepared and both primer and paint are to be applied as per manufacturer's specification. Painting works shall be carried out only by trained hands in order to achieve a high grade finish to the entire satisfaction of the Engineer. 7. 7.1 Damp Proofing Work Unless otherwise specified, damp proof course shall be 25 mm. thick cement
concrete (1:2:4) with stone chips graded 10 mm to 3 mm with 3% Cico or similar approved waterproofing compound conforming to IS:2645 by weight of cement. The proportioning, laying etc., shall be done is conformity with specification for cement concrete work. The damp proof course shall be used for all brick walls of the building. 8. 8.1 Roof Water Proofing Treatment Both flat and curved roods, whether accessible or inaccessible, shall provide with polyurethane based water proofing paint. Specification for Roof Water Proof Treatment with Polyurethane based Water Proof Paint: 8.2 Preparations of Surface
The top surface of the roof shall be chipped off where necessary and all loose particles, dust impurities, are to be removed by rubbing the entire roof surface with wire brush and by application of High Pressure Compressed Heated Air to have a complete dust free and moisture free surface. The roof surface, receiving polyurethane based Water Proofing paint, shall be provided with cement punning having smooth finish. A cross slope of 1 in 300 shall be provided in the roof of Building to allow proper drainage of rain water. 8.3 Specification of Materials
The polyurethane based paint is essentially an elastic and water proof film having a good adhesion to concrete; water and abrasion resistant properties and shall have long term weather proof characteristics. The paint/film material shall be of two components which is 125
to be mixed and processed as per manufacturer's specification. The mixture shall be homogeneous before applications, as it has tendency to settle. The polyurethane based water proofing system shall be manufactured by reputed manufacturers of proven recorded and shall be approved by the Central Building Research Institute (CBRI)/National Chemical Laboratory (NCL)/The Council of Scientific and Industrial Research/New Delhi (CSRI)/National Test House, Kolkata or similar such Government/Public Sector Undertakings. The materials are to be inspected & approved by the Engineer-in-Charge as per procedure to be mutually agreed upon the agency and in charge of the work. 8.4 Since the product has a very short self-life, the materials are to be used in the work
shall not be older than four (4) months from the date of manufacture (i.e. the date of bottling). Necessary Test Certificate of CBRI/NCL/CSIR/National House etc. are to be furnished by the contractor to the Department, for the materials procured for the water proofing work. 8.5 Application
The two components of polyurethane based water proofing system should be mixed as per manufacturer's specification before application. The tack coat should be applied by brushing or roller to the entire surface in normal temperature and 406 hours setting time should be allowed before application of the second coat. The record and final coat of polyurethanes based mixed water proofing sealing over the priming coat to be applied at normal temperature and curing time between 36 to 48 hours should be allowed. The application to be made by technically trained and approved applicators duly certified by the manufacturers. 9. 9.1 Flooring Patent Stone Floorings shall be 25mm. thick in M20 grade concrete with 10mm. to
6mm. stone ships laid in rectangular panel with diagonal length not exceeding 3.00M and finished smooth with neat cement punning 1.5mm thick. After finishing, the surface shall be left undisturbed for two hours and then with wet bags and after 24 hours cured by flooding with water and kept wet for at least 7 (seven) days. Required Camber or Slope should be provided in floor draining wash water, if necessary. 9.2 Cast-in-Situ Mosaic in floor shall be 25mm.thick (finished) laid in panels as directed
with necessary underlay of cement concrete (1:2:4) with stone chips with 12mm. thick terrazzo topping finished to 9 mm. after final grinding with 0 to 10 mm. size Mosaic chips 126
highly polished etc. - complete as per specification of IS;2114/1962. Cast-in-situ Mosaic in Skirting and Dado shall be 12mm. thick. The Mosaic work shall be of approved colour and to the entire satisfaction of the Engineer-in Charge. 9.3 'Ferro site' or 'Ironite' Flooring shall be 50mm. Thick to be laid in two layers. First a
layer of 25mm. thick patent stone flooring shall be laid in M15 grade concrete and allowed to dry. Then the second layer of 25mm.thick flooring of M15 grade concrete with 10mm.to 6mm. stone chips using at least 1Kg/Sqm of floor hardening compound of approved quality and make shall be laid and cured. The flooring shall be laid in rectangular panel sit diagonal length not exceeding 3.0 Meters. All floors with pump and motors, chlorinator and chlorine drums, pipeline higher than 300 mm diameter, electrical panel board, blowers, alum/coagulant storage room, unloading bay, stack yards for pump and motors shall be of this type of flooring. 10. 10.1 Iron Mongery The rain Water pipe of the materials and of size as specified shall be of approved
manufacture end jointed as follow: 10.1.1 For heavy cast iron pipes with gasket and lead properly caulked. 10.1.2 Where required these are to be run in chase left out in walls, columns, slabs and to be encased in cement concrete 1:2:4 (1 Cement, 2 Sand, 4 washed Stone Chips 19mm. down) with metal lath wrapping or with M.S. loops placed at approximately 325mm. centers or as directed by the Engineer-in-Charge. All pipes encased in walls, columns or under floors must be heavy cast iron with lead caulked joints. For exposed lengths of pipes, these are to be neatly secured clear from the finished wall face with nails and bobbing in the case of cast iron pipes, nails or screwed to hard wood tapping pugs embedded in wall. 10.1.3 All cast iron rain water pipes shall be painted two coats inside with approved anticorrosive paint. The exposed cast iron pipes shall be painted outside with two coats of ready mixed Synthetic Enamel Paints of approved make, shade and colour over a coat of priming of approved make. 10.1.4 The mouth of rain water pipes shall be fixed with C.I grating and the pipe jammed in position in 1:2:4 cement concrete with stone chips and neat finish on the surface.
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10.1.5 The work shall include all supply, fitting and fixture of materials cutting, making chases, encasing, painting, jointing, etc. - complete in all respect. The work shall include supplying, fitting, fixing, and jointing of all the specials required for the completed work. 10.1.6 Rain water Spouts shall be of C.I pipes cut to exact length as per approved drawing or direction of the Engineer-in-Charge and laid in position in 1:2:4 cement concrete with stone chips, adjoining roof being finished in neat cement. The interior faces shall be painted two coats with anticorrosive paint and the faces shall be painted with two coats of ready mixed Synthetic Enamel paint of approved make, shade and colour over a coat of priming of approved make. 10.2 Collapsible Gate
The M.S. collapsible gates will be obtained from manufacturer as approved by the Engineer-in-Charge. These shall be of mild bar type, out of 20 mm. channels and shall be top rung with roller bearing and shall have locking arrangement. Collapsible gates under 2.700 m. height shall be with 4 sets of lattices. Guide tracks shall be to the entire satisfaction of the Engineer-in-Charge. The gates shall be fixed in position, degusted, descaled and painted with 2 coats of approved ready mixed paint over a coat of approved anticorrosive primer. 10.3 Rolling Shutter
10.3.1 The M.S. roller shutter shall be obtained from manufacturer as approved by the Engineer-in-Charge. The roller shutter shall be of 18 G x 75 mm. galvanized mild steel laths of convex corrugation complete with one piece construction. These shall be fitted with pressed side guides and pressed bottom rail, brackets, door suspension shafts, top rolling springs (of strong English Continental Spring Steel Wire) with a four lever concealed lock as also separate locking arrangements for padlocks, pulling hooks, handles and top cover. The roller shutters shall be fixed in position with all accessories and the design and the workmanship shall be to the entire satisfaction of the Engineer-in-Charge. This shall be finished with two coats of approved ready mixed paint over a coat of approved anti corrosive primer. 11. 11.1 Structural Steel Work All Structural Steel to be used for gantry beam etc. shall be of tested quality
conforming to IS: 226 and IS: 2062 latest addition. Finished steel shall be free from cracks, lamination and other visible defects. Section shall be adequately protected from rusting and scaling. Rivets and bolts, nuts and washers shall 128
be of mild steel and comply with requirements of relevant IS Codes. Steel used for rails shall have tensile strength of about 50-60 Kg/Sq. mm. and yield point at 26 Kg/Sq. mm. The electrodes for welding shall conform to IS: 814. All steel work shall be fabricated and erected as per IS: 800 and IS: 806. Welding shall be carried out as per IS: 814, IS: 815, IS: 816 and IS: 823, all of the latest editions. 11.2 All steel work, after preparation of surface, shall be given a coat of red oxide zinc
chromate primer (IS: 2074) and finished with two coats of Synthetic enamel paint. Surface to be painted shall be thoroughly cleaned of mill scale, oil grease, rust etc. over coating and finishing paints shall be of well known make (viz., Jenson & Nicholson / British Paints (Berger Paints) / Shalimar Paints). The Contractor shall furnish details of Paints to the Engineer-in-Charge for approval of paints before commencement of painting work. 11.3 Steel work shall be hoisted and erected in position in a safe and proper manner.
No. riveting or permanent bolting shall be down until proper alignment has been made. For grouting, cement and clean fine sand shall be used in a proportion of 1:2 and properly mixed with water. All trapped pockets shall be fully vented for full penetration of grout. All grouting shall be cured for a minimum period of seven days. 12. Cable Trenches
12.1 The cable trenches should normally be of dimension 750mm x 600 mm (D x W) with insert plates made of M.S. of dimension 100 mm x 750 mm x 12 mm (W x D x Th) are to be provided on the wall side of the cable trench 600 mm apart all along. 12.2 The Cable Trenches shall be covered with precast concrete slabs of dimension 650
2
x 600 x adequate thickness to withstand a load of 500 Kg/m are to be provided as covers of trench all along. For easy access of cable from room to room, the design of the tie beam and level of the rooms may be adjusted to avoid bend in the cable. 12.3 The cable trenches shall be absolutely free from any obstructions as to allow the
cables to be lowered in the trenches from top only during laying. The space inside the trenches throughout the entire lengths shall in no case be encroached by any beam or columns. 13. Pockets & Holding down Bolts
Provision has also to be kept for pockets and holding down bolts as per requirement of the electrical and mechanical equipment at no extra cost. The extract details of such pockets and holding down bolts will be supplied to the Contractor as per specifications of the 129
suppliers of the equipment after award of the contract. It is contemplated that M.S. hangers shall be provided from the underside of slab/beam of the operating floor, and is tobe executed in a separate contract. However, for the above arrangement suitable pockets and holding down bolts are to be left. 14. Chequered Plates etc. These shall be manufactured from structural steel conforming to IS: 226. They shall be of the specified size, thickness and pattern as per relevant drawings or as directed by the Engineer-in-Charge. Cover plates will generally be of chequered plates with or without stiffeners as detailed in the drawings. Floor convenience, the Contractor shall prepare detailed floor plans of the layout of cover plates for floors and platforms so as to include all openings, cuts etc. and so as to match the patterns of adjacent cover plates/gratings. Where necessary, the floor will have to be made leak proof by properly welding cover plates. If necessary, packing shall be welded to the bottom of cover plates to raise the cover plates on sides, so as to provide necessary slopes as shown in the drawings or as directed by the Engineer-in-Charge in the floors and platforms to drain away any liquid failing on the floors and platform. Necessary gutters at the ends of platforms shall be provided for sloping floors and platforms as shown in the approved drawings or as directed by the Engineer-in-Charge. Kerbs of flats shall be provided where necessary, around openings and cuts in order to prevent liquids falling to lower floors or platforms. 15. Hand Railing
Double rows of 30 mm. dia. G.I. tubular hand railing fixed in G.I. stanchions shall be provided on the edge of walkways and platforms as specified. The stanchions shall be fixed with mild steel rag bolts with chromium plated cap nuts. The stanchions shall not be less than 1000 mm. high and placed at a distance not exceeding 2500 mm. The hand railing shall be fixed true to exact line and level. G.I. stanchions and hand railing layout shall be of architectural design with pleasing appearance. 16. 16.1 Sanitary Installations The Urinals shall be of flat back, front lipped having a size of 46.5 cm. x 36.5 x 26.5
cm. or nearest available size. The Indian type W.C. shall be of minimum 58 cm. Complete with foot rest in one piece. 16.2 All Sanitary works shall be of "Parry, "Neycer", "Hindusthan" or any other
equivalent make. They shall be of approved quality conforming to relevant IS Codes and 130
shall bear ISI Certification marks. All G.I. pipes shall be of ITC or equivalent make heavy quality conforming to relevant IS Code. Wheel valves and stop cocks shall be of gun metal and of "leader" or "Annapurna" or equivalent make as approved by the Engineer-in-Charge and shall conform to relevant IS Codes. 16.3 Two urinals, one Indian W.C., one European W.C. (Commode) have to be provided
in the toilet block of Pump Houses. 17. Manhole Covers
Heavy duty plastic fiber reinforced concrete manhole covers shall be of heavy duty type conforming to IS: 1726. 18. Sluice Gate/Pen Stock Gate
Cast iron single faced Thimble mounted Sluice Gate/Pen Stock Gate will be designed as per IS:13349/1992. 19. C.I. Sluice Valve
C.I. Sluice Valve conforming to IS 14846/2000 suitable for water works purposes and as per requirements of the Clear Water Reservoir / Clear Water Pump Sump. The class of Sluice valves shall be class-I with maximum working pressure of 7 Kg/Sq. Cm. and 5 Kg./Sq. Cm. for 450 mm. dia. and 750 mm. dia C.I. Sluice Valves respectively. 20. C.I. Cowl Ventilator
150 mm. dia Specially designed C.I. Cowl Ventilator shall be provided in the outer peripheral walls in between the underside of the reservoir roof and Top Water Level (T.W.L.) of the reservoir, in order to prevent breakage of the Cowl Ventilator, the same shall be encased with cement concrete of grade M 15 with nominal reinforcement as typically shown in the tender scheme drawing. 21. 21.1 Plastic Fibre Reinforced Concrete Manhole Cover M.S. Ladder etc. Manhole Cover
Heavy duty plastic fiber reinforced concrete manhole covers with frame should conform to relevant IS Code. The clear opening for access to the M.S. Ladder for going inside the reservoir shall be 600 mm. and the overall dimension of the heavy Duty Manhole Cover shall be specified by the Tenderer conforming to relevant IS Code. The manhole cover with frame shall be of 'Double Seal Type'. Location of manhole covers and frames are specified in the tender scheme drawing and the Tenderers are to include the cost thereof 131
in their offer. 21.2 M.S. Ladder
M.S. Ladder for going inside of the reservoir has been typically shown in the tender scheme drawing. The width of the ladder shall be 750 mm. with G.L. hand railing with M.S. angle posts. The steps of the ladder shall be provided with M.S. chequered plates with minimum 6 mm. in thickness. The rise and treads of the steps work of the ladder shall be provided with suitable anti-corrosive paints over two coats of primer as per manufacturer's specifications to be approved by the Department. There shall be 6 (six) numbers M.S. ladder in the locations shown in the Tender drawings. 21.3 Rung Ladder
Where over specified, shall be formed out of 20 mm. dia M.S. Rods. The rods forming Rung Ladder shall be properly bonded inside the R.C.C. walls. The spacing of Rung Ladder shall not exceed 300 mm. and the size of the rung formed shall be 300 mm. wide x 150 mm. deep. The rods are to be painted with anti-corrosive paint with suitable primer as per manufacturer's specification to be approved by the Department. 22. Level Indicator
One (1) Level indicator shall be provided at the Pump Sump of clear water pump house and ELSRs so that they can be visible from inside the operator's room in Pump House Building. The level indicator shall be manual type with PVC floor, guide wire, level indicator board etc. as per requirements.The arrangement and details to be get approved by the department. 23. Lightning Arrestor
Required sets of Lightning Arrestor shall be provided by the tenderer at the highest point of the Pump House Building, Annex building, Filter house, Chemical house conforming to the I.E. Rules specifications as per standard practice. The job includes supplying, fixing and commissioning of sufficient no. of lightening arrestors which includes air-terminals, separate earth electrodes, grid earthing and individual earthing with approved size of airterminals, earth electrodes, earthing strips as per IE rules/IS codes. Detail Calculations to be vetted by the department in the final design. 24. Motor Floor and Control Room
There must not be any column in the motor floor for easy movement of the Crane. 132
Similarly in the Control room cum office room, these must not be any column in the room. The motor floor should have suitable openings at appropriate location as per requirement of the pump manufacturer for lowering and taking up of pumps, motors, valves, entry for cable etc. The motor floor shall be suitably designed to take care of the vibration generated from the motor pump assembly while in operation. 25. Trial Run During trial run period (90 days), consumables viz., flocculants, disinfectants, oils, lubricants and man power etc., shall be borne by the contractor. The power supply and water will be provided by the employer. 26. Guarantees The Contractor shall give the following guarantees: 26.1 Civil and Structural Works The Contractor shall guarantee the plant against any structural failure due to faulty design, bad workmanship, substandard materials, etc. for a period of twelve months. Any defect found during the guarantee period shall be rectified by the Contractor to the satisfaction of the Engineer without any extra cost. 26.2 Plant and Equipment Even when a plant or equipment has been manufactured and / or marketed by a vendor, it would be deemed to have been supplied and installed under the contractors supervision. The Contractor shall provide back to back guarantee along with the vendor but shall solely be responsible for its repair/replacement. He shall not cite the vendor and claim absolvent. In addition, all equipment shall be free from any defects due to faulty designs, materials and / or workmanship. The equipment shall operate satisfactorily and performances and efficiencies shall not be less than the values guaranteed by the manufacturer and endorsed by the Contractor. Formal acceptance of the work or equipment covered under the Contract by the Engineer shall not be made until all the work done by the Contractor has satisfactorily passes all tests required by the specifications. If, during testing of work and / or equipment prior to formal acceptance, any equipment or materials shall fail in any respect to meet the guarantees, the Contractor shall replace such equipment in a condition which will meet the guaranteed performance. Any such work shall be carried out by the Contractor at his own cost and expenses in necessity thereof, shall in the opinion of the Engineer be due to the use of materials or workmanship not in accordance with the 133
Contract or to neglect or failure on the part of the contractor to comply with any obligation expressed or implied on the Contractor's part under the Contract. If in the opinion of the Engineer, such necessity shall be due to any other cause, the value of such work shall be ascertained and paid for as if it were additional work. If the Contractor shall fail to do any such work as aforesaid, required by the Engineer, the Employer shall be entitled to carry out such work by its own workman or by others and if such work is supposed to be carried out by Contractor the cost thereof, or may deduct the same from any money due or that may become due to the Contractor. 27. 27.1 Important Guidelines and Specifications Unless otherwise specified elsewhere, the work shall be carried out as per the
following specifications. Wherever any particular work is not covered in this entire document, the decision of the Engineer regarding the specification of the same shall be deemed final and binding on the Contractor. 27.1.1 All civil works shall be carried out as per specifications contained in other sections of these tender specifications. 27.1.2 All electrical works including supply of all electrical equipment shall be carried out as per specifications contained in other sections of the tender specification. 27.1.3 All mechanical works including supply of equipment shall be carried out as per specifications contained in other section of these tender specifications. 27.1.4 The erection and commissioning works shall be carried out as per specifications
contained in other section of these tender specifications, 27.2 A minimum free board of 500 mm shall be provided for all water containing
structures viz., collecting well, flash mixer, stand wells, filter beds, channels, etc. except underground reservoir and unless otherwise specified elsewhere. 27.3 For the convenience and ready accessibility to the operating level, each unit of the
treatment plant shall be so interconnected by walkways/gangways as will permit reaching one end of the treatment plant to the other by means of walkways/gangways without having any necessity to get down to the ground level. 27.4 Walkways and operating platforms shall be provided with hand railings as specified
in other section. 27.5 All Roofs shall be provided with water proof polyurethane paint,
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27.6 design. 27.7
All the exterior doors and windows shall be provided with R.C.C. chajja of approved
All windows and ventilators/skylights shall be provided with mild steel grills of
approved design. 27.8 Construction of permanent roads within the treatment plant site are within the
scope of this contract including at the porch of the filter house and annex building where R.C.C. slabs shall be provided. Tenderer shall also include the cost of construction of temporary access roads required for their construction of different units of the treatment plant and reservoir units for easy maneuver of their construction equipment. This would necessitate cutting of trees, clearing of bushes, filling of a pond, leveling and dressing of site, the cost of all of which shall be taken into account by the Contractor while arriving at their quoted cost. While planning of internal accesses within the plant area, every effort should be made to save as many trees as possible. It should be remembered that all trees within the campus of GRWW are the property of this Authority. Wherever cutting of trees becomes inevitable, the Contractor shall maintain an inventory of trees cut by the Contractor and handover the inventory as well as the trees cut to the Engineer.
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DIVISION 1
GENERAL SPECIFICATIONS
The I.S. Codes shall be those indicated or subsequent amendments thereon SL. No. A) I. Description I.S. No.
LIST OF INDIAN STANDARDS CEMENT 1. Ordinary and Low Heat Portland cement. 2. 3. Pozzolana Portland cement. 43 Grade or 53 Grade Cement 269/1976 1489/1976 8112/12269 Respectively
II.
AGGREGATES 1. Aggregates, Coarse & Fine, from natural resources, for concrete. 383/1970
2.
Sand for Masonry Mortar
2116/1965
3.
Methods of tests for aggregates for concrete:2386/1963
Part I Particle size and shape Part II Estimation of deleterious
2386/1963 (Part I)
Materials & Organic impurities
2386/1963
Part III
Soundness
2386/1963
4.
Specification for test sieves. Wire Cloth test sieves. 460/1978 (Part I)
III.
BRICKS 1. Common burnt clay building bricks 1077/1976
IV.
STEEL 1. Mild steel and medium tensile steel bars And hard drawn steel wire, Concrete
136
Reinforcement. Part I Mild Steel & Medium tensile Steel Bars. 432/1982
Sl. No.
Description
I. S. No.
2.
High strength deformed steel bars and wires for concrete reinforcement. 1786/1985
3. 4. 5.
High Tensile Steel for PSC Pipes. Hand Drawn Wire Bending and Flexing of Bars for Concrete Reinforcement.
1784/1986 (Part-I) 432/1953
2502/1963
6.
Recommendations for detailing of Reinforcement in reinforced concrete works. 5525/1969
V.
CONCRETE 1. Plain and reinforced concrete, Code of practice. 2. 3. 4. 5. Laying in Situ cement concrete flooring Sampling and analysis of Concrete 456/2000 2571/1970 IRC: 15/2002 3370/1967 IRC: 15/2002.
Code of practice for liquid retaining structures Code of practice of concrete roads
VI.
MASONRY 1. 2. Brick Masonry Construction of Stone Masonry 2212/1962 1597/1967
VII.
PIPES AND FITTINGS 1. 2. 3. Asbestos cement pressure pipes. Blue MDPE pipes. Specifications for Centrifugally Cast (Spun) D.I. Pipes for Water, Gas and Sewerage 8329/1980 1592/1980 4427/1996
137
4. 5.
D.I.Fittings for pipes for water, gas & sewerage:9523/1980 Dimensional requirements of rubber gaskets for Mechanical joints and push on joints for the use with C.I.D.I. Pipes 12820/1989
6.
C.I. Specials for Mechanical and push on Flexible joints for pressure pipe lines of water gas and sewerage 13382/1992
7.
Cast iron fittings for pressure pipes for water, gas and sewerage 1538/1976
8.
Cast iron detachable joints for use with Asbestos cement pressure pipes 8794/1988
9.
Rubber rings for jointing C.I. Pipes, RCC Pipes and A.C. Pipes 5382/1969 1363/1967
10. Bolts&Nuts to be used in jointing C.I.D.F. Pipes
VIII. 1.
WATER SUPPLY FITTINGS Sluice valves for water works purposes 14846/2000
2.
D.I. D/F Gate Valve
3896 (pt.2)/1985
3.
Surface boxes for sluice valves.
3950/1966
4. IX. 1.
Manhole covers and frames, cast-iron. LAYING OF PIPES Laying of Asbestos Cement Pressures Pipes
1726/1974
6530/1972
2.
Laying of MDPE Pipes
7634 (Pt. 2)/1975
138
3.
Laying of Cast-Iron Pipes.
3114/1965
4.
Laying of D.I. Pipes
3114/1965
X. 1.
MACHINERY Batch type concrete mixer. 1791/1968
2.
Sheep foot roller
4616/1968
XI. 1. 2.
SAFETY Safety code for excavation works. Safety Code for scaffolds and ladders 3764/1966
Part I Scaffolds.
3696/1966 (Part I)
Part II Ladders.
3696/1966 (Part I)
139
DIVISION-2 SITE WORK 2.1 Intimation about commencement of work
Before commencing the works and also during progress the bidder shall give due notice to the concerned authorities, the Municipality, the Roads and Buildings and Electricity Board, Telephone Department, the Traffic Department attached to the Police, other Departments and companies as may be required to the effect that the work is being taken up in a particular locality and that necessary diversion of traffic may be arranged for (refer S.No.12 of EMP attached as Annexure II). The bidder shall cooperate with the Departments concerned and provide for necessary barricading of roads, protections to existing underground mains, cables etc. Prior to commencement of the site work, the contractor shall identify affected access to all the private as well as public facilities and provide temporary access as detailed in the item S.No.14 of EMP attached as Annexure II. The contractor shall take special care to ensure that the access to sensitive receptors (such as schools, hospitals, religious places) are not affected at any point of contract execution. In all such places, contractor shall execute the work without affecting the functioning of the above places. 2.2 Cross Drainage
The bidder shall handle all flows from natural drainage channels intercepted by the work under these specifications, perform any additional excavation and grading for drainage as directed and maintain any temporary construction required to bypass or otherwise cause the flows to be harmless to the work and property. When the temporary construction is no longer needed and prior to acceptance of the work, the bidder shall remove the temporary construction and restore the site to its original condition as approved by the Engineer-in-Charge. The contractor shall not dispose excavated material near the cross drainage works viz., culverts, drains, streams so as not to affect the natural regime of the water flow. The cost of all work and materials required by this paragraph shall be included by the bidder in the unit prices quoted in the bill of quantities and no separate payment will be made for the same. 2.3 Stacking of Excavated Material
Where the location of the work is such and does not permit the deposition of excavated earth while digging trenches for laying pipes, the excavated earth should be conveyed to 140
a convenient place and deposited there temporarily, as directed by the Engineer-inCharge. Such deposited earth shall be reconvened to the site of work for the purpose of refilling of trenches, if such deposited soil is suitable for refilling. The unit rate for trench work of excavation and refilling shall include the cost of such operations. 2.4 Disposal of Surplus Earth and construction debris
The spoil earth which is surplus to that required for refilling and after allowing for settlement and other construction debris, will have to be removed, spread and sectioned at site approved by the Engineer-in-Charge. Payment will be made as per the unit prices quoted by the bidder for the item. It is estimated that the volume of Earth generation due to the project activity is 288990.30 cum. Excess earth quantities of 73009.98 cum proposed to be carted out and disposed at the low lying pockets within the ULB viz., Arundhati Nagar near Molla Reddy cheruvu katta (for raising of embankment bunds), Housing Board open park, Jirayath Nagar open park, Nulla Pocham Temple surrounding area, Govt. School area in Ashok Nagar. 2.5. Shoring, Strutting and Bailing out Water
The rate for excavation of trench work shall include charges of shoring, strutting, bailing out water wherever necessary and no extra payment will be made for any of these contingent works. While bailing out water care should be taken to see that the bailed out water is properly channelized to flow away without stagnation or inundating the adjoining road surfaces and properties.
141
DIVISION-3 EARTH WORK 3.1 General Prior to earthwork excavations contractor shall identify all the common property utilities (such as community taps, telephone/Electric cables, Street Lighting etc) that will be affected and provide advance notice (not less than 10 days) to the affected parties with dates of restoration. 3.1.1 Earth work diagrams and Data To the extent that they exist plans and earth work data prepared for the Governments (that is Government of Andhra Pradesh) studies of earth work for construction of the related works will be available for Inspection by the bidders in the Office of the concerned Engineer-in-Charge. Such information is made available solely for the convenience of bidders. The Government does not represent that this information is accurate or complete. Bidders are cautioned that this information is subject to revision and that the Government disclaims responsibility for any interpretations, deductions or conclusions which may be made there from. It is not intended that this earth work information will limit or prescribe the excavation and handling procedure of the contractor, and the Government reserves the right to utilize and distribute earth work materials during the progress of work as best serves the interest of the Government. 3.1.2 Compacting Earth Materials Where compacting of earth materials is required, the materials shall be deposited in horizontal layers and compacted as specified in this paragraph. The excavation, placing, moistening and compacting operations shall be such that the materials will be uniformly compacted throughout the required section and will be homogeneous, free from lenses, pockets, streaks, voids, lamination or other imperfections. The compaction shall be carried out in accordance with the relevant clauses of I.S 4701/1982. Classification of Soil Soil investigation works were carried out and the results showing classification of soil are reproduced below: 142
(a)
Excavation Except other-wise provided in these specifications, material excavated will be measured in excavation to the lines shown on the drawings or as provided in these specification, and all materials so required to be excavated will be paid for at the applicable prices bid in the schedule for excavation. No additional allowance above the price bid in the schedule will be made on account of any of the material being wet. Bidders and the contractors must assume all responsibility for deducting and concluding as to the nature of the materials to be excavated and the difficulties of making and maintaining the required excavation. The Government does not represent that the excavation can be performed or maintained at the paylines described in these specifications or shown on the drawings. Excavation for removal of debris and deposited earth on berms while forming roads is to be carried out as specified in relevant clauses of 154701-1982 as compared before lying of berms with the same setting of roads.
(b)
Excavation for Structures General Excavation for the foundation of structures shall be to the elevation shown on the drawings or as directed by the Engineer-in-Charge. In so far as practicable, the material removed in excavation for structures shall be used for back fill and embankments. Otherwise it shall be disposed off as specified in paragraph 2.4. Foundations for Structures The Contractor shall prepare the foundations at structure/sites by methods which will provide firm foundation for the structures. The bottom and side slopes of common excavation upon or against which the structure is to be placed shall be finished to the prescribed dimensions and the surfaces so prepared shall be moistened and tamped with suitable tools to form firm foundation upon or against which to place the structure. The Contractor shall prepare the foundation for the structures as shown on respective drawings. The natural foundation material beneath, the required excavation shall be moistened if required and compacted in place. Separate payment will not be made to the contractor for moistening and compacting the foundation of structures. The contractor shall include cost thereof in the price bid per cubic meter of the item of the Bill of quantities for preparation of foundations. 143
Whenever unsuitable material is encountered in the foundation for a structure the Engineer-in-Charge will direct additional excavation to remove the unsuitable material. The cost of such additional excavation shall be paid at the unit price bid in the Bill of quantities for earth. The additional excavation shall be refilled by selected bedding material and compacted. (c) Over Excavation If at any point in common excavation the foundation material is excavated beyond the lines required to receive the structure, or if at any point in common excavation the natural foundation material is disturbed or loosened during the excavation process, it shall be compacted in place or where directed, it shall be removed and replaced as follows. In excavation soils, the over excavation shall be filled in by selected bedding material and compacted. In excavation in rock it shall be filled with M5 grade cement concrete. Any and all excess excavation or over excavation performed by the Contractor for any purpose or reason except for additional excavation as may be prescribed by the Engineer-in-Charge and whether or not due to the fault of the contractor shall be at the expense of the contractor. Filling for such excess excavation or over excavation shall be at the expense of the contractor (d) Measurement for payment Excavation for structures will be measured for payment, for box cutting with vertical sides of foundation dimensions. The contractor will have to make his own arrangement for shoring, strutting, provision of adequate slopes for the sides to prevent slips etc., and no separate charge will be paid for any incidental charges arising either during excavation of foundation or construction of the structure. (e) Payment Payment for excavation for structures will be made at the unit price per cubic metre bid therefore in the Bill of quantities for excavation for structures. The unit price bid in the bill of quantities for excavation for structures shall include the cost of all labour and materials for coffer dam and other temporary construction, of all pumping and dewatering, of all other work necessary to maintain the excavation in good order during construction, of removing such temporary construction where required and shall include the cost of disposal of the excavated material.
144
3.3
Backfill
3.3.1 Back Fill Around Structures: (a) General The item of the schedule for backfill around structures including pipe portions of structures includes all backfill required to be placed under these specifications. (b) Materials The type of material used for backfill, the amount thereof, and the manner of depositing the material shall be subject to approval of Engineer-in-Charge. In so far as practicable backfill material shall be obtained from material removed in required excavations for structures. But when sufficient suitable material is not available from this source, additional material shall be obtained from approved borrow-areas. The borrow pit excavation shall be in accordance with clause-9.1 to 9.3 of I.S 4701/1982. Backfill material shall contain no stones larger than 80 millimeters in diameter. If the excavation for the foundation of the structure is in swelling soils, a layer of cohesive non-swelling soil conforming to I.S.9451/1980 should be interposed between the swelling soil of the structure and compacted to atleast 95% standard proctors density. (c) Placing Backfill Backfill shall be placed to the lines and grades shown on the drawings as prescribed in this paragraph or as directed by the Engineer-in-Charge. All backfill shall be placed carefully and spread in uniform layers not exceeding 150 mm, so that all spaces about rocks and clods will be filled. Each layer shall be watered and well compacted before the succeeding layer is laid, care being taken not to disturb the constructed structure. Backfill shall be brought up as uniformly as practicable on both sides of walls and all sides of structure to prevent unequal loading. Backfill shall be placed to about the same elevation on both sides of the pipe positions of the structures to prevent unequal loading and displacement of the pipe. (d) Measurement and Payment Excavation refill required to be placed about structures that is within the pay line limits for excavation for the structures, will be measured in place for payment as backfill about structure provided that where the contractor elects not to excavate material which is outside the limits of the actual structure or pipe, but within the pay 145
line limits of excavation, all such material will be included in the measurement for payment of backfill. The unit price bid there for in the Bill of quantities for excavation of foundation of structure shall include cost of backfilling about the structure upto ground level. No separate payment will be made for backfill of foundation. Refill of excavation performed outside the established paylines for excavation for structures shall be placed in the same manner as specified for the adjacent backfill and such refill shall be placed at the expense of the contractor.
146
DIVISION-4 MASONRY 4.1 Materials
4.1.1 Brick for Masonry General Bricks used for brick masonry shall conform to the relevant specifications of I.S. 1077-1986 common burnt clay building bricks shall be hand or machine moulded. They shall be sound, hard, homogeneous in texture well burnt and shall give a clear ringing sound when struck. They shall be clean, free from warping, distortion, cracks, chips, flaws, stones and nodules of free lime. Unless otherwise specified the sizes of the bricks shall be 190 x 90 x 90 mm. The compressive strength shall not be less than 40 Kg/Cm2. The percentage of water absorption shall not be more than 20 per cent by weight after 24 hours immersion in cold water. (b) Cost: The cost of collecting the bricks for masonry will not be paid for separately and their cost including the cost of transporting, stacking, royalty seigniorage charges shall be included in the unit price per cubic metre bid therefore in the relevant item in the bill of quantities. 4.1.2 Sand for Masonry General Sand shall generally conform to specifications given in paragraph 6.2.5 except that the sand for mortar shall conform to the grading of sand given in clause 4 of I.S.2116-1189 as detailed below in Table 4(b). Table 4(b): Grading of Sand for use in Masonry Mortars: Percentage passing by Mass 100 90 to 100 70 to 100 40 to 100 5 to 70 0 to 15
I.S. Sieve Designation 4.75 mm 2.36 mm 1.18 mm 600 Micron 300 Micron 150 Micron
147
A sand whose grading falls out-side the specified limits due to excess or deficiency of coarse or fine particles may be processed to comply with the standard by screening through a suitably sized sieve and/or blending with required quantities of suitable size and particles. The procurement of sand for masonry shall confirm to the specifications given in paragraph 6.2.5. Cost The cost of sand for masonry will not be measured and paid separately and the cost of sand including the cost of stripping, transporting and storing and royalty charges shall be included in the unit price per cubic metre bid therefore in the relevant item of work in the bill of quantities for which this and is required. 4.1.3 Cement General As per clause 4 of I.S. 456/1978 for the purposes of these specifications, cement used shall be any of the following with the prior approval of the Engineer-in-Charge Ordinary Portland (OPC) GRADES 43 & 53 Conforming to BIS : 811 : 12269 respectively (or) Portland pozzolana cement conforming to I.S. 1489 relevant amendments upto date. The provisions of this paragraph apply to cement for use in cast-in-place concrete required under these specifications. Portland cement required for items such as concrete pipes, precast concrete structural members and other precast concrete products, for grout and mortar and for other item is provided for in the applicable paragraphs of these specifications covering the items for which such portland cement is required. The water used in making and curing of concrete, mortar and grout shall be free from objectionable quantities of silt, organic matter, injurious amounts of oils, acids, salts, and other impurities etc., as per I.S. specification No.456/1978. The Engineer-in-Charge will determine whether or not such quantities of impurities are objectionable Such determination will usually be made by comparison of compressive strength, water requirement, time of set and other properties of concrete made with distilled or very clean water and concrete made with the water proposed for use. Permissible limits for solids when tested in accordance with I.S. 3025/1964 shall be as tabulated below.
148
Permissible limit for Solids Maximum permissible limit 1. 2. 3. 4. Organic Inorganic Sulphates (as SO4) Chlorides (as CL) 200 mg/litre 3000 mg/litre 500 mg/litre
2000 mg/litre for plain concrete work and for R.C.C. work 1000 mg/litre
5.
Suspended matter
2000 mg/litre
If any water to be used in concrete, mortar or grout is suspected by the Engineer-inCharge of exceeding the permissible limits of solids, samples of water will be obtained and tested by the Engineer-in-Charge in accordance with I.S. 3025/1964. 4.1.4. Mortar Preparation of Mortar Unless otherwise specified, the cement mortar used in Masonry works shall be cement mortar mix MM5 (1:5) grade using minimum 288 Kg. of cement per cubic metre of mortar. Mixing shall be done thoroughly preferably in a mechanical mixer. In such cases, the cement and sand in the specified proportions shall be mixed dry thoroughly in the mixer operated manually or by power. Water shall be added gradually and wet mixing continued atleast for 3 minutes. Water should not be more than that required for bringing the mortar to the required working consistency of 90 to 130 milli metres as required in clause 9.11 of I.S. 2250/1981. The mix shall be clean and free from injurious kind of soil, acid, alkali, organic matter or deleterious substance. Time of use of Cement Mortar Cement mortar shall be used as soon as possible after mixing and before it has begun to set, within 30 minutes after the water is added to the dry mixture. Mortar unused for more than 30 minutes should not be used and shall be removed from the site of work. The cost of such wasted mortar shall be borne by the bidder. The use of re-tempered mortar will not be permitted to be used for the masonry.
149
Tests of Mortar Mortar Test cubes shall be cast for the mortar used on the work and shall be tested in accordance with Appendix-A of I.S.2250/1965 code of practice for preparation and use of Masonry Mortars. Such cubes shall develop a compressive strength of at least 50 Kg/square centimetre for MM5 (1:5) Grade cement mortar mix, 75 Kg/square centimetre for MM 7.5 (1:4) grade cement mortar mix and 30 Kg/ square centimetre for MM-3 grade cement mortar mix. Mortar not conforming to the specifications will be rejected, and the cost of such wasted mortar shall be borne by the bidder. Measurement and Payment Cement Mortar will not be measured and paid separately and its cost, including cost of materials, transporting and placing shall be included in the unit price per cubic metre bid therefore in the bill of quantities of the contractor for the relevant finished item of work or which cement mortar mix mentioned in the above paragraph is required. 4.1.5. Dismantling of Structures
During course of excavation of drainage works certain dismantling of brick masonry / R.R. Masonry retaining walls in CM C.C M10 grade leveling course are to be carried out. These have to be carried out as specified under section 202 of A.P.S.S, and as per directions of Engineer-in-Charge and site cleared before facing up actual execution.
150
DIVISION-5 PLASTERING & POINTING 5.1 Section Materials
5.1.1 Sand for Mortar for Plastering and Pointing: (a) General: The sand for preparation of Mortar for plastering and pointing shall confirm to the following gradation, shown in Table 5(A). TABLE 5 (A): Requirements of Grading For Sands for External Plastering and Rendering Percentage I.S., Sieve I.S. SIEVE Designation 4.75 MM 2.36 MM 1.18 mm 600 Microns 300 Microns 150 Microns Class A 100 90 to 100 70 to 100 40 to 85 5 to 50 0 to 10 Class - B 100 90 to 100 70 to 100 40 to 95 10 to 65 0 to 10 by weight passing
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 sands shall be used generally for plastering and pointing, and when they are not available, Class B sands may be used with the approval of Engineer-in-Charge. The procurement of sand for Mortar for plastering and pointing shall conform to the specifications given in paragraph 6.2.5.
151
(b)
Cost: The cost of sand for mortar for plastering and pointing will not be measured and
paid separately, and the cost of sand including the cost of stripping, transporting and storing and royalty charges shall be included in the unit price per Cubic metre bid therefore in the relevant item of work in the Schedule A for which this sand is required. 5.1.3 Cement: The specifications and conditions specified for supply for cement in paragraph 4.1.4 shall be applicable here also. Portland pozzolana cement conforming to I.S. 1489/1976 shall be used for preparation of mortar for plastering and pointing work. Ordinary Portland cement Grades 43 & 53 may also be used in the event of non-availability of P.P.C. 5.1.4 Water The specifications and conditions specified for procurement of water in paragraph 4.1.5 shall be applicable here also. 5.2 5.2.1 Mortar Preparation of Mortar for plastering work: Unless otherwise specified, the cement mortar used in plastering work shall be in cement mortar mix of MM. 7.5 (1:4) grade, using minimum 360 Kg. of cement per cubic metre of mortar. The other specifications and conditions enunciated in paragraph 4.2.1 shall apply for this mortar for plastering work also. 5.2.2 Preparation of Mortar for Pointing The cement mortar used in pointing work shall be cement mortar mix of M.M 7.5 grade, using 480 Kg. of cement per cubic metre of mortar. The other specifications and conditions enunciated in paragraph 4.2.1 shall apply for this mortar for pointing work also. 5.3 5.3.1 Plastering with Cement Mortar Mix. Mm 7.5 Grade 20 Mm Thick Preparation of Surface The roughening of the background improves the bond of plaster. All joints shall be thoroughly raked. After roughening the surface, care shall be taken to moisten the surface sufficiently before plastering as otherwise rashly exposed surface may tend to absorb 152
considerable amount of water from the plaster. The surface shall be wetted evenly before applying the plaster. Care shall be taken to see that the surface is not too dry as this may cause lack of adhesion or excessive suction of water from the plaster. A fog spray may be used for this work. As far as possible, the plaster work shall be done under shade. 5.3.2 Laying of Plastering with Cement Mortar Mix MM.7.5 grade 20 mm thick The mortar used for plastering shall be stiff enough to cling and hold when laid. To ensure even thickness and true surface, plaster shall be applied in patches of 150 mm x 150 mm of required 20 mm thickness at nor more than 2 metres intervals horizontally and vertically over the entire surface to serve as guides. The surface of these guides shall be truly in the plane of the furnished plaster surface and truly plumb. The mortar shall then be applied to the surface to be plastered between the guides with a trowel. Each trowel full of mortar shall overlap and sufficient pressure shall be used to force it into thorough contact with the surface. On relatively smooth surfaces, the mortar shall be dashed on with the trowel to ensure adequate bond. The mortar shall be applied to a thickness slightly more than that specified, using a string, stretched out between the guides. This shall then be brought to a true surface by working with a long wooden float with small sawing motion. The surface shall be periodically checked with a string stretched across it. Finally the surface shall be rendered smooth with a small wooden float, over working shall be avoided. All corners, arises, and junctions shall be brought truly to a line with any necessary rounding or chamfering. If it is necessary to suspend the work at the end of the day, it shall be left in a clean horizontal or vertical line not nearer than 150 millimetres for any corner or arises or on parapet tops or on copings etc. When recommending the work, the edges of the old work shall be scraped clean and treated with cement slurry before the new plaster is laid adjacent to it. After the first coat is done, it shall be kept undisturbed for the next 24 hours and thereafter kept moist and not permitted to dry until the final rendering is applied. After the plaster has sufficiently hardened cement slurry with cream like consistency shall be applied as thinly and evenly and rubbed to a fine condition. The finished surface shall be cured with water for a period of 10 days. 5.4 Pointing To Stone Masonry with Cement Mortar Mix Mm.75 Grade The joints in the masonry shall be raked out to a depth not less than the width of the joint or as directed when the mortar is green. Joints are to be brushed clean of dust and 153
loose particles with a stiff brush. The area shall then be washed and the joints thoroughly wetted before pointing is commenced. 5.4.2 Flush Pointing with Cement Mortar Mix MM. 7.5 Grades for Rubble Masonry The pointing to be done shall be flush pointing with cement mortar mix MM. 7.5 grade. The mortar shall be pressed into the raked out joints according to the types of pointing required. The mortar shall not be spread over the corners, edges or surface of the masonry. The pointing shall then be finished as detailed below. The mortar shall be finished off flush and level with the edges of the stones, so as to give a smooth appearance. The edges shall be neatly trimmed with a trowel and a straight edge. The pointing shall be cured for seven days. 5.5 Measurement and Payment
Plastering: The measurement of plastering will be in units of square metres, and it shall be paid at the relevant unit price bid per ten square metres of Plastering in the schedule Bill of Quantities which unit price shall include the cost of materials, their conveyance, charges for preparation of mortar including mixing charges and charges for performing the plastering work as illustrated in this division, including curing. Pointing The measurement for pointing will be in units of square metres, and it shall be paid at the relevant unit prices per ten square metres bid in the schedule Bill of quantities which unit price shall include the cost of materials, their conveyance, charges for preparation of mortar including mixing charges and charges for performing the pointing work as illustrated in this division, including curing
154
DIVISION - 6 CONCRETE 6.1 6.1.1 Concrete Structures Concrete in Structures (a) (b) Concrete in structures shall conform to the requirements of Paragraph 6.2 Measurement and payment for concrete in structures will be made as prescribed in paragraphs 6.3 & 6.4. 6.1.2 Construction of Structures Cast-in-place concrete for the structures shall conform to the requirements of section. The structures shall be built to the lines, grades and dimensions shown on the drawings. The dimensions of each structure as shown on the drawings will be subject to such modifications as may be found necessary by the Engineer-in-Charge to adopt the structure to the conditions disclosed by the excavation or to meet other conditions. Where the thickness of any portion of a concrete structure is variable, it shall vary uniformly between the dimensions shown. Where necessary, as determined by the Engineer-in-Charge, the Contractor will be furnished additional detailed drawings of the structures to be constructed. The bidder will not be entitled to any additional allowances above the prices bid in the schedule by reason of the dimensions fixed by the Engineer-in-Charge or by reasons of any modifications or extensions of a minor character to adopt a structure to a structure at site, as determined by the Engineer-in-Charge. The cost of furnishing all materials and performing all work for installing timber, metal and other accessories for which specific prices are not provided in the schedule, shall be included in the applicable prices bid in the schedule for the work to which such items are appurtenant. 6.2 6.2.1 (a) General Concrete Requirements Composition General Concrete shall be composed of cement; sand, coarse aggregate, water and admixtures (if any) as specified, all well mixed and brought to the proper consistency.
155
(b)
Nominal maximum size of Aggregates In coarse aggregates to be used in concrete shall be as large as practicable,
consistent with required strength, spacing of reinforcement and embedded items, and placement thickness. The size of the coarse aggregate to be used will be determined by the Engineer-in-Charge and may vary incrementally according to the conditions encountered in each concrete placement. Nominal maximum size of aggregate for concrete in structures shall be as indicated in the relevant drawings appended to the contract documents. Smaller coarse aggregate than specified shall be used where in the opinion of the Engineer-in-Charge that proper placement of concrete is impracticable with the size of the aggregate specified in the drawings. (c) Mix Proportions The proportions of various ingredients to be used in the concrete for different parts of the work will be established by proper mix design by the Engineer-in-Charge during the progress of the work. In proportioning concrete, the quantity of both cement and aggregate should be determined by mass as per clause 9.2 of I.S. 456/1978 water shall be either measured by volume in calibrated tanks or weighted. All measuring equipment shall be maintained in a clean serviceable condition and their accuracy periodically checked. Adjustments shall be made as directed to obtain concrete having suitable workability, impermeability, density, strength and durability without use of excessive cement. The acceptance or rejection of concrete shall be as per the acceptance criteria laid down in clause 15 of I.S. 456/1978. The mix design and average concrete strength shall be adjusted according to the cube strength test results conforming to clauses 14.2, 14.3, 14.4, 14.5 of I.S. 456/1978. The bidder shall not be entitled for any additional allowances above the prices bid in the schedule due to adjustments of the mix proportions. The net water cement ratio exclusive of water absorbed by the aggregate shall be sufficiently low to provide adequate durability in concrete. The water-cement ratio for various grades of concrete shall be as determined and ordered by the Engineer-in-Charge. (d) Consistencies The slump of concrete at the placement shall be as follows: Reinforced Cement Concrete:
156
Sl.No. 1.
Placing Condition Concreting of lightly reinforced sections without vibration or heavily reinforced sections with vibration
Degree of Workability Medium
Value of Workability 25 mm to 75 mm slump for 20 mm
aggregate
2.
Concreting of heavily reinforced section without vibration
High
75 mm to 125 mm slump for 20 mm
aggregate ii) For plan concrete work, slump requirements mentioned in item - (i) above are
applicable. If the specified slump is exceeded at the placement, the concrete is unacceptable. The Engineer-in-Charge reserves the right to require lesser slump whenever concrete of such lesser slump can be consolidated readily into place by means of vibration specified by the Engineer-in-Charge. The use of any equipment which will not readily handle and place concrete of the specified slump will not be permitted. To maintain concrete at proper consistency, the amount of water and sand batched for concrete shall be adjusted to compensate for any variation in the moisture content or grading of the aggregates as they enter the mixer. Addition of water to compensate for stiffening of the concrete after mixing but before placing will not be permitted. Uniformity in concrete consistency from batch to batch will be required. 6.2.2 Concrete Quality Control Measures and Concrete Quality Assurance Test Programme. (a) Concrete Quality Control Measures: The bidder shall be responsible for providing quality concrete to ensure compliance of the bid requirements. (b) Concrete Quality Assurance Program: The concrete samples will be taken by the Departmental Engineers and its quality will be tested in the departmental laboratory as per the relevant Indian Standard Specifications I.S. No. 516/1959 and I.S. 1199/1959. Tests: The Government will obtain samples and conduct tests as specified in I.S. 456/1978, I.S. 1199/1959 and I.S. 516/1959. Test Facilities: The bidder shall furnish free of cost samples of all ingredients of concrete for testing and obtain approval from the Engineer-in157
Charge. He should also supply free of cost, the samples of all the ingredients of concrete for conducting the required tests. 6.2.3 Cement: General : Shall conform to paragraph 4.1.4. 6.2.4 6.2.5 a) Water: Shall conform to paragraph 4.1.5 Sand (Fine Aggregate) General The term sand is used to designate aggregate most of which passes 4.75 milli metre I.S. Sieve and contains only so much coarser material as permitted in Clause 4.3 of L.S. 383/1970. Sand shall be predominantly natural sand which may be supplemented with crushed sand to make up deficiencies in the natural sand gradings. All sand shall be furnished by the bidder from any source approved by Engineer-inCharge. Sand as delivered shall have uniform and stable moisture content. Determination of moisture content shall be made as frequently as possible, the frequency for a given job being determined by the Engineer-in-Charge according to weather conditions (I.S. 456-1978). b) Quality The sand shall consist of clean, dense, durable, un-coated rock fragments, as per I.S.383/1970. Sand may be rejected if it fails to meet any of the following quality requirements. Organic impurities in Sand: Colour no darker than the specified standard in clause 6.2.2 of I.S 2386 (Part-II)/1963. (Indian Standard method of test for aggregates for clearance Part-II estimation of deleterious materials and organic impurities). Sodium Sulphate Test for Soundness: The sand to be used shall pass a Sodium of Magnesium Sulphate accelerated test as specified in I.S. 2386 (Part-V)/1963 for limiting loss of weight. Specific Gravity: 2.6 minimum Deleterious Substances: The amounts of deleterious substances in sand shall not exceed the maximum permissible limits prescribed in Table I Clause 3.2.1 of I.S. 383/1970 (Indian 158
Standard specification for coarse and fine aggregate from natural sources for concrete when tested in accordance with I.S. 2386/1963. c) Grading The sand as batched shall be well graded and when tested by means of standards sieves shall conform to the limits given in Table-4 of I.S. 383/1970, and shall be described as fine aggregates, grading zones-I, II, III and IV. Sand complying with the requirements of any of the four grading zones is suitable for concrete. But, sand conforming to the requirements of grading Zone-IV shall not be used for reinforced cement concrete work. 6.2.6 Coarse Aggregate General For the purposes of these specifications, the term Coarse Aggregate designates clean well grade aggregate most of which is retained on 4.75 mm I.S. Sieve containing only so much finer material as permitted for various types described under clause 2.2 of I.S 383/1970. Coarse aggregate for concrete shall consist of uncrushed, crushed and partially crushed stone. Coarse Aggregate for concrete shall be furnished by the Contractor from the sources approved by the Engineer-in-Charge. Coarse Aggregate as delivered shall generally have uniform and stable moisture content. In case of variations, clause 9.2.3 of I.S 456/1978 shall govern during batching. Quality The Coarse aggregate shall consist of natural occurring (crushed or uncrushed) stones, and shall be hard, strong, durable, clear and free from veins and adherent coating, and free from injurious amounts of disintegrated pieces, alkali, vegetable matter and other deleterious materials. Coarse aggregate for concrete shall be separated into various nominal maximum sizes specified in the relevant drawings. Separation of the coarse aggregate into the specified sizes shall conform to the grading requirements specified in Table-2 of I.S. 383/1970, when tested in accordance with I.S 2386-(Part-I)/1963 (Method of test for aggregates for concrete Part-I Particle size and shape). Coarse aggregate for mass concrete may be separated as previously herein specified. Separation of the coarse aggregate into the various sizes shall be such 159
that when tested in accordance with I.S. 2386 (Part-I)/1963 shall conform to the requirements specified in Table-3 of I.S. 383/1970. Sieves used in grading tests will be standard mesh sieves conforming to I.S. 460 (Part-I)/1978 (Specification for test sieves Part-I wire cloth test sieves). 6.2.7 Mixing General The concrete ingredients shall be thoroughly mixed in mechanical mixers designed to positively insure uniform distribution of all the component materials throughout the concrete at the end of the mixing period. Mixing shall be done as per clause 9.3 of I.S. 456/1978. The mixer should comply with I.S. 1971/1968 (I.S. Specifications for batch type concrete mixers). The concrete as discharged from the mixer shall be uniform in composition and consistency from batch to batch. Workability shall be checked at frequent intervals as per I.S. 1199/1969. Mixers will be examined regularly by the Engineerin-Charge for changes in conditions due to accumulation of hardened concrete or mortar or to wear of blades. The mixing shall be continued until there is a uniform distribution of the materials so that the mass is uniform in colour and consistency and to the satisfaction of the Engineer-in-Charge. If there is segregation after unloading, the concrete should be remixed. Any mixer that at any time produces unsatisfactory mix shall not be used until repaired. If repair attempts are unsuccessful, a defective mixer shall be replaced. Batch size shall be at least 10% of, but not in excess of the rate capacity of the mixer unless otherwise authorized by the Engineer-in-Charge. Concrete Mixers Water shall be admitted prior to and during charging of mixer with all other concrete ingredients. After all materials are in the mixer, each batch shall be mixed for not less than the time specified by the Engineer-in-Charge. The minimum mixing time shall be 2 minutes. The minimum mixing time specified is based on average mixer performance. The Engineer-in-Charge will adjust the minimum mixing time as required by the observations of the mix delivered from mixer. Excessive over mixing which require addition of water to maintain the required concrete consistency will not be permitted.
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6.2.8
Forms General Forms shall be used wherever necessary, to confine the concrete and shape it to
the required lines. The bidder shall set and maintain concrete forms so as to insure completed work is within the applicable to clearance limits prescribed in clause 10 of I.S 456/1978. If a type of form does not consistently perform in an acceptable manner, as determined by the Engineer-in-Charge, the type of form shall be changed and method of erection shall be modified by the bidder subject to approval by the Engineer-in-Charge. Plumb and string lines shall be installed before, and maintained during concrete placement. Such lines shall be used by the bidders personnel and by the Engineer-inCharge and shall be in sufficient number and properly installed as determined by the Engineer-in-Charge. During concrete placement, the bidder shall continuously monitor plumb, and string line, form positions and immediately correct deficiencies. Forms shall have sufficient strength to with stand the pressure resulting from placement and vibration of the concrete and shall be maintained rigidly in position. Where form vibrators are to be used, forms shall be sufficiently rigid to effectively transmit, energy, form the form vibrators to the concrete, while not damaging or altering the positions of forms. Forms shall be sufficiently tight to prevent loss of mortar from the concrete. Chamfer strips shall be placed in the corners of forms and at the top of walls placements to produce leveled edges on permanently exposed concrete surfaces. Interior angle of intersecting concrete surface and edges of construction joints shall not be leveled except where indicated on the drawings. Suitable struts or stiffeners or ties shall be used for the form work wherever necessary. All supports shall be braced and cross braced in two directions. All splices and braces shall be secured by bolting unless specially intended otherwise. All struts shall be firmly supported against settlement and slipping by suitable means as directed. All supports shall be cut square at both ends and firmly supported against settlement and slipping. When the form work is supported on soils, planks, sleepers etc., shall be used to properly disperse the loads. In case, the supports rest on already completed beam or slab, suitable props shall be provided under the latter. The form work shall be of well seasoned timber or steel. When timber forms are used, they shall be lined with M.S sheet or other suitable smooth faced non-absorbent material as specified. Supports may be of timber or steel. Suitable wedges in pairs to facilitate adjustment and subsequent 161 releasing of forms shall be provided preferably at
the upper end of the supports. The details of the proposed form work and supports shall be submitted to the Engineer-in-Charge and got approved before erection. In case of columns, retaining walls or deep vertical component, the height of the column shall facilitate any placement and compaction of concrete and suitable arrangement may be made for securing the form to the already poured concrete for placing the subsequent lifts. No steel ties or wires used for securing this form work shall be left exposed on the face of the finished work. Suitable inserts for block outs for electrical and other service fixtures where necessary shall be provided in the required locations as specified. Cleaning and Oiling of Forms At the time the concrete is placed informs, the surfaces of the forms shall be free from encrustation of mortar, grout or other foreign materials. Before concrete is placed, the surface of the forms shall be oiled with a commercial form of oil. Removal of Forms The stripping of form work shall conform to clause 10.3 of I.S. 456/1978. The bidder shall be liable for damage and injury caused by removing forms before the concrete has gained sufficient strength. Forms on upper sloping faces of concrete such as forms on the water sides of warped transitions, shall be removed as soon as the concrete has attained sufficient to prevent sagging. Any needed repairs or treatment required on such sloping surfaces shall be performed at once and be followed immediately by the specified curing. To void excessive stresses in concrete that might result from swelling of forms, wood forms for wall openings shall be loosened as soon as the loosening can be accomplished without damaged to the concrete. Forms shall be removed with care so as to avoid injury to the concrete, and any concrete so damaged shall be repaired in accordance with paragraph 6.2.16. Cost The cost of furnishing all materials and performing all work for constructing forms, including any necessary treatment or coating of forms shall be included in the applicable prices bid in the schedule for the items of concrete for which the forms are used. 6.2.9 Concrete Surface Irregularities Surface Irregularities General
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Bulges, depressions and offsets are defined as concrete surface irregularities. Concrete surface irregularities are classified as abrupt or gradual and are measured relative to the actual concrete surface. Abrupt Surface Irregularities: Abrupt surface irregularities are defined herein as offsets such as those caused by misplaced or loose forms, loose knots in form Lumber, or other similar forming faults. Abrupt surface irregularities are measured using a straight edge held firmly against the concrete surface over the irregularity and the magnitude of the offset is determined by direct measurement. Gradual Surface Irregularities Gradual surface irregularities are defined herein as bulges and depressions resulting in gradual changes on the concrete surface. Gradual surface irregularities are measured
using a suitable template conforming to the design profile of the concrete surface being examined. The magnitude of the gradual surface irregularities is defined herein as a measure of the rate of change in slopes of the concrete surface. The surface irregularities shall not exceed 6 mm for bottom slab and 12 mm for side slopes when tested with a straight edge of 1.5 metres in length. The magnitude of gradual surface irregularities on concrete shall be checked by the bidder to insure that the surfaces are within the specified to tolerances. The Engineer-in-Charge will also make such checks to hardened concrete surfaces as determined necessary to ensure compliance with these specifications. Repair of Hardened Concrete not within specified tolerance Hardened concrete which is not within specified tolerances shall be repaired to bring it within those tolerances. Such repair shall be in accordance with paragraph 6.2.16 and shall be accomplished in a manner approved by the Engineer-in-Charge. Concrete repair to bring concrete within the tolerances shall be done only after consultation with a representative of Engineer-in-Charge regarding the method of repair. The Government shall be notified as to the time when repair will be performed. Concrete which will be exposed to public view shall be repaired in a manner which will result in a concrete surface with a uniform appearance. Grinding of concrete surface exposed to view shall be limited in depth such that no aggregate particles are exposed to view shall be limited in a depth such that no aggregate particles are exposed more than 1.5 millimetres at the finished surface. Where grinding causes exposure of aggregate particles greater than 1.5 millimetres at the finished surface, concrete shall be repaired by excavating and replacing the concrete
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Prevention of Repeated failure to meet tolerances When concrete placements result in hardened concrete that does not meet the specified tolerances, the bidder shall submit to the Government an outline of all preventive actions such as modification to forms, modified procedure for setting screeds, and different finishing techniques to be implemented by the bidder to avoid repeated failures. The Government reserves the right to delay concrete placement until the bidder implements such preventive actions which are approved by the Engineer-in-Charge.123 6.2.10 Reinforcing Bars General Reinforcing bars shall be placed in the concrete as shown in the drawings or as directed. Materials Unless shown otherwise on the drawings, the reinforcement to be used shall be or High Yield strength deformed (H.Y.S.D) bars of grade Fe-415 conforming to I.S. 1786/1979 (IS. Specifications for High Yield strength deformed steel bars and wires for concrete reinforcement). Placing Reinforcement shall be bent and fixed in accordance with the procedure specified in I.S. 2502/1963 (code of practice for bending and fixing of bars for concrete reinforcement). All reinforcement shall be placed and maintained in the position shown in the drawings; splices shall be located where shown on the drawings provided that the location of the splices may be altered subject to the written approval of the Engineer-in-Charge. Subject to the written approval of the Engineer-in-Charge, the bidder may for his convenience, splice bars at additional locations other than those shown on the drawings. All additional splices allowed shall be at the expense of the bidder. In order to meet design and space limitation on splicing, some bent bars may exceed usual clearance cutting and bending of such bars from stock lengths may be required at the site. Unless otherwise prescribed, placement dimensions shall be to the centre lines of the bars. Reinforcement will be inspected for compliance with requirements as to size, shape, length, splicing, position, and amount after it has been placed, but before being covered with concrete. Before reinforcement is embedded in concrete, the surfaces of the bars and the surfaces of any supports shall be cleaned of heavy flaky rust, loose mill scale, dirt, grease or other 164
foreign substances which in the opinion of the Engineer-in-Charge, are objectionable. Heavy flaky rust that can be removed by firm rubbing with burlap, or equivalent treatment is considered objectionable. As specified in Clause 11.3 of I.S. 456/1978 unless otherwise specified by the Engineer-inCharge, reinforcement shall be placed within the following tolerances: a) b) For effective depth 200 mm or less For effective depth more than 299 m + 10 mm + 15 mm
The cover in no case is reduced by more than one third of specified over or 5 mm whichever is less. (c) Reinforcement shall be securely held in position so that it will not be displaced
during the placing of the concrete and special care shall be exercised to prevent any disturbance of the reinforcement in concrete that has already been placed. Welding of bars shall be done as directed by the Engineer-in-Charge and in conformity with the requirements of clause 11.4 of I.S 456/1978. Chairs, hangers, spacers and other supports for reinforcement shall be of concrete, metal or other approved material. Concrete over shall be as shown on the drawings. (d) Reinforcement Drawings The Government will supply drawings of reinforcement details and bar bending schedules for adoption. (e) Measurement and Payment Measurement for payment of reinforcement bars will be based on the weight of the bars placed in the concrete in accordance with the drawings supplied by the Government when conformance with these specifications drawings has been determined at the time of embedment. Except as otherwise provided below, payment for furnishing and placing reinforcing bars will be made at the unit price per one kilogram bid in the bill of quantities for furnishing and placing reinforcing bars which unit price shall include the cost of reinforcing bars, attaching wire ties or other approved supports and of cutting, bending, cleaning, securing and maintaining in position reinforcing bars as shown on the drawings. 6.2.11 Preparation for Placing General No concrete shall be placed until all form work, installation of items to beembedded, and preparation of surface involved in the placement has been approved.
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All surfaces of forms embedded materials shall be free from curing compound, dried mortar from previous placement, and other foreign substances before the adjacent or surroundings concrete placement is begun. Prior to beginning concrete placement, the bidder shall make ready, a sufficient number of properly operating vibrators and operators, and shall have readily available additional vibrators to replace defective ones during the progress of the placement. The Engineers representative at the placement may require that the bidder delay the start of the concrete placement until the number of working vibrators available is acceptable. Foundation Surface All surfaces upon or against which concrete is to be placed shall be free from frost, ice, water, mud and debris. Rock surfaces shall be free from oil, objectionable coatings, and loose, semidetached and unsound fragments. Immediately prior to placement of concrete, surfaces of rock shall be washed with an air water jet and shall be brought to a uniform surface dry condition. Earth foundation surfaces shall be wet to a depth of 15 cm. or to impermeable material, whichever is less, before concrete is placed. Construction Joint Construction joints are defined as concrete surface upon or against which concrete is to be placed and to which new concrete is to adhere but which have become so rigid that the new concrete cannot be incorporated integrally which that previously placed. The provision of construction joints shall conform to clauses 12.4.1 and 12.4.2 of I.S. 456/1978. When the work has to be resumed on a surface which has hardened such surface shall be roughened. It shall be swept clean and thoroughly wetted. For vertical joints neat cement slurry shall be applied on the surface before it is dry. For horizontal joints the surface shall be covered with a layer of mortar about 10 to 15 mm thick composed of cement and sand in the same ratio as the cement and sand in concrete mix. This layer of cement slurry or mortar shall be freshly mixed and applied immediately before placing of the concrete. Where the concrete has not fully hardened all balance shall be removed by scrubbing the wet surface with wire or bristle brushes, care being taken to avoid dislodgment of particles of aggregate. The surface shall be thoroughly wetted and all free water removed. The surface shall then be coated with neat cement slurry. On this surface, a layer of concrete not exceeding 150 mm in thickness shall first be placed and shall be well rammed against
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old work, particular attention being paid to corners and close spots, and work thereafter shall proceed in the normal way. 6.2.12 General The Bidder shall notify the Engineer-in-Charge before batching begins for placement of concrete. Placing shall be performed only in the presence of an authorized Engineers representative. Placement shall not begin until after all preparations are complete to the satisfaction of the Engineer-in-Charge. All surfaces upon or against which concrete is to be placed shall be prepared in accordance with paragraph 6.2.11. Retampering of concrete will not be permitted. Any concrete which has becomes so stiff that proper placing cannot be assured shall be wasted. Concretes shall not be placed in standing water except with written permission of the Engineer-in-Charge and the method of placing shall be subject to approval. Concrete shall not be placed in running water and shall not be subjected to running water until after the concrete has hardened. Concrete shall be deposited as nearly as practical in its final position and shall not be allowed to flow in such a manner that the lateral movement will cause segregation of the coarse aggregate from the concrete mass. Methods and equipment employed in depositing concrete informs shall minimize clusters of coarse aggregate. Clusters that occur shall be scattered before the concrete is vibrated. Forms shall be constantly monitored and their position adjusted as necessary during concrete placement in accordance with paragraph 6.2.8. All concrete shall be placed in approximately horizontal layers. The depth of layers shall not exceed 25 cm. The Engineer-in-Charge reserves the right to require lesser depths of layers where concrete cannot otherwise be placed and consolidated in accordance with the requirements of these specifications. All construction joints which intersect exposed concrete surface shall be made straight and level to plumb as shown otherwise on the drawings. The placing of concrete shall be in accordance with clause 12.2 of I.S.456/1978. If concrete is placed monolithically around openings having vertical dimensions greater than 60 cm. or if concrete in decks, floor slabs or other similar parts of structures is placed Placing:
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monolithically with supporting concrete, the following requirements shall be strictly observed. Concrete shall be placed upto the top of the formed openings at which point further placement will be delayed to accommodate settlement of fresh concrete. If levels are specified beneath nearly horizontal structural members such as decks, floor slabs, beams and girders, such bevels being between the nearly horizontal members and the vertical supporting concrete below, concrete shall be placed to the bottom of the levels before delay of placement. The last 60 cm or more of concrete placed below horizontal members of levels shall be placed with a 50 mm or less slump and shall be thoroughly consolidated. In placing concrete on unformed slopes so steep as to make internal vibration of the concrete impractical without forming, the concrete shall be placed ahead of non-vibrating slip form screed extending approximately 0.75 metres back from its leading edge. Concrete ahead of the slip form screed shall be consolidated by internal vibrators so as to insure complete filling under the slip form. A cold joint is an unplanned joint resulting when a concrete surface hardens before the next batch is placed against it. Cold joints will be allowed only in the event of equipment breakdown or other unavoidable prolonged interruption of continuous placing. If such unavoidable delays in placing occur which make it appear that unconsolidated concrete may harden to the extent that alter vibration will not fully consolidate it, the Bidder shall immediately consolidate such concrete to a stable and uniform slope. If delay of placement is then short enough to permit penetration of the underlying concrete, placement shall resume with particular care being taken to thoroughly penetrate and reverberate the concrete surface placed before the delay. If concrete cannot be penetrated with vibrator, the cold joint shall be then treated as a construction joint. Care shall be taken to prevent cold joints when placing concrete in any part of the work. The concrete placing rate shall insure concrete is placed while the previously placed adjacent concrete is plastic so that the concrete can be made monolithic by normal use of vibrators. Concrete shall not be placed in rain sufficiently heavy or prolonged to wash mortar from concrete. A cold joint may necessary result from prolonged heavy rainfall. The bidder shall not be entitled to any additional payment, over the unit prices bid in the schedule for concrete, by reason of any limitation in the placing of concrete required under the provisions of this paragraph. 168
Transportation The transportation of concrete will be done as per clause 12.1 of I.S.456/1978. Consolidation The consolidation of concrete shall conform to clause 12.3 of I.S. 456/1978. Concrete shall be consolidated by vibrators. The vibration shall be sufficient to remove the undesirable air voids from the concrete, including the air voids trapped against the forms. After consolidation, the concrete shall be free of rock pockets and honey bomb areas and shall be closed snugly against all surfaces of forms and embedded materials. All concrete shall be properly consolidated before it hardens. Except as hereinafter provided, consolidation of all concrete shall be by immersion type vibrators. Immersion type vibrators shall be operated in nearly vertical position and the vibrating head shall penetrate and reverbate the concrete in the upper portion of the underlying layer. Care shall be exercised to avoid contact of the vibrating head with embedded items and with formed surfaces which will later be exposed to view. Concrete shall not be placed upon either plastic concrete until the previously placed concrete has been thoroughly consolidated. 6.2.13 Finished and Finishing: The requirements for finishing of concrete surface shall be as specified in this paragraph, paragraph 6.2.9 or as otherwise indicated on the drawings. The bidder shall notify the Engineer-in-Charge before finishing concrete. Unless inspection is waived, in each specific case, finishing of concrete shall be performed only when an Engineers representative is present. Finished concrete which is not within the specified tolerances shall be repaired in accordance with paragraph 6.2.16. Interior surface shall be sloped for drainage where shown on the drawings or as directed. Surfaces which will be exposed to the weather, and which would normally be level, shall be sloped for drainage. Floating may be performed by use of hand or power driver equipment. Floating shall be started as soon as the screeded surface has stiffened sufficiently and shall be the minimum necessary to produce a surface that is free from screed marks and is uniform in texture. Joints and edge shall be tooled where shown on the drawings or as directed. 6.2.14 Protection The bidder shall protect all concrete against damage until final acceptance by the Engineer-in-Charge. 169
The Bidder shall provide protection to prevent erosion to fresh concrete whenever precipitation either periodic or sustaining is imminent or occurring. When precipitation appears imminent, the bidder shall immediately make ready at the placement site all materials, which may be required for protection of fresh concrete. The Engineer-in-Charge may delay placement of concrete until adequate provisions for protection against weather are made. All fresh concrete surfaces shall be protected from contamination and from foot traffic until the concrete has hardened. Hardened concrete surfaces which have to receive finish shall be protected against damage from foot traffic and other construction activity by covering with protective mats, ply-wood, or by other effective means. Methods of protection shall be subject to approval by the Engineer-in-Charge. Concrete curing membranes shall be kept intact, and other curing materials and process shall be maintained as necessary to assure continuous curing for a minimum specified curing time. Protection of curing membranes and other curing methods shall be as described in paragraph 6.2.15. 6.2.15. Curing General The Bidder shall furnish all materials and perform all work required for curing concrete. The curing of concrete shall conform to clause 12.5 to I.S. 456-1978 and clause 5.8., IS: 3873/1978. Concrete shall be cured by water curing. The unformed top surfaces of bridges or culvert decks shall be cured for 28 days with damp sand cover or curing mat cover. The sand or curing mats shall not be kept so wet as to allow water to drain from them and stain other concrete. The sand or curing mats shall be removed after the expiry of the curing period. All concrete surfaces shall be treated as specified to prevent loss of moisture from the concrete until the required curing period elapsed or until immediately prior to placement of other concrete or back fill against those surfaces. Only sufficient time to prepare construction joint surfaces and to bring them to a surface dry condition shall be allowed between discontinuance of curing and placement of adjacent concrete. Forms shall be removed within 24 hours after the concrete has hardened sufficiently conforming to clause 10.3 of I.S. 456/1978, to prevent structural collapse or other damage
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by careful from removal. Where required, repair of all minor surface imperfections shall be made immediately after form removal and prior to curing. Minor surface repair shall be completed within 2 hours after from removal and shall be immediately followed by the initiation of curing by the applicable method specified herein. Concrete surfaces shall be kept continuously moist after from removal until initiation of curing. b) Materials: Concrete cured with water shall be kept wet for atleast 28 days from the time the concrete has obtained sufficient set to prevent detrimental effects to the concrete surfaces. The concrete surfaces to be cured shall be kept wet by covering them with water-saturated material by using a system of perforated pipes, mechanical sprinklers or porous-hose, or by other methods which will keep all surfaces continuously (not periodically) wet. All curing methods are subjected to approval of Engineer-in-Charge. c) Cost: The cost of furnishing all materials and performing all work for curing concrete shall be included in the price bid in bill of quantities for the concrete on which the particular curing methods are required. 6.2.16. a) Repair of Concrete
General Concrete shall be repaired in accordance with clause 5.7 to I.S. 3873/1978.
Imperfections and irregularities on concrete surface shall be corrected in accordance with paragraph 6.2.9 and clause 5.7 of I.S. 3873/1978. b) Types of Repair All repairs shall be made with concrete. Repairs to concrete surfaces and addition were required shall be made by cutting regular opening into the concrete and placing fresh concrete to the required lines. The chipped openings shall be sharp and shall not be less than 70mm in depth. The fresh concrete shall be reinforced and chipped and trawled to the surface to the surface of the openings. The mortar shall be placed in layers not more than 20 mm in thickness after being compacted and each layer shall be compacted thoroughly. All exposed concrete surfaces shall be cleaned of impurities, lumps of mortar or grout and unsightly stains.
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c)
Cost The cost of furnishing all materials and performing all work required in the repair of
concrete shall be borne by the Bidder. 6.3. Measurement of Concrete Measurement for payment of concrete required to be placed directly upon or against surfaces of excavation will be made to the lines for which payment for excavation is made. Measurement for payment of all concrete will be made to the neat lines of the structures, unless otherwise specifically shown on the drawings prescribed in these specifications. The unit of measurement will be cubic metre. In measuring concrete for payment, the volume of all openings, embedded pipes and metal work, each of which is larger than 0.1 square metres in cross section will be deducted. 6.4. Payment for Concrete Payment for concrete in the various parts of the work will be made at the applicable, unit prices bid therefore in the schedule, which unit price shall include the cost of furnishing all materials and performing all works required for the concrete construction, except that payment for furnishing and placing reinforcing bars will be made at the respective unit prices bid therefore in the schedule.
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DIVISION-7 MATERIALS REQUIRED FOR PIPELINE WORKS 7.1 Pipes 7.2 The Pipes required to be supplied for the works shall conform to the following I.S.
specifications depending upon the nature of material for pipe specified in the bid document. I.S. 8329/1977 for DI pipes. I.S. 4427/1996 for Blue MDPE pipes I.S. 4984 for HDPE Pipes and fittings The pipes supplied shall be subjected to all the tests specified in the relevant I.S. specifications before delivering at site and the manufacturers test certificate to this effect shall accompany each consignment delivered at site. In addition, the pipes shall be got tested by the Inspectorate of Director General of Supplies and Disposals at the manufacturers factory site and the relevant test certificate shall also be produced along with each consignment. The charges for conducting the tests shall be borne by the bidder only and these charges are not reimbursable by the employer. A list of firms that are on the approved list of suppliers to the Department will be supplied, on request. The bidder is at liberty to procure the pipes from any of the firms in the approved list of suppliers but the responsibility for the pipes conforming to the relevant I.S. specifications shall solely rest with the bidder only. The bidders rates for relevant items shall include not only the cost of pipes and taxes there on and testing charges but also the charges for transportation to site and all subsequent handling and other incidental charges. 7.3. Sluice Valves: The D.I. sluice valves to be supplied for use on the work shall conform to IS 14846 and material shall conform to IS 1865 and subsequent revision and contain the I.S. Certification mark. The valves shall be of non-rising inside screw type; provided with D.I. cap or wheel as the case may be and valve key rod. The other conditions contained in paragraphs above shall be applicable to the sluice valves also. 173
7.3.1 Butterfly Valves Butterfly valves shall comply with IS 13095 and be of double flanged or water pattern with metal or resilient seating and D.I. body. Valve shall be dropping tight at closure and be designated for drop tight shut-off of flow. The applicable tests in IS 13095 shall be applied at works to each butterfly valve. The body end parts shall be circular and the diameter not less than that of the nominal bore of taper pieces. The disc shall be in ductile cast iron with resilient seating ring in molded rubber or other material to the approval of the Engineer located in a landing on the disc and secured by a gunmetal retaining ring fixed with screws made from homogenous corrosion-resistant material. Shaft-stainless Steel to IS 6603 Sealing Ring: Resilient or suitably approved equivalent Retaining Ring & Seat: Stainless Steel IS 6603 The Contractor will ensure that the Butterfly Valve gearing provides sufficient closure time of the valve, to minimize the development of water hammer pressure. As a minimum provision, the gearing shall provide the time of closure to ensure at least two pressure waves reflections are accommodated within the time of closure. The above provision shall not absolve the Contractor in ensuring the providing valve having suitable time to ensure minimization of water hammer pressure. The valve shall be made by reputed manufacturer and the Contractor shall provide documentary proof of the satisfactory performance of the valves not less than 10 years in continuous service. 7.3.2 Proof of Design Test For acceptance of the make of the Butterfly valves by the Engineer, the Contractor shall furnish a certified statement (by recognized institution or laboratory) that proof of
design test were carried out as described in IS 13095 and all requirements were successfully met.
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7.4.
Air Valves: Air valves shall be single or double orifice pattern as specified with ductile cast iron
bodies. The inlet flanges shall be faced or drilled in accordance with IS 14845 to the appropriate diameter and the pressure rating of the pipeline concerned. The valve shall be capable of releasing air from the pipeline without restriction of rate of filling or flow due to back pressure and also to allow admission of air during pipeline emptying at a rate sufficient to prevent excessive depression of pressure in the pipe. Valves shall be designed to prevent the operating element being in contract with the pipeline liquid by approved means such as the provision of an auxiliary float chamber sufficiently large to isolate the orifice valves and seats throughout the rated operational range. Air valves shall be fitted with separate isolating sluice valve which shall be drop tight on closure and shall comply with the specification of sluice valves elsewhere herein and gearing shall be provided necessary to facilitate operation. Air valves shall be of a design which inhabits the entry of insects into the pipeline. All air relief valve and associated isolating valves shall be works tested and capable of withstanding the test pressures specified above for valves generally. All materials used in the manufacture of the valves shall conform to IS 14845. Triple cluster air valves shall be of combined small and large orifice valve pattern. The assembly shall be provided with a 12mm. tapping for draining purposes and the apping shall be closed with a brass screw plug. The design of the valve shall be such that there is no possibility of the ball of the large orifice being suddenly caught up in the escaping air stream during the filling of water main at high rates thereby closing the valve prematurely. The diameter of the balls in each unit of air valve shall be suitable for operating under the specified rated pressure. The minimum diameter of ball within the small orifice chamber shall be 125 mm for air valves rated at PN 10. For each triple cluster air valves location on large-diameter pipeline, the pipeline diameter and the physical features as shown on the drawings governing the maximum possible rate of air entry shall be taken into account by the Contractor when offering the air valve. The size of the air valve provided for each location shall be such that air valve provided for each location shall be such that air can be admitted at the rate necessary to 175
prevent a vacuum developing when any washout is opened or when a burst occurs at a critical point. The Contractor shall provide attested experimental data to confirm the adequacy of the air valves offered. For guidance; the capacity of inflow & outflow of air though Air Valve may be about 240 and 470 m3 / min. respectively. 7.5. Pressure-Reducing Valves Pressure-reducing valves (PRVs) shall be of the pressure compensated globe type, piston or diaphragm operated, complete with external hydraulic relay system and designed to reduce a variable inlet pressure to a pre determined constant outlet pressure at varying flows. The controlling pressure point shall either be at the valve or at a point in the distribution network some distance from the valve. Valves shall be drop tight under no flow conditions. Valve operation shall be achieved by the interaction of the inlet pressure, outlet pressure and an intermediate pressure produced by a pilot valve or relay system acting on the upstream side of the main valve. The relay control system shall consist of a hydraulic relay unit, orifice and strainer block, control valves and interconnecting small bore piping. The relay valve shall be manufactured completely in 316 stainless steel and shall consist of diaphragm, diaphragm guide, support piston, spindle, etc. The orifice/strainer unit shall have a body and internals of stainless steel. The pressure setting control valves and control piping shall be constructed in 316 stainless steel. The valve shall be designed such that the hydraulic relay system can be inspected, maintained or replaced without isolating the supply. All necessary repairs to the valve shall be possible without removing the valve from the line. The pressure setting shall be capable of being adjusted on site by the use of an adjusted on site by the use of an adjustment screw to alter the compression of the spring. The opening and closing speeds shall also be field adjustable by adjusting the flow regulation screw. The valves shall be capable of being fully opened or fully closed by respective opening and closing of upstream and downstream ground cocks. The valves shall be designed to provide the necessary loss of head and shall operate without hunting. The valve mechanism shall be piston operated, controlled from a servo diaphragm actuated by an adjustable spring balance relay comparing pressure generated across an integral orifice plate.
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The valve be coated internally and externally with a fusion bonded epoxy coating system to 300 microns dry film thickness, the internal coating material shall be suitable for potable water use, the valve being provided with the necessary certification. Nominal pressures will be PN 16 or higher pressures as otherwise indicated. Body ends shall be flanged and drilled to BS 4504, PN 16 or for the higher operating pressure indicated. Valve materials shall be as follows: Body and cover Internal valve Relay valve Valve parts and fittings Trims, ported guide and seating Diaphragm, seating or plunger Loading spring (if employed) Cylinder weights (if employed) Indicating rod Piston cast iron or ductile iron 316 stainless steel 316 stainless steel 316 stainless steel gunmetal to BS 1400 LG2C reinforced synthetic rubber spring steel cast iron or ductile iron 316 stainless steel 316 stainless steel
Valves shall be factory tested, and supplied with a test certificate indicating the valve serial number and the set pressure. 7.6 Tee-keys spindles
The Contractor shall supply tee-keys of square form head. Tee-keys shall be of mild steel and shall have uprights between 1000 and 1200 mm long and cross pieces between 600 and 800 mm long. Spindles shall be of galvanized mild steel, and fixed in secure galvanized steel trunnions secured to chamber walls by adequate galvanized hexagon raw bolts. Extension spindles shall be provided of sufficient length to enable washout tees on large diameter pipeline to be operated by a person standing on the roof of the chamber. 7.7. Delivery The materials of the Section shall be delivered to the Temporary storage buildings described in Part I. crates and other containers shall be opened as required by the Engineer as required at the store (and/or elsewhere) at an earlier stage of delivery to 177
permit inspection of the contents. They shall then be resealed and stacked within the store as the Engineer directs. The Contractor shall place additional marks on the containers as the Engineer may direct, so that the contents of each can subsequently be ascertained without further disturbance of the stack. 7.7. Pig Lead: The Pig Lead to be used for jointing the C.I. Spun Pipes shall conform to I.S. 782/1978. 7.8. Hemp Yarn: The Hemp Yarn to be used in jointing of various types of pipes shall conform to I.S. 6587/1966. 7.9. Rubber Insertion: The Rubber Insertion to be used for jointing Cast Iron D.I. double Flanged pipes shall conform to I.S. 638/1955. 7.10. Bolts and Nuts: The Bolts and Nuts to be used for jointing the D.I. double flanged Pipes shall conform to I.S. 1363/1967. 7.11 C.I. Surface Boxes: The C.I. Surface boxes to be used shall conform to I.S. 3950/1966. 7.12. C.I. Manhole Framers and Covers: The C.I. Manhole frames and coves to be used shall conform to I.S. 1726/1974. 7.13 Material for House Connections The Contractor shall furnish all the relevant particulars for the materials for house connection as per specification he intends to supply, together with samples of the items to the Engineer for his approval, prior to placing the order. (1) Brass Ferrules
Ferrules for water services shall be as per IS 2692. Ferrules shall be standard screw down pattern brass ferrule with female BSP screwed single outlet for MDPE/PVC pipes to BS 21 parallel thread. It shall have a main stem with 360 swivel outlet at 90 with control of water flow via a threaded inner plug.
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The ferrule shall be designed for underground installation, and to handle potable water with temperature upto 35 C, and also to withstand a working pressure of 15-20 bars. The design of ferrule shall permit the installation of service pipe via conventional drilling and tapping machine, under pressure or dry, and with or without service saddles, into DI, PE or PVC Pipes of different diameters. The material of the stem banjo, inner plug and top cap shall be Brass, conforming to IS 3004. The material of Banjo washer and top cap washer shall be polypropylene or Nitrile Rubber and Rubber and shall provide the sealing between the outer body and ferrule stem. The ingress of dirt shall be prevented by a polypropylene top plug. Service Pipe shall be as specified in the Bill of Quantities.
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DIVISION-8 LAYING AND JOINTING OF PIPELINES 8.1 Pipes The contract envisages civil works namely excavation of earth, laying, jointing and testing of pipelines and construction of masonry pits including fixing of valves such as sluice valves, scour valves, double air valves and surface boxes and auxiliary specials required for different types of pipe viz., HDPE Pipes, C.I. / D.I. spun pipes with socket and spigot ends or flanged ends of different diameters, MS pIpes etc. 8.2. Materials The materials used shall conform to the relevant specifications mentioned in Division-7.The surplus materials if any, left over due to additional purchase against possible breakages etc. will not be takeover by the department and payment will be restricted to the materials actually used on work. 8.3. Trench Work The trenches shall be so dug that the pipes may be laid to the required alignment gradient and depth. The width of trench above pipeline level shall be as small as possible but provide sufficient space necessary for jointing pipes. The walls of trenches shall be cut according to the slopes mentioned in relevant I.S. specifications. The trenches shall be kept free from water while laying and jointing the pipes and specials. The relevant clauses that govern the trench work and preparation of base for laying of various types of pipes are as detailed below: D.I. Pipe: HDPE Pipes: 8.4. IS 12288/1987 IS 4984/2000
Handling and Laying of Pipes Reasonable care shall be exercised in Loading, Transporting and Unloading of
pipes and specials. The pipes shall be lowered into the trench carefully and shall be laid true to alignment and gradient as specified and as per instructions of the Engineer-inCharge. The sections of the pipe shall be jointed together in such a manner that there shall be as little unevenness as possible along inside of the pipes. Necessary precautions shall be taken while laying as per the relevant I.S. specifications for the type of pipes used, as mentioned below: 180
D.I. Pipe IS 12288/1987 HDPE Pipes - IS 4984/2000 8.5. Jointing Before commencing jointing, the pipes shall be cleaned; the joints and the ends of the pipes shall be cleaned, preferably with a hard wire brash to remove loose particles. Where jointing is done using rubber ring, care should be taken to see that the rubber ring does not get twisted or deformed while pushing the ring into position. The jointing for various types of pipes shall conform to the requirements of the relevant I.S. specifications. 8.6. Anchor and Thrust Blocks Thrust blocks, suitably designed shall be provided wherever necessary to transmit hydraulic pressure as laid down in the relevant I.S. specification. Where the hydraulic thrust is in an upward direction, anchor blocks of sufficient weight shall be provided, to which the pipes shall be secured with steel strips. 8.7. Testing After the pipes are laid and jointed, as mentioned in 8.3.and 8.4 above, the pipe lines are to be subjected to hydrostatic pressure test. The procedure for conducting the hydrostatic pressure test is detailed in the relevant I.S. specifications for various types of pipes.. In portions of the pipelines, where the pipes have developed cracks or sweating, such pipes shall be removed and re-laid with new pipes and the pipelines re-tested to the entire satisfaction of the Engineer-in-Charge. No extra payment will be made on this account. The bidder has to make his own arrangement for procurement of the required testing apparatus. The pressure gauge used with the testing apparatus shall be subjected to such test as the Engineer-in-Charge deems fit to ensure the accuracy of the gauge. 8.8. Appurtenant Works All the valves should be checked before fixing in position to verify whether they are closing and opening freely or not. Masonry pits for enclosing the sluice valves, scour valve, and double air valves are to be constructed after fixing the valves in position at the locations shown in the drawings contained in bid documents. The earth work excavation, laying of plain cement concrete, construction of brick masonry and plastering, laying R.C.C. cover slabs shall conform to the relevant specifications contained in this volume. Fixing of valves and the specials shall conform to I.S. 3114 /1965 and as specified in the 181
drawings appended. The pits should be cleaned and surroundings leveled with excavated earth and the bid price shall include cost of all these operations. 8.9. Refilling After the pipelines are laid, jointed and tested in conformity to the relevant I.S. specifications and to the satisfaction of Engineer-in-Charge the pipeline trenches should be refilled with excavated earth in layers of 6 inches. The clods should be broken, sufficiently watered and consolidated. The surface should be brought to the original condition by using the excavated material to the extent possible and using additional quantities of gravel and metal as the case may be. The extra earth after bringing back to the original condition should be disposed of as stipulated in paragraph 2.4.
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DIVISION-9 DUCTILE IRON PIPES FOR WATER SUPPLY 9.1 Scope This specification covers the requirements for manufacturing, testing, supplying, jointing and testing at work site Ductile iron pipes and fittings used for water conveyance. Data sheet-- A covers the specific requirement for the project. 9.2 Applicable Codes
The manufacturing testing, supplying, jointing and testing at work sites of Ductile Iron pipes and fittings shall comply with all currently applicable statutes, regulations, standards and codes. In particular, the following standards, unless specified herein shall be referred. In all cases, the latest revision of the codes shall be referred to. If requirements of specifications conflict with the requirements of the codes and standards, this specification shall govern. 9.3 Materials gas and sewage specification. IS: 638: Sheet rubber jointing and rubber insertion jointing. IS: 1387: General requirements for supply of metallurgical materials. IS: 1500: Methods for Brinell hardness test for metallic materials. IS: 9523: Ductile Iron fittings for pressure pipes for water, gas and sewage. IS: 12820: Dimensional requirement., of rubber gaskets for mechanical Joints and push on joints for use with cast Iron pipes and fittings for carrying water, gas and sewage. ISO: 4179 Ductile iron pipes for pressure and non-pressureCentrifugal cement mortar lining General requirements. ISO: 2531: Ductile iron pipes, fitting and accessories for pressure pipe lines. Code of Practice IS: 12288 - Code of practice for use & laying of Ductile iron pipes. 9.4 Manufacturing
IS: 8329: Specification for Centrifugally Cast (spun) Ductile Iron pressure pipes for water,
9.4.1 General DI pipes and DI fittings shall be systematically checked for any manufacturing defects by experienced supervisors and a very high standard quality shall be maintained. Owner / Engineer shall at all reasonable times have free access to the place where the pipes and fittings are manufactured for the purpose of examining and testing the pipes and fittings 183
and for witnessing the test and manufacturing. All tests specified either in this specification or in the relevant Indian Standards shall be performed by the supplier/contractor at his own cost and in presence of Owner/Engineer if desired. For this, sufficient notice before, testing of the pipes and fittings shall be given to Owner/Engineer. If the test is foundunsatisfactory, Owner/Engineer may reject any or all pipes and fittings of that lot. The decision of Owner/Engineer in this matter shall be final and binding of the contractor and not subject to any arbitration or appeal. 9.4.2 Materials
The general requirements relating to the supply of material shall be as per IS: 1387. The material for DI fittings shall conform to IS: 9523. 9.4.3 Dimensions
The internal diameter, thickness and length of barrel, dimensions of pipes and fittings shall be as per the relevant tables of IS.8329/IS: 9523 for different class of pipes and fittings. The tolerances for pipes and fittings regarding dimensions and deviations from straight line in case of pipes shall be as per relevant IS codes. The standard weight of uncoated pipes and fittings and the permissible tolerances shall be per relevant IS codes. 9.4.4 Workmanship and Finish
The pipes and fittings shall be stripped, with all precautions necessary to avoid warping or shrinking defects. The pipes and fittings shall be free from defects, other than any unavoidable surface imperfections which result from the method of manufacture and which do not affect the use of the pipes in the opinion of Engineer. The pipes and fittings shall be such that they could be cut, drilled or machined. The hardness of the external unmachined surface shall not exceed 230 HBS. In the case of spigot and socket pipes and fittings for lead joints, the socket shall be without the centering ring. In the case of flanged pipes the flanges shall be at the right angles to the axis of the pipe and machined on face. The bolt holes shall be drilled and located symmetrically off the center line. The bolt hole circle shall be eccentric with the bore and bolt holes equally spaced. The flanges shall be integrally cast with the pipes and fittings and the two flanges of the pipes shall he correctly aligned. 9.5 Testing
9.5.1 Mechanical Tests Mechanical tests shall be carried out during manufacture of pipes and fittings as specified in relevant IS codes. The results so obtained shall be considered to represent all the pipes 184
and fittings of different sizes manufactured during that period and the same shall be submitted to Owner/Engineer. The method for tensile tests and the minimum tensile strength requirement for pipes and fittings shall be as per relevant IS codes. 9.5.2 Brinell Hardness Test For checking the Brinell hardness, the test shall be carried out on the test ring or bars cut from the pipes used for the ring test and tensile test in accordance with IS 1500. 9.5.3 Retests If any test piece representing a lot fails in the first instance, two additional tests shall be made on test pieces selected from two other pipes from the same lot. If both the test results satisfy the specified requirements, the lot shall be accepted. Should either of these additional test pieces fail to pass the test, the lot shall be liable for rejection. 9.5.4 Hydrostatic Test
For hydrostatic test at works, the pipes and fittings shall be kept under test pressure as specified in relevant IS codes for 15 seconds, shall be struck moderately with a 700 g hammer for conformation of satisfactory sound. They shall withstand the pressure test without showing any leakage sweating, or other defect of any kind. The hydrostatic test shall be conducted before coating the pipes and fittings. 9.6 Coating
Coating shall not be applied to any pipe and fittings unless its surface is clean dry and free from rust. All DI pipes and DI fittings shall be mortar lined on internal surface as specified in IS: 4179. 9.7 Marking
Each fitting shall have as cast, stamped or indelibly painted on it, the following appropriate marks. (a) (b) (c) (d) (e) Indication of the source of manufacture. The nominal diameter The last two digits of the year of manufacture. PN rating of flanges when applicable, and Any other mark required by the purchaser.
Marking may be done on the barrel of castings or on the outside of the sockets. marking.The fittings may also be marked with the Standard Mark.
BIS Certification
The use of the Standard Mark is governed by the provisions of the Bureau of Indian Standards Act, 1986 and the Rules and Regulations made there under. The details of conditions under which the
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license for the use of the Standard Mark may be granted to manufacturers or producers may be obtained from the Bureau of Indian Standards..
9.8
9.8.1
Fittings
Dimensional and other requirement for fittings for specified Diameter shall conform to the
details given in tables 15 to 31 section 3 of the IS specification code IS: 9523: 2000. 9.8.2 HYDROSTATIC TEST For hydrostatic test, the fittings shall be kept under pressure for 10
seconds. They shall withstand the pressure test without showing any sign of leakage, sweating or other defect of any kind. The test shall be conducted before the application of surface coating. 9.8.3 The fittings shall withstand the hydrostatic pressure given in Table.9.8-1 Hydrostatic test Table 9.8-1 (Refer Table No. 2 IS 9523-2000) Nominal Diameter DN (mm) Up to and including 300 Over 300 and up to and including 600 Over 600 and up to and including 2000 Hydrostatic Test Pressure at works, MPa 2.5 1.6 1.0
pressure for castings
9.8.4
Tolerances: The tolerance on dimensions of barrel and socket for push-on-joint fittings shall be as given in Table 9.8-2
Table 9.8-2: Tolerance on dimensions of barrel and socket for push-on-joint fittings (Refer Table No. 3 IS 9523-2000)
Nominal Diameter DN (1) 80 100 125 150 200 250 300
External Diameter DE
Wall Thickness mm
Nominal (2) 98 118 144 170 222 274 326
Tolerance (3) +1/-2.7 +1/-2.8 +1/-2.8 +1/-2.9 +1/-3.0 +1/-3.1 +1/-3.3
K12 (4) 7.0 7.2 7.5 7.8 8.4 9.0 9.6
K14 (5) 8.1 8.4 8.7 9.1 9.5 10.5 11.2
Tolerance (6) -2.38 -2.40 -2.42 -2.45 -2.50 -2.55 -2.60 Section VII. Work Requirements
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350 400 450 500 600 700 750 800 900 1000
378 429 480 532 635 738 790 842 945 1048
+1/-3.4 +1/-3.5 +1/-3.6 +1/-3.8 +1/-4.0 +1/-4.3 +1/-4.4 +1/-4.5 +1/-4.8 +1/-5.0
10.2 10.8 11.4 12.0 13.2 14.4 15.0 15.6 16.8 18.0
11.9 12.6 13.3 14.0 15.4 16.8 17.5 18.2 19.6 21.0
-2.65 -2.70 -2.75 -2.80 -2.90 -3.00 -3.05 -3.10 -3.20 -3.30
Tolerances for the various dimensions of flanges shall be as given in Tables 9.8-3 and 9.8-4 Table 9.8-3: Dimensions of standard Flange Drilling for Flange Fittings PN 10 (Refer Table No. 4 IS 9523-2000) (in mm) Nominal Diameter DN 80 100 125 150 200 250 300 350 400 450 500 600 700 750 800 900 1000 Dimensions of flange D (outer dia) 200 220 250 285 340 395 445 505 565 615 670 780 895 960 1015 1115 1230 b (Thickness) 16 16 16 16 17 19 20.5 20.5 20.5 21 22.5 25 27.5 29 30 32.5 35 Holes Dia of Holes Dia (d) 19 19 19 23 23 23 23 23 28 28 28 31 31 31 34 34 37 M16 M16 M16 M20 M20 M20 M20 M20 M24 M24 M24 M27 M27 M27 M30 M30 M33 Bolt Size, Metric
No. 4 8 8 8 8 12 12 16 16 20 20 20 24 24 24 28 28
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Table 9.8-4: Dimensions of standard Flange Drilling for flange fittings PN 16 (Refer Table No. 5 IS 9523-2000) (in mm) Nominal Diameter DN 80 100 125 150 200 250 300 350 400 450 500 600 700 750 800 900 1000 D 200 220 250 285 340 400 455 520 580 640 715 840 910 970 1025 1125 1255 No. 8 8 8 8 12 12 12 16 16 20 20 20 24 24 24 28 28 Dia (d) 19 19 19 23 23 28 28 28 31 31 34 37 37 37 40 40 43 M16 M16 M16 M20 M20 M24 M24 M24 M27 M27 M30 M33 M33 M33 M36 M36 M39 Outer Diameter Holes Bolt Size, Metric
Lengths of Fittings The permissible deviations on the lengths of fittings shall be as per Table 9.8-5. Table 9.8-5: Deviation on Lengths of Fittings (Refer Table No. 14 IS 9523-2000) Types of fittings Flange socket, Flanged Spigot, Collars, tapers Tees Bends 90 (1/4) Bends 45 (1/8) Bends 20 (30) and 11 (15) 80 to 1200 80 to 2000 80 to 2000 80 to 1200 50/-25 (15 + 0.03 DN) (10 + 0.025 DN) (10 + 0.02 DN) 80 to 1200 25 nominal Diameter DN mm Deviation in L & H mm
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9.9
Jointing
9.9.1 General Jointing of DI pipes and fittings shall be done as per the requirements of specifications and as per the relevant IS code. After jointing, extraneous material, if any, shall be removed from the inside of the pipe. In case, rubber sealing rings/gaskets are used for Jointing these shall conform relevant IS codes and shall be of such type as mentioned in 'Data Sheet- A. 9.9.2 Spigot and Socket Pipes
The Spigot and socket pipes and DI fittings shall have push on joints as specified in IS code/ as recommended by manufacturer. The gaskets/sealant used for push on joints/flanged joints shall be suitable for water conveyance. In jointing Ductile iron spigot and socket pipes and fittings with tyton flexible joints the contractor shall take into account the manufacturer's recommendations as to the methods and equipment to be used in assembling the joints. In particular the Contractor shall ensure that the spigot end of the pipe to be jointed is smooth and has been properly chamfered, that the rubber ring as per relevant IS code is correctly positioned in line, before the joint is made. The rubber rings and any recommended lubricant shall be obtained only through the pipe supplier or as otherwise directed by engineer. 9.9.3 Flanged Pipes
The gaskets used between flanges of pipes shall be compressed fibre board or natural/synthetic rubber conforming to IS: 638-1955 of thickness between 1.5 to 3 mm suitable for water conveyance and as specified by manufacturer. The fibre board shall be impregnated with chemically neutral mineral oil and shall have a smooth and hard surface. Its weight per square metre shall be not less than 112 g/mm thickness. Each bolt should be tightened a little at a time taking care to tighten diametrically opposite bolts alternatively. The practice of fully tightening the bolts one after another is highly undesirable. The bolts shall be of mild steel unless otherwise specified. They shall be coated with coal tar epoxy coating after tightening.The Bolts and Nuts to be used for jointing the D.I. double flanged pipes shall conform to I.S. 1363/1967. 9.10 Cleaning of Pipes and Fittings
Contractor shall ascertain that each stretch of pipeline is absolutely clear and without any obstruction by means of visual examination of the interior of pipeline suitably lighted by 189
projected sunlight or otherwise. The open end of an incomplete stretch of pipeline shall be securely closed as may be directed by Owner/Engineer to prevent entry of mud or silt etc. If as a result of the removal of any obstructions Owner/Engineer considers that damages may have been caused to the pipeline, he shall be entitled to order the stretch to be tested immediately. Should such test prove unsatisfactory, contractor shall amend the work and carry out such further tests as are required by Owner / Engineer. 9.11 Testing at Work Site
After the pipes and fittings are laid, jointed and the trench partially backfilled except at the joints the stretch of pipe line as directed by Engineer shall be subjected to pressure test and leakage test as per relevant BIS codes for a test pressure of twice the working pressure in case of DI pimping mains. Where any section of the pipeline is provided with concrete thrust blocks or anchorages, the pressure test shall not be made until at least five days have elapsed after the concrete was cast. If rapid hardening cement has been used in these blocks or anchorages, the tests shall not be made until atleast two days, have elapsed. Each section of' the pipe line shall be slowly filled with water and all air shall be expelled from the pipe by tapping at points of highest elevation before the test is made plugs inserted after the tests have been completed. The duration of test shall be 8 hours. No pipe installation shall be accepted until the leakage is less than the number cm3/hr as determined by the formula: QL =ND P 3.3 Where, QL = the allowable leakage in cm3/hr N = number of joints in the length of the pipeline. D = diameter in mm, and P = the average test pressure during the leakage test in kg/cm2 Should any test of pipe laid indicate leakage greater than that specified above, the defective joints shall be repaired by Contractor at no extra cost to Owner/Engineer until the leakage is within the specified allowance. Necessary equipment and water used for testing shall be arranged by Contractor at his own cost. Damage during testing shall be Contractor's responsibility and shall be rectified by him at no extra cost to Owner/Engineer. Water used for testing shall be removed from the pipe and not released in the excavated trenches. After the tests mentioned above are completed to the satisfaction of Owner/Engineer, the backfilling of trenches shall be done as per specifications in layers.
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9.12
Measurement
All pipes shall be measured according to the work actually done and no allowance will be made for any waste in cutting to the exact length required. Pipes and fittings shall be described by their internal diameter and length measured in running meters. The measurement shall be taken along the centre line of pipe excluding fittings which shall be measured separately. The lengths of pipes shall not include the portion of spigots within the sockets of fittings and pipes. The rate for providing, laying and jointing of DI pipes and fittings shall be deemed to include the cost of jointing material and testing at work site. 9.13 Miscellaneous If any damage is caused to the pipeline during the execution of work or while cleaning./testing the pipeline as specified, Contractor shall he held responsible for the same and shall replace the damaged pipeline and retest the same at his own cost of the full satisfaction of Engineer. Water for testing of pipeline shall be arranged by Contractor at his own cost. 9.14 Laying and Jointing of pipes
9.14.1 Pipes The contract envisages civil works namely excavation of earth, laying, jointing and testing of pipelines and construction of valve chambers including fixing of valves such as sluice valves, scour valves, double air valves and auxiliary specials required for D.I. spun pipes with socket and spigot ends or flanged ends of different diameters. 9.14.2 Materials The surplus materials if any, left over due to additional purchase against possible breakages etc. will not be takeover by the department and payment will be restricted to the materials actually used on work. 9.14.3 Trench Work The trenches shall be so dug that the pipes may be laid to the required alignment gradient and depth. The width of trench above pipeline level shall be as small as possible but provide sufficient space necessary for jointing pipes. The walls of trenches shall be cut according to the slopes mentioned in relevant I.S. specifications. The trenches shall be kept free from water while laying and jointing the pipes and specials.
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The relevant clauses of IS 12288/1987 govern the trench work and preparation of base for laying of DI pipes. 9.14.4 Handling and Laying of Pipes
Reasonable care shall be exercised in Loading, Transporting and Unloading of pipes and specials. The pipes shall be lowered into the trench carefully and shall be laid true to alignment and gradient as specified and as per instructions of the Engineer-in-Charge. The sections of the pipe shall be jointed together in such a manner that there shall be as little unevenness as possible along inside of the pipes. Necessary precautions shall be taken while laying as per the relevant I.S. specifications. 9.14.5. Jointing
Before commencing jointing, the pipes shall be cleaned; the joints and the ends of the pipes shall be cleaned, preferably with a hard wire brash to remove loose particles. Where jointing is done using rubber ring, care should be taken to see that the rubber ring does not get twisted or deformed while pushing the ring into position. The jointing of pipes shall conform to the requirements of the relevant I.S. specifications. 9.14.6 Anchor and Thrust Blocks Thrust blocks, shall be provided as per drawings and BOQ to transmit hydraulic pressure as laid down in the relevant I.S. specification. Where the hydraulic thrust is in an upward direction, anchor blocks of sufficient weight shall be provided, to which the pipes shall be secured with steel strips. 9.14.7 Testing After the pipes are laid and jointed, the pipe lines are to be subjected to hydrostatic pressure test. The procedure for conducting the hydrostatic pressure test to be as detailed in the I.S. 3114/1985 for D.I. pipes. Field testing of all HDPE gravity pipelines shall be done for
a test pressure of 1.5 times the maximum static head
In portions of the pipelines, where the pipes have developed cracks or sweating, such pipes shall be removed and re-laid with new pipes and the pipelines re-tested to the entire satisfaction of the Engineer-in-Charge. No extra payment will be made on this account. The bidder has to make his own arrangement for procurement of the required testing apparatus. The pressure gauge used with the testing apparatus shall be subjected to such test as the Engineer-in-Charge deems fit to ensure the accuracy of the gauge.
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9.15
Appurtenant Works
9.15.1 General All the valves should be checked before fixing in position to verify whether they are closing and opening freely or not. Valve chambers for enclosing the sluice valves, scour valve, and double air valves are to be constructed after fixing the valves in position at the locations shown in the drawings contained in bid documents. The earth work excavation, laying of plain cement concrete, construction of brick masonry and plastering, laying R.C.C. cover slabs shall conform to the relevant specifications contained in this volume. Fixing of valves and the specials shall conform to I.S. 3114/1965 and as specified in the drawings appended. The pits should be cleaned and surroundings leveled with excavated earth and the bid price shall include cost of all these operations. This specification covers the specifications for various appurtenances on Ductile Iron water transmission mains. Applicable Codes and Specifications The following specifications, standards and codes, including all official
amendments/revisions and other specifications and codes referred to therein, should be considered a part of the specification. 1) IS: 27: Pig Lead. 2) IS: 210 Grey Iron Castings. 3) IS: 8329: Centrifugally cast (spun) Ductile Iron pressure pipe for water, gas and Sewage. 4) IS: 14846: Specification for sluice valves for water works purposes (50 to 1200 mm size). 5) IS: 1537: Vertically cast iron pressure pipes for water, gas and sewage 6) IS: 1538: Cast Iron fittings for pressure pipes for water, gas and sewage 7) IS: 1364: Specification for hexagonal head bolts, (Part1 screws and nuts of product grades A& B to 5) (Size range M1.6 to M64) 9.15.2 Sluice Valves: The D.I. sluice valves to be supplied for use on the work shall conform to IS 14846 and material shall conform to IIS 1865 and subsequent revision and contain the I.S. certification mark. The valves shall be of non-rising inside screw type; provided with D.I.
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cap or wheel as the case may be and valve key rod. The other conditions contained in paragraphs above shall be applicable to the sluice valves also. 9.15.3 Air Valves: Air valves shall be single or double orifice pattern as specified with ductile cast iron bodies. The inlet flanges shall be faced or drilled in accordance with IS 14845 to the appropriate diameter and the pressure rating of the pipeline concerned. The valve shall be capable of releasing air from the pipeline without restriction of rate of filling or flow due to back pressure and also to allow admission of air during pipeline emptying at a rate sufficient to prevent excessive depression of pressure in the pipe. Valves shall be designed to prevent the operating element being in contract with the pipeline liquid by approved means such as the provision of an auxiliary float chamber sufficiently large to isolate the orifice valves and seats throughout the rated operational range. Air valves shall be fitted with separate isolating sluice valve which shall be drop tight on closure and shall comply with the specification of sluice valves elsewhere herein and gearing shall be provided necessary to facilitate operation. Air valves shall be of a design which inhabits the entry of insects into the pipeline. All air relief valve and associated isolating valves shall be works tested and capable of withstanding the test pressures specified above for valves generally. All materials used in the manufacture of the valves shall conform to IS 14845. Triple cluster air valves shall be of combined small and large orifice valve pattern. The assembly shall be provided with a 12mm. tapping for draining purposes and the tapping shall be closed with a brass screw plug. The design of the valve shall be such that there is no possibility of the ball of the large orifice being suddenly caught up in the escaping air stream during the filling of water main at high rates thereby closing the valve prematurely. The diameter of the balls in each unit of air valve shall be suitable for operating under the specified rated pressure. The minimum diameter of ball within the small orifice chamber shall be 25mm for air valves rated at PN 10 For each triple cluster air valves location on large-diameter pipeline, the pipeline diameter and the physical features as shown on the drawings governing the maximum possible rate of air entry shall be taken into account by the Contractor when offering the air valve. The 194
size of the air valve provided for each location shall be such that air valve provided for each location shall be such that air can be admitted at the rate necessary to prevent a vacuum developing when any washout is opened or when a burst occurs at a critical point. The Contractor shall provide attested experimental data to confirm the adequacy of the air valves offered. For guidance; the capacity of inflow & outflow of air though Air Valve may be about 240 and 470 m3 / min. respectively. 9.16 Refilling
After the pipelines are laid, jointed and tested in conformity to the relevant I.S. specifications and to the satisfaction of Engineer-in-Charge the pipeline trenches should be refilled with excavated earth in layers of 6 inches. The clods should be broken, sufficiently watered and consolidated. The surface should be brought to the original condition by using the excavated material to the extent possible and using additional quantities of gravel and metal as the case may be. The extra earth after bringing back to the original condition should be disposed of as in spoil dumps as directed by the Engineerin-Charge.
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DIVISION- 10 HDPE PIPES FOR WATER SUPPLY 10. HDPE PIPES. 10.1 HDPE pipes shall conform to IS 4984 with ISI Mark manufactured by a factory
having BIS certification. The pressure rating shall be as specified in the Bill of quantities. i. Colour:- Colour of the pipe shall be black with 3 blue stripes. Depth of stripes shall not be more than 0.2 mm ii. Marking:- Pipes shall be marked in white paint on either end and for coils at both ends or hot embossed on white base every metre throughout the length of pipe / coil with the following information. I. Manufacturer name / Trade name. II. Designation of pipe (Grade of raw material, class of pipe, nominal outside diameter) III. Lot number / Batch number IV. ISI Certificate Mark V. Raw Material manufacturer iii. Raw Material: - The contractor shall furnish certificate from the raw material manufacturer regarding the material used in the pipes for each consignment. The percentage of used material utilized in the manufacture of pipes shall not be more than 10. Is shall be pipe grade for water supply. iv. Length of straight pipes: Length of straight pipes shall be 5 to 20 m or as specified by the Engineer. Short Length of 3 m (min) up to a maximum of 10% of the total supply will be permitted unless otherwise mentioned. v. Coils: - The diameter of the coil shall not be less than 25 times the nominal outside diameter of the pipe without any kinks. vi. Method of measurement of diameter, thickness and ovality: Outside diameter shall
be taken as the average of two measurements taken at right angles for pipes up to 110mm dia. As an alternative, diameter shall be measured preferably by using a flexible PI tape of circometer, having an accuracy of not less than 0.01 mm. vii. Thickness shall be measured by a dial vernier or ball ended micro meter. Resulting
dimension shall be rounded to 0.1 mm. Outside diameter shall be measured at a distance 196
of at least 300mm from the end of the pipe.
In case of dispute, the dimension of pipes
shall be measured after conditioning at room temperature for 4 hours. viii. Ovality:- It is the difference between maximum outside diameter and minimum
outside diameter at the same cross section at 300mm away from the cut end. For coiled pipes, it shall be measured prior to coiling (or after re-rounding of pipes)
10.1.1 HDPE Fittings
All HDPE fittings/specials shall be fabricated or injection moulded at factory as per IS: 8360 (Part-I & Part-III) and as per IS: 8008 (Part-I to Part-IX) fittings will be butt welded on the pipes or other fittings by use of heat fusion. 10.1.2 HDPE bends and tee. HDPE bends and tee shall be plain square ended conforming to IS: 8360 (Part I, II&III). Bends may be fabricated by jointing several small section of pipe to reach the required angel. Tees may be moulded or fabricated from pipes elements. 10.1.3 HDPE Reducer The HDPE reducer must be moulded and shall be plain square ended as per (Part-1 & VII) 10.1.4 HDPE stub ends HDPE stub ends shall be square ended conforming to IS: 8008 (Part-I & VII) specification stub ends will be welded on the pipe. Flange will be of slip on flange type as given in clause 15.16 below. 10.1.5 Slip on Flanges Slip on flange shall be metallic flanges covered by epoxy coating or plastic powder coating. Slip-on-flanges shall be conforming to standard mating relevant flange of valves, pipes etc Nominal pressure rating of flanges shall be PN10 IS: 8008
10.2 Performance requirements: i) Visual appearance:- Internal external surfaces shall be smooth, clean and free from grooving and other defects. Ends shall be square with the axis of pipe. Slight shallow longitudinal grooves or irregularities in the wall thickness shall be permissible provided that the wall thickness remains within the permissible limits. The outside diameter, thickness, tolerance in thickness ovality shall be as shown in the following table. WALL THICKNESS (mm) FOR PE-80 PIPES. (Outside dia, ovality, tolerance in thickness are same as that of Grade PE 63 given in the table given under PE 63 pipes) 197
Nominal Dia 50 63 75 90 110 125 140 160 180 200 225 250 280 315 355
Pressure rating (kg/Sq.cm) 6 10 Min Max Min 2.9 3.4 4.6 3.6 4.2 5.8 4.3 4.9 6.9 5.1 5.8 8.2 6.3 7.1 10.0 7.1 8.0 11.4 8.0 9.0 12.8 9.1 10.2 14.6 10.2 11.5 16.4 11.4 12.7 18.2 12.8 14.3 20.5 14.2 15.8 22.8 15.9 17.7 25.5 17.9 20.0 28.7 20.1 22.3 32.3
Max 5.3 6.6 7.8 9.3 11.2 12.8 14.3 16.3 18.3 20.3 22.8 25.3 28.3 31.8 35.8
12.5 Min 5.6 7.0 8.4 10.0 12.3 13.9 15.6 17.8 20.0 22.3 25.0 27.8 31.2 35.0 39.5
Max 6.4 7.9 9.4 11.2 13.8 15.5 17.4 19.8 22.2 24.7 27.7 30.8 34.5 38.7 43.6
16 Min 6.9 8.7 10.4 12.5 15.2 17.3 19.4 22.1 24.9 27.6 31.1 39.5 38.7 43.5 49.0
Max 7.8 9.8 11.6 13.9 16.9 19.2 21.5 24.5 27.6 30.6 34.4 38.2 42.7 48.0 54.1
WALL THICKNESS FOR PE-100 (Outside dia, ovality, tolerance in thickness are same as that of Grade PE 63 given in the table given under PE 63 pipes)
Nominal Dia 50 63 75 90 110 125 140 160 180 200 225 250 280 315 355 10 Min 3.7 4.7 5.6 6.7 8.1 9.2 10.3 11.8 13.3 14.8 16.6 18.9 20.6 23.2 26.1 Pressure rating (kg/Sq.cm) 12.5 16 Min Max Min 4.6 5.2 5.7 5.8 6.5 7.1 6.8 7.7 8.5 8.2 9.2 10.2 10.0 11.2 12.4 11.3 12.7 14.1 12.7 14.1 15.8 14.5 16.1 18.1 16.3 18.1 20.3 18.1 20.1 22.6 20.4 22.6 25.4 22.6 25.1 28.2 25.3 28.0 31.6 28.5 31.5 35.5 32.1 35.5 40.0
Max 4.3 5.3 6.3 7.5 9.1 10.4 11.6 13.2 14.8 16.4 18.4 20.5 22.9 25.7 29.0
Max 6.4 8.1 9.5 11.4 13.9 15.7 17.6 20.1 22.6 25.0 28.1 31.2 35.0 39.3 44.2
i) Hydraulic Characteristics:-When subjected to internal pressure creep rupture test, the pipes shall not show signs of localized swelling, leakage or weeping and shall not burst during the test duration. The temperature, duration of test and included stress for the test shall be as per details given in the table below.
Test 1 Type Test 2 Acceptance Test Test Temp C 80 80 Test Duration (min holding time) 165 48 Induced Stress (Mpa) P.E. 63 PE 80 3.5 4.6 3.8 4.9
PE 100 5.5 5.7
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The internal test pressure for the above test shall be calculated by adopting the formula given below. P=2xpxs (d-s) Where p = test pressure in Mpa
s = minimum wall thickness in mm d = outside diameter in mm P = induced stress in Mpa as given in the table above. iii) iv) Reversion Test: Longitudinal reversion shall not be greater than 3% Overall migration test: - When tested from a composite sample of minimum of 3 pipes
as per IS 9845, the overall migration of constituents shall be within the limits specified in IS 10146. Density: - Composite sample of minimum of 3 pipes as per IS 7328 shall have a density of 940.3946.4 kg/cum at 27 deg C. The value of density shall not differ from the nominal value by more than 3 kg/cum as per clause 5.2.1.1 of IS 7328. vi) Melt flow rate (MFR): Composite sample of minimum of 3 pipes as per IS 2530 AT 190 deg C with nominal load of 5 kgpf, MFR shall be 0.4-1.0 g /10 minutes and also shall not differ by more than 30% of the material used in manufacturing of pipes.The MFR of the material shall be 0.41-1.10g/10 minutes when tested at 190 deg C with nominal load of 5 kgpf as determined by method prescribed in 7 of IS 2530. The MFR of the material shall be within +- 20% of the value declared by the manufacturer.
vii)
Carbon black content and dispersion: For composite sample of minimum of 3
samples in accordance with IS 2530, the carbon black content shall be within 2.5 + 0.5% and the dispersion of carbon black shall be satisfactory. Sampling, frequency of tests and criteria for conformity for acceptance tests: i) Lot it shall consist of same size, same pressure rating, same grade and manufactured
essentially under similar conditions. The number of samples to be collected for various tests based on the size of lot shall be as per the table given below. The pipes shall be selected at random for sampling. Starting from any pipe in the lot count them as 1,2,3,4 etc up to r and so on where r is 199
the integral part of N/n, N being the number of pipes in the lot and n is the number of pipes in the sample. Every Rth pipe so counted shall be drawn as to constitute the required sample size.
SAMPLE SIZE, ACCEPTANCE CRITERIA
Number of Pipes in lot 1 Upto 150 Do 151-280 Do 281-500 Do 501-1200 Do 1201-3200 Do 3201-10,000 Do 10000-35000 Do ii)
Sample number 2 First Second First Second First Second First Second First Second First Second First Second
Sample size 3 13 13 20 20 32 32 50 50 80 80 125 125 200 200
Cumulative Sample size 4 13 26 20 40 32 64 50 100 80 160 125 250 200 400
Acceptance number 5 0 1 0 3 1 4 2 6 3 8 5 12 7 18
Rejection Number. 6 2 2 3 4 4 5 5 7 7 9 9 13 11 19
Visual and dimensions:- They shall be checked from the first sample size. Pipes
falling to satisfy any of the requirements shall be considered as defective. The lot is satisfied if the number of defectives found in the first sample are less than or equal to the corresponding number given in column 6 of the table. The lot is defective if the number of defectives is greater than the number in rejection number. If the defectives number is between columns 5 and 6 the second sample of sizes shall be taken and examined. The lot is considered satisfactory, if the number of defectives found in the cumulative sample is less than or equal to the corresponding acceptance number. Otherwise it is considered not satisfactory. iii) Hydraulic characteristics, reversion, overall migration, MFR and carbon black / dispersion tests: The lot having satisfied visual and dimensional requirements only shall be taken up for further testing. A separate sample size for each of the tests shall be taken as stipulated below and selected at random from the sample already examined for visual and dimensional inspection. 200
All the pipes in the sample shall be tested for requirements. The lot shall be considered satisfactory if none of the samples tested fails.
10.3 Transporting and handling pipes, specials, appurtenances and safety, cutting, handling and safety
10.3.1 Transporting and handling:
Pipes and fittings must not be dropped, indented, crushed or impacted. Particular care should be taken to avoid scoring, scrapping and abrasion damage. Scores or scratches to a depth of 10% or more of wall thickness are sufficient to require rejection of the pipes and fittings. Pipes must not be stored or transported where they are exposed to heat sources likely to exceed 70O C e.g., vehicle exhaust gases. 10.3.2 Safety Precautions:i) ii) PE particles can be abrasive if they enter eyes. Molten PE produced by welding operation will adhere strongly to the skin in the event
of accidental contact. Should this occur, the affected part should be flooded with cold water. The molten or solidified material should not be removed from the skin and medical assistance should be obtained even for small burns. iii) Molten PE will yield a small quantity of fume especially at high temperatures. Work areas where welding is being carried out should be ventilated for safe working conditions. iv) In the event of fire, there are no restrictions on the type of extinguisher which can be used. 10.3.3 Storage. Pipe packs should be place on timber bearers approximately 2m c/c. Avoid long term stacking of pipes. Providing proper regard is given to sideways stability (ex: wind forces), packs which are usually 1.2 meters wide may be stacked up to 3m in height for straight pipes. Coils stacked horizontally shall be placed on pallets for convenient lifting or slinging and the height of coils shall be limited to 1.0m in height. 10.3.4 Lifting and unloading. Metal hooks, chains or slings must not be used without padding for lifting coils or pipes. Care shall be taken to avoid injury to personnel when cutting the steel restraining bands on coils. 201
10.4 Earthwork and pipe support.
a) b)
Earth work shall be as per the specifications given for CI pipes except the following. Trench widths shall be as per the following table.
c) The trench spoil material should be placed where it will not interface with stringing and jointing Pipes laid under the roads wider than 3.0 m
Sl No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Out sidedia Of pipe (mm) 50 63 75 90 110 125 140 160 180 200 225 250 280 315 355 Width of Trench (mm) 500 500 500 600 600 600 600 600 600 500 500 500 500 500 500 Depth of Trench (mm) 950 950 950 1100 1100 1100 1100 1200 1200 900 900 900 900 1000 1000 Remarks
Provide 100mm thick bedding where soils are poor or rock is met with. Increase the depth of trench by 100mm in such cases.
10.5 a)
PIPE LAYING.
The pipe line may be laid along side the trench and jointed there. Thereafter the
jointed pipe line shall be lowered into the trench carefully without causing undue bending. The pipe line shall be laid inside the trench with a slack of about 0.5 m per 100 m of pipe line (pipe line to be laid in a sinuous alignment) b) Permissible radius at changes in direction.
i) Changes in direction shall be achieved by cold bending at ambient temperature so long as the radius of curvature is not less than the values indicated below. Standard dimension ratio (SDR) Radius Remarks.
41 42 33 26 <21 40 x Dia 30 x Dia 25 x Dia 20 x Dia 1. SDR = Ratio of outside diameter and wall thickness
2. Ambient temperature shall be 20 degree C or more
ii) Fittings shall not be located on bent pipe and kept at least 1m away from the tangent point. iii) Thrust blocks shall be provided near connections made for PE to other pipe materials. 202
iv) Compressible material must be used around the pipe in the concrete. 10.6 EMBEDMENT (i.e., refilling the trenches up to 50-100mm above the top of pipe.)
Pipes should not be buried in contact with soil particle sizes larger than the lesser of 5% dia of the pipe of 20mm. Soil clods must be excluded from the pipe embedment zone (i.e., from top of bedding to the top of overlay) and under no circumstances should temporary supports such as bricks or timber be left under or in contact with pipes. If the excavated material is not granular, suitable granular material duly compacted should be provided in this zone in 10.7 50-100mm layers up to 50-100mm above the top of pipe.
CONCRETE ENCASEMENT AND THRUST (OR ANCHOR) BLOCKS
Pipes may be encased in concrete wherever necessary with provision for a mechanical key such as a welded thrust flange. Compressible material at least 3mm thick and at approximately 150mm from the face of concrete into the concrete shall be provided around pipes at the entry point and exit points to eliminate any potential sharp edges from rubbing against the pipe wall. Pipelines shall not be filled with water until the concrete has developed sufficient strength. 10.8 REFILLING THE TRENCHES OVER THE EMBEDMENT. a) b) It shall be done as specified for CI pipes except as provided herein. Delay the final back filling after compacting the embedment around the pipe until a
cooler period in the day to permit the pipe line to contract in length. Mechanical joints, especially flanged joints should be left exposed if possible until the line is tested. Pipes should not be left uncovered where there is a possibility of the trench filling with water due to rain, etc., as floatation of the empty pipeline will occur unless it is back filled to a height of at least several diameters. Backfill the trench above the embedment zone.
Sl No 1 2 3 4 5 6 7 8 9 10
Dia of pipe (mm) 50 63 75 90 110 125 140 160 180 200
Width of Trench (mm) 500 500 500 500 500 500 500 500 500 600
Depth of Trench (mm) 750 800 800 850 950 1000 1000 1000 1000 1200
Remarks
Provide mm thick bedding where soils are poor or rock is met with. Increase the depth of trench by 100mm in such cases.
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11 12 13 14 15
225 250 280 315 355
600 600 600 600 600
1200 1400 1400 1500 1500
Heavy Pipes laid under roads less than 3.0 wide / foot paths and no valves provided.
Sl No 1 2 3 4 5 6 7 8 Dia of (mm) 50 63 75 90 110 125 140 160 pipe Width of Trench (mm) 500 500 500 500 500 500 500 500 Depth of Trench (mm) 700 700 700 700 750 750 750 750 Remarks
Provide mm thick bedding where soils are poor or rock is met with. Increase the depth of trench by 100mm in such cases.
180
500
900
Compaction of backfill should not commence without at least 300mm of protective material covering the pipe. d) Measurement: While arriving back fill quantity with excavated material,the volume of pipe of outside diameters 315 mm or more shall be deducted.
10.9 JOINTING METHODS. Jointing between HDPE pipes and specials shall be done as per the latest IS: 7643 part II. Method of jointing between the pipes to pipes and pipes to specials shall be with butt fusion welding using automatic or semi automatic, hydraulically operated, superior quality butt fusion machines which will ensure good quality butt fusion welding up to of HDPE pipes. The commonly used joints are as follows :1. 2. 3. 4. 5. 6. Insert type joints. Compression fittings. Fusion welding. Threaded Joints Flanged joints, and Telescopic joints.
It is recommended to adopt Fusion Welding as this is a permanent type of joint Fusion welding is commonly used in HDPE and is permanent type of joint.
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10.9.1 Butt fusion welding: Jointing the HDPE pipes must be done with Butt welding equipment with the temperature and pressure recording arrangements. The pipe line may be laid along side the trench and jointed there thereafter the jointed pipe line shall be lowered into the trench carefully without causing undue bending. The pipeline shall be laid inside the trench with a slack of about 0.5 m per 100m of pipe line (pipe line to be laid in a sinuous alignment.) Pipe to be joined must be of the same wall thickness and the ends must be cut square. Unmatched wall thickness will require matching or chamfering of the greater thickness at an angle of 5 deg (1:4) or less to give the same thickness. The success of each weld is extremely dependent of cleanliness, temperature control and good equipment which has been properly maintained. The pipe ends should be dry and free of dust. Mating surfaces must be planed immediately before welding to remove surface material as polyethylene (PE) oxidizes on exposure to air. If these prepared surfaces are touched, there is a risk of contamination. The timing of the welding sequence is most important if consistent quality of weld id to be obtained. Times for the simultaneous heating of the pipe ends against the hot plate (mirror), mirror removal, the pressing of the melted pipe ends together to give required amount and shape of bead material and finally the cooling time whilst maintaining pressure are all of critical importance. If the pipe temperature is not uniform (eg: when welded is carried out in direct sunlight) an uneven pipe wall temperature will exist which could affect the uniformity of the weld. This temperature difference must be equalized by shielding the weld zone well in advance of making the joint. Covers on the ends of pipes remote from the weld will prevent cooling air from passing through the pipe interior and assist in keeping weld zone temperatures uniform. If the pipe temperature is not uniform (eg: when welded is carried out in direct sunlight) an uneven pipe wall temperature will exist which could affect the uniformity of the weld. This temperature difference must be equalized by shielding the weld zone well in advance of making the joint. Covers on the ends of pipes remote from the weld will prevent cooling air from passing through the pipe interior and assist in keeping weld zone temperatures uniform.
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The temperature of the hot plate will be in the range 200+10 deg C (takes about 30 minutes for electrical heating and more for blow torch) with the higher temperature recommended for PE 80 to PE 100 welds. When welding is being performed in windy conditions, the temperature may need to be raised slightly compensate for air cooling. If the temperature is too high, there is a risk of thermal degradation of the PE resulting in a weak joint. If it is too low, it causes a weak joint due to insufficient melted material. The temperature of the hot plate must therefore be checked regularly. For detecting the correct temperature crayon chalk shall be used. Around 200 degC,thecolour of crayon dot on the mirror changes within 2 seconds.The dot made shall be thin and if not, time taken will be more indicating a wrong temperature. It is important that the correct heating, jointing and cooling times be used. Excessive heating time will have the same effect as a temperature which is too high and possibly cause thermal degradation. Too short a heating time will result in insufficient melted material. The heating,jointing and cooling time should not vary significantly from the times shown in the table below. Otherwise the joint will not develop full strength. Longer cooling times are however permissible. Excessive pressure will squeeze the melted PE out of the joint and weaken it. HEATING, JOINTING AND COOLING TIMES.
Wall thickness (mm) 2 4 6 8 10 12 Note : Initial bead Width(mm) Soak time Max. t3 & t4 T2 (sec) (Sec) SDR 41 17 9 30 4 3 3 60 5 4 3 90 5 4 4 120 6 4 4 150 7 5 4 180 8 5 4 Final bead Min t6 Min t5 (Minutes) (minutes) with (mm) Min Mad 5 7 9 11 13 15 4 5 6 7 8 9 6 8 9 10 12 13 11 12 13 14 15 16
1 1 1 1 1 1
1. 13 must be as short as possible eg: a delay of only 3 sec can cause a temperature drop of 15 deg C or more. 2. 3. b) i. ii. t2 time of contact between the plate and pipe ends after relieving the pressure p2 Excessive pressure will squeeze the melted PE out of the joint and weaken it. Butt fusion procedure. Clamp the pipes in the butt fusion machine. If practicable keep the brand markings in life.
iii. Wipe the pipe ends, inside and out, with a clean cloth to remove water, dift, muck etc., 206
iv. Align the pipe ends and clamp in place v. vi Plane both ends until they are perfectly square. Remove the plastic shavings from the vicinity of pipe ends without touching the
prepared surface as any contamination at this stage will be detrimental to the welding process. vii. viii Bring together the two pipe ends and ensure they are aligned. Check the hot plate (mirror) temperature (range 200-240 deg C) and make certain
the surfaces are clean. It is good practice to make dummy welds daily, prior to welding sessions as a means of cleaning the mirror. That is, the weld procedure should be taken to the heat soak stage, when the process can be aborted. The hot plate surfaces must not be touched with metal implements or tools. A damaged or dirty mirror will result in a poor joint. ix. Move the pipe ends in to contact with the hot plate and a steady pressure of about
2 kg/sq.cm (P1) while a uniform bead forms around the circumference of both pipe ends. This procedure is to ensure that the entire face of the pipe heats uniformly through positive contact with the mirror. x. When a satisfactory bead height has formed, relieve the pressure but maintain
contact pressure between the plate and pipe ends of 0.5 kg/sq.cm (P2) until the recommended time t2 (heat soak time) has elapsed. xi. Back the pipe ends away from the mirror. When removing the mirror, make sure it
is not wiped across the molten pipe ends. Xii Relax the contact pressure and carefully remove the clamps only after ensuring
the joint has fully solidified. Do not stress the joint or debead until the required cooling time has elapsed.
10.9.2 Flanged Joints These are used for jointing MDPE and HDPE pipes particularly of larger size to valves and vessels and large size metal pipes where strength in tension is required. It consists of flanges either loose or welded to the pipe ends. It is recommended that suitable metallic backing plates be used to support the polyethylene flanges to enable them to be bolted
207
together. Injection moulded polyethylene flanges with metal inserts of 6 to 9 mm thickness may also be used. In most cases, sealing is improved by incorporating a natural or synthetic rubber gasket between polyethylene flanges (see Fig 6.).
10.9.3 Telescopic Joint
Any joint (socket and spigot type) that permits sliding of the free end (spigot end) inside the socket with a rubber or suitable gasket, without any leakage is called telescopic joint. The socket could be an integral part of the pipe at one end or two ends or a special coupler into which the free ends (spigot ends) of the pipes are pushed to achieve a water tight joint.
These joints are normally weak in longitudinal pull and hence need anchoring wherever such a tendency of longitudinal pull is likely in the pipe line. In the case of telescopic joints, one external anchorage is generally necessary at each end of the pipe line, at valve and at all changes of direction. The supports of the side connection should ensure that excessive lateral bending does not occur. In small diameter the coupler itself could be modified to have a split, threaded, grip type gasket of hard materials in addition to O ring type of rubber gasket (for water tightness) to prevent any slipping out of the free end of the pipe in longitudinal pull. 10.9.4 Test to Establish Perfectibility/potability of work Specimen of pipe shall be tested to establish the suitability for use in carrying potable water (i) Smell of the extract (ii) Clarity of the colour of the extract (iii) Acidity and Alkality (iv) Global migration UV absorbing material Heavy metals (v) Unreacted monomers (styrens) and biological tests
10.10 QUALITY CONTROL a) i. Visual inspection of joints. The beads should be uniform and symmetrical without any sharp notches. Refer
the butt fusion weld section profiles given below which are useful to check the quality of joints. ii. Inspection of Bead after removal: Use an approved bead removal tool to remove
the bead. Do not remove bead by chipping or chiseling. Examine the underside of bead. It shall be solid and rounded with a broad root. Hollow beads with a thin root or curled edges should be rejected. (When the bead is bent to reverse the curvature, there 208
should be no sign of any slits or fissures (given below) b) Melt area assessment: The joint being tested is cut transversely into a strip approximately 20mm wide and 150mm long. A small flame played on the exposed cut edge of the weld will cause differential shrinkage of the fusion melt and the parent pipe. The pattern thus created will illustrate whether too much pressure has been applied and thus squeezed out most of the melt. c) Tensile strength The test specimens are to be prepared as shown in the figure below. Condition the specimens in air at 20+2 deg C for, <12 hours for pipes of wall thickness up to and including 12.7mm or < 24 hours for pipes of wall thickness over 12.7 mm. Test specimen containing the weld zone is shall not fail to a stress which must not be less than 0.8 of that of the virgin parent pipe. The test is performed with the bead removed. A normal pressure test on a welded pipe sample at 80 deg C should meet the requirements for pipe which does not contain weld material. The grip separation rate should 50mm /min + 10% Note the failure stress and mode of failure (ductile, tearing or brittle failure) d) Acceptance criteria. If all specimens are visually sound and separate in a ductile manner,the welding can be judged as satisfactory. If the specimens exhibit brittle separation modes, the welds of the batch require further investigation. Number of samples to be tested is given below.
Pipe Size (mm) Min number of samples. >90 <110 >110 <180 >180 <315 >315 10.11 Field hydraulic testing: Field testing of all HDPE gravity pipelines shall be done for a test pressure of 1.5 times the maximum static head 2 4 6 7
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DIVISION 11 HOUSE SERVICE CONNECTION MATERIAL 11.1 Material and Design Specification
Saddle Body: Non corrosive Engineering Plastic (PP / PE) body moulded with Stainless steel threaded metal insert for tapping outlet. Also, the stirrup metal plate shall be duly embedded in the plastic body, except at the place of nut-bolt lungs. Threading size and dimensions shall conform to IS: 554. The body shall have retaining cavity housing for internal and external retention of the elastomeric seal. Sealing shall be achieved by pressure exerted by the body while fastening the saddle straps & body on the pipe. Saddle Strap: Saddle straps shall be made of stainless steel 304 grade to prevent corrosion over the long service life. Strap Insulation: Elastomeric (rubber) insulation / lining shall be such that none of the Stainless Steel Strap is in direct contact with the pipe. It shall ensure a firm non slip grip mounting on the pipe prevent the saddle from rocking or creeping on the pipe, as might be caused by vibration, pressure or excessive external loading. Saddle Seal: It shall be virgin rubber SBR Grade 30 / NBR (NSF 61 approved). It shall be of type pressure activated hydro-mechanical design. It shall be contoured gasket to provide a positive initial seal which increases with increase in the pressure. Gasket shall be gridded mat, with tapered ends, with the outlet section having o-ring contacting the saddle body multiple o-ring contacting the pipe, preferably with a Stainless steel reinforce ring insert moulded to prevent expansion under pressure. Nuts-Bolts Washer: Stainless Steel Type 304, NC rolled thread, Tightening torque for 1/2 (M12) nut-bolt: 1415 kg.m and for 5/8 (M 16) nut-bolts: 21-23 kg.m
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11.2
Technical Specification for House Service Connection Materials
A. Electro fusion Fittings All the electro fusion fittings included in this document in this document should be designed for use in water distribution systems and be manufactured / supplied by manufactures having ISO 9001:2000 certifications for their quality systems. The products should comply with the following specific requirements. 1. The products shall comply with the requirements of BS EN 12201-3/ 2003, BS EN 15553 or ISO 8085-3 2. All the fittings shall be of SDR 11 rating. 3. The product group used for drinking water applications should have undergone type test by WRc-NSF, U.K. according to BS 6920 and a certificate from either WRc-NSF or WRAS (Water Regulations Advisory Scheme) should be available evidencing this fact. 4. All the products shall be manufactured by injection moulding using virgin compounded PE 80 (MDPE) polymer having a melt flow rate between 0.5 1.1 grams/10 minutes and shall be compatible for fusing on either PE 80 or PE 100 distribution mains manufactured according to the relevant national or international standards. The polymer used should comply with the requirements of BS 3412 and / or BS EN 12201-1. 5. The fittings intended for water distribution applications shall be coloured blue for the clear identification of the services. 6. All the electro fusion products should be individually packed so that they can be used instantaneously at site without additional cleaning process. The protective packing should be transparent to allow easy identification to the fittings without opening the bags. 7. The electro fusion products should be with only a single heating coil to fully electro fuse the fitting to the adjoining pipe or pipe component as applicable. The heating coils shall be terminated at terminal pins of 4.0 or 4.7 millimetre diameter, protected with terminal shrouds. Each terminal shroud should be additionally protected with polyethylene shroud caps. 8. No heating element shall be exposed and all coils are to be integral part of the body of the fittings. The insertion of the heating element in the fittings should be part of the 211
injection moulding process and coils inserted the injection moulding process or attached to the body of the fitting as a separate embedded pad etc. are strictly not acceptable. 9. The pipe fixation shall be achieved by external clamping devices and integral fixation devices are not acceptable. 10. The brand name, size, raw material grade, SDR rating and batch identification are to be embedded as part of the injection moulding process. Each fitting should also be supplied, with a bar code sticker, for fusion parameters attached to the body for settings the fusion parameters on an automatic fusion control box. The barcode sticker should also include the fusion and cooling time applicable for the fitting for the manual settings of a manual fusion control box. 11. The fittings should be V-regulated type designed to fuse at a fusion voltage of 40 volts AC. 12. The heating elements should be designed for fusion at any ambient temperatures between -5 to +40 degree centigrade to a constant fusion time i.e. without any compensation of fusion time for different ambient temperatures. 13. A limited path style fusion indicator acting for each fusion zone as visual recognition of completed fusion cycle should be incorporated into the body of each fitting near the terminals. The fusion indicators should not allow the escape of the molten polymer through them during or after the fusion process. 14. All the sockets in the electro fusion fittings should include a method of tapping controlling the pipe penetration (pipe positioned / stopper). Additional Requirements for the Tapping Saddles 1. The saddles should be the top loading type which are to be clamped on the mains
for fusion using the custom made top loading clamps exerting 1500N (150 kilograms approximately) top load. 2. The tapping saddles should be supplied with suitable adaptor for proper positioning
of the top loading clamp into the saddle. 3. The torque required to operate the cutter after fusion on the PE mains should not exceed 45 N m. 4. The tapping saddles will have female threaded outlet to connect either a flow
regulating ferrule or a threaded pipe or a transition adaptor fitting as the case may be. 212
5.
The threaded outlet should be from sizes 1/2 2 BSP to suit the required outlet
connections. 6. 7. The outlets should be reinforced with female threaded metal inserts to SS 304 The tapping on the PE mains may be achieved by a custom built metal cutter
supplied by the manufacturer one each for the standard packing box. B. COMPRESSION FITTINGS Compression fittings used for House service connection comply as per ISO 14236 1. Material of Construction
Compression fittings material shall confirm to ISO 14236. Clause 5 a. b. c. d. e. f. 1. Body-Polypropylene Nut / Cap Polypropylene Clip Ring-POM (Acetylic Resin) Packing bush - Polypropylene O Ring - NBR Threaded metal inserts SS 304 with BSP Threads Pressure Testing
The pressure rating of compression fittings shall be as per Clause 8 of ISO 14236 which is PN 16. 2. Dimensions
The Dimension of compression fittings shall be as per Clause 7.1 of ISO 14236. 3. Performance Requirements
The compression fittings shall be tested as per ISO 14236. Following Test methods shall be performed. Clause 8.2.1 Clause 8.2.2 Clause 8.2.3 Clause 8.2.4 Clause 8.3.2.1 Clause 8.3.3.1 Leak tightness under internal pressure Resistance to pull out Leak tightness under Internal Vacuum Long term Pressure Test for Leak tightness of Assembled joint MRS Valve as per ISO 9080 Resistance to Internal Pressure
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4.
Effects on Quality of Water
The compression fittings for intended for conveyance of Potable water for Human consumption to be tested to comply with BS 6920 specifications in any of the laboratories like DVGM / KIWA / SPGN / WRc NSF and certificate of compliance to be produced for the following parameters: a. b. c. d. e. Odour & Flavour of water Appearance of Water Growth of Micro Organism Extraction of substance that may be of concern to Public Health (Cyto Toxicity) Extraction of Metals
For clear identification of the water services, the nuts of the fittings should be coloured blue while the body to be black. All fittings with threaded ends should be with BSP threads. C. U PVC BALL VALVES (STOP COCKS) Balls Valves used for HOUSE Service Connections comply with ISO 4422, Part 4. 1. Material of Construction
Ball Valve material shall confirm to as per Clause 4 of ISO 4422 a. b. c. d. Body and Handle - UPVC Seals - PTFE O Ring - NBR / EPDM Material of Construction for compression end will as per
Specifications for Compression fittings 2. Pressure Testing The pressure of the Ball Valve shall be as per ISO 4422 shall be PN 16. 3. Dimensions
The Dimension of the Ball Valve shall be as per Table 3 of ISO 4422. 4. Performance Requirements
The Ball Valves shall be tested as per ISO 4422. Following test methods will be performed. Clause 7.1 Clause 7.2 Clause 7.3 Clause 7.4.1 Clause 7.4.2 214 Resistance of Valve Bodies to internal pressure Crushing Test Endurance Test Seat and Packing Test Operating Torque Test
The Ball Valves intended for conveyance of Potable water for Human consumption to be tested to comply with BS 6920 specifications in any of the laboratories like DVGM / KIWA / SPGN / WRc NSF and certificate of compliance to be produced for the following parameters: a. b. c. d. e. Odour & Flavour of water Appearance of Water Growth of Micro Organism Extraction of substance that may be of concern to Public Health (Cyto Toxicity) Extraction of Metals D. MDPE Pipes These specifications are for MDPE Blue PE 80 Pipes for House Service Connections of Dia 20 mm to 32 mm OD. 1. Raw Material Raw Material used to Manufacture MDPE Blue Pipes shall be Virgin Natural Resin PE 80 containing that anti oxidants, UV Stabilizers & Pigments which are necessary for Manufacturing of Pipes. The Density of Pipes shall be in the Range 0.926 to 0.940 g/cm3 confirming to ISO 4427 Standard. The PE 80 Resin Shall Have MRS of 8 Mpa. 2. Effect on Water Quality The MDPE PE 80 Blue Pipes shall confirm to Clause 3.5 of ISO 4427 for conveyance of water for Human consumption. Also the pipes intended for conveyance of Potable water for Human consumption to be tested to comply with BS 6920 specifications in any of the laboratories like DVGM / KIWA / SPGN / WRc NSF and certificate of compliance to be produced for the following parameters: a. b. c. d. e. 3. Odour & Flavour of water Appearance of Water Growth of Micro Organism Extraction of substance that may be of concern to Public Health (Cyto Toxicity) Extraction of Metals Pressure Testing The pressure rating of MDPE Blue PE 80 Pipes shall be confirming to Clause 4.1 of ISO 4427/1996 215
4.
Colour of Pipes The Colour of MDPE PE 80 Pipes shall be Blue confirming to Clause 3.2 of ISO 4427/1996
5.
Dimensions The pipe dimensions shall be as per latest revision of Clause 4.1 of ISO 4427/1996
and pipes upto diameters 32 mm shall be supplied in Coils of 300 m. The internal diameter, wall thickness, length and other dimensions of pipes shall be as per relevant tables of ISO 4427/1996. Each pipe shall be of uniform thickness throughout its length. The wall thickness of the PE 80 Pipes shall be as per the table given below: Nominal Dia of MDPE Pipe (mm) 20 25 32 Wall Thickness Minimum 2.3 2.3 3.0 Maximum 2.8 2.8 3.5
PR rating PN 16 PN 12.5 PN 12.5
The dimension tolerance shall be as per ISO 4427 Clause 4.1.3 6. Performance Requirements The Pipe supplied should have passed the acceptance test as per ISO 4427. The manufacturer should provide the test certificates for the following tests. 1 2 3 4 5 6 Melt Flow Rate Density Oxidation and Induction Test Hydrostatic Test Pigment Dispersion Test Longitudinal Reversion Test
These tests should be performed in the in-house laboratory of the pipe manufacturer. The Employer will depute Third party Inspection Agency to the Pipe manufacturing facility of the manufacturer to inspect the pipes as per QAP approved by Engineer in Change.
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DIVISION 12 TREE 1. Introduction The plantation scheme for the proposed water supply project was prepared based on requirements of IRC: SP: 21 / 2009 and the major locations identified in the project are WTP, ELSRs, and Pump houses. The care towards the plantation is taken during the design stage itself to mitigate the pollution & enhance the aesthetic and scenic beauty of the proposed water supply scheme. PLANTATION STRATEGY
2. Objectives The main objectives of tree plantation are as follows: Reducing the impacts of air pollution Natural noise barrier Arrest of land erosion Providing much needed shade during the daytime Enhancement of an aesthetic view of the sub-project areas. Climatic amelioration
3.
Species Selection Grasses, shrubs and trees are the main species that are readily available in India.
Where possible, the use of non-native species should be avoided since they can out compete and displace native plants leading to loss of native biodiversity. To maximize the chances of success, one should try to select species whose growing conditions roughly match the environmental conditions of the project site. Care should also be taken to select species with root systems that match the nature of the soil movement at the project site. During the selection of species preference should be given towards rapid growing and pest and disease resistant species. Flowering, ornamentals plants and climbers can also be planted in the project to provide beauty. 4. Plantation Pattern The type of plantation would be based upon the requirements and the feasibility of the sites along the project corridor. The availability of the space in the WTP, ELSRs, and Pump houses is a major guiding factor for plantation. The plantation pattern to be followed is:
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The first row of plants along the outer periphery of the GLSR & ELSRs and along the pump houses will be of small to medium height plants planted at a spacing of 3m c/c and the distance from the second row should be 3m. The plants for the second row are mainly shade bearing species. The height of the plant should be between 1.5m to 2m.
5.
Tasks of the Contractor As part of this project implementation, the Contractor shall plant and maintain a
minimum of 36 nos. of trees as compensatory afforestation in the WTP, GLSR, ELSR and pump house areas. The specific roles and responsibilities of the Contractor include: 6. Identification of the plantation stretches in GLSR, ELSR and pump houses areas. Plantation of the 2 year old saplings in the plantation stretches and Maintenance for one year including watering, removal of weed, litter and debris from the vicinity of the plantation. Ensure the protection of the tree guards provided to the saplings from trampling and browsing by the cattle. Guidelines for Plantation
6.1 General 6.1.1 Scope Contractor to furnish all materials, labour and related items necessary to complete the work and specified herein. 6.1.2 Materials Plant Materials shall be well formed and shaped true to type, and free from disease, insects and defects such as knots, sun-scaled, wind burn, injuries, abrasion or disfigurement. All plant materials shall be healthy, sound, vigorous, free from plant diseases, insect's pests, of their eggs, and shall have healthy, well-developed root systems. All plants shall be hardy under climatic conditions similar to those in the locally of the project. Plants supplied shall confirm to the names listed on the plant list given in Table -1. Besides these plant species, the Contractor shall supply other species as desired by the Employer. Under no circumstances non-native species which might have a negative impact on the ecology of the area shall be permitted. No plant material will be accepted if branches are damaged or broken. All material must be protected from the sun and weather until planted.
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All plants shall conform to the requirements specified in the plant list. Except that plants larger then specified may be used if approved, but use of such plants shall not increase the contract price if the use of the larger plant is approved, the spread of roots or ball of earth shall be increased in proportion to the size of plant. Deliver plants with legible identification labels. Table -1: List of Plants Proposed in the Project Row Number 1st Row (Flowering Plants) 1st Row (Flowering Plants) Bengal Babul Acasia auriculiformis Gulmohar Gulmohar Pink Cassias Cassia Grandis Local name of specie(s) Scientific name Alternative plant species Scientific name
Ganneru Chettu Nerium oleander
2nd Row (Shade Plants)
Neem or kondavepa or turaka-vepa
Melia azedarach
Mango Tree Ganuga or Kanji
Magnefera indica Pongamia pinnata
2nd Row (Shade Plants)
Rain Tree
Samanea Saman
Akashamalli (Sweet scented flowering plant)
Millingtonia hortensis
TopSoil (Sweet Earth / Good Earth): Topsoil or good earth shall be a friable loam, typical of cultivated topsoil of the locality containing at least 2% of decayed organic matter (humus). It shall be taken from a well drained arable site. It shall be free of subsoil, stones, earth skids, sticks, roots or any other objection able extraneous matter or debris. It shall contain no toxic material. No topsoil shall be delivered in a muddy condition. It shall have pH value ranging in between 6 to 8.5. The sweet earth for each plant is estimated to be 0.201 cum. Root System: The root system shall be conducive to successful transplantation. While necessary, the root ball shall be preserved by support with Hessian or other suitable material. On soils
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where retention of a good ball is not possible, the roots should be suitably protected in such a way that the roots are not damaged 6.1.3 Condition Trees shall be substantially free from pests and diseases, and shall be materially undamaged. Torn or lacerated roots shall be pruned before dispatch. No roots shall be subjected to adverse conditions such as prolonged exposure to drying winds or subjection to water logging between lifting and delivery. 6.1.4 Supply and Substitution Upon submission of evidence that certain materials excluding the plant Species prescribed are not available at time of contract, the Contractor shall be permitted to substitute with an equitable adjustment of price. All substitutions shall be of the nearest equivalent species and variety to the original specified and shall be subjected to the approval of the Engineer In Charge. 6.1.5 Packaging Packaging shall be adequate for the protection of the plants and such as to avoid heating or drying out. 6.1.6 Marking Each specimen of tree bundle shall be legibly labeled with the following particulars: 6.2 6.2.1 Its name The name of the supplier, unless otherwise agreed. The date of dispatch from the nursery. Tree Planting Plants and Shrubs Trees should be supplied with adequate protection as approved. After delivery, if planting is not to be carried out immediately, balled plants should be placed back to back and the ball covered with sand to prevent drying out. Bare rooted plants can be heeled in by placing the roots in prepared trench and covering them with earth, which should be watered into, avoid air pockets round the roots and shrubs shall be planted with the approval of Engineer In Charge. 6.2.2 Digging of Pits Tree pits shall be dug a minimum of three weeks prior to plantation. While digging the pits, the topsoil up to a depth of 30cms may be kept aside, if found good (depending upon site conditions), and mixed with the rest of the soil. If the side of the below, it shall be replaced with the soil mixture as specified further here in. If the soil is normal it shall be Section VII. Work Requirements 220
mixed with manure; rivers and shall be added to the soil if it is heavy. The bottom of the pit shall be forked to breakup the subsoil. 6.2.3 Back Filling The soil backfilled watered through end gently pressed down, a day previous to planting, to make sure that it may not further settle down after planting. The soil shall be pressed down firmly by treading it down, leaving a shallow depression all-round for watering. 6.2.4 Planting No tree pits shall be dug until final tree position has been pegged out for approval. Care shall be taken that the plant sapling when planted is not be burried deeper than in the nursery, or in the pot. Planting should not be carried out in water logged soil. Plant trees at the original soil depth; soil marks on the stem is an indication of this and should be maintained on the finished level, allowing for setting of the soil after planting. All plastic and other imperishable containers should be removed before planting. Any broken or damage roots should be cutback to sound growth. The bottom of the planting pit should be covered with 50mm to 75mm of soil. Bare roots should be spread evenly in the planting pit; and small mound in the center of the pits on which the roots are placed will aid on even spread. Soil should be placed around the roots, gently shaking the tree to allow the soil particles to shift into the root system to ensure close contact with all roots and prevent air pockets. Backfill soil should be firmed as filling proceeds, layer by layer, care being taken to avoid damaging the roots. The manure and feriliser utilisation in plantation are :Compost 20 Kg, Super Phosphate 1 Kg, Neem Cake 2Kg, and Pesticides (Lindane or Endosulfan Dust) 100 g. The sweet earth of 0.201 cum shall be used for planting. 6.2.5 Staking Newly planted trees must be held firmly although not rigidly by staking to prevent a pocket forming around the stem and newly formed fibrous roots being broken by mechanical pulling as the tree rocks. The main methods of staking shall be: A single vertical shake, 900mm longer than the clear stem of the tree, driven 600mm to 900mm into the soil. Two stakes as above driven firmly on either side of the tree with a cross bar to which the stem is attached. Suitable for bare-rooted or Ball material. A single stake driven in at an angle at 45 degrees and leaning towards the
prevailing wind, the stem just below the lowest branch being attached to the stake. Section VII. Work Requirements 221
Suitable for small bare-rooted or Ball material. 6.2.6 Tying Each tree should be firmly secured to the stake so as to prevent excessive movement. Abrasion must be avoided by using a buffer, rubber or Hessian, between the tree and stake. The tree should be secured at a point just below its lowest branch, and also just above ground level: normally two ties should be used for tree. These should be adjusted or replaced to allow for growth. 6.2.7 Watering The Contractor should allow for the adequate watering in of all newly planted trees immediately after planting and he shall during the following growing season, keep the plant material well watered throughout the maintenance period of one year. 6.3 Tree Guard
The fencing of a single row plantation is generally done by using tree guards. In the proposed project the ornamental circular iron tree guard with welded mesh having 50 cm diameter is proposed. The specifications for the tree guard with welded mesh is given in Figure -1.
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Figure -1: Ornamental Tree Guard with Welded Mesh
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SECTION VII B TECHNICAL SPECIFICATIONS FOR CIVIL WORKS (ELSRs, CW Sumps/GLSRs) 1. Special Notes All water retaining structures shall be built in RCC M 30. The water retaining
structures shall be hydraulically tested as per IS 3370 Part A, which shall be done in the Engineers presence.
1.1
The layout of the plant as shown on the drawing attached is not binding on the tenderer but is only indicative.
1.2
Underground soil and water aspects to be investigated thoroughly and design of relevant structures to be carried out afresh by the Contractor at his/their own cost and be submitted to the Employer or his authorized Engineer Officer for approval. No claim on cost on this exercise will be entertained.
1.3
The tenderer shall not quote for works differing from the specifications of the tender unless specifically permitted elsewhere in the tender documents.
1.4
The suitability of the plant will not be decided only by the low capital cost but the economy in the operational costs will also be considered. For this purpose all relevant details should be furnished.
1.5
There shall not be any ambiguity in the offer. Tender containing any ambiguity may be interpreted in a manner advantageous to the Employer.
1.6
If not mentioned elsewhere in the tender documents, the contractor shall provide the following arrangements :
a) Water supply to different treatment processes namely chemical dosing; disinfection shall not be made solely dependent on the operation of clear water pumps. Separate pumping arrangement for supplying water to alum solution tank and chlorine dosing equipment are to be provided. b) Disposal of drainage of the treatment units shall be made by gravity system as far as practicable. If ultimate disposal has to be pumped, emergency gravity overflow must be provided.
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c)
Particular care shall be taken for satisfactory disposal of sludge from the clarifier.
d)
All electrical components, appliances, switches, flow measuring devices etc., installed outside shall be well protected from rain and other weathering effects by providing sheds, enclosures, canopies etc.
e)
All sluice valves, gates and its passages should be placed under proper sheds as per instruction of E.I.C.
f)
The levels of different units e.g the underground reservoir,elevated level reservoirs, pump houses etc would be fixed in such a way that the all units can be isolated and kept dry (free from water) for maintenance.
g)
All valves sluice gates, etc. shall be of reputed make and shall conform to available I.S. Specifications. In case of non-availability of relevant I.S. specifications it should conform to British Standard Specification or American Standard Specification.
1.7
The reservoir head works being a typical process plant, it is imperative that the layout of the plant inclusive of all Civil, Mechanical and Electrical Components should meet the requirements of Indian Factory Act. Indian Explosives Act and all other relevant statutes of the State and Central Government. The contractor has also to procure Explosive License for use of chlorine during Trial Run. All Structures, Vats, implements etc. forming part of on-site emergency plan shall be provided by the contractor.
1.8 1.9
The system should be designed to provide a net output of 11.50 MLD. Proper bypass arrangements will be provided so that the water could be flown avoiding the using the ELSRs during their periodical maintenance works.
2.
WATER TREATMENT PLANT The requirements and the design criteria for different units of the water treatment plant as given herein below are mandatory. All water retaining structures shall be tested for water tightness(hydraulic test). Th design of the WTP shall be done keeping in mind future expansion requirements, supported by preliminary designs and lay out diagram for future expansion shown in dotted lines.
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2.1. Stilling Chamber: The stilling chamber should be connected to the water inlet by means of a sluice valve on one side and a venturi flume connected to the flash mixer on the other side. The capacity of the stilling chamber, inlet channel including venturi flumes should be sufficient to deal with a flow of 9.0 MLD raw water with required overloading. The inlet chamber shall have a sluice valve of suitable size with sluice gate to enable connection to the future expansion. 2.2. Flash Mixer
The capacity of flash mixer shall be designed for the following parameters to treat the raw water. a) b) c) d) e) f) g) Detention period shall be 30 seconds. Ratio of tank height to diameter shall be between 1:1 and 3:1 Ratio of impeller diameter to tank diameter shall be 0.2 to 0.4. Shaft speed of the propeller shall be greater than 100 RPM. Velocity induced in the water shall be about 2/3 of the peripheral speed and not less than 3.0 M/Second. Position of the impeller should be at the center of the liquid and 0.9 M below the water surface. Head loss shall be 20 to 60 cm of water.
Necessary bye-pass arrangements should be made to direct feed the filter beds duly byepassing flocculator at time of necessity. Gravity type desludging arrangements should be provided to meet the emergency requirements of flush mixer independently wherever such a necessity arises. 2.3 a) Chemical House: Storage space for Alum. The space should be sufficient to store 3 months requirements of alum calculated at: i). Average dosage of 50 ppm. ii). Maximum storage height of 2.0 Meters. iii). Extra space of 50% for movement and storing other chemicals. A room shall be provided at suitable location in chemical house as a separate unit, for storage of alum for rooms and convenient handling and there shall not be any direct communication from other rooms like compressor room and wash water pump set room, lest the equipment gets rusted. No switchboard shall be provided, in alum room. It should be of dam proof construction, properly drained. Special precaution against flooding should be taken. A minimum floor area (as rquireed) should be provided for storing the alum.
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b)
Alum Solution Tanks These should hold one days requirement of 5% strength of alum solution at the maximum dosage rate of 50 ppm. Each 3 tanks should hold 8 hours supply with one tank extra as stand bye. The top of solution tank should not be higher than 1.0 meter from the floor of the platform with a minimum free board of 0.3 m, proper approaches with RCC / aluminum ladder should be provided. Necessary required inlet water supply pipe arrangements be provided with ceramic tiles.
c)
Alum Bins: These shall be designed for holding 7 days requirement of alum cakes near solution tanks. These have to be constructed in the chemical house.
d)
Solution Feedings: These shall be of automatic type capable of adjustment of the orifice to regulate the dosage of alum solution required for the flow of raw water in the channel. Rigid PVC tube and diaphragm valve are to be used with inter connecting arrangements so that solution from anyone of the alum dissolving tanks can be applied through a float operated proportional feed mechanism.
2.4
CLARIFLOCULATOR The floculator should have the following capacities. 1. Total Capacity 2. Flocculator Capacity 3. Clarifier capacity . Flocculation and clarification shall be carried out in a specially designed two-compartment tank. The area of the tank shall be determined on the basis of over flow rate, which shall be 30m3/day/m2 to 40m3/day/m2. The volumetric efficiency of the basin shall not be less than 50%. The weir load shall be below 300m3/meter. Clarifloculator shall be preferably of radial flow type satisfy the following design criteria. As per hydraulic designs. As per hydraulic designs. As per hydraulic designs
(a)
FLOCULATOR i) ii) iii) iv) v) vi) Detention period Depth Peripheral velocity (speed) paddles or 0.3 m/sec Revolution of the paddles Paddles Area Head Loss 30 Minutes. 2.4m to 3.60m 2/5 peripheral velocity speeds of the 1 to 5 RPM. 10 to 15 % of the tank Sectional area in the place of the shaft. 150 mm.
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(b)
CLARIFIER i) ii) iii) iv) v) vi) Detention period Surface Loading 2.5 hours 30 to 40 m3/m2 (Clear Clarifier area only) 1.8 m Minimum. 15cms/sec to 25 cms/sec 0.5 to 1.5 cm/sec. 1 in 12 to 18
Depth Velocity through Intel ports Flow through velocity Bottom slope -
The clarifier bridge, railing and assembling parts shall be provided with coats of anticorrosive epoxy paint. vii) viii) Size of dispersion walls Outlet weir loading 1/5 to 1/10 dia. not greater than 300 m3/day/m.
The annular launder to receive clarified water shall be on the outside of the clarifier wall. A brass weir shall be provided for discharging clarified water into the annular launder. A suitable walkway with G.I. pipe hand railing shall be provided alround the clarifloculator to facilitate movement around the unit for maintenance purpose. 2.5 Filter House Minimum of 4 No. of rapid gravity filter bed of rectangular type should be provided. The area of each filter bed shall be based on the following criteria. Rate of filtrations Hours of working Shape of bed 80 litres / minute / Sqm. 231/2 hours/day. Rectangular in the ratio of length to breadth as 5:4 or 4:3.
The filters shall be arranged so as to accommodate pipe galleries and a filtered water channel. The filters shall be designed for a head loss not more than 2 meters and for cleansing by air followed by water. The pipe size should be designed on the basis of designed flow rate and the size of valves shall be equal to the size of pipe dia. a) Under Drainage System (PVC 10 Kg/cm2) This should comprise of laterals connected to a central manifold, which should serve to collect the filtered water and to uniformly distribute the wash water at the time of back washing. The under drainage system should satisfy the following criteria. 1) 2) 3) Ratio of the length to diameter of the lateral shall not exceed 60. Size of perforation 5 to 12 mm dia. Spacing of perforations along the material shall be 8 cms for 5 mm perforation and 20 cms for 12 mm perforation.
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4)
Ratio of the total area of the perforations in the under drainage system to the total cross sectional area of the laterals should not exceed 0.5 for perforation of 12mm and should decreases to 0.25 for perforations of 5 mm.
5)
Ratio of the total area of the perforations in the under drainage system to the entire filter area, may be about 0.3%.
6)
Spacing of laterals closely approx. the spacing of offices and shall be 30 cm. for satisfactory diffusion but limited by the total head available.
7) 8)
Rate of washing not less than 60 cm. per minute for a period of 10 minutes. Ratio of cross sectional area of main fold to the total cross sectional area of the laterals should be between1.5 to 2 (preferably 2).
9) b) 1)
Filter head loss shall be not more than 2.0m. Specification for Filter Sand: Filter sand should in general, be of such size as to hold large quantity of flow, without permitting its passage through the filter bed, at the same time maintain the faltering efficiency.
2) 3)
It should not create or increase difficulties in washing. It should permit long filter runds.
4) When washed, it should clean itself from the adhering particles without requiring a very high velocity of wash water, which would result in carrying away the same particles. 5) The effective size particles should be 0.45 to 0.70 mm and its uniformity sufficient should be in between 1.30 and 1.70. 6) 7) The depth of filter sand should be 75 cm. Filter sand shall be of hard and resistant quartz or quartzite and free from clay, fine particles, soft grains, dirt of every description, dust, roots and other impurities. It should contain less than 2 line and magnesium as carbonate. 8) 9) Soluble fraction in Hydrochloric acid shall not exceed 5% cu/Metre. Expansion of filter sand during washing shall not be less than 50 crn/Metre.
10) Ignition loss should not exceed 0.7% by weight. 11) Specific gravity shall be in the range of 2.55 to 2.6. 12) c) Wearing loss shall not exceed 3%. Specification for Gravel Bed Gravel bed shall prevent sand from entering the under drainage system and shall support sand and shall aid uniform distribution of wash water and shall be 45 cms thick and graded as follows:
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5mm to 2mm 12mm to 5mm 20mm to 12mm 40mm to 20mm 60mm to 40mm Total
10 cm 8 cm 8 cm 8 cm 11 cm 45 cm
Gravel laid should be spherical, hard, clean and uniform in quality, durable and long pebbles and should not contain any sand, clay or other impurities. The outlet clear water pumping system to clear water channel shall be designed to handle 25% overloading condition. d) 1. General Requirements Walkway shall be provided around each filter, it shall be atleast 1.20 m wide on all the sides. The common walkway over the intermediate walls shall be atleast 1.20m. GI Hand railing shall be provided around the filters. No columns shall obstruct the walkways of
filters. Operating platforms shall be atleast 2.5 m. wide. Brackets shall be provided in the columns of the filter house so that runners and plants can be provided for repairing the filter roof etc. There shall be direct access from operating platform of filters to the laboratory rooms.
2.
A notch shall be provided in the clear water canal of filters with free flow conditions. This facilitates prevention of back flow from clear water reservoir. Wash water channel and
pure water channel shall be away from each other to avoid pollution. Otherwise the MWL of the wash water channel shall be below the invert level of pure water channel. Wash water troughs may be provided with M.S. Steel plates with lining inside and outside and the section may be semi-circle. No pipes or specials shall be proposed in wash water channel, to allow free flow of wastewater. Glazed tiles shall be provided for each inspection chamber. 2.6 Wash water Tank This shall be a separate overhead tank with a capacity sufficient for continuous washing of one filter for 10 minutes duration without refilling. The elevation shall be such that it maintains the rate of rise as specified earlier after over coming all the losses through filter under drain piping valves, filter sand and gravel etc.
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2.7
Blower Air blower of reputed make of require capacity to supply air 600 cft. For scouring the filter
sand one bed at a time shall be provided with all required pipe connections etc., complete. 2.8 Chlorination Plant This shall be of gravity type of reputed make of required capacity capable of supplying chlorine at a maximum dosage of 4mg/lit in duplicate with 100% stand-bye, Chlorination room shall be located separately on the forward direction with reference to main filtration plant. Sufficient space must be provided in the chlorination equipment enclosure to store the stock of cylinders required for a month. No steel work shall be provided in chlorinator room, there shall be two compartments and the chlorine cylinder shall be kept in another room so that the pumping equipment if required to be installed will not be damaged. There shall not be any opening between pumping room and cylinder room. Ramp shall be provided at a suitable place for loading and unloading the chlorine cylinders. Sufficient space should be provided to place weighing machine, suitable gas masks shall also be provided at a special place. Only HDPE pipes shall be used for carrying water-chlorinated water etc. A suitable size water tank shall be provided to roll any
cylinder in case any leakage occurs safety equipment to take any leaks shall be supplied. 2.9 Laboratory The laboratory platforms at convenient level for keeping apparatus to carry out the physical and chemical tests with required cupboard arrangement under the platform shall be provided. The platform shall be in polished cuddapah slab with minimum thickness of 25mm. A big sink shall be provided for washing the Laboratory equipment etc., glazed tilling shall be provided from wash water tank and G.I. pipe and 150 mm dia shall be provided to carry wastewater from the sink. Sl. No. 1. 1. Description of the item 2. RAW WATER INLET STILLING CHAMBER a) C.I. Sluice valve of appropriate size with necessary tailpieces complete. b) Pedestal type flow meter 0 to 12 mld (Integrated, reading and recording type of reputed make) One Set One No. Unit 3.
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2. CHEMICAL DOSING EQUIPMENT a) Alum dosing mechanisms b) Alum Dissolving Mechanism for each of Alum Solutions tanks 4 Nos. c) Alum Solution feed pipe arrangements complete along with control valve. d) Platform weighing machine of 500 Kg capacity 3. FLASH MIXER CHAMBER: a) Mechanism for instantaneous mixing of Alum solution with raw water. b) Gravity type desludge mechanism up to disposal point 4. CLARIFLOCULATOR: a) b) c) d) e) Central Mechanism for Driving Bridge over rails motors and fabrication of walkways with hand rails Mechanism for flocculation and raking in the flocculation compartment with driving motors Mechanism for raking in clarifier compartment Central scrapper frame with brushes. Sludge discharge device with a minimum size of 250 mm dia CI pipe, sluice valve along with necessary pipe connections etc., for complete with telescopic desludging. FILTRATION PLANT a) b) c) d) Filter media of gravel and sand of suitable characteristics Filter under drainage system of suitable capacity Wash water and waste water gutters and appurtenances. The influent and effluent pipe gallery together with valves, inlet and out let connections including all appurtenances. Automatic rate of flow controller for each filter bed. Flow gauge for each filter bed for inlet and out let. Loss of head gauge for each filter bed Air blower of suitable capacity along with air pipe system complete for air scour. Back wash arrangements complete with water main. (i) Wash water pumpsets of suitable capacity (centrifugal) in duplicate with connections suitable capacity and suction delivery connections (ii) Wash water tank pipe connections, control valves and controllers etc., complete. Surface wash system comprising of necessary pipe connections, controls etc., complete. One Set One Set One Set One Set One Set One Set One Set One Set One Set One Set One Set One Set One Set One Set One No.
5.
e) f) g) h) i) j)
One Set One set One set One No. One set One set.
k)
One set
232
Bypass arrangements to feed filter beds directly including necessary pipe connections diversion arrangements etc., complete. m) Suitable length of 600 mm dia PSC 6 KSC class clear water main from filtration plant outlet upto inlet of clear water sump with valves specials etc., n) All the jointing material suitable bolts, washers, should be provided with GI materials. 6. ISOLATED CHLORINATION PLANT a) Gravity type gaseous chlorinator of appropriate capacity to give a dosage of 4 mg/l b) Solution feed equipment with pipe line control valves and other fittings etc., complete. c) Spares for Chlorination equipment d) Platform scale type weighing machine of 1000 Kg capacity e) Chlorine cylinders and safety equipment as noted in BOQ 7. LABORATORY EQUIPMENT a) Comparator test set for measurement of residual Chlorination using chloro-scope. b) pH Test kit with different discs for measurement for pH c) Jar test apparatus for determining optimum alum dosage d) Turbidity meter e) Analytical balance with weights box. f) Fume cup board
l)
One set
One set
One complete job
One No. One set One set One No.
One No.
One Set One No. One No. One No.
One No. One No. One Set
g) Conductivity meter h) Equipment and reagents required for analyzsing alum percentage in the ferric alum.
One set i) Test bench fully equipped with glass apparatus for sampling and testing of water before and after treatment One set j) Equipment and reagents required for analyzing chlorine percentage in bleaching powder. k) Necessary furniture: (i) Wooden Stools (ii) Wooden Almarah (Big Size)
One No. One No.
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8.
a) Erection and testing charges of the plant and the equipment supplied under item No. 1 to 7 b) Trail run and maintenance charges for a period of 90 days including all labour charges and chemicals & consumables. Energy and water will be supplied free of cost by the department during this period (The rate of 8.a. and 8.b. be shown separately) Testing of the treated water and comparing with CPHEEO Standards. SPARES AND WORKING TOOLS:
One Unit One Unit
9. One Set Necessary spares and working tools required for normal working of the plant for a period of 3 years with list of tools proposed to be supplied. NOTE: The inlet and outlet control system of the whole plant should be capable of taking an over load of 25% and Filter losses of 5% for 23.50 working hours per day over the stipulated capacity.
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(I)
CIVIL WORKS. Sl. No 1. 1. Description of work 2. a) Construction of 10 m dia. (internal) RCC Intake well cum Pump House within Sri Ram Sagar lake, about 1000 m inside One Unit Unit 3.
b) Construction of RCC Bridge, 800 m long from Intake Well, towards bank, within Sri Ram Sagar lake One Unit
c) Costruction of earth filled formed road with moorum topping within Boulder masonry retaining walls on both sides, about 200 m long, to connect RCC Bridge and the bank of Sri Ram Sagar lake, within the lake
One Unit
One Unit
d) Costruction of Transformer yard and its switch room, cable trenches and Barbed wire fencing with gate etc. One Unit
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2.
a) Laying including supplying fitting fixing, with Specials and Valves, Raw Water Pumping main (DI/K-9), about 19000 m long One Unit
a) Construction of 11.5 MLD Conventional Water Treatment Plant at Yanamgutta area of Armoor town with usual components, as given in the BOQ One Unit
c)
RCC Clear Water Reservoir, 1000 KL, with pipe One Unit
connections One Unit d) RCC Clear Water Pump House, with pipe One Unit
connections
e) RCC NP3 S/S Sludge line, 200 mm dia.,110 m One Unit f) Sludge sump cum Pump House and Distribution box, with pipe connections One Unit
g) Sludge Pond (twin unit) with collection well etc.
One Unit
h) Electrical Transformer yard, switch room, Cable trenches, Barbed wire fencing etc.
One Unit
i) Cascade Aerator Fountain with pipe connections
One Unit
j) Administrative Building
One Unit
k) Staff quarter building, having four flats
Two Unit
l) Internal roads (CC), Internal drains, Boundary wall etc.
One Unit
236
a) ELSRs, 450 Cu.M X 16 M Staging height b) Repair and rejuvenation of existing GLSR c) Watchman Quarter at Reservoir HW sites d) Internal Roads at Reservoir HW sites e) Internal Drains at Reservoir HW sites f) Bouindary walls with gates Reservoir HW sites
Three Units One Unit Four Units Four Units Four Units Four Units
a) Laying including supplying fitting fixing, with Specials and Valves, Clear Water Pumping main (DI/K-9), One Unit about 7820 m long b) Laying including supplying fitting fixing, with Specials and Valves, Distribution main (DI/K-7 and HDPE), about . m long c) Clamping arrangement of pipelines along Bridges & Culverts, at several locations
One Unit
One Unit
6.
a) Pumps and Motors, at Raw Water Pump House, and Clear Water Pump House Two Units
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7.
a) Electrical Transformers, cables, to plant components providing internal electrical cables from sub-station to various panels and controls required for the operation of the electrical equipments b) Providing internal wiring and following lighting equipment with all fittings and fixtures complete at the Intake HW site, WTP site and Service Reservoir sites. Necessary tube light points. Necessary ordinary light points Necessary plug points Necessary sodium vapor lamps outside the Intake HW, Filtration plant, Service Reservoir sites, for yard lighting. Exhaust fans near Chlorination plant Electrical fans 185 mm dia of good make Lighting arrestor (Aluminium) Main Busbar distribution system PLANT DRAWINGS: Supply 6 sets of complete drawings of the plant mounted on cloth One Unit MAINTENANCE MANUALS: Supply of 3 sets of brochures of instructions on operation and maintenance of the treatment plant and machinery with regular Raw water and Clear water Analysis reports from Regional Medical Colleges One Unit Two Units
i. ii. iii. iv.
v. vi. vii. viii. ix. 7.
8.
NOTE: Adequate number of ladder steps, walk ways, hand rails around Pump Houses etc., where required shall be provided. Inter connection facilities shall be provided to move freely. The minimum moving space between the hand rails should be maintained not less than 1.50 M on the moving bridge and on the operation platform. The minimum width of walkway staircase should be of 1.50 Mts. Care should be taken for allowing gravity flow of Wash Water for emptying GLSRs by adjusting the levels upto nearby disposal point. Proper drainage arrangement alround the Reservoirs be provided. The hydraulic structure should be complied with BIS specifications as well as standard specifications for building structures and subjected variations and approval by the competent authority. The site of work should be leveled as directed by Departmental Officers incharge of work.
238
The specification for civil work i.e., earthwork excavation, back filling, laying plain and Reinforced concrete, masonry, painting, plastering, flooring with antiskid floor tiles 1st class doors, windows, white washing, painting with antifungal weather proof painting, finishing, hand railing etc. shall conform to the technical specifications as discussed in this section VII under different Divisions above.
3.0 CONSTRUCTION OF ELEVATED SERVICE RESERVOIRS AND OTHER WATER RETAINING STRUCTURES 3.1 SCOPE OF CONTRACT: The contract envisages construction of an Elevated Service Reservoir/Water Retaining Structure in reinforced cement concrete including earth work excavation, supply and fixing of accessories as specified supply, hoisting, keeping in position and jointing of C.I. double flanged pipes, specials and valves and construction of valve pits as required. The designs and drawings shall be submitted by the contractor and obtain departmental approval for proceeding with the work. 3.1.1 DESIGN PARAMETERS: The ELSRs shall be designed and constructed considering the following design parameters. 3.2 For 1000 KL and above minimum of 2 rows of columns shall be provided. Wind pressure upto 150 kg/sqcm shall be considered in the designs. The ESLSs shall be designed considering seismic zone-III. Dog legged staircase shall be provided for ELSRs of capacity 500 KL and above. Spiral staircase shall be provided for ELSRs of capacity below 500 KL. Relevant BIS standards shall be followed in the designs. MATERIALS: : : Shall conform to the requirements of Section 4.1.3.(Division-4) Shall conform to the requirements of Section 4.1.4.(Division-4)
3.2.1. Cement 3.2.2. Water
3.2.3. Sand (Fine Aggregate) :Shall conform to the requirements of Section 6.2.5.(Div-6) 3.2.4. Coarse Aggregate 3.2.5. Bricks 3.2.6. Reinforcement :Shall conform to the requirements of Section 6.2.6.(Div-6) :Shall conform to the requirements of Section 4.1.1.(Div-4) : The steel to be used as reinforcement in the structure shall conform to I.S. 1139-1966 in the case of mild steel and I.S. 1781979 (Grade Fe 415) in the case of deformed bars or HYSD. 3.2.7. Cast Iron Pipes, : Shall conform to the relevant clauses of Division 7.
239
Specials, Manhole Covers, Valves and Jointing Material 3.2.8. Lightening Arrestor : Shall conform to the requirements of I.S. 3070-1794 Shall conform the toe departmental requirements and shall include brass pulley, bracket, nylon thread, numbered in MTs and 1/10th of MT with moving index etc. 3.3 SITE CLEARANCE: Shall conform to the requirements of Division 2. The quoted rate shall include cost of all operations as envisaged in this section. 3.4 EARTH WORK: The earth work excavation shall conform to the requirements of Division 3. The quoted rate shall include cost of all operations required for completing the structure as per the departmental plans and specifications. 3.5. 3.5.1. CONCRETE: General : The cement concrete work to be carried out under this contract shall be M30 and conform to the general requirements detailed in Division 6. : The construction of the structure shall conform to the requirements of I.S. 3330 Part, II and IV. : The concrete to be used shall be of M 10 Grade conforming to I.S. 456-1978. : The concrete to be used for these members shall be M 20, unless otherwise specifically mentioned in the drawing, conforming to I.S.456-1978. : The concrete to be used for the rest of the members like floor slab/done, beams, side wall, roof slab/dome shall be of M 20 grade conforming to I.S. 456-1978.
3.2.9. Float operated Water : level Indicator and gauge
3.5.2. 3.5.3. 3.5.4.
Constructional Requirements Leveling Course, Footings, Columns braces, R.C.C. ladders and staircase
3.5.5.
Other Members
3.6
RCC VALVE / METER CHAMBERS: The RCC valve / Meter chambers shall be constructed for access to the operating valves as
shown in the departmental drawings. The various items involved like concrete (M20) in foundations and side walls, plastering in cement mortar cover slabs in RCC etc., shall conform to the relevant sections in this volume.
240
3.7
RCC THRUST BLOCKS: The RCC thrust blocks shall be constructed for the inlet and outlet arrangements as shown in
the departmental drawings. The various items involved like earthwork, M30 concrete, HYSD steel etc., shall conform to the relevant sections in this volume. 3.8 3.8.1 C.I. PIPE CONNECTIONS: The vertical pipe connections shall be hoisted and fixed true to plumb without any deviation from the vertical as directed by the Engineer-in-Charge or his authorised. 3.8.2 3.9 3.9.1 The jointing of pipes shall conform to the requirement in Division 8. RCC VENTILATORS: The RCC ventilators to be provided on the top of the roof slab/dome. The ventilators shall be provided with good quality mosquito proof nylon mesh. 3.9.2. The RCC ventilators shall be fixed as directed by the Engineer-in-Charge or his authorised representative. 3.10. FIXING OF OTHER ACCESSORIES: The lightening arrestor shall be fixed in accordance with the requirements of I.E. Act, 1910 and rules thee under as amended from time to time. The water level indicator shall be fixed as directed by the Engineer-in-Charge or his authorised representative. It should be ensured that the index moves smoothly without any friction over the gauge in order to give correct indication of the depth of the water available in storage. 3.11 TESTING: The structure after completion shall be subjected to water tightness test at fully
supply level, as laid down in clause 10 of I.S. 3370 (Part-I) 1965. The filling of the reservoir shall be gradual and not more than 15 cms. of raise in water level per day shall be permitted. The structure shall satisfy the water tightness requirements as indicated in clause 10.1.1 or 10.1.2 of I.S. 3370 (Part-I) 1965 as the case may be. 3.12 FINISHING: A smooth dense surface free from work ridges shall be ensured. After satisfactory completion of testing of the reservoir for water tightness all external surfaces of concrete shall be painted with two coats of snowcem cement of approved colour and quality over a printing coat as per the directions of the Engineer-in-Charge. 3.13 GUARANTEE: The structure and all the appurtenant fixtures shall be guaranteed for satisfactory functioning for a period of 12 months from the date on which all defects have been rectified and the reservoir has been filled upto MWL and satisfies the water tightness test mentioned in Clause 10.1.1. above.
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4.0
CLEAR WATER SUMP The scope of work includes designing, drawing and construction of the underground
reservoir complete with inlet, outlet, overflow and scouring arrangement.. 4.1 The construction should be done according to the specifications given under relevant divisions in case of over head service reservoir. 4.2 The structure should be constructed in M 30 grade concrete duly using either shutter or plywood centering and shuttering materials. Necessary steel reinforcements should be provided in accordance with the drawings enclosed in the bid. All the members which are in contact with water should be water tight. Necessary inlet, outlet, Scour, and overflow arrangements may be provided while centering stage itself, without allowing damage or drilling holes in the walls, slabs, etc., after construction. The following accessories shall be provided to the structure as directed by Engineer-in- Charge. C.I. inlet, outlet, Scour, and overflow pipes of required diameter and length as per specifications mentioned in Division 7. C.I. light type Manhole cover of 600 mm dia. As per I.S. specifications No. 1726. R.C.C. ladder of 450 mm width inside the reservoir. A pit of 0.5 x 0.5 mts. Size is to be provided within the floor to accommodate foot valve, in case of clear water sumps.
242
SECTION VII C TECHNICAL SPECIFICATIONS FOR EQUIPMENT 1. Labels
1.1 All valves, reduction gears and other similar items shall be labeled as to their function. The letters shall be engraved on the underside of a beveled colorless transparent plastic level not less than 3mm thick engraving being filled, and the underside painted and sealed to form a complete label having white letters with background to standard practices. A list of label designations shall be submitted to the Engineer for approval before manufacture. 1.2 2. All labels must be affixed to apparatus before final acceptance tests are carried out. Guarding of Shafts
2.1 All rotating shafts, couplings, gears, flywheels, belt drives, etc. shall be fully guarded, and comply to the requirement of the Indian Factories Act. Guards shall be designed to provide ready access to bearings, greasing points, thermometer pockets and other check points to allow routine observations to be made by the operating staff without danger or the need to dismantle any part of the guard. Hinged doors let into the guards with adequate fastenings shall be provided where necessary to facilitate access to the check points. 2.2 Guards shall be of mild steel of an approved gauge and be of the fully covered in type and securing arrangements for guards shall be of substantial construction. 2.3 All mild steel used in the production of guards shall be hot dipped galvanized and nuts, bolts, and washers shall be an ionized unless otherwise specified. 2.4. Drawings of guards etc. shall be submitted to the employer for approval before manufacture. 3. 3.1 GENERAL REQUIREMENT, WORKMANSHIP & DESIGN OF PLANT The plant shall be new, of sound workmanship and of robust design.
3.2 The General mechanical and electrical design of the plant (Water Treatment Plant, Clear Water Pumping Station & UGR) and particularly that of the bearings, contacts and other wearing parts shall be governed by the need for long periods of service without frequent maintenance and attention being necessary. 3.3 Unless otherwise specified, all items of plant shall be rated for continuous service at the specified duties under the prevailing atmosphere and operational conditions on site. 3.4 All component parts of the plant shall be manufactured to a strict systems of limits and complete inter changeability of similar parts is required. 3.5 All parts subject to wear shall be readily accessible. 3.6 Provision shall be made for taking up wear in all bearings and other wearing-parts or for easy replacement if adjustment is not practicable. Ball & roller bearings shall be interchangeable all with similar items from alternative makers. Parts list shall include alternative reference numbers & maker. 3.7 The positions of all greasing and oiling points shall be arranged so as to be readily accessible for routine servicing. Where necessary, to achieve this, suitable extension pipes shall be fitted, Lubrication grease points shall comprise hexagon headed nipples Section VII. Work Requirements 243
except where the lubrication required is of a special nature; in such event they shall be fitted with metal labels to indicate the special lubricant required. Where continual grease or oil feeding is required the capacity of the reservoir shall be sufficient for not less than seven days continuous service. 3.8 Suitable packers and/or shims shall be fitted for ease of adjustment and realignment of all machinery units; particular attention shall be given to combine sets. 3.9 Where fitted bolts, spigots or other means for precise location are not employed in the assembly of the plant, locating dowels shall be fitted on completion of erection, to the satisfaction of the Engineers. 3.10 All pipes shall be checked for alignment and matching of flanges or connections before being secured; they shall not be sprung into position. 3.11 If during the maintenance period any moving parts show, in the opinion of the Engineer, signs of undue wear or unsuitability for the purpose for which they are installed they shall be replaced free of cost notwithstanding that they may otherwise be working in a satisfactory manner. 4. STEEL STRUCTURAL
4.1 All steel structural shall conform to IS: 226/1962 except for M.S. Plates over 20 mm thickness which shall conform IS: 2062/1962. 4.2 Rails will be carbon or medium manganese steel, conforming to latest IRS T-12 or IRS -T-18 specifications. 4.3 For detailing and construction of welded connections all provisions of IS: 816 (latest) & IS: 823 (latest) shall apply. 4.4 All rivets and bolts are to be generally of 20 mm or 22 mm dia, except where otherwise required or noted. Where no load is shown, in the trusses; bracings or latticed members, minimum 2 Nos. 20 mm dia, rivets, bolts or equivalent welding to be provided. Bolted connections shall be provided at temporary sides and ends where future extensions are indicated. 4.5 All connections are to be riveted, welded or fitted with high strength friction grip bolts except for hand rails and cat walkways which may be bolted (black bolts). Unless otherwise stated, all bolts under direct tension are to be provided with one spring washer. 5. Bolts and Nuts 5.1 M. S. bolts and nuts shall conform to IS: 1363, 1364 and 1367 (latest). All nuts, bolts and washers coming in contact with water shall be anodized/galvanized by process which does not make the threads uneven. All bolts, nuts and washers coming in contact with any corrosive liquid or in corrosive atmosphere shall be made of stainless steel, 316 or Nylon depending upon the nature of the service. 6. Chequered Plates, etc. 6.1 These shall be manufactured from structural steel complying with the requirements of IS: 226. They shall be of specified size, thickness and pattern as per relevant drawings or as directed by the Engineer. For cover plates, stiffeners shall be provided where necessary or as detailed in the drawings. Cover plates will generally be chequered plates (unless otherwise specified) with or without stiffeners. If required and necessary, the Contractor shall also prepare detailed floor plans for the layout of the cover plates for floors and platforms so as to include all openings, outs, etc. and so as to match the patterns of adjacent cover plates to raise the cover plate on sides, so as to provide slopes Section VII. Work Requirements 244
in the floors and platforms to drain away any liquid falling on the floors and platforms. It such cases, slopes shall be provided as shown in the drawings or as directed by the Engineer. Necessary gutters at the ends of platforms shall be provided for sloping floors and platforms as shown in the drawings or as directed by the Engineer. Where necessary, kerbs of flats shall be provided around openings and cuts so as to prevent liquids falling to lower floors and platforms. 7. Open Thread Mesh Plating
7.1 The Contractor shall supply and install galvanised (hot dipped after fabrication) mild steel open thread mesh flooring at pipe trenches and on the rotating bridge decking including all kerbing. The plating shall be designed to withstand a maximum uniformly distributed load of 1000 kg/m2. The plating shall be divided into panels weighting not more than 50 kg. and each complete with nosing all round. Cut outs shall be provided and trimmed so that the plating may be removed without disturbing the machinery. 8. HAND RAILING
8.1 Double rows of 30 mm, dia. G.I. tubular hand railing fixed in C. I. Stanchions shall be provided on the edge of the walkways and platforms as specified. The stanchions shall be fixed with mild steel rag bolts with chromium plated cap nuts. The stanchions shall not be less than 1000 mm high and placed at a distance not exceeding 2500 mm. The hand railing shall be fixed true to exact line and level, C.I. Stanchions and hand-railing layout shall be of architectural design with pleasing appearance. 9. 9.1 Painting (Steel Structures) The recommendations contained in IS: 1477 - Code of Practice for painting
9.2 Surface preparation. The surface, after preparation, shall be given two coats of red lead primer before painting. 9.2.1 Paints shall only be applied to surface which have been adequately prepared as defined in this specification. 9.2.2 All surfaces to be painted shall be thoroughly cleaned and dried. No painting shall be carried out in damp weather, or whilst dampness prevails from any cause, or during adverse weather conditions such as dusty, windy weather or dew, rain and such moist atmosphere prevails. 9.2.3 The surface to be pained shall be cleaned of all rust, dirt, loose mill scale, oil, grease, or any other foreign matter which might affect the painting. After completion of the pre-cleaning, the surface shall be immediately covered with the primer. 9.2.4 Where the coat of the primer has been damaged exposing original metal surface, a fresh primer coat shall be applied after cleaning. 9.3 Application of Paints or Primer 9.3.1 Priming coat shall be applied by brushes, under coat and finish coat shall be applied by spray painting or brush. Painting by rags or cloth is not allowed, Areas adjacent to spray painting shall have protection from blown spray.
245
9.3.2 Before drawing the paint from the container it should be well stirred and should be stirred at intervals in a smaller container used for painting with smooth clean stick while it is being applied by brush. 9.3.3 In no case subsequent coat or coats shall be applied over another until the previous coat has been left for at least 24 hours for drying. 9.3.4 Coverage of paints (sqm/litre) shall be governed by the manufacturer's specification. 9.4 Material specification - Primer and synthetic Enamel Paint 9.4.1 The primer coat shall be of red lead primer unless otherwise specified. 9.4.2 Synthetic Enamel Paint shall be high gloss alkyd enamel with excellent flow and quick drying properties offering outstanding exterior durability under varying weather conditions. This paint should be suitable for all types of surfaces over respective primers and under-coatings. Compositions - The material shall be based on synthetic resins. It shall be free from nature resins or modified natural resins and shall be of such a composition as to satisfy the requirement of I.S. 2932. 9.4.3 Where contact with water is expected, the metallic surface shall be protected with anticorrosive epoxy paint as instructed as approved by Engineer. 9.5 Preparation of paints All paints shall be thoroughly and carefully stirred and mixed before use in accordance with the manufacturers recommendations. Thinners shall only be added to paints as and when recommended by the paint manufacturer. 9.6 Storage of Paints All the paints shall be stored in Air-tight containers; precautions shall be taken by the Contractor against any possible fire hazards. The Contractor will take care to see that whenever the paint container is opened the entire quantity of the paint is used for the days work in order to ensure that fresh paint is used every day. The Contractor shall not be allowed to bring into the site those containers of paint which are not sealed by the paint manufacturer or those on which the manufacturers seal is broken. 9.7 Extent of Painting All structural steel work like frames, bridge, stirrer, railing, ladders, platforms piping supports structures, reduction gears, pumps, etc. associated with the plant shall be painted. 9.8 Inspection Each coat of paint shall be inspected and approved before the succeeding coat is applied. If any defects are observed, the portion will be repainted by the Contractor, after removing the old paint 9.9 Colour Code This will be decided by the employer and informed to the Contractor before starting the job.
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9.10
System of painting
Following system shall be followed for painting of all metal parts and all priming. Over coating and finishing paints shall be of well known make. The Contractor shall furnish the details of paints to the Engineer for approval of paints before commencement of painting work.
I. SUBSTRATE : STRUCTURAL STEEL /CAST IRON Primer coating System A (to be followed unless otherwise specified) Total D.F.T. = 150 microns Red Lead Primer (two coats) 50 microns Over coating Approved quality under coat (one coat) 25 microns Finishing Approved quality Synthetic Enamel (3 coats) 75 microns.
Drying = 24 hours between coats.
Systems B (after a metallic coat of zinc to a thickness of
Each Primer (one coat)
Zinc Chromate Primer (one coat)
Approved quality Synthetic Enamel_ (two coat)
25 microns
25 microns
50 microns
(0.075 mm) Total D. F. T = 100 microns Drying - Each primer to over coated within 2 hours: Give 12 hours drying between subsequent coats. System C (in case of damage to steel work during transportation assembly, storage etc.)
System D (for parts immersed under water, metal to be cleaned by shot blasting) II. SUBSTRATE System E Pretreatment
Metal pretreatment solution, (one coat).
247
Priming Approved quality Primer (one coat) 25 microns Finishing Patch prime and finish bare metal as per the existing. Finishing Approved quality pitch epoxy coating (two coats) 200 microns Total DFT = 225 microns. Drying = 24 hours between coats Full Cure,7days. ZINC OR GALVANISED IRON OR ALUMINIUM (Parts not immersed under water) Priming Each Primer Over coating Zinc Chromate (one coat) Primer (one coat) 25 microns Total D. F. T. 25 microns microns
Finishing Approved quality Synthetic Enamel (two coats) 50 microns Drying = Each primer to be over coated within 2 hours, Give 12 hours drying between subsequent coats. 10 Coupling
10.1 The tenderer shall provide the coupling for motors and pumps together with a suitable guard complying with BS: 1943 and BSC: 3004. The material of the guard shall be of anti-spark types. Couplings shall incorporate all necessary flexibility for axial, lateral and torsional movements to deal with the shock vibratory and driving requirements of the transmitted loads. 11. Sluice Valves and Penstocks
Sluice Valves and penstocks shall be provided with brass direction indicator plates fixed at the centre of the hand wheels with G. M. cap nut, where hand wheels are not provided. 11.1 Sluice valves shall conform to IS: 780 Class I for valves upto 300 mm. dia. and IS 2906 of appropriate Class commensurate with the pressure (1.5 times of the working pressure) for valves above 300 mm, dia. in all respects. The valves shall Substitute IS 2060 Clause II by ISI Certification marking. The sluice valves shall be installed and maintained in accordance with IS: 2685. All valves of 600 mm dia, and larger shall be provided with by-pass arrangements of proper size. Any sluice valve installed outdoor below ground level shall be provided with suitably designed masonry water tight valve chambers with RCC.Cover as per approved drawings or instruction of the Engineer. 248
11.2 Penstocks shall be suitable to withstand the water pressure on front or back as the case may be. They shall be of strong heavy pattern of the type and shall be obtained from an approved manufacturer. All single faced cylinder gates (pen stocks) shall be mounted on C.I. puddles and shall have two gunmetal faces. The screws of penstocks shall work in gunmetal bushes or nuts. They shall be manufactured as per IS: 3042. 11.3 All extended spindles of penstocks or sluice valves coming in contact with water shall be made from corrosion resistant steels. 12. Hand-Wheels for Valves / Penstocks
12.1 Hand-wheels shall be of cast iron and shall have cast on the upper side of the rim the mark OPEN and SHUT with appropriate directions for valves and penstocks installed outdoor. Indoor valves C.I. Pipes (Socket & Spigot) IS: 1536 (L. A. Class) C.I. Pipes (Flanged ClassA) C.I. Fittings (Socket & Flange medium class) IS: 1538 Mixed Steel Tubes \, Tubular and Other wrought steel fittings Electrically welded steel Pipes High Density Polyethylene Pipes (Series II) Un-plasticized P.V.C. Pipes IS: 4985 Asbestos Cement Pressure Pipes (Class II) IS: 1592 13. Reflux Valves IS: 1239 IS: 3589 IS: 4984 IS: 1537
13.1 The reflux valves shall be of robust construction and shall be of the single door/multi door swing check pattern. It shall be tested to a pressure of 14 kg/cm2. The body, cover and hinge shall be of cost iron (not less than grade 20 of IS: 210) and the hinge pin of bronze, and the seat ring in the body of gunmetal; larger sizes shall have cast iron door with gunmetal ring. The internal assembly of the reflux valve shall be such that it can be lifted bodily out of the valve without disturbing the pipeline. Reflux valves (300 mm bore or above) shall be provided with bye--pass arrangement of proper size. All reflux valves upto 600 mm bore shall be single door type. All valves above 600 mm bore shall be of multiple door type. Reflux valves shall be installed horizontally unless otherwise specified. An arrow showing the direction of flow shall be cast integral with the valve housing. 14. Jointing
14.1 The jointing shall be made with compressible rubber (IS: 638) of thickness 3mm, blots and nuts. The bolts and nuts shall be of mild steel and these shall conform to IS: 1362 and 1363 unless otherwise specified. 14.2 The bearing surface of the nuts shall be smooth and the nuts shall be taped at right angles to the surface to ensure axial loading. Bolts and nuts shall be coated with a rust preventing lubricant after threading of tapping. 15. C.I/P.V.C/H.D.P.E/A.C. Pipes & Specials 15.1 The design manufacture shop testing, erection testing and commissioning of all piping and special shall conform to the following: 249
16.
Pipe Work
16.1 Pipes and fittings for filter pipe gallery, wash water supply, wash and waste water pump suctions and deliveries shall be of cast iron flanged and /or S & S and suitable for the maximum working pressure, including surge pressures. On the wash main an expansion joint of approved design at the appropriate position shall be provided. Pipe with puddle flanges shall be supplied in all cases where the pipes pass through the walls of the water retaining and basement structures. Detachable fixtures shall be provided whenever possible for case of maintenance. 16.2 Small bore pipes for pump vents, cooling water supply, etc. shall be of heavy gauge galvanized iron. Galvanized iron pipes upto 50 mm bore may be supplied with screwed and socketed joints, larger sizes shall have screwed flanges. 16.3 Copper pipes upto 25 mm bore may have compression rings, larger sizes shall be flanged. 16.4 16.5 All pipes to pressure vessels etc shall have flanged connections. All pipe works shall be supplied to the limits specified..
16.6 The layout and design of the pipe work shall be such as to facilitate its erection and the dismantling of any section for maintenance. Where a common delivery is used, individual pump delivery branches shall be joined to it in a horizontal plane. Adequate supporting arrangements for all pipes shall be included except in cases where they can more conveniently be supported on concrete cradles to the Contractors design. 17. Grouting
17.1 Tenderer will include in his price all cost for labour and materials for grouting in all fixings, pipes and any other fittings at the time of construction work. The Contractor will make arrangements for delivery of such items which will be grouted in the building work in time so that construction work can proceed smoothly without any interruption whatsoever. 18. Supports & Fixings
18.1 All supports, fixing bolts, screws and other fixings shall be provided by the Contractor and his price shall be inclusive of such items. 19. Driving Unit Support
19.1 Each driving unit shall be supported on a cast iron or fabricated steel frame or guide rails as appropriate. The fabricated frame shall be constructed to afford adequate access to the coupling between the driving motor and driven unit. 20. Dissimilar Metals 20.1 Where metals of dissimilar character are used in construction, precautions shall be taken to prevent deterioration of the structures due to electrolytic action. 21. Bearings
21.1 Bearings shall be of type, size and construction to ensure that the plant and equipment of which they form part shall operate efficiently and continuously under normal operating conditions without overheating and with minimum inspection and attention. 250
21.2 Housing and enclosures of bearing assemblies shall be suitable for the worst atmospheric conditions in which they are required to work. All ball and roller bearings shall conform to the International Boundary Plan (ISO). Liners and bushes of plain bearings shall be easily renewable. 21.3 Provision shall be made for ready lubrication of all contact surfaces having relative movement. Contact surface of bearings and the lubricant shall be such that there is no corrosion, electrolytic action or excessive wear. 22. Speed Reducers
22.1 All reduction gear boxes shall be of approved make and design with service factor not less than 2.0 and shall be continuously rated. Extra roller bearings to be provided so as to cater for overhung load. All speed reducers shall be of heavy duty type design. All gears shall be capable of transmitting starting overload 100% (minimum). Gears subject to axial thrust shall not be fitted with keys for location. Shaft shall be fitted with oil and dust seals. All gear boxes with oil bath lubrication shall be equipped with dipstick, drain plug and breather. Speed reducer with vertical output shaft shall be of heavy duty Stirrer Class. 23. Lubrication 23.1 In designing the equipment, consideration shall be given to ensure that adequate lubrication is achieved with the minimum of attention. The central turntable assembly /wheel bearings shall be pre-packed with ample quantity of grease of appropriate grade and as far as practicable parts shall be so designed that these are not required to be lubricated more frequently than once per month. Adequate provision shall be made for the lubrication of the bearings from convenient points on the bridge decking. 23.2 All equipment, pipelines and fittings for lubrication system shall be manufactured from corrosion resistant materials or shall be suitably protected against corrosion. 23.3 Lubricating oil, grease and graphite paints and seals which require manual replenishing shall be clearly visible and readily accessible. Units to be filled with oil shall be arranged for easy filling without spillage. Protection shall be provided to prevent excess lubricant dripping into platforms and floors. Where connections have to be broken frequently and loss of oil is possible, connections shall be self sealing. 23.4 The grade type and frequency of lubrication to be used shall be stated on metallic lubrication parts permanently attached to the plant. Lubricating oils and grease shall be designated by approved trade name or in terms of mineral, vegetable, animal or blends of this basis together with their viscosity and flash point characteristics and not as Light or Heavy. 24. Couplings Drives & Clutches
24.1 Couplings shall incorporate all necessary flexibility for axial, lateral and torsional movements to deal with the shock vibratory and driving requirements of the specified transmitted loads. 24.2 All couplings shall be guarded. In couplings of the male /female type, the male section shall be located at the driving end of the coupling. 24.3 Rigid shaft couplings shall have minimum of six bolts and each half shall be marked to indicate it matching half coupling. 24.4 Flexible couplings exposed to dust shall be fitted with oil resisting muffs.
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24.5 Couplings used for connection of electric motors to drive machinery shall be of the flexible type in cases where a break on the coupling is incorporated; this shall be located on the driven half of the coupling. 24.6 Fluid couplings shall be equipped with a fluid level indicator; Type of fluid required shall be indelible marked on the coupling casing. 24.7 Plates clutch couplings shall be fully engaged and shall be steel bronze type running in oil, or dry type with steel plates and dices with non-metallic facings. 24.8 All belts used on belt drives shall be of the endless type. The number of belts used shall be sufficient for the transmitting load without slip or overheating. Tension on multi belt drives shall be uniform and facilities shall be provided to enable assessment to be made to ensure uniform tension. Without slip, Jockey tensioning devices shall not be used. 24.9 Chain driven shall be of the case hardened roller type and be simplex, duplex or triplex as necessary for efficient and quiet transmission of the specified loads. Wheels used on chain driven assemblies shall have precision machine cut teeth. The assemblies shall incorporate facilities for chain adjustment to take up roller wear. 24.10 All pinions, wheels and couplings shall be pressed on to the associated shaft and keyed as necessary, or make solid with the shaft. 25. Centrifugal Pumps
25.1 The pumps shall be designed to give prolonged running at the specified output under site conditions. The pumps shall be manufactured and tested as per IS: 6595 and other relevant Codes. Waterways through the pumps shall be smooth in finish and free from recesses and obstructions. The pumps shall be so placed that these can be put into operation without priming and that these shall not draw air under any condition. 25.2 Eye rings and wearing plates wherever used shall be of substantial construction and renewable. 25.3 The rotating elements shall be statically and dynamically balanced before final assembly. 25.4 The impeller shall be readily withdraw able from the pump casing without the need to disconnect the adjoining pipe work and with minimum disturbance to pump drive shafting. This provision is particularly applicable for recirculation pumps and sludge pumps. 25.5 The suction arrangement shall be such as will avoid pre-rotation in the suction pipe work and present a good flow pattern at the entrance to the impeller. The NPSH requirement shall be satisfied keeping a margin of 0.5 m. at least. 25.6 Pump bodies, impellers, covers, brackets, bearing blocks, wearing plates, eyerings, supports, etc. shall be of best quality closed grained cast iron (not below grade 20 of IS: 210) for wash water pumps while these for sludge / recirculation pumps shall be with NPSH requirement to be satisfied keeping a margin of 0.5 m. at least and non-clog, back pull out", horizontal, centrifugal type with material of construction as follows: Casting CI, IS 210 FG 260, Impeller - Stainless Steel 316, Shaft - C 40 Pumps casings shall be substantial construction to give long life under all types of working conditions, Special care shall be exercised in the manufacturing process to avoid undue stress being set up in the finished product. 25.7 Shafting shall be of adequate sizes and proper material to avoid the possibility of 252
fatigue failure and shall be shock and corrosion resistant for pumps handling corrosive liquid. The shafts of pumps fitted with conventionally packed glands shall be made especially wear resistant by providing suitable stainless steel or equal sleeves. Intermediate shaft (wherever used) shall be made up in suitable lengths coupled together with a steady bearing adjacent to each coupling. For vertical single entry pumps a short length of shafting above each pump shall be readily removable to facilitate the withdrawal of impeller. 25.8 Glands may be fitted with conventional soft packing. Means for readily removing lantern rings, where fitted, such as tapped holes, shall be provided. Conventional packed glands shall be provided with water flushing or spring loaded non-return greasing arrangements,. The lantern rings for soft packed glands shall be provided with means for ensuring their correct location and for checking this under running conditions. A sufficient number of turns of packing shall be allowed above and below the lantern ring to avoid wastage of grease include flushing water, pipe work, fittings, valves, etc. 25.9 Air release arrangements shall be fitted from the high point of the pump casing (and else if considered desirable by the manufacturer). The pipe work shall be not less than 20 mm nominal bore. The discharge from the air release pipe work shall be arranged to avoid striking platforms and ladders. A shut off valve of Saunders required full bore straight through type, or equal approved, shall be fitted at the high point(s). Above this valve shall be fitted a bronze check valve of approved nature. The air release pipe work shall be fitted with crosses to facilitate rodding. Where this pipe work passes through a wall into a wet wall the bore shall be increased to 25 mm and it shall be terminated with an elbow directed downwards. 25.10 The pump drainage arrangements shall be fitted as close to the lowest point of the pump suction as is practicable. The drain valve shall be not less than 50 mm bore, Drainage pipe work shall be led to the floor drainage system and not discharge direct to the floor. 25.11 Gland drainage arrangements shall be fitted; the drainage parts shall be not less than 12 mm bore. Pipe work shall be led to the drainage system. 25.12 Detachable plates shall be fitted around the gland access areas to confine any liquid which may be thrown out in the event of gland failure. 25.13 Air release and pump drainage pipe work shall be of G.I. pipe work unless otherwise directed. 25.14 Pressure and compound gauges of approved make shall be fitted to each pump. The gauges shall be mounted on a mahogany base bracketed to the pump casing, unless otherwise specified. The diaphragm body shall be screwed to Saunders type 25 mm full bore straight through pattern cast iron diaphragm valve, or equal approved. The valve shall be attached to the pipe work at the gauge tapping points. Pressure gauges shall have scales reading meter head of water and in kg/cm2. Compound gauges shall additionally read upto 759 mm of mercury vacuum. 25.15 the drive motor, switch gears electrical works required for the completion of the job shall be carried out as per technical specification stated in section H.
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26.
Weighing Machine
26.1 The platform type weighing machine shall have a dial not less than 500 mm diameter. The platform shall not be less than 900 mm square. Indicator graduation shall be 1000 kg x 2 kg. The indicator shall provide shadow less line to line indication of weight. Platform shall be of cast iron and it shall be mounted on ball bearings. Strong back rail shall be provided on the platform, Scale shall be mounted on four cast iron wheels enclosed in a cast iron frame. Machine shall be capable of absorbing shock loading. The whole mechanism shall be housed within adjust proof and moisture proof housing. The instrument shall be suitable for using in corrosive atmosphere and handling alum. A locking device shall be provided to prevent damage to the indicator mechanism during movement of scale.
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SECTION VII D TECHNICAL SPECIFICATION OF ELECTRO-MECHANICAL WORKS SPECIFICATION FOR MECHANICAL WORKS
1. GENERAL SPECIFICATION
1.1
General Information
This specification intends to cover Engineering, supply and storage at site, erection, testing, commissioning and trial run including operation and maintenance as specified elsewhere of various mechanical plant and equipment as per specification, schedule of items, requirements, terms and conditions and finally as per the direction of Engineer to make different unit perfectly operative and successful in all respect. Any plant, equipment or mechanical works which is found to be unsuitable for specific use under the stipulated conditions shall be dismantled and replaced by proper plant, equipment or mechanical works entirely at the cost of the contractor for successful completion, commissioning and operation of the plant. The contractor shall provide all necessary tools and tackles required for erection works and equipment and instruments for testing and commissioning including all other items necessary for testing and efficient execution of the contract. The contractor will also provide all labour, supervising and administrative staff along with transport arrangement during erection and commissioning period. The installation work includes supply of all fittings and fixtures, hardware, consumables and sundry items as required for successful installation and commissioning of the plant. The scope of work shall not be limited to only supply of items as per schedule but also include all other items not specifically mentioned but required for successful installation and commissioning of the plant / equipment and to operate properly as per relevant technical specification. The scope will include supply of materials at site in packed and good condition and any damage is to be rectified or the material to be replaced by the contractor by new one without any extra cost. All plant and equipment shall be insured against all types of damages, theft etc. during transit, storage, erection and commissioning and insurance coverage will continue till the maintenance period expires and the plant is handed over to Engineer at the cost of the contractor. For the purpose of design and construction the following data shall be considered: For the purpose of design and construction the following data shall be considered: a) b) c) d) e) f) Peak ambient temperature Average ambient temperature Peak relative humidity Wind Velocity Seismic Zone as per IS Climatic condition 430 C 350 C 100% 44 m/sec Zone-II Hot, Humid & Dusty
However, the maximum temperature and humidity shall not occur simultaneously.
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TECHNICAL REQUIREMENTS
1.2 MATERIALS AND WORKMANSHIP
1.2.1 Introduction This specification intends to cover the general standards of materials to be supplied and the workmanship required to be ensured by the contractor. All component parts of the works must, unless otherwise specified comply with the provisions of this part and shall be subject to the Engineers approval of Manufacturers Quality Assurance Plan (QAP). 1.2.2 Standards The proposed plant and equipment along with their material of construction must conform to the latest revision of relevant IS/BS/DIN/ASTM/ANSI/ISO or to any other equivalent standard it shall be to the latest revision of that standard at the date of Tender opening. The contractor may propose the use of any relevant authoritative Internationally recognized Reference Standard including Indian Standard at no extra cost to Engineer. The equipment, material of construction and workmanship performed shall comply with these standards. Any equipment / item offered to other standard the same and material of construction shall be at least equal preferably superior to those specified and details of the superiority shall be furnished. In the event of any dispute between this specification and the codes of equipment / item, provisions of this specification shall govern. The titles of various standards referred to in this specification for pumps and other mechanical works are indicated hereunder for ready reference. This list does not necessarily covers all the Standards referred to : Standard No. IS 210 IS 318 IS 807 IS 1239 IS 1367 IS 1536 IS 1537 IS 1538 IS 1710 Grey Iron Casting Leaded Tin Bronze Ingots and Castings Code of Practice for design, manufacture, erection and testing (structural portion) of cranes and hoists Mild Steel tubes, tubular and other wrought steel fittings Technical Supply Conditions for Threaded Steel Fasteners Centrifugally cast (Spun) iron pressure pipes for water, gas and sewage Vertically cast iron pressure pipes for water, gas and sewage Cast iron fittings for pressure pipes for water, gas and sewage Specification for pumps Vertical Turbine, Mixed and Axial flow, for Clean Cold Water
Title
256
Standard No. IS 2062 IS 2266 IS 2312 IS 2685 IS 2974 Part 3 & 4 IS 3109 IS 3177 Steel for general Specification
Title structural General purposes
Steel Wire Ropes for purposes Specification
Engineering
Propeller type ac ventilating fans Code of practice for selection, installation and maintenance of sluice valves Code of practice for design and construction of machine foundations for rotary type machines Specification for Short link chain, Grade M(4) Code of practice for Electric Overhead Travelling Cranes and Gantry Cranes other than Steel Work Cranes Specification for Phosphate Treatment of Iron and Steel for Protection Against Corrosion Specification for Pressure and Vacuum gauges Specification for Point Hooks with Shank for General Engineering Purposes. Specification for Electric Wire Rope Hoists Gears Spur and Helical Gears Calculation of Load Capacity Specification for Hot-dip Zinc Coatings on Mild Steel Tubes Technical requirements for roto dynamic special purpose pumps Specification for Swing Check Type Reflux (NonReturn) Valves for Water Works Purposes - Single Door Pattern Specification for Swing Check Type Reflux (NonReturn) Valves for Water Works Purposes Multi Door Pattern Specification for Rubber Sealing Rings for Gas Mains, Water Mains and Sewers Specification for Sewage and Drainage Pumps Code of practice for phosphating of iron and steel Specification for Sewage Screens Centrifugally Cast (Spun) Ductile Iron Pressure Pipes for Water, Gas and Sewage Specification Code for acceptance test for centrifugal, mixed flow and axial pumps class C
IS 3618 IS 3624 IS 3815 IS 3938 IS 4460 (Parts 1 to 3) IS 4736 IS 5120 IS 5312 (Part 1)
IS 5312 (Part 2)
IS 5382 IS 5600 IS 6005 IS 6280 IS 8329 IS 9137
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Standard No. IS 9523 IS 10981 IS 11388 IS 11592 IS 13095 IS 13349 IS 14845 IS 14846 IS 15310 -
Title Specification for Ductile Iron Fittings for Pressure Pipes for Water, Gas and Sewage Class of acceptance test for centrifugal, mixed flow and axial pumps class B Recommendations for Design of Trash Racks for Intakes Selection and Design of Belt conveyors Code of Practice Butterfly valves for general purposes Specification for single faced cast iron thimble mounted sluice gates Resilient Seated Cast Iron Air Relief Valves for Water Works Purposes Specification Sluice Valve for Water Work Purposes (50 1200 mm size) Specification Hydraulic Design of Pump Sumps and Intakes Guidelines
Materials General Each and every equipment / item covered in this Works shall be most suitable for the duty concerned and shall be new and of reputed make / approved quality, free from any defect and selected for long life and minimum maintenance. Non-destructive tests, if asked for in this specification, shall be carried out. Any equipment / item supplied proves to be unsatisfactory after installation, Engineer shall have all the right to operate / use the same till the rectification / replacement is carried out by the contractor. The rectification / replacement will be done without interfering with the overall plant operation as far as possible. Unless otherwise specifically agreed upon in advance the maximum allowable period for the above rectification / replacement will not exceed six months. All submerged moving parts of the plant e.g. shaft, spindle, rotating element, faces etc. and all parts in direct contact with water shall be completely resistant to corrosion and abrasion and shall maintain their properties without ageing due to the passage of time, operating load, environment, heating due to operation or any other cause. Workmanship General Workmanship and finish in general shall be best of its quality and must be in accordance with latest workshop practice. 100% interchangeability must be maintained among all components of similar type of equipment / item. Material of construction of the spares shall be same as it is for original component and shall be interchangeable among similar equipment. Machining limits and fits on renewable parts shall be accurate and to specified tolerances so that replacements can be done easily. 258
Noise and vibration level will never exceed the allowable limit for particular equipment. The rotating parts shall be both statically and dynamically balanced so that when running at normal speed at any load upto the maximum, there shall be no vibration beyond permissible limit due to lack of balance. All parts, which can be worn or damaged by dust, shall be totally enclosed in dust proof enclosure. All necessary accessories required for satisfactory and safe operation of the plant shall be supplied by the contractor unless it is specifically excluded from the scope. Provision of lifting lugs, eye bolts etc. shall be provided to facilitate handling of heavy equipment. All flanges shall be drilled as per IS: 1538. All flanges shall be full or spot faced at the back and thickness shall be uniform throughout. The periphery of the flange shall be concentric with the bore and finished smooth. All castings and fabricated items shall be finished smooth allover. 1.3 Equipment Design
All the plant and equipment under this specification must be new and of proper grade and quality suitable for prevailing climatic and working conditions at site. They shall be of sound workmanship, robustly designed for long reliable operating life and shall be capable of 24 hours per day continuous operation for prolonged period with minimum maintenance. Special care shall be taken for changes in temperature, stability of paint finish for high temperatures, derating of machinery, thermal overload services, cooling systems and the choice of lubricants for anticipated high and prolonged operating temperatures. The manufacturer may be called upon to demonstrate this for any component part either by service records or evidence about similar equipment already installed elsewhere or by relevant type test. As far as possible, routine maintenance and repair should not require the services of highly skilled personnel. The material of construction of the equipment / item shall be so selected that the economic life of the plant is not less than 15 years taking into account their location and service. The equipment shall be designed to provide easy access to and replacement of parts which are subject to wear without the need to dismantle / replace the whole plant. All parts in contact with water shall have a minimum life of 3 years from new to replacement or repair. Where major dismantling is required to replace / repair a part, the life of such part shall not be less than 10 years. Design features shall include the protection of plant against any damage caused by vermin, dirt, dust and dampness and to reduce the risk of fire. Plant shall operate without undue noise and vibration and components shall be designed to withstand the maximum stresses under the most severe condition of normal duty. At site installation the magnitude of peak to peak vibration will be limited to 50 microns and noise level shall be limited to 85 dBA at a distance of 1.86 m. The materials shall be highly resistive to change their properties due to passage of time, climatic condition, and service environment or due to any other cause which may have an adverse effect on the smooth and trouble free performance or life of the equipment. Outdoor installed plant shall have additional features to prevent unauthorized operation or tampering. 259
1.4 1.4.1
Testing at Works General
Tests of the equipment / item at the manufacturers works will be carried out in accordance with the specifications and Engineers approved QAP. All inspection, examination and testing shall be performed conforming to relevant Standards. Engineers Inspecting Officer shall witness the tests and inspect important plant and equipment as specified in this specification of relevant equipment / item. In respect to other equipment, the manufacturer shall carry out the tests and test results to be furnished. The instruments used for such tests shall be calibrated and certified by an approved independent testing authority not more than 15 days prior the test date in which they would be used. The test results / certificates will be furnished to the Inspecting Officer after the commencement of the tests. Engineer reserves the right to impound any instrument immediate after test for independent testing. Manufacturers test certificates showing the readings obtained, calculations and details of relevant calibration certificates shall be produced prior to every test. Only defect-free and sound material meeting the technical requirements of this specification and in accordance with a high standard of Engineering would be acceptable to Engineer. If during or after testing, any equipment / item fails to achieve the specified duty or otherwise proved to be defective the same shall be modified / replaced as required, retested and re-inspected, if required, by Engineer. At least 21 days advance notice shall be served to Engineer for witnessing any test. No material will be accepted without the above described inspection having been carried out or officially waived in writing by Engineer. 1.4.2 Test Certificate Each consignment of plant delivered to site must have been tested at manufacturers works or at other approved test house in accordance with the relevant IS or approved standard (such tests being referred to herein as Works Tests). The test reports for each such consignment must be furnished to Engineer before delivery at site. Certificates shall be clearly identified by reference number to the material being certified and shall include information required by the relevant reference Standard / specification clause. 1.5 Welding
All welded fabrication to be done as per the latest revision of BS 5135/ Equivalent and the contractor shall submit the detailed drawings of fabrication showing the sizes of welds, weld preparation together with the details of application codes, electrode specification etc. to Engineer before the commencement of fabrication for approval. No welding shall be carried out without approval of Engineer and no alteration shall be made to any approved details of weld preparation or size without prior approval of the authority. 1.5.1 General Welding Requirements Inspection and quality of surveillance shall not be limited to the examination of finished welds. All aspects of materials, fabrication procedures and tests procedures shall be subject to the approval of Engineer. The equipment used shall be most suitable for the 260
quality of work specified. The method employed shall produce best results and to be tested at site by actual demonstration. Haphazards striking of electrodes for checking arc are not permitted. The arc should be struck either on the joint or a starting tag. The starting tag shall be of the same material or a material compatible with the base metal being welded. In case of any inadvertent strike on place other than the welding, the zone affected should be ground finished and examined by dye penetration test. Final welds shall be suitable for appropriate fabrication of the non-destructive tests of the weld. While grinding is required, the weld shall be blended into the parent metal without gouging or thinning of the present metal in any way. Uneven and excessive grinding may be a cause for rejection. Fillet weld shall preferably be convex and free from undercutting and overlap at the toe of weld. The specified leg lengths, convexity and concavity shall not exceed 1.5 mm. The non-pressure parts e.g. lugs, brackets etc. shall also be done by qualified welders in accordance with the design details and material specifications. Temporary attachments shall be removed in such a way that the parent metal is not damaged. The temporary attachment zone shall be dressed smooth and examined by dye penetration test. All tack welds shall be made as per specified methods and by qualified welders. The quantity and size of tack welds shall be kept as minimum as possible but shall be of adequate strength to maintain joint alignments. All tack welds shall be visually checked and if found defective, the same shall be completely removed. During final run of weld, tack welds shall either be removed completely or shall be properly prepared by grinding / filling their starting ends so that they may be satisfactorily incorporated in the welds. The defects shall be removed by grinding / chipping / gouging. All welding repairs shall be carried out as per the proper welding methods and by qualified welders. Preparation of weld repair shall have the prior approval of Engineer. Re-welded zones shall be checked as per the procedures followed for original welds and the repair procedures shall be approved by Engineer. 1.6 Castings
Cast iron, used for various equipment, shall be of close grained, gray, standard quality. The homogeneous structure shall be free from non-metallic inclusions and other injurious defects. The unmachined surfaces of castings shall be smooth and free from all foundry irregularities. Minor casting defects in depth not exceeding 12.5% of total wall thickness and which will not any way affect the strength and service of the casting may be repaired by approved welding techniques with prior intimation to Engineer. The Engineer shall be notified of large defects and no repair welding of such defects shall be carried out without prior written approval from Engineer. If the removal of metal for repair should reduce the stressresisting cross-section of the casting by more than 25% or to such an extent that the computed stress in the remaining metal exceeds the allowable stress by more than 25%, then the casting shall be rejected. Test pieces cast along with the main casting shall be marked, if specified or otherwise, by the manufacturer to check the physical and chemical properties of the casting. Any defect considered to be a major defect by Engineer is not acceptable. Welding repaired castings for minor defects shall be stress relieved. All castings subject to hydraulic pressure shall be pressure tested to at least 1.5 times the maximum expected pressure or 2 times the working pressure whichever is higher and certified copies of the 261
test results shall be forwarded to Engineer for acceptance of the casting. Non-destructive tests as desired by Engineer would be required for any casting having defects whose extent cannot otherwise be judged, or to determine the soundness of repair welds. 1.7 Forgings
All major stress bearing forgings shall be manufactured to standard specifications. Forgings shall be subjected to either magnetic particle test or dye penetration test at the areas of fillets and change in sections. The testing shall be conducted after proof machining (10 microns). Any defect, which will not be finally machined, will be gouged out fully, inspected either by dye penetration test or by magnetic particle test to ensure that the defect is fully removed and to repair adopting approved repair procedure. Any indication, which proves to penetrate deeper than 2.5% of the finished thickness of the component, shall be informed to Engineer giving all details, e.g. location, length, width and depth. For the magnetic particle inspection the choice of wet or dry particles shall be the manufacturers discretion. All forgings shall be demagnetized after test and shall be heat treated for stress relief. The name of the maker and particulars of the heat treatment proposed for each such forging shall be submitted to Engineer. The Engineers inspector may inspect such forgings and identify test pieces to check physical and chemical properties and witness such tests at manufacturers works. 1.8 Fasteners and Washers
All bolts, studs, nuts and washers used in the plant shall conform to the requirements of the relevant standard. The fasteners shall be of the best quality of specified grade and machined as required. Bolts shall be of one-piece construction and shall be of sufficient length so that only one thread shall show through the nut in fully tightened condition. Fit bolts shall be of light drive fit in the reamed holes they occupy and shall have the threaded portion of such diameter that it will not be damaged in driving. The fit bolts shall have identification mark to ensure correct assembly at site. Washers, locking devices and anti-vibration arrangements shall be provided wherever required. Jointing hardware for the entire plant shall be provided with sufficient spares to cater for 1 year for site losses. Bolts for structural members shall be provided with taper washers wherever necessary to ensure that no bending stress is caused on the bolt. Where there is a risk of corrosion, the fasteners design shall take into account the corrosion allowance and the maximum stress will not exceed half the yield stress of material under any condition. The fasteners subject to frequent adjustment, removal etc. for regular operation and maintenance shall be made of nickel bearing stainless steel. The manufacturer shall supply all holding down, alignment and leveling bolts complete with anchorage, nuts, washers, dowel pins, packing etc. required to erect the plant on its foundation along with base plates, frames and other structural parts necessary to spread the loads transmitted by the plant to foundations without exceeding the design stresses. The contractor shall provide to the satisfaction of Engineer, reasonable excess quantities to cover wastage of those consumable which may be normally subject to waste during erection and commissioning period.
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1.9
Lubrication
The equipment manufacturer shall furnish a complete schedule of recommended oils and other lubricants to Engineer. The number of different types of lubricants shall be kept to minimum. The details of lubricant such as quantity required, viscosity, make, No. etc. to be submitted to Engineer for approval before incorporating the same in the Maintenance Manual. For grease lubricated roller type bearings lithium base grease is preferred. The equipment manufacturer shall also indicate indigenously available equivalent lubricants with complete details to enable the client to arrange for regular supply in case of non-availability of specified brand. For grease lubrication it is preferred to have pressure system which does not require frequent adjustment or recharging. Frequent, for this purpose, means more than once in a month and grease systems having shorter periods between greasing should be avoided. Wherever required for accessibility, grease nipples shall be placed at the end of the extension piping and when a number of such points can be grouped conveniently, the nipples shall be brought to a battery plate mounted in a convenient position. The grease nipples shall be of same type and size for each part of the plant. Arrangements shall be provided to prevent bearings being overfilled with either grease or oil. If more than one type of grease is required for particular plant, separate grease gun for each type to be supplied with permanent marking. Oil container shall be supplied complete with oil level indicator of sight glass type; where this not applicable the container shall be provided with dipstick. The indicator will show the levels at all temperatures, which may occur during plant operation. The maximum and minimum levels shall be clearly visible in the sight glass type from the operating floor and the same shall be easily dismantled for cleaning. The sight glasses shall be firmly held and encased in metal protection in such a manner that they can not be accidentally dislodged. The lubrication systems shall be designed not to cause any fire and pollution and special protection must be taken to prevent any leakage of lubricant and coming in contact with any electrical equipment, heated surfaces or any other source of fire. Initial filling of oil, grease, electrolyte and similar material for relevant plants will be done by the contractor. All types of lubricants as required for 1 years operation of entire plant will be supplied by the contractor. 1.10 Name Plates, Rating Plates and Labels
Nameplate and rating plate made of stainless steel shall be permanently fixed at conspicuous position of each item of the plant. These plates shall incorporate manufacturers name and address, Serial No., Type, details of duty at which the equipment has been designed to operate, diagrams, and direction of closing / opening for valves, direction of rotation of pumps etc. as may be required. The operating and indicating devices shall have securely attached to them or engraved the designations of their function and manner of use. Details of proposed inscriptions shall be submitted to Engineer for approval before taking for manufacturer. Above plates and labels on electric equipment shall be of non-flame propagating materials, either non-hygroscopic or transparent plastic with engraved lettering of contrasting colours. Fixing shall be done by means of non-corrosive screws or drive rivets. Uses of adhesives are not permitted. 263
Warning labels shall be provided wherever necessary to warn against risky circumstances or substances. Inscriptions or graphic symbols shall be in black on yellow background and of internationally accepted standards. Instruction labels shall be provided where safety procedures to be followed, such as, wearing of protective clothing are essential to protect personnel from hazardous or potentially hazardous situations. These labels shall have inscriptions or graphic symbols in white on a blue background. 1.11 Operation and Maintenance Manual
The contractor shall furnish 6 copies of operation and maintenance manual specific for the plant equipment and installation, giving detailed description, as built assembly drawings, part lists, operating instructions, repairs and periodical maintenance. The said manual shall not merely contain manufacturers literature and brochures, which shall be in addition to detailed manual prepared for the plant. All records drawings, wiring diagrams, curves etc. shall also be a part of the manual. 1.12 The Operation and maintenance manual shall include the followings : Schedule of equipment supplied along with manufacturers name and address, Model No., Catalogue No. etc. Schedule of routine maintenance for all the equipment. Schedule of spares supplied with their part identification numbers. Schedule of tools and tackles supplied. Sectional arrangement drawings of major item e.g. pump, valves etc. with part identification list, metallurgy of component and with dismantling procedures. General arrangement drawing of whole plant showing the as built installation. Schematic diagram showing cooling and lubricating system of bearings. Full and comprehensive operation and maintenance instructions including fault detection for all equipment supplied. Copies of Test Certificates Pump performance curves as tested System head curves Schedule of recommended lubricants and their equivalents, which must be locally available. Painting
1.12.1 General The equipment manufacturer shall clean, prepare the surface and apply primer / protecting coating as per specification at their works. Parts to be painted may be cleaned but surface defects will not be filled in before testing at the manufacturers works. The items subject to hydraulic test shall be tested before any surface treatment. After test, all surfaces shall be thoroughly cleaned and dried out, if required, by washing with an approved dewatering fluid prior to surface treatment. Unless otherwise specified, all painting shall be done strictly in accordance with the paint manufacturers instructions. 264
All protective coating shall be suitable for use in hot and humid climates. 1.12.2 Painting at shop All stages of painting including cleaning, surface treatment etc. at the manufacturers works may be inspected by Engineer at their discretion. Cast iron and mild steel items shall be sand blasted to near mirror cleaning before painting. Sharp corners, edges etc. shall be broken before sand blasting. A primer coat of zinc rich epoxy resin base coating of at least 75 microns dry film thickness is to be provided. In addition, the parts are to be provided with adequate number of coats of coal tar epoxy polyamine coating to a dry film thickness of at least 175 microns including primer coating. 1.12.3 Painting at site After site receipt, all items of plant shall be examined for damage of paint and the damaged portions shall be cleaned to the bare metal, rust, if any, to be removed; procedures as mentioned above to be followed and finally paint coats to be done with similar paint. Cast iron and mild steel 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 inclusive of the primer coats. All sharp edges, fasteners and other items difficult to be painted shall receive brush coats 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. For fabricated steel work the same shall be done after assembly. Before finalising the paints, the contractor / manufacturer shall submit to Engineer the full details of paints he proposes to use together with colour charts for gloss finishes for approval. All paint and coating thickness shall be measured by approved Elcometer or coating thickness gauge. 1.13 Packing and Protection Before dispatch from manufacturers works the equipment shall be adequately protected and packed so as to reach the site intact and undamaged. The method of protection and packing must be suitable to withstand the conditions, which may be experienced in shipment and delivery to site. It should also be suitable to withstand long period of storage at outdoor. Engineer shall be given at least 15 days notice before packing. Any crate / package should not contain items of plant intended for incorporation in more than one part of the works. All items of Plant shall be clearly marked for identification as per packing list, which shall be placed in each crate / package and protected in a waterproof cover. All crates and packages shall be clearly marked with water and weatherproof paint to show the weight and position of sling attachment. They shall also be marked to identify the packing lists. Bearing surfaces and similar bright parts shall be protected from corrosion by application of rust preventive lacquer, high melting point grease or similar fluid. Sufficient quantity of appropriate solvent shall be provided with the packing for removal of this protection. Each crate / package shall have a clear indelible and as far as possible, indestructible unique identification cipher, also quoted in the packing list inside it. Three copies of packing lists shall be sent separately to Engineer at the time of shipment. 265
All flanges and matching surfaces shall be protected by wooden templates or similar. The fasteners used for securing these templates shall not form part of final installation. 1.14 Acceptable Makes
The Equipment offered shall be of reputed make with proven performance and ISO: 9000 organisation. The manufacturer must have supplied equipment of similar types and duties for at least 10 installations and those are running satisfactorily at least 5 years. The performance certificates for 5 such installations to be furnished. Installation means separate order/ pumping station. 1.15 Guarantee All equipment/ items shall be guaranteed against defective design, manufacture and / or workmanship for a period of 18 months from the date of dispatch or 12 months from the date of successful commissioning whichever is later. Contractor shall be responsive for complete operation and routine as well as breakdown maintenance of the installation including supply of all spares and consumables during the guarantee period and the cost shall be included in the offer. No extra payment will be made on this account. 1.16 Design and Performance Requirements (Applicable for all Pumping Stations) All the water transportation systems described shall be capable of conveying their rated capacities as specified in Particular Specification. Pipe sizes, unless specified otherwise shall be selected by the Bidder based on optimization studies. The procedures and results of the optimization studies shall be furnished by the Bidder as part of his Bid Proposal. However, for the purpose of such pipe sizing, recommended velocities at pump suction and discharge will be guided by the velocity chart given below: Recommended Velocity Chart for Pipe Sizing Sl. No. Description of pipe Velocity Pipe size 50-150 mm m/sec. 1.5 2.0 1.0 1.2 Velocity Pipe size 200 mm and above m/sec. 1.8 2.5 1.2 2.0 / 1.5
1 2
Pipelines at pump discharge & column pipe Pipelines at pump suction / Bell Mouth
Unless otherwise specified, Bidder shall provide standard pipes in respect of size, in all services covered under this specification. The total dynamic head (TDH) of all pumps shall be obtained by conducting detailed system resistance calculations. Bidder shall furnish these calculations and system resistance curves superimposed on pump modified characteristic curves along with his Bid proposal. The indicative TDH for different pumps are furnished in Particular Specification. However, actual TDH shall be finalized by the Bidder and following general guidelines shall be adhered to by the Bidder towards computation of same. a) The duty point (BEP) static head in each pumping system shall generally be obtained by considering the low water level, unless specifically mentioned
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and maximum discharge points elevation. It shall also take into account all the highest levels encountered in the route. b) Frictional losses in pipes shall be calculated based on Hazen & Williams Formula considering C=120. A minimum 10% margin shall be provided over and above the calculated frictional losses. Frictional losses in fittings shall be calculated as per Hydraulic Institute Standard.
c)
All pipes and fittings shall be designed to withstand a pressure not less than 2.0 times the working pressure of the respective system pumps. Following valves, fittings and appurtenances shall be provided by the Bidder as minimum requirement for each of the pumping system, as applicable. i. ii. iii. iv. Scour or drain valves of suitable size at suitable locations for adequate drainage of pipelines. Thrust blocks and expansion joints/loops at suitable locations. Pipe supports / racks complete with all accessories Any other accessories as required for safe and reliable operation of respective pumping system. The pump sump/s (reservoirs) shall be provided with isolation valves if specifically mentioned. The valves shall be watertight type and shall be of identical size/dimensions to facilitate interchangeability. The respective pump house shall also accommodate the following equipment/ facilities, as applicable. I. All auxiliary equipment related to pump sets such as piping complete with valves and fittings. II. Ventilation system for the entire pump house III. Separate bays for loading, unloading and maintenance IV. Overhead HOT / EOT and Monorail crane as specifically mentioned complete with all accessories V. Dynamic head of pump to be ascertained by bidder after proper survey work. Other general layout criteria as specified in Particular Specification shall also be adhered to while designing the pump house.
The basic design philosophy of the pump houses (new construction) are as follows v.
vi.
vii.
All piping having its scope upto clients terminals shall be suitably matched. All necessary details regarding interfaces will be intimated to successful Bidder. 1.17 Information to be furnished after the award of Contract a. The successful bidder shall furnish the following drawings/ data/manual/calculations etc. within 30 days of issuance of Letter of Intent to the client for approval. All the supplies and inspection will be carried out as per the approved drawings and specifications. b. Final versions of all the drawings, documents etc. of the equipment showing all dimension and major parameters. c. Cross-sectional drawings of the equipment incorporating part identification list and material of construction. 267
d. Foundation drawings showing details of fixing, grouting, total weights of equipment, plinth sizes, anchor bolts etc. along with all design loads and their direction and points of application. e. Piping arrangement drawings for sealing, lubricating, cooling etc. for all equipment. f. Manufacturers certified performance curves of the equipment indicating all parameters along with all relevant technical specification/particulars. g. Drive data h. Water volume and pressure requirements for stuffing box sealing and bearing lubrication etc. with complete details of all ancillary equipment including water pumping system, piping, valves etc., and interface requirements for work by others, if any. i. Details of grease/oil lubrication system including the proper quantity of grease/oil and frequency of bearing lubrication. j. Equipment/ item manufacturers QAP to be submitted for approval. k. All other drawings, data, documents etc. the supplier feels to be approved by the client. l. Operation and maintenance manual (before commissioning of the plant).
2. 2.1
STANDARD SPECIFICATION Vertical Raw Water Pump
(Wet Pit Installation) 2.1.1 General Pump shall be of vertical shaft, single / multi stage, single flow, wet pit type suitable for handling raw water containing loose silt, gritty and floating matter complete with bowl, column pipe, discharge head and base plate with all accessories, as applicable driven by single speed vertical solid shaft flange mounted motor. The pump speed should not be more than 1500 rpm. The design, manufacture and performance of the pumps shall conform to the latest revision of IS/BS/DIN/ISO Standards/ Specification. In particular, the equipment shall conform to the latest revision of the following specification. IS: 1710: IS: 5120: Specification for pumps vertical turbine mixed and axial flow Technical requirements for roto-dynamic special purpose pumps.
And Hydraulic Institute Standard, USA. The pump shall have stable performance throughout the whole range of its operation i.e. from zero flow to run out condition. The pump of a particular category shall be identical and shall be suitable for parallel and continuous operation. The pumps impeller shall preferably be of non-overloading type.
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The pump shall be designed to be protected against reverse direction of rotation due to raw water returning through the pump. The weight of rotor assembly, including line shaft and the unbalanced hydraulic thrust of the impeller shall be carried out by the thrust bearing provided in the bearing housing. The equipment shall be capable of developing the required total head at rated capacity for continuous trouble free operation. The head capacity curve of the pump shall be continuously rising towards the shut-off with highest head at shut-off. The pump shall operate trouble free, smooth and without any undue noise and vibration. The magnitude of peak to peak vibration at shop and at site installation will be limited to 75 microns and 50 microns respectively at the bearing housing. Noise level shall be limited to 85 dBA at a distance of 1.0 m. 2.1.2 Constructional Features
2.1.2.1 Bowl Assembly This will be single / multi stage mixed flow type with discharge co-axial with shaft. Pump shall have provision for adjustment of impeller in vertical direction from an accessible location, preferably at the housing, where separate thrust bearing for the pump is provided. The adjustment mechanism must take into consideration the extension of the line shaft due to hydraulic down thrust, weight of the shaft and impeller. 2.1.2.2 Discharge Head, Motor Stool & Sole Plate Pump shall be of above the floor discharge type. The discharge head shall be of substantial construction in mild steel and shall incorporate full diameter elbow of diameter same as that of column pipe. A motor stool of substantial construction in mild steel shall be provided. Thrust bearing and flexible coupling for pump-motor shall be accommodated in the motor stool. Sole plate/ Base plate of adequate thickness and in one piece shall be provided above the discharge elbow. 2.1.2.3 Column Pipe Column pipe shall be flanged and of bolted connection. Column pipe shall be designed for full internal vacuum. In case of multi-piece column pipe (single piece length should not be more than 1500 mm) and shaft assembly, the design shall permit raising/lowering of the pump assembly piece by piece without any difficulty. Any fixtures, clamps, etc. necessary for such purpose shall be supplied by the manufacturer. The manufacturer shall also submit a write-up describing clearly the procedure of handling the pump.
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Impeller Shaft & Line Shaft Shaft size shall be selected on the basis of maximum torque to be applied in the pump shaft. Critical speed of the shaft shall be sufficiently away from the pump operating speed and in no case shall lie between 80% and 120% of the rated speed. Impeller shaft shall be guided by bearings provided above and below the impeller shaft assembly (at discharge bowl and at suction bell). The butting faces of the shaft shall be machined square to the assembly and the shaft shall be chamfered at the edges. Line shaft may be of single or multiple pieces as required. In case of multiple pieces, line shaft shall be coupled as per the standard practice of the manufacturer. For screwed coupling, screw directions shall permit tightening of the joint during pump operation. Replaceable shaft sleeves shall be furnished at applicable locations, particularly under stuffing box and at other locations, as considered necessary. 2.1.2.4 Bowl Liner Replaceable liner (wearing ring) shall be provided on bowl. 2.1.2.5 Stuffing Box The pump shall be provided with deep groove stuffing box with bronze lantern ring for clear water flushing. An easily accessible bronze split gland shall be provided to facilitate adjustment or removal and replacement of the packing. 2.1.2.6 Bearings Shaft bearings Adequate number of properly designed bearings shall be provided for smooth and trouble free operation of the pump. Number of bearings shall consider the number of shaft pieces used and the critical speed of the shaft. Bearings shall be lubricated by self water only. Thrust bearing Thrust bearing of adequate size and capacity shall be provided to take the vertical thrust of the impeller arising out of the pump operation and dead weight of the rotating components. Life of the thrust bearing shall be guided by the design standard of the pump and should not be less than 1, 00,000 hours. Thrust bearing shall be capable of running continuously at maximum load. Thrust bearings shall be either grease or oil lubricated. Lubrication arrangement shall be such that the lubricant does not contaminate the handling fluid. The arrangement shall also be adequate to protect the bearing, while the pump coast down to stop in case of power failure at the station. Pre-lubrication of the thrust bearing, if recommended by the pump manufacturer, shall be taken care of in designing the lubrication system.
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Cooling of the thrust bearing, if necessary, shall be done by the external water and complete cooling arrangement shall be supplied with the pump. 2.1.2.7 Reverse Rotation The pump impeller and other rotating components shall be designed for reverse rotation, when subject to reverse flow at rated pump discharge and head. 2.1.2.8 Drive Unit The pump will be driven by vertical; flange mounted solid shaft electric motor. The drive equipment shall be air-cooled. A heavy-duty flexible coupling shall be provided between motor and pump. Unless otherwise specified, motor power rating shall be the maximum of the following requirements. a) b) 15% margin over the pump shaft input power at the rated working condition. 10% margin over the maximum pump shaft input power required within its full range
of operation including the shut off point. c) Pump shaft input power required considering over loading of the pump assuming
single pump operation in the event of tripping of the other pump (s) operating in parallel. Material of Construction (Subject to confirmation by the Pump Manufacturer considering water quality) Bowl Bowl Liner Diffuser Cone Column pipe Discharge elbow Impeller Shaft sleeve Shaft bearing Sole plate Line shaft Impeller shaft Line shaft coupling Fastners Suction bell2.5% Motor stool Flow straightner : : : : : : : : : : : : : : : : 2.5% Ni-Cast Iron, IS : 210, FG 260 Stainless steel, ASTM-A-276 Type 316 Ti 2.5% Ni-Cast Iron, IS : 210, FG 260 Mild steel, IS : 2062 (minimum 10 mm thick) Galvanized as per IS : 4736 Mild steel, IS : 2062 ( minimum 10 mm thick) Duplex Stainless Steel, ASTM-A-351 Gr. CD4 MCu Stainless Steel, AISI :410 Cutless Rubber Mild Steel, IS :2062 Stainless Steel, AISI :316 Stainless Steel, AISI : 316 Stainless Steel, AISI : 316 Stainless Steel, AISI : 316 Ni-Cast Iron, IS : 210, FG 260 Mild Steel, IS : 2062 Mild steel, IS : 2062, Galvanized as per IS : 4736 Section VII. Work Requirements
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Bush bearing Painting
Bronze, BS : 1400, LTB 6
The pump set shall be painted with zinc rich epoxy primer plus two coats of coal tar epoxy paint. The paint shall be spray applied and dried in a painting booth to avoid ingress of foreign particles especially when the painted surface is not completely dry. Inspection & Testing at Manufacturers Works The manufacturer shall carry out the following specific tests and inspections to ensure that the equipment furnished lie in strict conformance with the specification and in accordance with codes/ standards and good engineering practice. a) Material identification and testing shall include but shall not be limited to the following components: b) Bowl and Suction bell Impeller and Bowl liner Shafts and shaft sleeves Couplings Bearings Column pipes
Discharge head i) The entire surface of the impeller castings shall be subjected to Dye Penetration Test as per ASTM E 165. ii) Shafts shall be subjected to Dye Penetration and Ultrasonic Test.
iii) Bowl liner shall be subjected to Dye Penetration Test. iv) Witnessing of NDT / review of NDT reports. v) Static balancing test for impeller and Dynamic balancing test of complete rotating assembly as per ISO-1940 or equivalent International Standard. vi) Complete inspection of assembled pump. c) Dynamic Balancing
Rotating components of the pump shall be statically balanced. The complete rotor assembly shall be dynamically balanced at a speed not less than the rated speed of pump. Test procedure and acceptance limits shall be guided by the relevant testing codes and standards.
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d)
Hydrostatic Testing
Hydrostatic test shall be done for the following components with water at a pressure 1.5 times of closed valve pressure with maximum impeller size or 2.0 times of pump duty point pressure whichever is higher. Pressure shall be maintained for a period of not less than 30 minutes. While arriving at the above values, maximum suction pressure shall be taken into account. i) ii) iii) e) Bowl and Suction bell Column Pipe Discharge Head
Performance Test at Shop i) Each pump shall have to be tested to determine its performance curves. These tests are to be conducted in presence of clients representative as per the requirements of Hydraulic Institute Standards, USA (ASME Power Test Code PTC 8.2)/ BS: 599 or any other equivalent standard but the tolerances on head, discharge and power shall be as specified in Hydraulic Institute Standard, USA. ii) Performance tests are to be conducted to cover the entire range of operation of the pumps. These shall be carried out to span 130% of rated capacity upto shut-off condition. A minimum of five combinations of head and capacity are to be achieved during testing to establish the performance curves, including the design capacity point, shut-off point and the two extremities of the range of operation specified. After completion of performance test, all pumps shall be stripped down for inspection of internals. iii) Testing of all the pump sets for the same pumping station with a common motor is acceptable provided the same motor forms a part of supply under the contract. Each pump shall be tested at its rated speed for the entire working range. iv) NPSH tests are to be conducted on one pump of each type at 3% head drop conditions. v) Mechanical run test shall be carried out on all pumps to determine the vibration and noise levels etc. This test shall be conducted at site also. However, test value at site shall be used for the acceptance of the equipment. vi) Bearing temperatures shall be determined by a contact type thermometer. A running time of at least 30 minutes shall be maintained for this test at shut-off head if sufficient water is not available for a complete test. vii) All instruments and equipment required for such tests shall be provided by the manufacturer and the instruments shall be calibrated and certified by an approved
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independent testing authority not more than 15 days prior to the test in which they will be used. viii) Reports and test certificates of above tests shall be submitted to the client for approval. ix) The bidder shall submit in his proposal the facilities available at the manufacturers works to conduct the above mentioned Inspection and Testing. f) Testing at site
All pump sets shall be tested at site in the presence of manufacturers expert. The QH and Power parameters can be measured with suitable measuring device to be arranged by contractor at no extra cost. 2.2 2.2.1 Valves Sluice Valve Unless otherwise specified all the sluice valves will be rising spindle type, flat face, bolted bonnet with solid wedge disc and manually operated by hand wheel. The valves above and including 400 DN shall be provided with spur/bevel gear arrangement for operation and be fitted with by-pass arrangement. The sluice valve will be as per IS:14846/S 5150/DIN 3352 at their latest revision. The pressure rating of the valve will be as per the specific standard followed taking into account the operating pressure. Wherever specifically mentioned the valve shall be fitted with extended spindle, head stock along with hand wheel for easy operation from the operating platform. Material of Construction: Body, Bonnet, Wedge, Stuffing Box Gland Spindle Body Seat and Disc Seat Packing Fasteners Extended Spindle Head Stock Hand wheel 2.2.2 Reflux Valve Double flanged with hinged single/multi swinging disc complete with bypass arrangements will have to be provided. For sizes 450 DN and above tilting disc type valves are preferred. The valve will be of flat face bolted cover and will be fitted with renewable body and disc seat. The reflux valve will be as per IS:5312/BS:5153/ISO 2531 at their latest revision. The pressure rating of the valve will be as per the specific standard followed taking into account the operating pressure. : : : : : : : : Ductile Iron, IS:1865, Gr. 500/7 Stainless Steel, AISI410 Bronze, IS:318 Gr. LT B2 Greasy jute packing IS:1367, Class 4 / 4.6 Mild Steel, BS:970, EN8 Cast Iron,IS:210, FG 260 Cast Iron, IS:210, FG 260
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Material of Construction Body, Disc, Cover Trunion Shaft Body Seat Disc Seat Fasteners 2.2.3 Automatic Air Release Valve : : : : : Ductile Iron, IS:1865, Gr500/7 Stainless steel, AISI 410 Gun Metal Natural Rubber IS:1367, Class 4 / 4.6
All the air valves installed shall be double acting type with nominal pressure rating of PN 10 and in accordance with ISO 2531. Body ends shall be flanged with flat faces and drilled to relevant IS/BS/DIN/ISO standard for PN 10. Each valve will be fitted with screw down isolating valve to permit inspection of valve without shutting the water line. Material of Construction Body, Cover, Cowl Body seat, Disc Face, Stem Nut Stem Fastener : : : : Ductile Iron, IS:1865, Gr500/7 Bronze, IS:318, Gr LTB2 Stainless steel, AISI 410 IS: 1367, Class 4/4.6
Inspection & Testing at Manufacturers Works The manufacturer will submit their QAP for Engineers approval including the following tests and inspections which will be carried out at the manufacturers works. a) All the major components of each valve shall be physically and chemically tested by
approved independent testing authority to confirm the material quality. The manufacturer shall intimate the Client, the relevant Standard to be followed for testing. All components subject to testing shall be identified, and only those which are tested successfully shall be used for the manufacture of final product. All test results shall be submitted for Clients approval. Material test certificates of valve components shall be furnished before despatch. b) Hydrostatic Test The pressure retaining components of all valves shall be tested at the pressure stipulated in the relevant standard followed. The manufacturer should inform the Client regarding the pressure ratings of the valves and all the test certificates to be submitted before despatch of the materials. (c) Painting All the valves shall be painted with zinc rich epoxy primer plus two coats of coal tar epoxy paint. The paint shall be spray applied and dried in a painting booth to avoid ingress of foreign particles especially when the painted surface is not completely dry.
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2.3
Pipes, Fittings& Dismantling Joints One set of double flanged ductile iron pipes and fittings, as applicable for suction and
delivery branches and for common delivery main (if not specifically mentioned) for all the pump sets shall be provided. The bidder shall include all pipes and fittings for connection to the rising main upto the stipulated length outside the pump house building. The pipes and fittings shall be as per latest revision of IS 8329/ IS 9523 / Equivalent and must be suitable to withstand the pressure tested to at least double the close valve pressure. The diameter and length of the pipes shall be determined from the specified velocity of the raw / clear water and size of the pump house. The delivery pipe of the pump shall be connected with the pump through enlarger immediately before and after the pump so as to restrict the velocity of raw / clear water in the pipe line at suction and delivery side. For all pumping stations the piping system inside the pumping station shall contain one number dismantling joint at suction and at delivery line of each pump to facilitate the erection and maintenance of plants. Each suction / delivery pipe line shall include one puddle collar at the exit of the wet sump / pumping station where the pipe line is below G.L. All the pipe lines will be protected with anticorrosive paints of required quality to suit the site climatic condition. All pipes and fittings must be cement mortar lined. Pipes sizes above 1000 dia will be of mild steel, IS: 2062 of minimum wall thickness 12 mm. Necessary rubber insertion of suitable thickness shall be provided at all the flanged joints complete with supply and erection of necessary number of bolts, nuts, washers of suitable sizes. 2.4 Gauges All the pumps shall be provided with dial type pressure gauges of suitable range at suction and at delivery flanges as applicable complete with copper tubing and control cocks. The gauges shall be of direct mounted type. The dial size of each pressure gauge shall not be less than 150 mm. The material of construction shall be suitable for raw / clear water pumping station installations. Each pressure gauge shall be complete with pressure snubber and of suitable class of enclosure. Accuracy shall be + 1.0% of full scale range or better. Scale range shall be selected so that normal system pressure is approximately 50% of full scale. The gauges should conform to the latest revision of IS : 3624 / BS:1780 / Equivalent. 2.5 Hand Operated Overhead Travelling Gantry Crane & Hoist (HOT) The pumping stations, if not specifically mentioned shall be provided with one number hand operated overhead travelling (HOT) crane of sufficient capacity to handle the heaviest item requiring
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lifting for maintenance and installation purposes and it shall be possible to use the crane for loading and unloading the equipment from truck. The contractor shall justify the crane capacity by supporting load data. It shall consist of single/double girder, as specifically mentioned in Particular Specification, manually operated gantry crane provided with appurtenance, auxiliaries and materials required to make the travelling crane fully operational and capable of effective performance for the rated duty. Crane shall be designed in accordance with IS:3177/ IS : 807/BS:2573/ Equivalent at its latest revision. The term crane shall include gantry rails, platform with handrails for maintenance purpose, end stops, holding down bolts, suitable suspension fittings, carrier, trolley, hoist, and other track accessories etc. required for complete installation. Sufficient slings, ropes, shackles, lifting beams etc. shall be supplied to handle all items or equipment covered by the crane. They shall be labelled or marked with the safe working load (SWL) and the purpose for which they are intended. The crane and all slings, ropes, shackles and other lifting equipment supplied shall be tested by the manufacturer at his works. The tests shall be carried out at 125% of Safe Working Load and Test Certificates shall be furnished. All access ladders and platforms necessary to carry out maintenance and repairs shall be provided and installed by the supplier. The design of the crane assemblies shall provide a factor of safety of Five based on the maximum capacity load on all mechanical parts of the system. The factor of safety shall be computed in relation to the ultimate strength of the material used to manufacture the component. The design of all structural members shall provide an allowance for vertical impact of 30% with respect to total live load. A minimum allowance of 25% of the combined weight of hoist, trolley and live load shall be provided for lateral impacts. Girders shall be so designed that vertical deflection caused by the safe working load in the central position (without taking into consideration the impact factor) shall not exceed 1/900 of the span. Site tests shall be carried out by the supplier who shall supply the necessary materials for the test load. The test load shall be removed from site by the supplier after successful tests have been carried out. Crane Bridge Requirements The Crane Bridge shall conform to the following detailed specifications. Top Riding End Trucks These shall have carriage of adequate strength and be fabricated from structural steel to resist all loads to be imposed on them under service conditions including collision with end stoppers. The carriages
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shall be equipped with bumpers at each end to engage stops on crane runways. Carriages shall have hardened wheels equipped with anti-friction bearings. Bridge Girders This shall be designed in accordance with the design parameters stipulated earlier in this section. A fulllength anti-skid maintenance platform shall be provided on the long transverse drive side girder. Platform shall be supported on brackets welded to bridge girder. Runway Beams If standard rail sections are used as runway beams the sectional weight should not be less than 51.89 kgs/m. If beams are fabricated, design and materials for all loads shall conform to the latest revision of IS:807 and IS: 3177 or relevant BS standards and other applicable requirements for travelling cranes specified by IS/BS/Equivalent standards. Wheels These shall be flanged with treads accurately machined or ground to size. Wheels shall be of forged or cast steel. Treads and flanges shall be heat-treated to a minimum Brinell Hardness of 425. Hoist The contractor shall furnish manual hoist of the type most suitable for particular application under consideration. The hoist shall be suitable for mounting on the carrier or trolley, which are furnished by the manufacturer of the overhead track system. The carrier or trolley, from which the hoist is suspended, shall be provided by the contractor. Hook The hook shall be of forged steel, supported on a ball or roller thrust bearings. Hook shall rotate freely on thrust bearing and shall be fitted with safety catches and the hook block shall incorporate fully guarded rope sheaves. Name Plate Nameplates shall be permanently fixed to the bridge and load block. Capacity shall be stated in Tonnes. Nameplates shall be clearly legible from the floor and shall contain the manufacturers name and address. Factory Tests All tests specified in IS:3177/BS:2573 / Equivalent under Inspection and Testing, shall be carried out in the presence of client or his representative who shall be given at least 15 days notice of the scheduled date and place of inspection.
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Site Tests After installation, the unit shall be put through all of its operations using 125% of normal operating load. Inspections shall be done for proper installation, operation, alignment and lubrication. On conclusion of the tests to the satisfaction of the Client he shall be furnished with manufacturers Test Certificates. Painting The crane shall be painted with zinc rich epoxy primer plus two coats of coal tar epoxy paint. The paint shall be spray applied and dried in a proper enclosure to avoid ingress of foreign particles especially when the painted surface is not completely dry. 2.6 Monorail Crane with Chain Pulley Block
Monorail mounted hand operated chain pulley block to be provided at the locations shown in the drawings shall be as per the requirement of BS:3243/ Equivalent. It shall be of required capacity having adequate chain length. The load chain shall conform to BS:2902/Equivalent. Guide shall be provided for effective guidance to the load chain and a stripper for effective disengagement of chain from wheel. Idler wheels shall be provided in the block to prevent twisting of chain and bending of links. The load chain length shall be more than the minimum length required to achieve the lift by not less than 3 links per fall. The lifting hook shall be forged heat treated alloy or carbon steel conforming to BS:2903 / Equivalent. The bottom hook shall be so designed that it can swivel in the loaded condition without twisting the load chain. The top hook shall be so designed that it can swivel in no load condition. The length of the hand chain shall be such that the lowest point of the suspended loop shall hang at least 500 mm above the operating level. Hand chain wheel shall be flanged and guides shall be provided to prevent coming out or jamming the chain. Gears shall be machine cut from carbon steel conforming to BS:4670 / Equivalent. Chain pulley block shall be provided with an automatic load brake to prevent self-lowering of load and shall be of screw and friction disc type and gear shall be resistance less during hoisting. The hoist block shall be tested for 150% overload through a length of lift which will ensure that every part of the block mechanism and each tooth of gear comes under load. The track shall be either rolled or fabricated section and shall be considered as a simple beam for determining the capacity. In determining the size of the track the load on the load carrying tension flange shall be assumed to be at the point central to the span of the track. The allowable stress on the tension flange shall be 20% of the ultimate strength of the material used. All necessary clamps, hanger rods, and other fittings from which the track is suspended shall be considered as part of the track system. Track hangers shall support the load resulting from the maximum loading condition. The allowable stress for hanger rods shall be determined from the root area of the rod. Means shall be provided to allow for the vertical adjustment of the track both Section VII. Work Requirements
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before and after the system has been put in operation so that track can be erected and maintained level. Where the track is suspended from hanger rods, track shall be braced laterally and longitudinally to prevent excessive sway and lock nuts or other means shall be provided to prevent the nuts from backing off the rods. Where multiple rods are used at a suspension point, consideration shall be given to the unequal load induced in the rods. In the design of hanger rods, the allowable stress shall be 20% of the ultimate strength of the material used. The trolley shall be fabricated from structural steel (IS:2062) of suitable sections. Trolley wheels shall be drop forged or rolled steel with heat treated treads and flanges or cast iron with chilled tread and shall have a minimum treat hardness of 425 Brinell. Wheel bearings shall be single or double row, combination of radial and axial thrust, anti-friction precision type. Bearings shall be pre-lubricated and sealed or provided with fittings and seals for pressure lubrication. The contractor shall justify the size of monorail offered supported by design calculations. Painting The monorail structure shall be painted with zinc rich epoxy primer plus two coats of coal tar epoxy paint. The paint shall be spray applied and dried at site after erection 2.7 Exhaust Fan
Exhaust fans shall be provided at the places specifically mentioned for ventilation purpose. The cast aluminium alloy blades shall have high efficiency aerofoil section. Blades shall be directly mounted on motor shaft, dynamically balanced and shall conform to IS:2312. The means provided for securing the fan mounting or fan casing to the wall shall be such as to provide a secure fixing without damage to the fan or wall. The drive motors shall be TEFC, squirrel cage, induction type suitable for 240 Volts + 10%, 1
phase OR 415 Volts + 10%, 3 phase, 50 Hz AC supply with IP54 enclosure and class B insulation. Suitable designed guards shall be provided at the inlet and outlet side to prevent accidental contact. No inflammable material shall be used in the construction of fan. Moulded parts, if used, shall be of such materials as to withstand the maximum temperature attained in the adjacent component parts. The fan shall have protective insulation may be of all insulated construction or have either double insulation or reinforced insulation. Each fan should be provided with a 10 sq.mm mesh bird screen. The sheet used for the cowl shall be 14 SWG. The finish will be stove enamelled glossy paint/epoxy paint with specially pre-treated components to enhance corrosion resistance.
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The number and size of exhaust fan will be determined taking into account 12 complete changes of air per hour to the service area. 2.8 2.8.1 Woltman type Flow Meter The Woltman type meter shall be AMR compatible with Pulse Emitter Pre-Equipped. Meter
is a Removable Element Woltman water meter in sizes 100mm to 500mm for cold water. Magnetic drive, lower transmission resistance. The measuring mechanism shall be removable from the body for checking, maintaining and replacing without removing the body. Water temperature: T50 or T30 Water pressure: <1.6MPa. The meter shall be suitable for installation in any position with the direction of flow as indicated by the arrow cast in the meter body with the register face upwards. It shall have a Dry dial register to ensure clear reading. Register capable of 3600 rotation. Meter shall not be affected by external magnetic field. Meter to conform to IS: 2373, ISO 4064 and EEC marked. The meter shall be capable of generating 4x 20mA signals
2.9
Horizontal Split Casing Pump (Clear Water Application)
2.9.1. General Pump shall be horizontal split casing, single stage centrifugal type, horizontally driven with shaft directly and flexibly coupled with the driving electric motor. The pump will be suitable for handling raw water containing loose silt, gritty and floating matter and clear water as well. The pump will be fitted with double entry, enclosed type impeller which is to be securely held on the pump shaft. The casing is horizontally split so that by removing the upper half casing and bearing caps, the entire rotating assembly can be removed for inspection or repairs without disturbing the pump alignment or pipe connections. The suction and delivery branches will be situated in the should not be more than 1500 rpm. The design, manufacture and performance of the pumps shall conform to the latest revision of IS / BS / DIN / ISO Standards / Specification. In particular, the equipment shall conform to the latest revision of the following specification. IS: 5120: Technical requirements for roto dynamic special purpose pumps. Hydraulic Institute Standard, USA IS: 10981: Class of acceptance test for centrifugal, mixed flow axial pumps Class B. The pump shall have stable performance throughout the whole range of its operation i.e. from zero flow to run out condition. The pump of a particular category shall be identical lower half casing. The pump speed
281
and shall be suitable for parallel and continuous operation. The pumps impeller shall preferably be of nonoverloading type. The weight of the rotor assembly and the unbalanced hydraulic thrust of the impeller shall be carried out by the thrust bearing provided in the bearing housing. The equipment shall be capable of developing the required total head at rated capacity for continuous trouble free operation. The headcapacity curve of the pump shall be continuously rising towards the shutoff with highest head at shutoff. The pump shall operate trouble free, smooth and without any undue noise and vibration. The magnitude of peak to peak vibration at shop and at site installation will be limited to 75 microns and 50 microns respectively at the bearing housing. Noise level shall be
limited to 85 dBA at a distance of 1.0 m. Constructional Features Casing Horizontal axially split volute type, suction and discharge nozzles and supporting feet are cast integral with lower half casing. The internal surface shall be smooth and free of rough spots. The casing shall be provided with priming funnel and air release vent, tapping shall be provided for installing suction and delivery pressure gauges. Impeller Impeller shall be double suction enclosed type and balanced both statically and dynamically. Renewable wearing rings shall be provided on both impeller and casing. Pump Shaft The shaft shall be of one-piece construction solid type and will be designed to take all types of loads such as torsion, tensile, bending and dynamic etc. Pump shaft shall be provided with replaceable sleeves particularly under stuffing box and at other locations, as considered necessary. Pump Bearings Pump bearings shall be antifriction type capable of running continuously at maximum load. The bearings shall be able to take normal thrust loads due to unbalanced hydraulic loads on the impeller plus the weight of all rotating parts of the pump. Pump bearings shall be designed with a minimum life of 1, 00,000 hours. The bearings shall be grease lubricated and shall be maintenance free. 282
Flexible Coupling The pump shaft shall be coupled to motor shaft through flexible coupling. The coupling shall comprise of pin and rubber bushes. Each half shall be statically and dynamically balanced for transmission of power without vibration and shall be keyed to respective shaft. The coupling halves shall have precise machined surfaces for facilitating alignment. Suitable guard for coupling shall be provided. Reverse Rotation The pump impeller and other rotating components shall be designed for reverse rotation, when subject to reverse flow at rated pump discharge and head. Stuffing Box The pump shall be provided with deep groove stuffing box with bronze lantern ring for clear water flushing. An easily accessible bronze split gland shall be provided to facilitate
adjustment or removal and replacement of the packing. Base Plate (Base Frame) The pump and motor shall be installed on common base plate / frame to accommodate both pump and motor. Suitable machined sole pieces shall be welded on top of base plate for mounting pump and motor. The base plate shall be constructed from steel channels / plates. The base plate shall be fabricated and supplied by the pump manufacturer only. The base plate shall be offered for inspection during factory test of pump. Drive Unit The pump will be driven by horizontal; foot mounted solid shaft electric motor. The drive equipment shall be air-cooled. A heavy-duty flexible coupling shall be provided between motor and pump. Unless otherwise specified, motor power rating shall be the maximum of the following requirements. a) 15% margin over the pump shaft input power at the rated working condition. b) 10% margin over the maximum pump shaft input power required within its full range of operation including the shut off point. c) Pump shaft input power required considering over loading of the pump assuming single pump operation in the event of tripping of the other pump (s) operating in parallel. 283
Material of Construction (Subject to confirmation by the Pump Manufacturer considering water quality)
Pump Casing Impeller MCu Shaft sleeve Base Plate Pump shaft Fastners Bush Bearing Painting
: 2.5% Ni-Cast Iron, IS : 210, FG 260 : Duplex Stainless Steel, ASTM-A-351 Gr. CD4
: Stainless Steel, AISI: 410 : Mild Steel, IS: 2062 : Stainless Steel, AISI: 316 : Stainless Steel, AISI: 316 : Bronze, BS: 1400, LTB 6
The pump set shall be painted with zinc rich epoxy primer plus two coats of coal tar epoxy paint. The paint shall be spray applied and dried in a painting booth to avoid ingress of foreign particles especially when the painted surface is not completely dry. Inspection & Testing at Manufacturers Works The manufacturer shall carry out the following specific tests and inspections to ensure that the equipment furnished lie in strict conformance with the specification and in accordance with codes/ standards and good engineering practice. a) Material identification and testing shall include but shall not be limited to the following components: 284 Pump Casing Impeller Shaft Sleeve Pump Shaft Bush Bearing Wearing Rings (Impeller & Casing)
b) i)
Tests shall also include but shall not be limited to the following: The entire surface of the impeller castings shall be subjected to Dye Penetration Test as per ASTME 165. ii) Shaft shall be subjected to Dye Penetration and Ultrasonic Test. Witnessing of NDT / review of NDT reports. Static balancing test for impeller and Dynamic balancing test of complete rotating assembly as per ISO/1940 or equivalent International Standard.
iii) iv)
v)
Complete inspection of assembled pump.
c) Dynamic Balancing Rotating components of the pump shall be statically balanced. The complete rotor assembly shall be dynamically balanced at a speed not less than the rated speed of pump. Test procedure and acceptance limits shall be guided by the relevant testing codes and standards. d) Hydrostatic Testing Hydrostatic test shall be done for the Pump Casing with water at a pressure 1.5 times of closed valve pressure with maximum impeller size or 2.0 times of pump duty point pressure whichever is higher. Pressure shall be maintained for a period of not less than 30 minutes. While arriving at the above values, maximum suction pressure shall be taken into account. e) Performance Test at Shop i) Each pump shall have to be tested to determine its performance curves. These tests are to be conducted in presence of clients representative as per the requirements of Hydraulic Institute Standards, USA (ASME Power Test Code PTC 8.2)/ BS: 599 or any other equivalent standard but the
tolerances on head, discharge and power shall be as specified in Hydraulic Institute Standard, USA. ii) Performance tests are to be conducted to cover the entire range of operation of the pumps. These shall be carried out to span 130% of rated capacity upto shut-off condition. A minimum of five combinations of head and capacity are to be achieved during testing to establish the performance curves, including the design capacity point, shut-off point and the two extremities of the range 285
of operation specified. After completion of performance test, all pumps shall be stripped down for inspection of internals. iii) Testing of all the pump sets for the same pumping station with a common motor is acceptable provided the same motor forms a part of supply under the contract. Each pump shall be tested at its rated speed for the entire working range. iv) NPSH tests are to be conducted on one pump of each type at 3% head drop conditions v) Mechanical run test shall be carried out on all pumps to determine the vibration and noise levels etc. This test shall be conducted at site also. However, test value at site shall be used for the acceptance of the equipment. vi) Bearing temperatures shall be determined by a contact type thermometer. A running time of at least 30 minutes shall be maintained for this test at shut-off head if sufficient water is not available for a complete test. vii) All instruments and equipment required for such tests shall be provided by the manufacturer and the instruments shall be calibrated and certified by an approved independent testing authority not more than 15 days prior to the test in which they will be used. viii) Reports and test certificates of above tests shall be submitted to the client for approval. The bidder shall submit in his proposal the facilities available at the manufacturers works to conduct the above mentioned Inspection and Testing. f) Testing at site All pump sets shall be tested at site in the presence of manufacturers expert. The QH and Power parameters can be measured with suitable measuring device to be arranged by contractor at no extra cost. 2.10 Valves
2.10.1 Sluice Valve Unless otherwise specified all the sluice valves will be rising spindle type, flat face, bolted bonnet with solid wedge disc and manually operated by hand wheel. The valves above 286
and including 400 DN shall be provided with spur/bevel gear arrangement for operation and be fitted with by-pass arrangement. The sluice valve will be as per IS: 14846 / S 5150/DIN 3352 at their latest revision. The pressure rating of the valve will be as per the specific standard followed taking into account the operating pressure. Wherever specifically mentioned the valve shall be fitted with extended spindle, head stock along with hand wheel for easy operation from the operating platform. Material of Construction: Body, Bonnet, Wedge, Stuffing Box Gland: Ductile Iron, IS: 1865, Gr. 500/7 Spindle Body Seat and Disc Seat Packing Fasteners Extended Spindle Head Stock Hand wheel : : : : : : : Stainless Steel, AISI410 Bronze, IS: 318 Gr. LT B2 Greasy jute packing IS: 1367, Class 4 / 4.6 Mild Steel, BS: 970, EN8 Cast Iron, IS: 210, FG 260 Cast Iron, IS: 210, FG 260
2.10.2 Reflux Valve Double flanged with hinged single/multi swinging disc complete with bypass arrangements will have to be provided. For sizes 450 DN and above tilting disc type valves are preferred. The valve will be of flat face bolted cover and will be fitted with renewable body and disc seat. The reflux valve will be as per IS: 5312/BS: 5153/ISO 2531 at their latest revision. The pressure rating of the valve will be as per the specific standard followed taking into account the operating pressure. Material of Construction Body, Disc, Cover Trunion Shaft Body Seat Disc Seat Fasteners 287 : : : : : Ductile Iron, IS: 1865, Gr 500/7 Stainless steel, AISI 410 Gun Metal Natural Rubber IS: 1367, Class 4 / 4.6
2.10.3 Butterfly Valve The valves will conform to IS: 13095 / BS: 5155 / DIN: 3354 / AWWA C 504. The valves will operate smoothly and steadily in both the direction, free from flow induced vibration. The valves will be provided with light shut-off closures suitable for frequent operation. The valve disc will rotate 900 from full open to full close and is suitable for throttling duty also. The valves will be of double flanged ends and the body will be provided with lifting lugs. The valve disc will be of solid streamlined slab design with no ribs. The seat ring will be replaceable type and will be bolted on the body. The rubber seal on the disc will be easily replaceable type to facilitate removal at site. The seat design shall be of non-jamming and self-cleaning type. The gearings will be of adequate size to open and close the valves under full indicated unbalanced pressure. Material of Construction Body Disc Disc cover Body ring : Ductile Iron, IS: 1865, Gr 500/7 : Ductile Iron, IS: 1865, Gr 500/7 : Ductile Iron, IS: 1865, Gr 500/7 Stainless Steel IS: 6603 Gr. 04 Cr 19, Ni 9 / ASTM A 276 Type 304 Clamping ring : Stainless Steel IS: 6603 Gr. 04 Cr19, Ni9/ASTM A351 CF 8 Disc seal Stub and Drive shaft Cover for NDE Spacer Gasket Split Thrust Ring Flanged Bush Packing for Bush Dowel pin : Nitrile rubber : Stainless Steel, IS: 6603 Gr 12 Cr 12 : Mild Steel, IS: 2062 Gr. Fe 410 WA : Mild Steel, IS: 2062 Gr. Fe 410 WA : CAF, IS: 2712 Gr. W/3 : Aust Iron, IS: 2749 GrASG Ni 20 Cr 2 : Bronze, IS: 318 LTB2 : PTFE (Teflon) : Stainless Steel, ASTM A276 Type 410
288
Spacer D.E U Cup Seal and O Ring U Seal Retaining Bush Adaptor Plate U Seal Retaining Washer Hardware in contact with water
: Mild Steel, IS: 2062 Gr. Fe 410 WA : Nitrile Rubber : Bronze, IS: 318 LTB2 : Mild Steel, IS: 2062, Gr.Fe 410 WA : Bronze, IS: 318 LTB2 : Stainless Steel, ASTM A276 Type 304
Hardware not in contact with water : Carbon Steel, IS: 1367 Class 4/4.6 Inspection & Testing at Manufacturers Works The manufacturer will submit their QAP for Engineers approval including the following tests and inspections which will be carried out at the manufacturers works. a) All the major components of each valve shall be physically and chemically tested by approved independent testing authority to confirm the material quality. The manufacturer shall intimate the Client, the relevant Standard to be followed for testing. All components subject to testing shall be identified, and only those which are tested successfully shall be used for the manufacture of final product. All test results shall be submitted for Clients approval. Material test certificates of valve components shall be furnished before dispatch. b) Hydrostatic Test The pressure retaining components of all valves shall be tested at the pressure stipulated in the relevant standard followed. The manufacturer should inform the Client regarding the pressure ratings of the valves and all the test certificates to be submitted before despatch of the materials. Painting All the valves shall be painted with zinc rich epoxy primer plus two coats of coal tar epoxy paint. The paint shall be spray applied and dried in a painting booth to avoid ingress of foreign particles especially when the painted surface is not completely dry. 2.11 Pipes, Fittings & Dismantling Joints
One set of double flanged ductile iron pipes and fittings, as applicable for suction and delivery branches and for common delivery main (if not specifically mentioned) for all the pump sets shall be provided. The bidder shall include all pipes and fittings for connection 289
to the rising main up to the stipulated length outside the pump house building. The pipes and fittings shall be as per latest revision of IS 8329/ IS 9523 / Equivalent and must be suitable to withstand the pressure tested to at least double the close valve pressure. The diameter and length of the pipes shall be determined from the specified velocity of the raw / clear water and size of the pump house. The delivery pipe of the pump shall be connected with the pump through enlarger immediately before and after the pump so as to restrict the velocity of raw / clear water in the pipe line at suction and delivery side. For all pumping stations the piping system inside the pumping station shall contain one number dismantling joint at suction and at delivery line of each pump to facilitate the erection and maintenance of plants. Each suction / delivery pipe line shall include one puddle collar at the exit of the wet sump / pumping station where the pipe line is below G.L. All the pipe lines will be protected with anticorrosive paints of required quality to suit the site climatic condition. All pipes and fittings must be cement mortar lined. Pipes sizes above 1000 dia will be of mild steel, IS: 2062 of minimum wall thickness 12 mm. Necessary rubber insertion of suitable thickness shall be provided at all the flanged joints complete with supply and erection of necessary number of bolts, nuts, washers of suitable sizes. 2.12 Gauges
All the pumps shall be provided with dial type pressure gauges of suitable range at suction and at delivery flanges as applicable complete with copper tubing and control cocks. The gauges shall be of direct mounted type. The dial size of each pressure gauge shall not be less than 150 mm. The material of construction shall be suitable for raw / clear water pumping station installations. Each pressure gauge shall be complete with pressure snubber and of suitable class of enclosure. Accuracy shall be + 1.0% of full scale range or better. Scale range shall be selected so that normal system pressure is approximately 50% of full scale. The gauges should conform to the latest revision of IS: 3624 / BS: 1780 / Equivalent. 2.13 Monorail Crane with Chain Pulley Block
Monorail mounted hand operated chain pulley block to be provided at the locations shown in the drawings shall be as per the requirement of BS: 3243/ Equivalent. It shall be of 290
required capacity having adequate chain length. The load chain shall conform to BS: 2902/Equivalent. Guide shall be provided for effective guidance to the load chain and a stripper for effective disengagement of chain from wheel. Idler wheels shall be provided in the block to prevent twisting of chain and bending of links. The load chain length shall be more than the minimum length required to achieve the lift by not less than 3 links per fall. The lifting hook shall be forged heat treated alloy or carbon steel conforming to BS: 2903 / Equivalent. The bottom hook shall be so designed that it can swivel in the loaded condition without twisting the load chain. The top hook shall be so designed that it can swivel in no load condition. The length of the hand chain shall be such that the lowest point of the suspended loop shall hang at least 500 mm above the operating level. Hand chain wheel shall be flanged and guides shall be provided to prevent coming out or jamming the chain. Gears shall be machine cut from carbon steel conforming to BS:4670 / Equivalent. Chain pulley block shall be provided with an automatic load brake to prevent self-lowering of load and shall be of screw and friction disc type and gear shall be resistance less during hoisting. The hoist block shall be tested for 150% overload through a length of lift which will ensure that every part of the block mechanism and each tooth of gear come under load. The track shall be either rolled or fabricated section and shall be considered as a simple beam for determining the capacity. In determining the size of the track the load on the load carrying tension flange shall be assumed to be at the point central to the span of the track. The allowable stress on the tension flange shall be 20% of the ultimate strength of the material used. All necessary clamps, hanger rods, and other fittings from which the track is suspended shall be considered as part of the track system. Track hangers shall support the load resulting from the maximum loading condition. The allowable stress for hanger rods shall be determined from the root area of the rod. Means shall be provided to allow for the vertical adjustment of the track both before and after the system has been put in operation so that track can be erected and maintained level. Where the track is suspended from hanger rods, track shall be braced laterally and longitudinally to prevent excessive sway and lock nuts or other means shall be provided to prevent the nuts from backing off the rods. Where multiple rods are used at a suspension point, consideration shall be given to the unequal load induced in the rods. In the design of hanger rods, the allowable stress shall be 20% of the ultimate strength of the material used. 291
The trolley shall be fabricated from structural steel (IS: 2062) of suitable sections. Trolley wheels shall be drop forged or rolled steel with heat treated treads and flanges or cast iron with chilled tread and shall have a minimum treat hardness of 425 Brinell. Wheel bearings shall be single or double row, combination of radial and axial thrust, anti-friction precision type. Bearings shall be pre-lubricated and sealed or provided with fittings and seals for pressure lubrication. The contractor shall justify the size of monorail offered supported by design calculations. Painting The monorail structure shall be painted with zinc rich epoxy primer plus two coats of coal tar epoxy paint. The paint shall be spray applied and dried at site after erection. 2.14 Exhaust Fan
Exhaust fans shall be provided at the places specifically mentioned for ventilation purpose. The cast aluminum alloy blades shall have high efficiency aerofoil section. Blades shall be directly mounted on motor shaft, dynamically balanced and shall conform to IS: 2312. The means provided for securing the fan mounting or fan casing to the wall shall be such as to provide a secure fixing without damage to the fan or wall. The drive motors shall be TEFC, squirrel cage, induction type suitable for 240 Volts + 10%, 1 phase OR 415 Volts + 10%, 3 phase, 50 Hz AC supply with IP54 enclosure and class B insulation. Suitable designed guards shall be provided at the inlet and outlet side to prevent accidental contact. No inflammable material shall be used in the construction of fan. Molded parts, if used, shall be of such materials as to withstand the maximum temperature attained in the adjacent component parts. The fan shall have protective insulation may be of all insulated construction or have either double insulation or reinforced insulation. Each fan should be provided with a 10 sq.mm mesh bird screen. The sheet used for the cowl shall be 14 SWG. The finish will be stove enameled glossy paint/epoxy paint with specially pre-treated components to enhance corrosion resistance. The number and size of exhaust fan will be determined taking into account 12 complete changes of air per hour to the service area. 2.15 Sump (Dewatering) Pump
The Sump (Dewatering) Pump shall deal mainly with gland packing seepage water and raw / clear water that may be emptied out of the main pumps, pipes and specials during maintenance and repairs. They will also deal with water used to hose down the dry pit. 292
The pump will be vertical / horizontal, centrifugal, single stage with non-clog impeller driven by electric motor. The speed of the pump should not be more than 1450 rpm. The motor output power must have at least 25% margin over pump input power at duty point and the motor will never be overloaded throughout the entire pump operating range as shown in the performance curve. The pump performance must be stable from zero discharge to run out condition. The design, manufacturer and performance of the pump shall comply with the latest revision of applicable Indian / International Standards. The pump shall be capable of developing the required total dynamic head at rated discharge and will be suitable for continuous operation. The head-capacity curve of the pump shall be continuously rising towards the shut-off with highest head at shut-off. The impeller of the pump shall preferably be of non-overloading type. The pump shall operate trouble free, smooth and without any undue noise and vibrations. The pump casing shall be of cast iron (IS: 210, FG 200) and the impeller shall be semi open / closed, non-clogging properly balanced and constructed of 1.5% nickel cast iron, having smooth surface for high efficiency. The shaft shall be of stainless steel (AISI: 410) ground and polished at bearing points. The dewatering pump shall be complete with cast iron base plate (if required), sluice valve at delivery and foot valve with strainer at suction. The pump shall be provided with required length of 50 DN galvanized iron pipes of medium quality as per IS: 1239 along with specials to connect the suction and delivery branch of pump. The motor shall be vertical / horizontal rigidly or flexibly coupled, flanged or foot mounted drip-proof construction and suitable for operating at 240 Volts 10%, 1 phase OR 415 Volts 10%, 3 phase, 50 Hz, AC supply. It shall be of constant speed, squirrel cage induction type with DOL starting. Assembly and Testing The pump shall be individually assembled and tested with respective motor at manufacturers works as per relevant standard / specification. Painting The pump set shall be painted with zinc rich epoxy primer plus two coats of epoxy paint. The paint shall be spray applied and dried in the painting booth to avoid ingress of foreign particles especially when the painted surface is not completely dry.
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3. PUMPING SYSTEM
Armoor Water Supply System

Sri Ram Sagar Lake Raw Water Pumping Station (Intake) This raw water pumping station situated at Sri Ram Sagar Lake is dedicated to transmit raw water from the reservoir intake to the inlet chambers of the WTP at Yanamgutta Village which is about 18 km away and the level differences are as follows. Level difference between H.W.L. at Intake and Discharge Point Level is 47.0 m (380 333 = 47) and the same between L.W.L. at intake and Discharge Point Level is 62.50 m (380.00 317.50 = 62.50). The average i.e. Duty Point Level difference, Static Head is 54.75 m. The total demand for Horizon Year 2026 is 9.70 MLD (D = 22 hrs) and the same for Horizon Year 2041 is 12.60 MLD (D = 22 hrs.) The pumps selected are of Vertical Turbine type. Nos. of pumps to be installed for both the Horizon Years are 3; 2 working and 1 standby. For Horizon year 2026 each pump discharges 4.85 MLD i.e. about 225 m3/hr and for Horizon Year 2041 each pump discharge 6.30 MLD i.e. about 290 m3/hr. The pumps will have over the floor discharge and installed on Intake Well at the reservoir. For full demand 2 nos pumps will run in parallel. All pumps are fitted with required sizes of pipes and fittings including dismantling joints to restrict the flow velocity below 2.5 m/sec. At pump delivery 1 no. Non-Return Valve and 2 nos Butterfly Valves, 1 No. electrically operated and 1 no. manually operated are installed. The pumps will have strainer at its suction. Taking into consideration the full demand of Horizon Year 2041 the Common Header size has been finalized to 500. The pump house will be installed with an E.O.T. Crane of 5 Te capacity to handle heaviest load during erection and maintenance. The Header is fitted with 1 no Flow Meter. All pumps are fitted with pressure gauges at their delivery. Required numbers of Exhaust Fans are installed in the pump house. Yanamgutta Village Clear Water Pumping Station (at WTP CWR) This pumping station will cater to 7 ELSRs at different zones and 2 tapping points one at Perkit Village and other at Mamidipalle. 294
The total demand for Horizon Year 2026 is 8.75 MLD (D = 22 hrs) and the same for Horizon Year 2041 is 11.44 MLD (D = 22 hrs.) The pumps selected are of Horizontal Axial Split with double entry impeller type. Nos of pumps to be installed for both the Horizon Years are 3; 2 working and 1 standby. For Horizon Year 2026 each pump discharges 4.375 MLD i.e. about 200 m3/hr. and for Horizon Year 2041 each pump discharges 5.72 MLD i.e. about 260 m3/hr. There are 2 chambers in the Clear Water Reservoir (CWR). These chambers are connected with all 3 pumps through a Common Suction Manifold. Common Suction Manifold is connected with the chambers by Bell Mouths and Butterfly Valves, manually operated. At the suction of each pump manually operated Sluice Valve is installed whereas at the delivery of each pump 1 no. Non-Return Valve and 1 no. manually operated and 1 no. electrically operated Butterfly Valve are fitted. All pumps are fitted with required sizes of pipes and fittings including dismantling joints to restrict the flow velocity below 2.0 m/sec at suction and below 2.5 m/sec at delivery. The Common Header coming out from the pumping station has various diameters to suit the flow velocity and to balance the pumping head required for different ELSRs. These diameters have been finalized taking into account the flows of both Horizontal Years. The Common Header at the pumping station exit is installed with 1 no Flow Meter. The pump house will be installed with an E.O.T. Crane of 3 Te capacity to handle the heaviest load during erection and maintenance. Sump pumps for seepage water drainage and service pump for various utilities are provided in the pump house. Required ranges of Compound Gauges and Pressure Gauges are installed at suction and delivery of pumps. Pump House is installed with required numbers of Exhaust Fans.
PARTICULAR SPECIFICATION Raw Water Pumping Station Liquid Data Liquid Handled Temperature Total Dissoleved Solids Total Suspended Solids pH Value Raw Water Ambient,Peak-50C,Average - 40 C 250 mg / ltr 45 mg / ltr 7.5 to 8.5 Section VII. Work Requirements Sri Ram Sagar Lake Raw Water Pumping Station
295
Sp.gr Total BOD5 Clear Station Water Pumping
1.00 Nil
Yanamgutta WTP Clear Water Pumping Station
Liquid Data Liquid Handled Temperature Total Dissoleved Solids Turbidity pH Value Sp.gr Total BOD5 Civil & Hydraulic Data Pumping Station Designation Civil Data Existing Ground Level, m Finished Ground Level, m Plinth Level, m Motor Floor Level, m Pump Floor level, m Sump Bottom Level, m Wet Well Diameter, m Pump House Soffit Level, m Hydraulic Data Maximum Water Level at Suction, m Minimum Water Level at Suction, m Discharge Level, m *Highest in the Supply System 1. Vertical Raw Water Pump Pumping Designation Service Type Station Sri Ram Sagar Lake Raw Water Pumping Station Raw Water Mixed Flow vertical Section VII. Work Requirements (+) 333.00 (+) 318.00 (+) 380.00 (+) 374.00 (+) 371.20 (+) 401.129* N.A N.A (+)334.00 (+)334.00 (+)334.00 (+) 316.00 10.00 (+) 341.50 (+) 374.00 (+) 374.00 (+) 374.60 (+) 369.60 (+) 369.60 (+) 369.60 N.A (+) 380.60 Sri Ram Sagar Lake Yanamgutta Village Raw Water Pumping Clear Water Pumping Station Station Clear Water Ambient Peak-50C Average - 40 C < 250 mg / ltr < 1.0 NTU 7.5 to 8.5 1.00 Nil
296
Designation Duty Location Design Capacity, m3 / hr Numbers required TDH at design (Bowl), m Speed, rpm capacity
RW Pump Continuous Indoor 225 3 78.50 < 1500
Minimum Bowl efficiency 80 required at design capacity, % Numbers of Pumps working Numbers of Pumps standby 2 1
Numbers of Pumps working in 2 parallel Range of Operation Design & Constructional features Materials of Construction Supply of Accessories & Services Tests and Inspection Between 70% and 130 % of rated capacity As per "Standard Specification" As per "Standard Specification" As required and as per "Standard Specification" As per "Standard Specification"
Pumping Station Designation Service Type Designation Duty Location Design Capacity, m3 / hr Numbers required TDH at design capacity, m Speed, rpm
Yanamgutta WTP Clear Water Pumping Station
Clear Water Horizontal Axially Split with Double Entry Impeller, Foot Mounted CW Pump Continuous Indoor 200 3 50.50 < 1500
Minimum efficiency required 80 at design capacity, % Numbers of Pumps working Numbers of Pumps standby 2 1
Numbers of Pumps working in 2 parallel Range of Operation Between 70% and 130 % of rated capacity Section VII. Work Requirements
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Design & Constructional Features Materials of Construction Supply of Accessories & Services Tests and Inspection
As per "Standard Specification" As per "Standard Specification" As required and as per "Standard Specification" As per "Standard Specification"
2. Valves Sri Ram Sagar Lake Yanamgutta WTP Clear Raw Water Pumping Water Pumping Station Station Not Applicable Rising Spindle 10 250 3
Pumping Station Designation
A. Sluice Valve Type Nominal Pressure, PN Size, Dia, mm Numbers required A. Reflux Valve Type Nominal Pressure, PN Size, Dia, mm Numbers required B. Butterfly Valve
Swinging Disc / Tilting Disc 16 200 3 10 200 3
Type Nominal Pressure, PN Size, Dia, mm
Double Eccentric 16 200 10 200 3-Electrically-Operated 3-Manually-Operated
Numbers required
3 - Electrically Operated 3 - Manually Operated
C. Butterfly Valve at CWR Type Nominal Pressure PN Size, Dia, mm Numbers required For All Valves Design & Constructional Features Materials of Construction Supply of Accessories & Services Tests and Inspection
Not Applicable Double Eccentric 10 350 - Manually Operated 2
As per "Standard Specification" As per "Standard Specification" As required and as per "Standard Specification" As per "Standard Specification" Section VII. Work Requirements
298
3. Pipes & Fittings (Double Flanged) Pumping Station Designation Pressure Rating Sri Ram Sagar Lake Yanamgutta WTP Clear Raw Water Pumping Water Pumping Station Station PN16 Approx. DN Length (mm) 200/150 200 250 PN10 Approx. Length (mm) 250 250 300 1300 1300 1000 2000 14. Straight Pipe 15. Straight Pipe 16. Straight Pipe 17. Parddle Collar 18. Blank Flange 19. Cross Material of construction Tests and Inspection 500 1 250 200 400 250 400 2000 4000 1800 1000 -
Qty. No. 3 3
DN 250/200 200/150 250 200 400
Qty No. 3 3 3 3 1 3 1 3 3 4 4 3 3 3 3 5 3 3 2
1. Taper* 2. Taper* 3. Dismantling Joint 4. Dismantling Joint 5. Dismantling Joint 6. Tee 7. Tee 8. 90 deg. Bend 9. Bell Mouth 10. Straight Pipe (Between Tees) 11. Straight Pipe (after 90 deg. Bend 12. Straight Pipe (Between Cross) 13. Straight Pipe
500/200 500 500 500 750 1500
3 1 2 1
400/200 400/250 350 350 400 400 350
400 / 350 / 250 As per "Standard Specification" As per "Standard Specification"
Notes : *1. Taper smaller side bore i.e. pump suction and delivery size will be as per pump manufacturer's standard. 2. Short piece / puddle collar/straight pipe length will only be finalized as per equipment dimensions, locations and wall thickness.
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4. Gauges Sri Ram Sagar Lake Yanamgutta WTP Clear Water Raw Water Pumping Pumping Station Station Station Range, Kg / Qty. No. Cm2 Pressure Gauge at Delivery 0 - 16 3 side Compound Gauge at Not Applicable Suction side Range, Kg / Cm2 0 - 10 (-)1.0 - (+)1.0
Pumping Designation
Qty. No. 3 3
5. Electrically Operated Overhead Travelling Gantry Crane & Hoist (EOT) Pumping Designation Type Numbers required Capacity, Te Span, mm (Approx) Long Travel, mm (Approx) Lift, mm (Approx) Design & Constructional Features Materials of Construction Supply of Accessories & Services Tests and Inspection Station Sri Ram Sagar Lake Raw Water Yanamgutta WTP Clear Pumping Station Water Pumping Station Double girder Electrically Double girder Electrically Operated Operated Overhead Overhead Travelling Travelling 1 1 5 5000 10000 22500 As per "Standard Specification" As per "Standard Specification" As required and as per "Standard Specification" As per "Standard Specification" 3 5000 16500 8500
6. Monorail Crane with Chain Pulley Block Pumping Station Designation Capacity, Te Long Travel, mm (Approx) Lift, mm (Approx) Numbers required Design & Constructional Features Materials of Construction Supply of Accessories and Services Test and Inspection Yanamgutta WTP Clear Water Pumping Station 1.0 16500 8000 1 As per "Standard Specification" As per "Standard Specification" As required and as per Specification" As per "Standard Specification" "Standard
300
7. Exhaust Fan Pumping Station Designation Type Sweep, mm Numbers required Air to be removed, m3 / hr Sri Ram Sagar Lake Raw Water Pumping Station Axial Flow 300 4 6,600 Yanamgutta WTP Clear Water Pumping Station Axial Flow 300 6 9,800
8. Flow Meter Sri Ram Sagar Lake Yanamgutta WTP Clear Raw Water Pumping Water Pumping Station Station Ultrasonic Raw Water Ambient 40 1 mm Kg / cm2 m3 / hr m / sec Constructional 500 7.90 100 - 1000 0.14 - 1.41 IP 67 Ultrasonic Clear Water Ambient 40 1 400 5.10 100 - 1000 0.22 - 2.21 IP 67
Pumping Station Designation Type Liquid Transmitted Liquied Temperature C Numbers required Pipe Dia, Duty Point Pressure, Flow Range Velocity Range Protection Design & Features
As per "Standard Specification" As per "Standard Specification"
Materials of Construction Supply of Accessories Services Tests and Inspection
&
As required and as per "Standard Specification" As per "Standard Specification"
9. Sump (Dewatering) Pump Pumping Station Designation Service Type Duty Location Design Capacity, m3 / hr Numbers required / P.S. Yanamgutta WTP Clear Water Pumping Station Seepage Water Non-clog, Centrifugal Continuous Indoor 27 2 Section VII. Work Requirements
301
TDH at Design Capacity, m Speed, rpm Design & Constructional Features Materials of Construction Supply of Accessories & Services Tests and Inspection
10 < 1450 As per "Standard Specification" As per "Standard Specification" As required and as per "Standard Specification" As per "Standard Specification"
10. Service Water Pump Pumping Station Designation Service Duty Location Numbers required Design Capacity, m3 / hr TDH at Design Capacity, m Yanamgutta WTP Clear Water Pumping Station Potable Water Continuous Indoor 1 6 To be decided by the Bidder considering the sump depth and overhead tank height
Speed, rpm 1425 Minimum Set Efficiency Required at Design Capacity, % 40 As per "Standard Specification" Design and Constructional Features Material of Construction Supply of Accessories & Services Tests and Inspection As per "Standard Specification" As required and as per "Standard Specification" As per "Standard Specification"
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SECTION VII E TECHNICAL SPECIFICATION FOR ELECTRIC MOTORS
SCOPE
1.1 This specification covers the general requirements of the drive motors. 1.2 Motors shall be furnished in accordance with both this general specification and the accompanying driven equipment specification. 1.3 2 In case of any discrepancy, the driven equipment specification shall govern. STANDARDS
All motors shall conform to the latest applicable IS Publications except when otherwise stated herein or in the driven equipment specification. 3 Service Conditions
3.1 The motors shall be installed in hot, humid, tropical atmosphere in polluted area with coal dust and/or fly ash. 3.2 Unless otherwise noted, electric equipment/system design shall be based on the service conditions and auxiliary power supply given in the annexure of this specification. 3.3 For motors installed outdoor or exposed to 100% humidity, the effect thereof shall be considered in the determination of the design. 4. Type and Rating 4.1 Induction Motors 4.1 Motors shall be general purpose, constant speed, squirrel cage, three phase, and induction type, vertical. 4.2 All motors shall be rated for continuous duty. They shall also be suitable for long period of inactivity. 4.3 The motor rating provided shall at least have 20% margin over the input power requirement of the driven equipment at rated duty point. 4.4 The motor characteristics shall match the requirements of the driven equipment so that adequate staring, torque, accelerating, pull up, break down and full load torques are available for the intended.
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5 5.1
Performance Running Requirements
5.1.1 Motor shall run continuously at rated output over the entire range of voltage and frequency variations as given in the annexure. 5.1.2 The motor shall be capable of working satisfactorily at full load for 5 minutes without injurious heating with 75% rated voltage at motor terminals. 5.2 Starting Requirements
5.2.1 Motor shall be designed for direct on line staring at full load voltage, Starting current shall not exceed 6 times full load current for all auxiliaries subject to IS tolerance. 5.2.2 The motor shall be capable of withstanding the stresses imposed if started at 110% rated voltage. 5.2.3 Motor shall start with rated load and accelerate to full speed with 80% rated voltage at motor terminals.
5.2.4 Motor shall be capable of three equally spread starts per hour, two starts in quick succession both form cold condition and hot condition. 5.2.5 Pump Motor subject to reverse rotation shall be designed to withstand the stresses encountered when starting with non-energised shaft rotating at 125% rated speed in reverse direction. 5.3 Locked Rotor Withstand Time
5.3.1 The locked rotor withstand time under hot condition at 110% rated voltage shall be more than motor staring time by at least 2.5 seconds for motors upto 20 seconds starting time and by 5 seconds for motor with more than 20 seconds starting time. 5.3.2 Starting time mentioned above is at minimum permissible voltage of 80% rated voltage 5.3.3 Hot thermal withstand curve shall have a margin of at least 10% over the full load current of the motor to permit relay setting using motor rated capacity. 6 6.1 Specific Requirements Enclosure
6.1.1 All motor enclosures shall conform to the degree of protection IP 44 unless specified.
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6.2
Cooling
6.2.1 The motor shall be SPDP, self-ventilated type, in IP 44 enclose. 6.3 Winding and insulation of Stator & Base Rotor
6.3.1 All insulated winding shall be of copper. 6.3.2 6000 V motors shall be class F insulation. 6.3.3 All other motors shall have class B insulation. Any substitution of class B insulation must be submitted to the Employer for approval. 6.3.4 The rotor bars and end-rings shall be made of 99.9% electrolyte grade copper. 6.4 Bearings
6.4.1 Motor shall be provided with anti-friction bearings grease lubricated. 6.4.2 Bearings shall be provided with seals to prevent leakage of lubricant or entrance of foreign matters like dirt, water etc. into the bearing area. 6.4.3 Grease lubricated bearings shall be pre-lubricated and shall have provisions for inservice positive lubrication with drains to guard against over lubrication. 6.4.4 Lubricant shall not deteriorate under all service conditions. The lubricant shall be limited to normally available types with IOC equivalent. 6.5 Noise and Vibration
6.5.1 The noise level shall not exceed 6.5 db (A) at 1.5 metres from the motor. 6.5.2 The peak amplitude of the vibration shall be within IS specified limits. 6.6 Motor Terminal Box
6.6.1 Motor terminal box shall be of detachable type and located in accordance with Indian Standards clearing the motor base plate/foundation. 6.7 Noise and Vibration
6,7,1 The noise level shall not exceed 6.5 db (A) at 1.5 metres from the motor. 6.7.2 The peak amplitude of the vibration shall be within I.S. specified limits. 6.8 Motor Terminal Box
6,8.1 Motor terminal box shall be of detachable type and located in accordance with Indian Standards clearing the motor base plate/foundation. 6.8.2 Terminal box shall be capable of turning 360 in steps of 90 unless otherwise approved.
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305
6.8.3 The terminal box shall be split type with removable cover with access to connections. 6.8.4 The terminal box shall have sufficient space inside for termination/connection of XLPE insulated armored aluminum/copper conductor cables for the main motor and XLPE insulated cable leading to Reactor and Capacitor Bank. 6.8.5 Terminals shall be stud or lead wire type, substantially constructed and thoroughly insulated from the frame. 6.8.6 The terminals shall be clearly identified by phase markings, with corresponding direction of rotation marked on the non-driving end of the motor. 6.8.7 The terminal box shall be capable of withstanding maximum system fault current for duration of 0.25 sec. 6.8.8 For 6000 V motor, the terminal box shall be phase segregated type. The natural leads shall be brought out in a separate terminal box (not necessarily phase segregated type) with shorting links for star connection. Accessories shall be furnished, as listed below, or if otherwise required by driven equipment specification or application. 7.1 Space Heater 7.1.1 Motor of rating 30 KW and above shall be provided with space heaters, suitably located for easy removal or replacement. 7.1.2 The space heater shall be rated 240V, 1 phase 50 Hz and sized to maintain the motor internal temperature above dew point when the motor is idle. The heaters shall be provided with pre-set thermostats of adequate capacity. 7.1.3 For motor below 30 KW, the motor winding shall be suitable for continuous heating from 230V single phase 50 Hz supply. 7.2 Temperature Detectors
7.2.1 All 6000 V motors shall be provided with six (6) winding temperature detectors two (2) per phase all equally distributor. 7.2.2 6000 V motor bearing shall be provided with duplex type temperature detectors. 7.2.3 The temperature detectors mentioned above shall be PT-100 type. 7.3 Indicator/Switch
7.3.1 Dial type local indicators with alarm contacts shall be provided on a scanner to demonstrate inter alia and following. a. 6000 V motor bearing temperature b. 6000 V motor, winding temperature. 7.4 Option (b) Squirrel Cage Induction Motor
The electric power shall have to be obtained from the mains of M/S. CESC Ltd. of 6000 Section VII. Work Requirements 306
volts, 3 phase, 50 c/s A.C. The electric motor shall be of high starting torque type with double cage/ trislot/sash bar rotor squirrel cage induction motor, foreign make of 8-pole construction. It shall be provided with CACA enclosure. The windings of the stator shall be open slots. As the motor is to be directly coupled with the pump, it must have necessarily the same speed as the speed of the pump at designed point of operation, of the pump. The rating of the motor shall be 400 KW or more to match with the pump (0.5 MGH). The motor shall be capable of being started direct-on-line (D.O.L.) with a maximum of accelerating time say' not more than 1.1 seconds, while being coupled with the pump. The motor must be suitable for running the pump continuously on full load without endue temperature rise. The motor shall be constructed according to relevant I.S./B.S./DIN specification or equivalent foreign specification. The temperature rise of the motor on continuous full load run shall not be more than 72 C over the maximum ambient room temperature of 45 C the motor shall be suitable for two hot starts in succession with another after 15 minutes. The motors shall be supplied with temperature scanner. The constructional feature of the Motor shall include the following: 7.4.1 The rotor bars (Copper) of the rotor shall be well machined and insulted and tightly placed and fitted inside the rotor slots, the latter being broached in smooth finish. 7.4.2 The ends of rotor bars of the rotor shall be turned to round the section and shall
0 0
be introduced and tightly fitted in the drilled holes of the rotor bar shorting rings before being brazed. 7.4.3 In any case, the rotor be sturdily constructed so as to ensure trouble free starting
three & four times a day without rotor bar fracture inside or outside the rotor or slots or rotor bar end brazing failure or development of cracks in the brazed joints of the rotor bars with shorting rings. The rotor must carry a guarantee of at least 20,000 starts @ two or three starts per day without any rotor bar failure or any other type of rotor failure. 7.4.4 The stator of the motor shall be provided with metal clad terminal box suitable for
termination, 6.0 KV rated 3-Core 150 Sq. mm. size Aluminimum Conductor XLPE Cable of mass impregnated, non-draining type, complete with cable, sockets, terminal glands, armour clamp, earthing terminals etc. so as to comply with the Indian Electricity Acts & Rules. The terminal of the stator inside the Terminal Box shall be so designed that a 150 Sq. mm. size Aluminium Conductor Cable of XLPE type can be connected in parallel for effecting connection to the power factor improving capacitor and for this a second cable terminating gland shall be provided inthe Cable Terminating Box. The star connection of 307
the stator shall be brought out in another terminal box to be mounted on the stator body on the other side. 7.5 The motor shall be with CACA Enclosure capable of rotation in both directions if
possible. 7.5.1 The motor shall be fitted with ani-condensation heaters of adequate rating and suitable for 230 Volt, A.C. Mains voltages, the terminals of the same being brought out in a separate terminal box to be mounted on the stator body. 7.5.2 The bearing and stator of the motors shall be fitted with the required numbers of RTDs (6 Nos. in stator winding & 2 Nos. in motor bearing DE & NDE Housing) and the terminals of the same being brought out in a separate terminal box to be mounted in on the stator body. 7.5.3 The insulation of the stator windings shall be "F" class with "B" class temperature
rise to ensure trouble free operation in an atmosphere, the relative humidity in which may exceed 90%. 7.5.4 The rotor of the motor shall operate on grease-lubricated ball, roller and thrust bearings of the adequate size and rating of say over 1,00,000 working hours. 7.5.5 The bearing housing shall be mounted on the motor end shields in such a way that the dismantling of the rotor from the stator body for maintaining purpose can be easily achieved. The motor shall be of horizontal axis and footpad mounted with adequately sized holding down bolts. Dowel pinholes by the side of the holding down bolt holes, in the footpads of the motor shall also be provided. 7.5.6 Weight of the stator, weight of the rotor and the weight of the whole motor shall be clearly mentioned. 7.5.7 On the name plate of the motor, the following should be clearly impressed. i) Output in K.W. ii) Stator Voltage iii) Stator Connection iv) Stator full load current +p.f. v) Frequency vi) Rotor RPM at full load vii) Class of insulation and temperature rise viii) Weight of the motor. ix) Year of manufacture x) Name of manufacturer xi) PF at full load. Motors of Laurence & Scott. England / Helmke Orbis, Germany will only be accepted. 8. Accessory Terminal Box
8.1 Accessory terminal box shall be complete with double compression brass glands and pressure type, terminal to suit Authoritys cable connections.
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8.2
Drain Plug Motor shall have drain plugs so located that they will drain the water, resulting from the
condensation or other causes from all pockets of the motor casing. 8.3 8.3.1 Lifting Provisions Dowel Pins
The motor shall be designed to permit easy access for drilling holes through motor feet or mounting flange for installation of dowel pins after final alignment of the motor and driven equipment. 8.3.2 Paining
Motor including fan shall be painted with corrosion proof paints. 9 Tests
Upon completion, each motor shall be subjected to standard routine tests as par I.S. In addition, type test of at least 2 nos. motors as per choice of the customer, shall be performed. Further any special tests called for in the driven equipment specification shall be performed. The manufacturers/ tender have to bear the travel costs for two representatives of the Employer to the manufactures factory to witness such tests. 9.1 Six (6) copies of routine test certificates and type test certificate shall be submitted for approval prior to the dispatch of the motors from the manufactures factory. 10 SPARES
Two years spare parts are to be supplied as specified separately recommended spares for five (5) years operation shall be quoted along with the bid clearly identifying the part nos. with recommended quantities. 11 Drawings, Data & Manuals
Drawing, data& manuals for the motors shall be submitted as indicated below: 11.1 Along with the bid a) Individual motor data sheet as per Annexure. b) Type test report. 11.2 After Award of the Contract for Approval. a) General Arrangement Dimensional Drawing b) Foundation Plan & Loading. c) Cable end box details d) Space requirement for motor removal e) Thermal withstand curves hot & cold. f) Starting and speed torque characteristics at 80% & 100% voltage g) Complete motor data. h) Erection & Maintenance manual.
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1.0 SERVICE CONDITIONS Average Grade Design ambient Air Cooling Water 2.0 : : 500C 360C : Approx. 6.0M Relative Humidity Isoceraunic Level Seismic Zone IV
AUXILIARY POWER SUPPLY Supply H.T. Supply Description 6000 V, 50 Hz non effectively earthed L.T. Supply 415V, 3, 50 Hz effectively earthed 230V, 1, 50Hz effectively earthed Motors above 200W to 160 KW Motors below 200, W Lighting space heating A.C. control & protective devices D. C. alarm, control & Protective devices Consumer Motors above 160 KW
D.C. Supply
110V DC unearthed
3.0
RANGE OF VARIATION A. C. Supply Voltage : +/- 10% Frequency : +/- 5%
During starting of large motor the voltage may drop to 80% of the rated voltage for 60 seconds. All electrical equipments during starting shall successfully ride over such period without affecting system performance. Miscellaneous Electric power shall have to be obtained from the mains of APTRANSCO of 6000 V, 3phase, 50 cycles, AC. The electric motor shall be of high starting torque type with double cage/trislot/ sash bar rotor squirrel cage induction motor of 8-pole construction. It shall have provided with CACA enclosure. The winding of the stator shall be in open slot. As the motor is to be directly coupled with the pump, it must have necessarily the same speed as the speed of the pump at design point of operation, of the pump. The rating of the motor shall be 600 KW or more to match with the pump (2700 m3/hr). The motor shall be capable of being started direct on line with a maximum of accelerating time say, not more than 1.1 second, while being coupled with the pump. The motor must be suitable for running the pump continuously on full load without undue temperature rise. The motor 310
shall be constructed according to relevant BS or DIN specification. The temperature rise of the motor on continuous full load run shall not be more that 72 C over the maximum ambient room temperature of 45 C. The motor shall be suitable for two hot start in succession with another after 15 minutes. The motor shall be supplied with temperature scanner.
Check List of the Motors Being Offered 1.01 1.02 1.03 1.04 1.04.01 1.04.02 1.05 1.06 1.,07 Manufacturer Rated output in Kw No. of Poles Speed -do- at present phase load condition -do at future phase load condition Nos. offered Type of duty & duly designation (as per IS 325) Whether the motor is capable for operation after one hot restart and/or 3 hourly restarts (equi-spaced). Supply condition Rated Voltage (Volta) Allowable variation in voltage (%) Frequency (Hz) Allowance variation in frequency No. of Phases Stator connection Currents Full load current No load current Starting current (%) of full load current Efficiency Full load efficiency Efficiency at present phase load condition Power factor Full load power factor Power factor at present phase load Power factor at future phase load No load power factor Method of starting Torque Starting torque (% of full load torque) Maximum torque (% of full load torque) Acceleration time (seconds) from dead stop : : : : : : : : : : : : : : : : : : : : : : : :
o o
1.08 1.08.01 1.08.02 1.08.03 1.08.04 1.08.05 1.08.06 1.09 1.09.01 1.09.02 1.09.03 1.10 1.10.01 1.10.02 1.11 1.11.01 1.11.02 1.11.03 1.11.04 1.12 1.13 1.13.01 1.13,02 1.14
: : : :
311
1.14.01 1.14.02 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.23.01 1.23.02 1.23.03 1.23.04 1.24 1.24.01 1.24.02 1.24.03 1.24.04 1.24.05 1.24.06 1.25 1.26 1.27. 1.28 1.28.01 1.28.02 1.28.03 1.29 1.30 1.31 1.32
With 100% terminal voltage With 85% terminal voltage Safe stall time - Cold/Hot Class of Insulation Ref. ambient (Temperature OC) Temperature rise in (CC) by resistance method & class in which limited Type of enclosure Degree of protection Installation Shaft orientation & mounting Space heaters Number Rating (Watts) Voltage, Phase, frequency Whether separate terminal bod provide for Bearing Driving end Non driving end Anticipated life (hours)_ Recommended lubricant & Qty. Whether separate lubricant nipple provided Interval of lubrication (Hours) Whether winding temperature detectors & bearing temperature detector provided Whether separate terminal box for BTDs RTDs provided Approx. weight of the motor (kgs) Dynamic load (kgs) Normal running condition Starting condition Short circuit condition GD2 value of load to motor shaft (kg.M2) Painting Earth terminal & lifting lug provided (Y/N) Technical leaflets/literatures provided or not
: : : : :
: : : : : : : : : : : : : :
: : :
: : :
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SECTION VII F Technical Specifications for Electric Motors, Controls Etc of WTP. 1. 1.1 General This specification covers the design, manufacture, testing, supply, erection and motor control center, electric motors and other electrical installations such
commissioning of the
as lighting, grounding and cabling etc, for the water treatment plant at PH Office premises, and shall be considered as an integral part of the relevant specification for equipment of the treatment plant. The equipment shall be designed, manufactured and tested in accordance with latest Indian Standard s and code of practice published by the Bureau of Indian Standard whenever available. The Electrical equipment shall also conform to the latest I. E. Rules as regards safety, earthing etc. 1.2 Systems Particulars
Voltage 415 Volts +/- 10% Frequency 50 Hz +/- 3%; Phase - 3 Phase 4 wire Fault Level 25 MVA at 415 Volts. 1.3 Climatic Condition
Climatic conditions are tropical, humid and dusty, maximum humidity often reaches 100% but the conditions of maximum humidity and maximum temperature do not occur simultaneously. The atmosphere is polluted as such the conditions are conducive to fungus growth and corrosion. Maximum ambient temperature 450C Annual rainfall 3000 mm (Approx.) Elevation Below 10 metres 2. 2.1 Motors Motors of treatment plant shall be of squirel cage type induction motors capable to operate
at a supply voltage 415 V +/- 10%, 50 Hz +/- 3% with class B insulation horizontal type & shall conform IS:325 -1996 for use as prime mover to drive water treatment plant pumps of various capacity. Performance curve of Motors are to be furnished. 2.2 Motors for lower capacity shall be provided with DOL starting. Auto transformer start or star
delta starting are to be incorporated for higher capacity Motors in such a way so that Voltage drop at starting remains within 6% of the rated Voltage. The type of starter shall be as specified by the Engineer for each motor. All the main power contactors for any motor starter unit (STAR & DELTA OR ELSE) should be of same and adequate rating. 2.3 Air Circuit Breakers are to be used as per requirement for supplying power to the motor. 2.4. The motor terminals shall be suitable for entry of requisite number of cables of armored P.V.C. insulated, 1.1 kv grade. 2.5 Over load, under voltage, over current earth fault relays are to be provided for motors
above 50 kw rating.
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2.6
Motors shall be provided with local/ remote start stop push button switches and lock out
switches located near the motor wherever specified. 2.7 Motors shall be capable of starting against full load and accelerate satisfactorily at a
minimum voltage of 85% of the rated terminal voltage. 2.8 Locked rotor current of motors at rated terminal voltage shall not exceed 600% of the rated
full load current and the safe stalls time of the motor shall be less than the corresponding accelerating time. 2.9 The capacity, speed, starting torque and other characteristics of the motors such as axial
thrusts, accelerating and stalled time capacities etc. shall be as required for the driven equipment. Motor for indoor type shall be designed for at least 500C temperature over 450C & for outdoor type this shall be 500C over ambient 500C. All motors shall be provided with ball and/or roller bearings. The chemical pump drive motors shall have life sealed bearings. Motors shall be suitable for one cold and two hot starts in quick succession. 2.10 The following data for the motors proposed to be supplied shall be furnished at the time of
submitting the tender: Name of the Manufacturer Application (i.e. driven equipment) Quantity Motor input KW: Guaranteed output of motor with pump operating at duty point (KW) Type of enclosure Class of insulation Voltage (Volts) Frequency (Hz) Phase Type of bearings Temperature rise over an ambient temperature of 450C (0C) Type of starting Starting current (max) % of full load Starting torque (max) % full load Accelerating time Full load speed Rated power factor Motor efficiency a) At full load b) At 75% full load
Confirmation that back to back guarantee from the manufacturer shall be furnished.
314
2.11.
Motors shall be subjected to necessary type test (at least 40% of the motor as per choice of
the Engineer) and routine tests to prove that they are free from electrical and mechanical defects and establish that the design and construction of the motors are satisfactory. 2.12. Requisite (but not less than six) copies of certified dimensioned outline drawings, test
reports and instruction books of the motor shall be submitted by contractor for superintending Engineers approval. 3. 3.1 Starting Equipment (Motor Control Centre) The design, manufacture and testing of various equipment covered by this Specification
shall comply with the latest issue of Indian Standard specification. 3.2 The incoming breaker of the Main M.C.C. shall be of required amperage (details to be
submitted by the Tenderer) moulded case circuit breaker (MCCB). The breaker shall be provided with CTs and PTs. for metering and protection. The protection includes over load, earth fault, under voltage and differential. 3.3 The motor starter unit shall be fully draw out type incorporating in isolating switch, high
rupturing capacity fuse, contactor type air circuit breaker suitable for Direct on line auto/manual, local/remote starting. 3.4 Where H.R.C. fuses are used, proper Co-ordination to prevent undue tripping under
starting condition shall be ensured. 3.5 The isolating switch shall be capable of breaking safely the full load current of the
associated motor. 3.6 The motor control center shall be sheet steel cubicles, indoor/outdoor, floor mounting free
standing type. It shall be totally enclosed, dust tight and vermin proof. It shall be of modern design of nearly U-shape having vertical and inclined faces. So that it can be operated conveniently by the person sitting in a revolving chair in front of the M.C.C. The motor control center shall be sheet steel cubicle, indoor/outdoor, floor mounted free standing vertical type. It shall be totally enclosed, dust-tight and vermin proof. 3.6.1 The sheet steel used shall not be less than 2.0 mm thick and the surface shall be free from
dents and hammer marks. 3.6.2 The cubicle shall be of uniform height and depth throughout its length and suitable barriers
shall be provided between the modules associated with outgoing circuits. 3.6.3 It shall be of front type with all switches, push buttons, indicating lamps on the front, the
rating of switch fuses, contractor, etc, shall suit the rating of the driven equipment and shall be arranged neatly in different compartments. 3.6.4 The frame work of MCC should be done by ISMC 75 & shall have the switches, switch fuse
units, starters and contractor etc. in multitier compartments independent of back plate. The compartment shall be so inter-locked that it shall not be possible to open the door with switch in closed position. 3.6.5 The number of tier to be provided in such panel shall be determined on the following basis : Section VII. Work Requirements
315
For motor upto 6 HP 4 Tiers For motor over 5HP & upto 50 HP 3 Tiers For motor over 50 HP 2 Tiers 3.6.6 The M. C. C shall be provided with aluminium alloy busbars suitable for the required current
capacity with mechanical strength properties approximating closely with that of copper. The bus bar shall be housed in separate chamber and shall be supported on unbreakable, non-hygroscopic hylam supports rightly held to the frame work of the chamber and shall be pained to identify various phases. The current density should be within 1 Amp/mm2 busbar & it should be capable of withstanding a short circuit fault current of 50 K.A. (R.M.S.) for 1 sec. 3.6.7 A cable compartment shall be provided for each module for easy termination of all incoming
and outgoing cables. Adequate supports shall be provided for the cables where necessary. 3.6.8 The cable compartment shall be provided with covers which can be removed for easy
access during cabling. 3.6.9 The M.C.C. shall be completely factory wired with control cable of P.V.C insulated wire of
minimum 2.5 sq. mm copper and shall be fitted with identification ferrules at each end. 3.6.10 The termination shall be of adequate current rating and sizes to suit individual feeder requirements. Suitable cable lugs shall be provided for cable connections. 3.6.11 The Contactor's contact points shall be silver plated and rated to carry the maximum short circuit current without any damage or pitting. 3.6.12 There shall be adequate number of N/O and N/C auxiliary contacts suitably rated on each breaker. These contacts shall be operated mechanically from the main shaft of the breaker and shall be so located as to be accessible from the front. 3.6.12 The auxiliary contacts in the trip circuits shall close before the main contacts and shall open after the main contacts have opened. All other contacts shall close simultaneously with the main contact. 3.6.14 The M.C.C. shall be supplied complete with cable boxes for the incoming. Cable entry shall be at the bottom of panel. Sufficient space for entry of power and control cables shall be provided in motor control centers. 3.6.15 The M.C.C panels shall be provided with copper ground bus which shall be securely mounted across the inside base of the panels. No solder connection will be accepted. A continuous earth bus of size 25X6 mm shall run the throughout the length of the panel with drilled holes at the end for connecting the same with ring earthling earth bus bar. 3.6.16 The switch shall be mounted inside and easily accessible on opening the panel front door. 3.6.17 The M.C.C. units shall be provided with identification and circuit levels, name plates etc. 3.6.18 The M.C.C shall be provided additional loops as per details overleaf and also any other additional loops as may be considered necessary.
316
Sl. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 3.7
Equipment/Unit Provision for Spare over actual number of motors Flash Mixer 1 Alum Agitator 2 Clarification unit Scraper 2 Flocculator 2 Sludge pumping 1 Back wash water pumping 1 Recirculation of waste water 1 Air blower 1 Chlorination Booster 1 Alum solution make up water pumping 1 Rest of the motors 1 Lighting 2 The motor starters shall be housed in separate compartments and the various
compartments shall be joined together to form a rectangular free standing rigid assembly with dead front. The whole assembly along with the buses shall be suitably reinforced and braced to withstand all mechanical and electrical forces resulting from an dead short circuit, They shall be tropicalized and provided with heaters for stand by duty. 3.8 All motor starters below 50 kw rating shall be provided with electronic O/L protection. While
providing fuse for protection, co-ordination must be ensured to the effect that the 415 volts incoming feeder breakers do not trip before the fuse blows. If considered necessary timer relays shall be included in the scope of supply. 3.9 All feeders and starters above 5 kw shall be provided with Ammeters with current
transformer of proper rating. 3.10 All tests shall be performed in accordance with relevant I.S. test codes. and arrangements
made for witnessing by the Engineer, at the premises of the manufacturer. The Contractor shall supply 6 (six) copies of certified test reports of the factory test carried out on each breaker. 3.11 The tenderer shall submit a list of spares recommended by the supplier for three years of
operation of the M.C.C. along with their itemized price. 3.12 The following drawing and type test reports in triplicate shall be submitted along with the
tender for the purposes of preliminary study : i) General outline and dimension drawings of the motor control center giving as many details as possible. ii) Wiring and control diagram. iii) Reports of type test conducted on prototype switch gear. iv) Illustrative and descriptive literature. 4. 4.1 Power and Control Cable All 415 V power cables shall be of 1.1 KV grade standard aluminium conductor, PVC
insulated armoured and the control cables shall be of copper conductor, PVC insulated armoured, All power and control cables shall be laid neatly in covered masonry cable trenches, while selecting cable sizes suitable derating factor (at least 25%) shall be considered. Tenderers shall furnish a list giving type, size and length of the cable proposed to be used, for approval of E.I.C.
317
4.2
Cable use for clarifier power supply shall have at least two spare cores each. Free and of
the spare cores shall be properly sealed and clamped. 4.3 All cables within buildings shall be laid neatly on walls or on trays as the case may be and
shall be readily accessible for inspection and/or replacement. 5. 5.1 Current Collector on Flocculation & Clarification Units Current collector rings shall be constructed form phosphor bronze (or equal approved
materials) of ample cross section and shall be widely spaced to facilitate maintenance and oviate flashover. The shall be contained in brush holders fitted with adjustable springs for applying the correct pressure on the brushes throughout their life. The brush gear must be designed so that no current is carried by the springs. The whole brush assembly shall be continuously rated and shall be capable of removal as a unit without disturbing the collector rings. The current collector ring assembly shall be properly insulated and housed in a dust, vermin, weather and splash proof enclosure and shall be securely fixed with central pivot /or turntable as appropriate. The enclosure shall have thorough anti-rust treatment. The central rotating number shall have ball bearing at both ends. The entire arrangement shall be compatible to Plate Settler Clarification units and Flocculation units. 6. 6.1 ILLUMINATION Internal lighting shall be provided in all buildings of the plant including the weigh bridge
cabin. Lighting shall also be provided near all outdoor equipment of the plant and for general outdoor inspection at night (for security) around each superstructure unit. 6.2 The wiring for lights, fans, weigh bridge, flow metering instruments, plugs and power plug
points shall be carried out nearly through heavy gauge, galvanized surface conduits with necessary junction boxes. 6.3. The intensity of illumination for lighting of different sections of the plant shall be between
150-300 lux depending on the working condition of the related section and shall be properly coordinated to keep balanced three phase voltage. 6.4 Industrial type fluorescent lamps with vitreous enameled reflect complete with chokes,
starters, etc, of renowned and approved manufacture shall be used in all places of the plant except in control room, laboratory, entrance hall and chlorination room where decorative fluorescent fittings with diffusers shall be used. 6.5 In Clarification units deck industrial type dispersive reflector, vitreous enameled finish shall
be used. 6.6 250 watt sodium vapor lamps shall be provided at the following places :
Entrance to chemical house, Entrance to chlorine drum room, Entrance to Filter Annexe building.
318
Rear entrance to Filter house. 6.7 A three pin 5 Amps, lighting plug shall be provided on each switch board for controlling
lights and fans. 7. 7.1 Ceiling and Exhaust Fans There shall be required nos. ceiling fans of 1200mm sweep in control room and in
laboratory and requisite number of exhaust fans in laboratory 8. 8.1 Power Plug There shall be required number of 15 Amps power plug in the filter house, control room, in
pump room and in the laboratory in the chemical house. There shall be of industrial type. 9. 9.1 10. 10.1 Grounding / Earthing The earthing system shall be as per IS 3043. Control Switches in the Laboratory All electrically operated instruments to be used in the laboratory shall be completely wired
with necessary control switches. 11. 11.1 Electrical Testing Equipment The following electrical testing equipment shall be supplied : 1 No. Multi-range Tong Tester.
1 No. Avo-meter. 1 No. 500 V Megger. 1 No. Multi Meter (Electronic) 12. 12.1 Inspection All the electrical equipment and accessories must be of reputed and approved make and
shall conform to relevant I.S. Specifications. Where I.S. Specifications are not available relevant B. S. or A.S.T.M. Specifications will apply. All the installations must be in accordance with the Indian Electricity Rules and I.S. Codes of practice of latest edition. 12.2 It shall be the responsibility of the Contractor to take the approval of Government Inspector
for Electrical installation. All costs for getting the approval shall be borne by the Contractor. 13. 13.1 Labels All electric motors, Starters, Switchgears, Distribution boards, Isolating Switches, Switch
fuse units pillars and other similar items shall be labeled as to their function.
319
SECTION VII G SPECIFICATIONS FOR TRANSFORMERS & FEEDER LINES 1. Power Distribution Transformer
315/63/25 KVA outdoor plinth mounting, double wound CRGO core type, 11000 Volts/433Volts, Delta/Star, 3 Phase 50 cycles transformer, manufactured in accordance with IS 2026-1977. The transformer shall be of Vector group DYN 11. The neutral shall be brought out separately on bushing for earthing the neutral. The transformer shall be continuously rated for specified KVA output at full load and nominal voltage, having no load ratio of 11000 Volts/433 volts and taps on H.V. side for primary voltage variation of plus and minus 2.5%. It shall be designed for satisfactory operation at any supply voltage plus/minus 10% of rated voltage of 11000 volts and with frequency variation of 3% above or below the normal value of 50 HZ. It shall be suitable for operation in parallel with the other transformer. It shall have impedance voltage between 4% and 5% preferably 4.75%. The transformer shall be oil immersed natural Air cooled, contained in a steel tank provided with radiators to facilitate cooling. The temperature rise of the transformer above cooling air temperature when tested at the rated KVA shall not exceed the limits indicated in table 4 of IS 2026 1977 Part-II. It shall be fitted with off tap changing switch with tap position indicator suitable for padlocking. The transformer shall be supplied complete with first filling of oil as per IS 335 and with standard accessories including the following. (i) Off circuit tap changing switch with locking arrangement. Conservator with drain plug, filling hole, cap and oil level indicator. Dehydrating Silica Gel breather. Air release device. Thermometer pocket with 15 cm dial type thermometer. Pressure relief vent. Filter valve with plug. Drain valve with plug. Lifting lugs. Bi-directional flat roller. Diagram and terminal marking plate. Two Earthing terminals. Terminal arrangement. H.V. Side 11 KV cable box suitable for 95 sq.mm XLPE cable. L.V. side Cable box suitable for 185 sq.mm. A1. Conductor, 1.1 KV PVC armoured cable. 320
The contractor shall furnish details of technical data, dimensions, weight, oil content etc. The relevant drawings, test reports/certificates etc., shall be furnished as per this specification. 11 KV 400 AMPS 3 POLE AB SWITCH. 2.1 SCOPE:- This specification covers manufacturing testing and supply of 11 KV 400 AMPS 50 Hz Air Break switches for outdoor installation in horizontal configuration. The switches are suitable for operation under off load conditions only and are intended for use on Distribution Sub- stations. 2.2 DESCRIPTION OF THE MATERIALS:The 11 KV A.B. Switch sets shall confirm to the following parameters:i) Number of poles 3 ii) Number of Post insulator per pole 2 nos. 12 KV post insulator iii) Nominal system voltage 11 KV iv) Highest System Voltage 12 KV v) Rated frequency 50 Hz vi) System earthing effectively earthed. vii) Rated nominal current 400 amps viii) Altitude of installation. Not exceeding 1000 M 2.3 STANDARDS: - The AB Switch Set shall conform to the following standards:-
IS-9920 (Part-I to V.) IS-2544/1973 ( for porcelain post insulators) IS-2633, (for galvanisation of ferrous parts.) or its latest amendments if any. 2.4. INSULATOR MAKE:-
12 KV post Insulators complete with post and cap duly cemented to be used in the AB Switch Set conforming to IS-2544/1973 The contractor shall furnish the type test certificate of the post insulators from their manufacturer for reference and scrutiny. The contractor shall mention make, type of insulation materials, metal fittings, Creepage distance, protected Creepage distance, tensile strength, compression strength, torsion strength and cantilever strength. 2.5 TECHNICAL DETAILS:-
2.5.1 General:The 11 KV A.B. Switch Set shall be the gang operated rotating single air break type having 2 post insulators per phase. The operating mechanism shall be suitable for manual operation from the ground level and shall be so designed that all the three phases shall open or close simultaneously. The Switches shall be robust in construction, easy in operation and shall be protected against over travel or straining that might adversely affect any of its parts. The required base M.S. Channel ( hot dip galvanised) phase coupling rod, operating rod with intermediate guide braided with flexible electrolytic copper, tail piece of required current carrying capacity and operating mechanism with ON & OFF positions shall be provided. The operating rod shall be medium guage of 32mm diameter nominal bore G.I. pipe single length 6 metres. The phase coupling rod for gang operation shall be of medium gauge 25mm dia nominal bore G.I. Pipe. The Rotating post insulators shall be 321
provided with suitable bearing mounted on a base channel with 8 mm dia thrust collar and 6mm split pin made out of stainless steel. The operating down rod shall be coupled to the spindle ( minimum dia - 32mm) for gang operation through another suitable bearing by two numbers 10mm dia stainless steel bolts with double nuts. All the bearings shall be provided with grease nipples. All metal ( ferrous) parts shall be galvanised and polished. The pipe shall be galvanised in accordance with IS-4736/1968. The post insulators should be fixed with the base channel using Galvanised Nuts and Bolts. 2.6 TESTS & TEST CERTIFICATE:Type Test:- Certificates for the following type tests conducted within five years proceeding to the date of opening of tender) on a prototype set of A.B Switch in a Govt. Approved Testing Laboratory shall have to be submitted for reference. Dielectric Test (impulse and one minute power frequency withstand voltage test.) Temperature rise test ( for contacts and terminals) Short Time current and peak withstand current test. Mainly active load breaking capacity test. Transformer off-load breaking capacity test Line charging breaking capacity test Cable charging breaking test Operation and mechanical endurance test Mechanical strength test for post insulator, as per IS-2544/1973 shall be furnished Test for galvanisation of metal (ferrous) parts.
Routine Tests: The following routine tests shall have to be conducted on each set and results are to be furnished. 2.7 Power frequency voltage dry test .Measurement of resistance of main circuit Tests to prove satisfactory operation. Dimension check Galvanisation test. GUARANTEED TECHNICAL PARTICULARS:-
The tenderer shall furnish the guaranteed technical particulars duly filled in the proforma after award of contract. 322
2.8
COMPLETENESS OF EQUIPMENT:-
All fittings, accessories or apparatus which may not have been specifically mentioned in this specification but which are usual or necessary in equipment of similar plant shall be deemed to be included in the specification and shall be supplied by the Tenderer without extra charge. All plant and equipment shall be completed in all details whether such details are mentioned in the specification or not. 2.9 INSPECTION:
Routine tests shall be conducted at the place of manufacturer. The successful bidder has to furnish routine test certificate and guaranteed certificate for approval prior to offer of materials for inspection for each consignment of offer. 3.0 11KV 3 POLE H.G. FUSE SETS. 3.1 SCOPE:
This specification covers the manufacture, testing and supply of 11 KV, 200 Amps 3 pole, H.G. Fuse Sets. 3.2 (a) The 11 KV H.G. Fuses shall be suitable for outdoor operation in horizontal configuration under the climatic conditions specified. It shall be of the following ratings:1. 2. 3. 4. 5. 6. 7. 8. 3.3 Number of Poles No. of insulator per pole Nominal system voltage Highest system voltage Rated frequency System Earthing Rated normal current Altitude of installation STANDARDS: 3 2 nos.12 KV post - Insulators 11 KV 12KV 50 Hz Effectively earthed 200 Amps Not exceeding 1000 M.
The H.G. Fuse set shall conform to the following standards. IS-9385/1980 (for high voltage expulsion fuses and similar fuses) 3.4 IS-2544-1973 (for porcelain post insulators or its latest amendments if any IS-2633-1979 (for Galvanisation of ferrous parts) INSULATOR MAKE:-
12 KV post insulator complete with pedestal cap duly cemented to be used in 11 KV H.G. Fuse sets conforming to IS-2544/1973
323
3.5
TECHNICAL DETAILS:-
The H.G. Fuse sets shall have adjustable arcing horns made of solid copper rod having 7.62 mm dia. The horns shall be fitted with screwing devices with fly nuts for fixing and tightening the fuse wire. It shall have robust terminal connectors of size 80mm x50 mm x 6 mm made of copper casting ( 95% minimum copper composition) duly silver plated with two numbers of 12mm dia brass bolts and double nuts with flat brass washers. The connector should be capable of connecting crimpable conductor up to 80 Sq.mm. size (ACSR/Alloy) with bimetallic solderless sockets .The H.G. Fuse Set shall suitable for horizontal mounting on sub-station structures. The minimum clearance between the adjacent phases of the fuse set shall be 760 mm and the centre to centre (distance between two post insulators of the same phase) shall be 410 mm. All metal (ferrous) parts shall be galvanized and polished. Only 12 KV post insulator (original cemented and not pin insulators shall be used for the H.G. Fuse Set. 3.6 TESTS & TEST CERTIFICATE:-
Certificate for the following type test conducted ( within 5 years preceding to the date of opening of Tender) on a prototype set of H.G. Fuse set in a Govt. approved Testing Laboratory shall have to be submitted for reference and Scrutiny. Dielectric test (impulse & one minute wet power frequency withstand voltage test.) Temperature rise test ( for terminals). Mechanical strength test for the post insulator as per IS-2544/1973 .Test for galvanization of metal (ferrous) parts. ] 11 KV Lightning Arrester (L.A)
4.0 4.1
TESTING SCOPE
This Specification covers supply, testing, inspection before despatch, forwarding, packing, transportation to site, Insurance (both during transit & storage), storage, erection, supervision, testing and commissioning of 11 KV Surge Arrestor (L.A). 4.2 TECHNICAL
The Station Class Surge Arrestor shall be heavy duty, metal oxide, gapless type generally for installation on the 11 KV side of 11/0.433 KV Distribution Substation. The performance requirements are as follows:
Performance Characteristics of Surge Arresters
Nominal System Voltage Class Arrestor voltage rating Rated frequency Continuous operating voltage, rms Leakage current through arrestor at operating voltage 11 KV Station Class 12 KV 50 Hz 9.6 KV Less than 1 mA
324
Long duration discharge class Nominal 8/20s discharge current peak Maximum Lightning impulse residual voltage with 8/20s discharge current peak Maximum switching impulse residual voltage peak Maximum residual voltage with steep current peak High current impulse test value (4/10s wave) Insulator housing impulse withstand voltage, 1.250s wavepeak Insulator housing power frequency voltage withstand capability for one minute (wet) peak Minimum creepage distance of insulator Minimum protected creepage distance
Class 2 10 kA 32KV(31KV*) 28 KV (24 KV*) 38 KV (34 KV*) 100 KA 41.6 KV 29.68 KV 380 mm Not Applicable
* Figures shown in bracket are preferred ratings. Insulation withstand voltage of arrester housing shall be related to the residual voltages in accordance with clause 5.1 of IEC: 99.4
GUARANTEED TECHNICAL PARTICULARS OF 11 KV 400 AMPS A.B. SWITCHES -----------------------------------------------------------------------------------------Sl.No particulars 11 KV 400 Amps A.B. Switches as offered by (desired value) the tender. -----------------------------------------------------------------------------------------1 2 3 4 -----------------------------------------------------------------------------------------1. Makers name and country or origin To be specified by the by the tenderer. 2. Type of Switch Rotating type only 3. Suitable for mounting Horizontal only 4. Number of supporting post insulator per phase 2 nos.12 KV . 5. Post Insulator. as per ISS-2544/1973 (a) Makers name & country of origin To be specified by the tenderer (b) Type of cemeting cemented only. To be quoted original (c) One minute power . frequency withstand voltage Dry 35 KV RMS (d) One minute power frequency withstand voltage Wet. 35 KV RMS. (e) Visible discharge voltage - 9 KV RMS. (f) Dry Flashover VoltageTo be specified by the tenderer (g) Power frequency puncture withstand voltages 1.3 times of actual dry flash over volage. (h) Creepage distance 230 mm minimum. (actual creepage distance for which type test have been conducted is to be specified by the tenderer). 325
6.
a) b) 7. (a) (b) 8. 9. 10. 11 12 13 14. 15. 16. (a) (b) 17. (a)
Impulse withstand voltage for positive and negative polarity ( 1.2/50) mircro second wave). Across the isolating distance To earth & between poles One minute power frequency withstand voltage Across the isolating distance To earth and between poles Rated normal current and rated frequency. Rated short circuit making capacity Rated short time current. Rated peak withstand current Rated mainly active load breaking capacity Rated Transformer off load breaking capacity Rated line charging breaking capacity Rated cable charging breaking capacity Minimum clearance between adjacent phases Switch Closed. ( centre to centre) Switch opened. (centre/edge of blade) Temperature rise: Temperature rise should not exceed to maximum limit as specified below at an ambient temperature not exceeding in 40C Copper contacts silver faced Terminal of switch intended to be connected to external conductor by bolts or screw at an ambient temperature at 40C should not exceed 50C .
85 KV (peak) 75 KV (peak)
32 KV (RMS) 28 KV (RMS) 400 amps. 50 Hz 25 KA (peak). 16 KA (RMS) 40 KA (RMS) 10 A 6.3 A( rms)
2.5 A ( RMS) 10 A ( rms)
760 mm
380 mm 65C
18.
Vertical Clearance from top of 254 mm (minimum) insulator cap to mounting channel Type of contact
19.
a) Self aligned, high pressure jaw type fixed contacts of electrolytic copper of size 80 x 50 x 8 mm duly silver plated. Each contact should be revetted with three nos. Copper rivets with a bunch (minimum 3 mm thick) consisting of copper foils, each may vary from 0.15 Section VII. Work Requirements 326
mm to 0.25 mm. The total thickness of copper foils per jaw should be 6 mm. Jaw assemblings are to be bolted through stainless steel bolts and nuts with stainless steel flat and spring washer. b) Solid blade type moving contact of electrolytic copper size 220 mm x 50 mm x 8 mm duly silver plated. c) Pressure spring to be used in jaw contacts shall be phosphorous bronze having 8 nos of turn x 28 mm height x 14.4 mm diameter with 14 SWG wire (minimum six No. springs shall be used.) 20. Connectors.
Terminal connectors for both movable and fixed should be of copper casting ( minimum 95% copper composition. The fixed connector shall of size 80 x 50 x 8 mm and the size of movable connector shall be size 80 x 50 x 8 mm with machine finishing duly silver plated with 2 nos. 12 mm dia holes provided with suitable brass bolts and double nuts with brass flat washers and 2 Nos. solderless bimetallic sockets for each connector suitable up to 80 Sq.mm conductor. 21. Moving Contact Movable contact is to be supported by galvanised angle of 50 x 50 x 5 mm in each phase and the moving contact are to be bolted through 2 nos stainless steel bolts and nuts with stainless steel flat and spring washers, suitable. 22. Galvanisation a) Iron parts shall be not deep galvanised as per IS-2633/1972. b) The pipe shall be galvanised as per IS-4736/1968. 23. Details of phase:(a) Coupling Rod - 25 mm nominal bore G.I. pipe medium guage. (b) Operating Rod - 32 mm nominal bore G.I. pipe medium guage single length 6 mtrs. The detailed dimension of the G. I. pipe as per IS-1239 (Pt.I) is mentioned below:-----------------------------------------------------------------------------------------------Nominal outside Diameter Base diameter thickness ------------------------------------------------------------------------------------------------Max. Min. 25 mm 34.2 mm 33.3 mm 3.25 mm 32 mm 42.9 mm 42 mm 3.25 mm -------------------------------------------------------------------------------------------------c) Arcing Horn - 10 mm dia G.I. Rod with spring assisted operation. d) Force of fixed - To be specified by the tenderer contact spring e) Copper braided flexible 320 mm length of flexible electrolytic tops, copper tape or braided chord (with tin coated) having minimum weight 450 gms. Per meter and both ends shall be crimped with copper sockets through brass bolts and nuts with brass flat washers two nos of suitable copper Section VII. Work Requirements 327
sockets shall be used at both ends. The minimum no. of flexible wires should be 1536 of 36 SWG for each flexible chord. f) Quick break device: Lever mechanism g) Bearings 4 nos. self lubricant bearing to be provided with grease nipple including 4 the bearing being a thrust bearing. h) Locking arrangement:-Pad Locker & Key arrangement at both ON & OFF position. i) Earth Terminal: To be provided at base channels. 24. Supporting Channels - 75 mm x 40 mm M.S. Channel hot dip galvanized. 25. Weight of each pole - To be specified by the tenderer complete:N.B. i) Ferrous parts shall be duly galvanised as per IS-2633/1972 & Non-ferrous parts shall be silver plated. ii) Certificate from a Govt. Approved Laboratory regarding composition of copper in electrolytic copper casting of materials should be submitted during inspection of materials at the cost of tenderer.
GUARANTEED TECHNICAL PARTICULARS FOR H.G. FUSE SET 11 KV 200 AMPS, 3 POLE -------------------------------------------------------------------------------------------------------------Sl.No particulars (Desired Value) Values offered by . the tender --------------------------------------------------------------------------------------------------------------1 2 3 4 --------------------------------------------------------------------------------------------------------------1. Name of the manufacturer and To be specified by the country of origin. By the tenderer. 2. 3. Operating voltage Number of insulators per phase Rated normal current and normal frequency. 11 KV 2 nos.12 KV Post Insulator per phase
4.
200 Amps.50 Hz
5.
Vertical clearance from top of insulator cap to Mounting Channel - 254 mm (minimum) Height of the riser for carrying 150 mm from the horns - cap (top) of insulator. Post Insulator. Name of the manufacturer & country of origin 328 - To be specified by the tenderer
6. 5. (a)
(b) (c) (d) (e) (f) (g) (h)
Type of cementing One minute power fre-
To be quoted original cemented only 35 KV RMS.-frequency withstand voltage, Dry
One minute power frequency withstand voltage, Wet 35 KV RMS.-. Visible discharge voltage 9 KV (RMS) Dry Flashover Voltage- To be specified by the tenderer Power frequency puncture 1.3 times of actual dry withstand volts, flash over voltage. Creepage distance 230 mm minimum. (Actual creepage distance for which type test have been conducted is to be specified by the tenderer) Impulse withstand voltage (1.2/50 micro second wave positive & negative polarity.
8 (a) (b) 9. (a) (b)
Across the isolating distance - 85 KV (peak) To earth & between poles - 75 KV (peak) One minute power frequency withstand voltage Across the isolating distance, 32 KV (RMS) To earth and between poles, 28 KV (RMS) -
10. Details of Arcing Horns Solid Copper rod having 7.62 mm Dia. silver plated provided with screwing arrangement on the fuse carrier made of copper casting for fixing fuse wire. (Total length 63.5mm). All the bolts, nuts and washers should be made out of brass. 11. Riser Unit (150 mm dia) a) Riser cum connector made out of copper, total height). Casting (with minimum 95% copper composition) having riser size 50 mm height x 30mm width x 8 mm thickness and connector size 80x 50x 6 mm duly silver plated and machine finishing provided with 2 nos.12 mm dia brass bolts & brass double nuts with flat brass washer and 2 nos. solderless bimetallic sockets per each connector suitable up to 80 mm sq. conductor. b) 100 mm height G.I. riser made of 19 mm nominal bore medium gauge G.I. pipe welded with 2 nos G.I. Flat of 30 x 5 mm at both ends fixed with 10 mm dia stainless steel, bolts and nuts with flat stainless steel spring washers. 12. Supporting Channels - 75 x 40 x 6 mm M.S. Channel (galvanized)
13. Galvanisation - All ferrous parts should be galvanized as per IS-2633/1972 & all non-ferrous parts should be duly electroplated with silver. 14. Weight of each pole - To be specified by the tenderer.(complete).
N.B.:- Certificate from a Govt. Approved Laboratory regarding composition of copper in electrolytic copper casting and galvanization as per ISS may be furnished during inspection of materials at the cost of tender. 329
Technical Specification For 11kv Feeder Lines, Materials Support Poles, Cross Arms And Bolts & Nuts SCOPE OF WORKS The scope of works include execution with complete procurement, manufacturers quality assurance, shop testing (including type testing where specified/required), transportation, storage, erection, including all civil/structural works, site testing, commissioning of all items & materials as elaborated below including all associated activities that though not exclusively specified here in but are required for the completion of the entire works under this package. GENERAL REQUIREMENTS & INSTRUCTIONS For HT line the scope covers detailed survey, pole spotting, optimization of pole location, testing, fabrication and supply of all type of transmission line poles including cross arms, angles, channels, braces, top brackets, stay sets, bolts, nuts and washers, all types of insulators, and all type of pole accessories like, phase plate, number plate, danger plate, anti-climbing device, stay sets. Guarding arrangements, etc. selection of type of foundation for different poles and casting of foundation for pole footing; and erection of poles, supply and application of paint, pole earthing, fixing of insulators, supply of conductors & accessories, stringing of conductors along with all necessary line accessories and testing and commissioning . Bidder is required to follow statutory regulations stipulated in Electricity Act 2003, Indian telegraph act 1889, I.E. Act 1910, Electricity (Supply) Act 1948, Indian Electricity Rules 1956 with all amendments till date and other local rules and regulations referred in this specifications. 3. PSCC POLES
PSCC Poles shall be of solid rectangular type with an overall length of 8.0 M suitable for use in 11KV overhead power lines and double pole structures associated with the lines and for 11/0.433 KV substations. 4. APPLICABLE STANDARDS
Except when they conflict with specific requirements in this Specification, the PSCC poles shall comply with the relevant provisions made in the following Indian Standards or the latest versions thereof., IS: 1678, Specification for prestressed concrete poles for overhead power, traction and telecommunication lines, IS: 2905, Method of test for concrete poles for overhead power and telecommunications lines., IS: 7321, Code of Practice for selection, handling and erection of concrete poles for overhead power and telecommunication lines 5. 5.1 APPLICATION 8.0 M Poles (140 Kg)
These poles shall be used at tangent locations for 11kv in wind pressure zones of 75kg/M2 in accordance with REC Construction Standards No. A-5.
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6. 6.1
MATERIAL Cement
The cement used in the manufacture of pre-stressed concrete poles shall be ordinary or rapid hardening Portland cement conforming to IS:269-1976(Specification for ordinary and low heat Portland cement) or IS: 8041 E-1978(Specification for rapid hardening Portland cement). 6.2 Aggregates
Aggregates used for the manufacture of pre-stressed concrete poles shall confirm to IS: 383 (Specification for coarse and fine aggregates from natural sources for concrete). The nominal maximum size of aggregates shall in no case exceed 12mm. 6.3 Water
Water should be free from chlorides, sulphates, other salts and organic matter. Potable water will be generally suitable. 6.4 Cover
The cover of concrete measured from outside of pre-stressing tendon shall be normally 20mm. 6.5 Earthing
Earthing shall be provided by having length of 8 SWG GI wire embedded in concrete during manufacture and the ends of the wires left projecting from the pole to a length of 100mm at 250mm from top and 150mm below ground level. 7. STEEL MATERIALS
7.1 Scope: This specification covers the manufacturing, testing of 100X50 MM MS CHANNEL 75X40 MM MS CHANNEL 50X50X6 MM MS ANGLE As per I.S:2062 and its latest amendments for grade A 7.2 Standards:
The steel materials shall comply with the requirements of latest issue of IS 2062 Gr A except where specified otherwise. 8. 8.1 8.2 11 KV INSULATORS PIN INSULATORS DISC INSULATOR Nominal Voltage Minimum number of discs is string Visible discharge voltage Wet power frequency one minute withstand voltage 331 11 KV 1 9 KV rms. 35 KV rms.
Power frequency puncture voltage Impulse withstand voltage peak Minimum creepage distance Minimum protected creepage distance Minimum mechanical failing load for conductor sizes of 232 MM2 AAAC 80 & 100 mm2 55 mm2 8.3 Tests
75 KV 320 mm -120 KN 90 70
Type, acceptance and routine tests shall be carried out and results given along with certification as appropriate in the Technical Data Schedule and Test Certificates Schedule of this specification. 8.4 Type tests
The following type tests are required : Visible discharge test; Impulse voltage withstand test; Wet power frequency voltage withstand test Electro-mechanical failing load test for string insulator units (porcelain type) 24 hour mechanical strength test; 8.5 8.6 Acceptance Tests The test samples having withstood the routine tests shall be subjected to the following tests according to the sampling procedure of IEC 383 clause 23 : Verification of dimensions 24 hour mechanical strength test Electro-mechanical failing load test for string insulator units (porcelain type) Puncture test; Porosity test (porcelain only ); Test for galvanization of ferrous parts Routine tests
The following routine tests shall be conducted on each set and results are to be furnished for consideration: Visual examination;
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9.
Tensile load test; Power frequency voltage test; STAY INSULATORS (11 KV)
The insulators shall be suitable for use on the distribution system with conditions as shown in the sections on Service Conditions and System Conditions 11 KV Stay insulators shall be used on L.V stays. 9.1 Performance Characteristic shall be strictly as per relevant IS. Materials The insulators shall be brown glazed porcelain . 11 KV LINE FITTINGS SCOPE This Specification covers supply, testing, inspection before despatch, forwarding, packing, transportation to site, Insurance (both during transit & storage), Storage, Erection, Supervision, testing and commissioning of 11KV Line Fittings. Measurements and Tests for Stay Wire
Required Value (Grade 4) Nominal size of stay wire: Nominal Diameter of Individual Wires : Minimum Diameter of Individual Wires : Maximum Diameter of Individual Wires: Minimum ultimate tensile strength of individual wires Minimum percent elongation at rupture before stranding Minimum percent elongation at rupture after stranding Wrapping test for ductility : Turns on and off its own diameter Lay ratio of finished strand Minimum weight of zinc coating before stranding Minimum weight of zinc coating after stranding Chemical test : Sulphur and phosphorus content 7/4.00 mm 4.00 mm 3.90 mm 4.10 mm 700 N 5% 4.25% 8 19 to 21 490 g / mm2 475 g/ mm2 Less than or equal to 0.060 % each
10. 10.1
10.2
11.0 ALL ALUMINIUM ALLOY CONDUCTORS (AAAC) 11.1 SCOPE This specification covers Supply, Testing, Inspection before despatch, forwarding, packing, transportation to sites, Insurance (both during transit & storage ), storage, erection, supervision testing & commissioning of all sizes of All Aluminium Alloy Conductors of the aluminium magnesium- silicon type 11.2 STANDARDS Except where modified by the specification, the Aluminium Alloy Conductor shall be designed, manufactured and tested in accordance with latest editions of the following standards. 333
IEC/ISO/Other International Standard IEC :1089
IS
Subject Round wire concentric standard conductors lay overhead electrical
IS 398 IS 9997 IEC 502 : 1994
Alluminium Alloy Stranded Conductors Alluminium Alloy redraw rods for electrical purposes Extruded solid dielectric insulated power cables for rated voltages 1.0 KV up to 30 KV Alluminium Magnesium Silicon alloy overhead line conductors Reels and drums of bare conductor. wire for
IEC 104 IS 1778 BS : 6485-1971 2 H.T. Switch Gear
PVC covered conductors for overhead power lines.
The offer of the tender shall include complete design of the H.T. switch gear, current transformer ratio, size of the incoming cable, size of outgoing feeder cable for motor, transformer etc. The cable entry boxes at the near end of H.T. breaker and the terminal box of the motor should be designed according to the size of the cable offered in the tender. The capacity of the incomer H.T. breaker, outgoing feeder breaker and bus bars should be specified in the tender. The H.T. Switch gear shall be of 6.6 KV, 250MVA indoor vacuum circuit breaker, 400A/800A single/ double break, trip free horizontally grout, vertical/horizontal isolations complete with solenoid closing mechanism and anti-pumping relay. The solenoid closing mechanism shall be suitable for 110 Volt DC. The VCB shall be mounted on a brake carriage complete with self-contained manually operated fully interlocked, raising the lowering mechanism with integral earthing and circuit earthing. The operating mechanism shall normally be operated from remote electrical control but arrangement should also be made for local electrical control. Mechanical device shall also be provided on the breaker for manually tripping and closing. Each set of the circuit breaker shall have the following features: a) 1 set mechanical ON & OFF indicator b) 1 rear entry cable box with glands suitable for 11 KV XLPE cable. c) 1 set of indicating lamp Red & Green. 334
d) 3 current transformers of suitable ratio and accuracy class shall be provided e) 2 shunt trip coils rated for 110 VDC. f) 1 Space heater with ON & OFF switch. g) 1 suitable label. h) Local/Remotes elector switch f) Auxiliary switch with required contact. In addition, 2 nos. PT Resin cast and dual point provided in the incoming breakers suitable for 3 phase, 50c/s system with a ratio of 6 KV/110 volts 200 VA, class B with necessary arrangement so that anyone can be connected to the meter and relaying circuit. Symmetrical breaking capacity of the circuit breaker shall be 21.8 KA at 6.6 KV and making capacity shall be 47 KA at 6.6 KV. The short time ratio of the circuit breaker shall be 21.8 KA for 1 sec at 6.6 KV. The circuit breaker shall be capable of carrying rated current at 45C ambient Temp. Without derating.Continuous earth bar shall be provided for the entire length of Switchgear.The circuit breaker shall conform IS-2516/1877 with latest amendment.The cburden of C.T. should not be less than 15 VA. The H.T. switch board shall comprise of 7 panels as follows. 3 Medium Voltage Switch Board.
The M.V.S.H shall be 440 volts grade, 3 phase and neutral, 50 HZ, AC distribution switch board sheet steel clad, compartmentalized, cubical pattern, dust and vermin proof, floor mounted free standing type design having 400 ampere MCCD with horizontal bus bar at top with facility for extension on both side. The incoming & outgoing feeder compartments shall be arranged vertically one above the other in multitier formation in standard sized panels, The height of the panel may be such that oil feeder can be operated from the working floor. Each compartment, should be adequately specious for cable termination and maintenance work and fitted with doors interlocked with the resection switches or circuit breakers so that they are not open able in switch/circuit breaker in closed condition. The entire switch board shall be sectionalized in easily transportable sections, each with suitable lifting hooks. The sections should be so designed that they can be easily coupled joined together at site without any special tools or equipment. The entire switch board shall be integrally mounted 0.1 a mild steel channel frame base of size ISMC.75 having grouting holes and anchoring bolts of suitable size and length. The cubicles should be a rigid folded type construction made of M.S. steel. The frame work shall be made of sheet steel of minimum thickness of 3mm and outer shell of steel of minimum thickness of 2mm. All 335
sheet shall be dent free, smooth, straight, and properly annealed, Access of all cable entering the switch board shall be from the bottom through removable screwed gland plate of thickness 3mm Feeders in a multi-ter panel shall have common cable alley on either side for rise of cable. All openings of the control panel including doors, covers & gland plates shall be properly gasketted by soft rubber gasket to make it dust proof. All bus bars, main and auxiliary risers and interconnections between bus-bars and feeders and also between components of the feeder shall be of electrolytic grade copper conductions. For bus-bars rectangular flat conductor shall be supported on non-hygroscopic type insulating support of adequate mechanical and electrical strength. The bus-bars shall be wrapped by inculsting PVC tape or sleeves, the supports should be suitably spaced to give mechanical rigidly for withstanding stress due to system fault level of 50KA for 1 sec. Normal current density in busbars shall not exceed 1.5 Amp. sq.mm. For interconnection between risers busbars and feeders, flat rectangular conductors may be used for feeders of rating 100 Amp. and above,. For Feeders, of rating below 100 Amp, PVC insulated standard copper conductor cables of 1100 volts grade may be used. All control circuit wiring shall be done by 2.5 sq. mm. PVC insulated standard flexible copper conductor cable of 1100 volt grade. All power circuit and control circuit cable terminations shall be by use of crimped type cable lugs only. All fasteners used shall be cadmium plated passivated. Terminals for control circuit shall be of pressure clamp type of reputed make, like ELMEX or equivalent. Continuous copper earth bus of size 50 x 6 sq.mm. all along the length of the switch board with termination arrangement at both ends shall be provided with oxidation inhibiting grease/compound shall be used at all joints. The switch board shall be finished with two coats each of Zinc-rich primer paint and synthetic enamel finish paint. Paint drying shall be by slove baking prior to application of pair 1. The steel surface shall be degreased, derusted and phosphated, followed by application of nitor cellulose surfacer to achieve a smooth finish. Type Test certificate for all electrical switch gears and components from respective manufacturer are to be submitted along with routine test certificate of the switch gear on completion of the inspection. The medium voltage switch board shall have components of following ratings : Two nos. Incomers. One No. bus coupler, M.C.C.s of 400A, 440 Volt Grade, C.T.s for in corners and outgoing feeders volt meter for incomers selectors switches, push button and indicating lamp sets etc.TPN SPN switch fuse unit feeders, comprising of 125ATPN-4 nos. 63ATPN-6nos. 32ATPN-18 nos. 32ASPN-10 nos. 16ASPN-6 nos. M.C.C.B.s meters, switches shall be front mounting type. 336
4 4.1
Cable H.T. Cables and Jointing
The cables shall be 11KV grade, XLPE, 3 core, armoured, to be laid in ground masonry trench/metal trays having conductors of high conduction electrolyte aluminium. The core shall be stranded and the insulation shall be suitable for the working condition as obtained in the pump room and manufactured strictly according to relevant ISS, Further the cable shall be suitable for 50 c/s earthed neutral system. The sizes of the cable should be ascertained from the capacity of the motor, transformer, etc, indication of sizes are to be given in the offer some shall be included in the tender process. After the cables have been laid slowly and carefully in a standard way, all cable trenches will be filled up or covered with checkered plate or R.C.C. slab according to the direction of Engineer in Charge and the cost of such installation shall be included in the tender prices. Where necessary cables shall be supported on clamps of approved type and be properly protected with trays, pipes or other protective coverings. All electrical joints should be done with socket of suitable size so as to prevent undue heating. All jointing materials, compound and other accessories shall be included in the tender price and all such jointing must be done by the contractor in accordance with the provisions of I.E. rules. All responsibilities for holding the statutory, High pressure Test to be conducted/witnessed by the power supply Authorities and demonstrating the layout/other test to the satisfaction of the Govt. Electrical Inspector before commissioning rest entirely with the contractor Tenderer shall have to make all necessary arrangements for all tests and inspections within the quoted period. 4.2 M.V. Cables and Jointings
M.V. Cables should be 1.1 KV grade PVC insulated and armoured Al. Conductor 32 crore 3 1/2 core as required. The core shall be standard and the installation shall be suitable for the working condition. The cable should be laid in underground trenches 450 mm width x 760 mm average depth, with brick protection on the top of the cable with 16 nos. bricks parameter and filing up the trenches with shifted soil, leveling up and restoring the surface to the satisfaction of the Engineer-in-Charge. Where cable is laid in masonry trench/metal trays, the cable, trenches (where applicable) shall be filled up with sand or covered with chequred plate /RCC slab according to the direction of Engineer-in-Charge. Where necessary cables shall be supported on clamps of approved type and shall be properly protected with G.I. conduct or other protective covering as per direction of Engineer-inCharge. All jointing should be of dry type to be done with hydraulic crimping machine where 337
applicable & done in accordance with the provision of I.E. rules. All jointing materials compound other accessories should be included in the tender price. 4.3 Control cable and jointing
Control cables shall be PVC insulated at least 1100 volts grade multi-copper conductor and armoured of suitable size. The control cable should be terminated with proper glands etc. Name of the manufacturer, details of insulation, armouring overall size of the cable, gross weight of cable per hundred meter run of each core should be mentioned in the tender as per Data Sheet, as follows: 4.4 Data Sheet
1.00 H.T. Cables 1.01 Makes 1.02 Voltage grade & type 1.03 Size and Approx. length from various point to point as per B O C & specification. 2.00 M V Cables 2.01 Makes 2.02 Voltage grade & type 2.03 3.00 3.01 3.02 3.03 4.00 4.01 4.02 4.03 5 size and approx. length various point to point as per B O O & specification. Control cable Makes Voltage grade & type. Size and Approx length from various point to point as per B O O &specification. Co axial shielded cable/signal cable. Makes Voltage grade & type Size and Approx length from various joint to point as per B O Q & specification. Power Factor Improvement Capacitor and 0.2% Reactor
Suitable Bank of capacitor and reactors shall be fitted with motor so that power factor of each motor is improved to 0.95. The capacitor and reactor shall have suitable cable terminate box. The reactor shall be natural air coiled type. The capacitor shall preferably be oil filled natural cooled type and shall be equipped with self-conform to relevant I.S. specification. The reactor shall preferably be dry type. Detailed capacity of the capacitor and reactor should be offered along with the tender as 338
per Data Sheet, as follows: 5.1 Data Sheet for Capacitors & Reactors
A) Capacitors i) Make ii) Rating The delivery side of each pump shell be provided with 1 No. Electrical Actuator operated non rising spindle type sluice valve, 1 No. pump discharge valve capable of inching operation, 1 No. Dismantling joint, duck foot bend & short pieces. The diameter of the valves and joints shall be of 700mm. iii) Whether the Capacitor is capable to improve the power factor of the motor at present phase load condition to 0.95 Yes/No. iv) Rated Voltage v) No. of units vi) Type of internal connections vii) Type of connection with motor Viii) Rated Current ix) Cooling system x) Dielectric xi) Whether discharging resistances have been Provided xiv) Standard is which conform B) Reactors i) Make ii) Rating iii) Type of insulation iv) Cooling system v) Type of connection with capacitor vi) Standard to which conform 6 Earthing The total installation shall be effectively earthed by providing a ring earthing. Each earthing set shaft consist of twin G.I. pipes of not less than 2 dia of sufficient length the electrode 339
shall be buried deep. the ground upto the depth of moist earth which shall not be less than 12.0 form ground level and must be 6.0 away from the pump house structure. The bottom portion of the electrodes shall be properly perforated and shall be filled up with black smith dust. One cast iron cap properly screwed of approved type and design and shall be fitted on the top of the electrode and the cap shall be properly provided with suitable lugs for fixing box electrically and mechanically of the connection leads to the earth bus inside the station. After fixing and drawing out of the earth leads, the top portion of the earth, electrode upto 1 ft. shall be properly brick pitched and shall be lifted with water proof bituminous compound. The connecting load shall be copper bus 1 wide and 1/4 thick shall be laid at a depth of not less than 3 - 0 from ground level and shall be properly brick covered The leads shall be connected to copper each busbar inside the pumping station by means of washers, nuts bolts etc. The nos. of individual earthing connected to the Earth bus should such that after installation. the earth resistance of the system must be well below one station. One connection copper bus bar 1 wide and 1/4 thick shall be provided so that the frames of all electric motors, switch gears\, transformers and other electrical acceptations and installation shall be connected to the above copper earth bus by two separate copper tape of adequate dimension. All metallic cover framer, equipment, installation etc, shall be earthed to the full satisfaction of Engineer in charge and the Govt. Electrical Inspector. The earthing and bonding shall be according to the I.E. Rules 1956, with amendment of 1990. All non-current carrying metal parts associated with H.V. installation shall be effectively earthed to a grounding cistern as mat which will a b c Limit the touch and step potential to tolerable values. potential through ground earth wires, cable sheath fences, pipe lines etc. Maintain the resistance of the earth connection to such a value as to make operation of the protective device effective. The same must be approved by the Govt. Electrical Inspector and shall pass the statutory tests. The successful tenderer shall have to submit the detailed and fully dimensioned drawing of the whole electrical system showing the proper earthing duly approved by the Govt. Electrical Inspector before commencement of the actual installation work. The distance between each individual Earthing should not be more than 6 meters. 7 Lighting System
Luminaries: Industrial Medium bay luminarie type SDK 102 with SON 150W & HDK 102 with Son 250W lamps are to be provided in a row alternatively in the beams at the motor 340
floor ceiling. Fluorescent lamps are also to be fixed on the wall of the motor floor. The positions are to be fixed as per requirement. The illumination level would be 150 Lux. In the lower deck suitable number of SGK 27 with SON 70 watt lamps are to be provided for maintaining 100 Lux illumination at pump floor level, The control rooms lighting should be provided with TL D 36 watt cool day light type fluorescent. Lamps with decorative type fixtures, illumination level would be 200-250 Lux in the corridors, toilets, Trim shine type luminarie with 40W fluorescent lamps are to be provided to generate adequate lighting at all units of water treatment plant, pump house and substation. At the entrance exists of all units of water treatment plant, pump house and sub-station should be provided with SGK 27 with SOM 70 watt lamps and bulk head fittings with incandescent lamps of adequate wattage. 8 Wiring
All wiring installation work must be as per relevant I.S. with proper distribution network. M.C.B are to be used in distribution boxes, there must be colour segregation for power / Neutral/ground wires. Prior to taking up the work, necessary wiring diagram showing junction Boxes, distribution boxes, switches, earthing system is to be placed for approval of the E.I.C. 9 Ventilation System General Description of Arrangement
In order to remove the heat on account of running of pump and motor, exhaust fans are to be provided with main protection cowl and bird screens at pump house and substation as directed by the Engineer.
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SECTION VII H General Conditions for Erection & Commissioning 1. Unloading, Handling & Storage
1.1. The Contractor shall be responsible for the delivery at site/sites of all equipment, material and supplies required for the fulfillment of the contract upto handing over of the plant to the Employer. 1.2 The Contractor shall at his own expense and responsibility transport or shift to plant site, all materials, equipment and supplies furnished for the purpose of this contract. All movement of materials and equipment to and from storage shall be at the expense of the Contractor. Space for storage facilities will be provided by the Employer at the site of the work as available. If the Contractor does not promptly shift and place for use in the premises, where the work is to be done, any material, equipment or supplies delivered, the Employer may do so, and charge all the costs thereof to the Contractor and in any event the Employer shall not be responsible for any damages, arising out of, or in any way connected with such shifting or placing of the same. The Contractor shall further after shifting, unpack the materials, verify contents against invoices and notify shortages or breakages to the Engineer within one week of the receipt of materials and equipment at site, failing which the Contractor shall be held responsible for any consequences. 1.3 If requested by the Engineer, the planned method of transport of equipment shall be submitted to the Engineer for approval. This approval shall not relieve the Contractor of any responsibility for the safety of the equipment and personnel. 2. Contractor Remaining Informed as to Conditions
2.1 The Contractor shall inspect, examine, obtain all information and satisfy himself regarding all matters relating to the execution and maintenance of the works to be carried out under the contract or any hindrances or interferences to or with the construction or maintenances of the works from any cause whatsoever including any other operations of works which may or will be carried out on or adjacent to the site of the works before or during the construction or maintenance of the works under the contract and shall make allowance for all such contingencies in the contract price and will not raise any claims or objections against the Employer in respect of any of the matters mentioned above. 2.2 The Contractor shall take field measurements when or where necessary before detailing, ordering or fabricating any material. 2.3 The acceptance of the order or making of a contract will be construed as evidence that such an examination was made and later claims for labour, equipment or materials required or for difficulties encountered, which could have been foreseen, will not be allowed. 3. Prosecution of the Work
3.1 The Contractor shall furnish adequate, courteous and competent labour, supervisors and engineers of all classes for the duration of the work to maintain progress of erection in accordance with the requirement of the scheduled completion date, and shall begin the work included in the contract at such time as well ensure its completion as specified and shall complete the same, free of all liens and charges, at or before the time specified for completion. The Contractor shall make available qualified engineers for 342
placing the equipment in operation, carrying out the necessary tests and trials and the training of Employer's operating staff, as directed by the Superintending Engineer. 3.2 The Contractor shall be completely responsible for the satisfactory construction, erection, testing and commissioning of the works notwithstanding that he may have been assisted by the Engineer in doing so. 4. Work Performed At Contractor's Risk 4.1 The Contractor shall take all precautions necessary and shall be responsible for the safety of the work to be performed by him, and shall maintain all lights, guards, signs, temporary passages, or other protections necessary for the purpose. The Contractor shall be responsible for any loss or damages to his personnel, materials, tools or other articles used or held for use in connection with such work. Such work shall be carried on to completion without damage to any work or property of the Employer or of others and without interference with the operation of existing machinery or equipment. 5. Constructions Tools, Equipment and Site Facilities 5.1 The Contractor shall, at his own expense, furnish all necessary false work, erection tools, hoist, cranes, air compressors, rigging, skids, cribbing, blocking, scaffolding, sheet piles, equipment, appliances, materials and supplies required for erection and/or testing for performances and start up (hereinafter in this section called 'construction tools and equipment') that may be required to accomplish the work under contract unless otherwise provided for. Adequacy of such shall be to the entire satisfaction of the Engineer. 5.2 All piping for service and drinking water to work area shall be furnished, installed and maintained by the Contractor at his own cost. He shall also furnish, install and maintain at his own cost the power lines, junction boxes or any other electrical receptacles, apparatus or equipment from starting points, to his area. 5.3 The Employer shall not be responsible or held liable for any damage to person or property consequent upon the use, misuses or failure of any construction tools and equipment used by the Contractor or any of his sub-contracts, even though such construction tools and equipment may have been furnished, rented or loaned to the Contractor or any of his agents by the Employer. The acceptance and/or use of any such construction tools and equipment by the Contractor or his agents shall be construed to mean that the Contractor accepts all responsibility for an agrees to indemnify and save harmless the Employer from said use, misuse or failure of such construction tools and equipment for which the Employer may be liable. 5.4 The Contractor shall bear and pay all charges including freight, clearing, insurance, duty on all construction tools and equipment furnished by him. 6. Travelling and Living Expenses 6.1 The contract price shall include all salaries and wages, all travelling time and expenses and boarding and lodging allowances for all personnel furnished by the Contractor and all payments which the Contractor may have to make in relation to the work of the labourers and other personnel employed for complete installation. 7. Simultaneous Work by Others
7.1 The Employer reserves the right to perform or have performed in and about the works during the time when the Contractor is performing his work hereunder such other work as the Employer desires and the Contractor shall make all reasonable effort to perform his work hereunder in such manner as will enable such other work to be performed without hindrance from the Contractor and will make no claim for damages 343
against the Employer arising out of such other work or interference there from. The Contractor will work in harmony with such other contractors regardless of race, religion, colour or national origin and any dispute between contractors shall be arbitrated by the Employer if necessary. 8. START-UP AND GUARANTEES 8.1 Until such time as the equipment or material installed and erected under the contract is finally accepted by the Employer in keeping with the terms and conditions of this contract and associated specifications the responsibility for proper testing, maintenance and efficient operation of the same shall be that of the Contractor. Prior to start-up, the Contractor shall be required to service the equipment and during start-up render such assistance as may be necessary or requested for by the Employer. 8.2 Where the equipment has not been manufactured by the Contractor, the manufacturer's recommendations for installation of the same shall be strictly adhered to and any defects developing due to faulty installation and/or erection during start-up or during a trial run and period of one year from the date of commissioning shall be rectified, remedied or made good by the Contractor through the manufacturer if considered necessary by the Employer at his own expense. When the equipment has been manufactured by the contractor himself, Rectification within similar period is compulsory. 9. 10. Employer Use of Equipment Removal of Debris
10.1 The Contractor shall at all times keep the site free of rubbish, debris and surplus materials so as to render the place of work clean and safe for all personnel working in that area and upon completion of the work shall remove all rubbish and waste materials resulting from his work and leave the works and work site on a clean and finished condition. If the contractor fails to comply, such work will be performed by the Employer at Contractors expense. 10.2 Whenever demolition or other work of any kind creates harmful dust or fumes, equipment for the complete protection of all personnel and property against dust fumes shall be installed, maintained and effectively operated by the Contractor as required by statute. The Employer shall have the right to use the materials and the equipment as he requires, even prior to final acceptance. All such equipment shall be of a type approved by the State govt. / Central Govt. / or municipal or any other regulatory body and the expression harmful dust or fumes shall have the meaning assigned to it be such appropriate regulatory body. 11. Contractors Obligations 11.1 Over and above the responsibilities of the Contractor stipulated in this document, the following obligations shall be fulfilled by the Contractor. 11.1.1 The Contractor shall satisfy the Engineer that adequate provision has been made. a) to carry out his instructions fully and with promptitude; b) to ensure that parts required to be inspected before use are not used before inspection; and c) to ensure that adequate supervision is provided at all stages of the work and each portion of the work is checked for accuracy before erection. 344
11.1.2 The Contractor shall make necessary arrangements including provision of suitable spaces and facilities for testing, for inspection at any stage of manufacture of plant and equipment by the Engineer or his agents, as and when deemed necessary by the Engineer; the time schedule for any inspection will, however, follow the inspection schedule suggested by the Contractor and agreed upon by the Engineer during scrutiny of delivery plan. Irrespective of any inspection and tests made by the Engineer, the Contractor shall be entirely responsible for the proper execution of the Contract notwithstanding any approval which may have been given by the Engineer or the work or of tests carried out either by the Engineer or the Contractor. At least 15 days notice shall be required for inspection to be carried outside the state. 11.1.3 The Contractor shall at his own cost. a) b) Establish and maintain the area placed at his disposal for office/storage purposes. Provide the necessary power and water connection from the supply mains and install and maintain the temporary distribution lines within the working area; Erect and maintain necessary offices and storage space; Provide temporary lighting at erection site required for erection; Arrange for personnel accident insurance for his/their own personnel at site; Arrange adequate security lighting and watch system to safeguard the equipment from any type of mishandling, theft, fire hazards etc. during the construction period, period of Trial Run and defect liability period of 12 months; Gardening and commissioning; landscaping and beautification of the site before
c) d) e) f)
g) h)
Curved Glow Signboard on each gate covering entire width of gate including supporting frame structures and all electrical accessories. The details of the signboard and its writings shall be as per instruction of the Engineer Identification metallic signboard for each units of the plant including supporting frame structures and all electrical spotlight arrangements. The details of the signboard and its writings shall be as per instruction of the Engineer. Among other requirements of the Building and other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996, the contractor shall construct and maintain all labour accomadation in such a fashion that uncontaminated water is available for drinking, cooking and washing and all sanitary facilities shall be maintained as referred in EMP attached as Annexure I & II.
i)
j)
11.1.4 The Contractor shall design, manufacture, erect and dismantle any false work, staging temporary support, etc. required for safe and accurate plant and equipment erection and structural steelwork and shall be fully responsible for the adequacy of the same. The cost of such work shall be deemed to have been included in the raise quoted in the Schedule of prices. 345
11.1.5 The contractor shall, if so required by the Engineer, furnish drawings and design of such false work, staging etc. 11.1.6 The Contractor shall provide for the convenience of inspection/testing adequate temporary and sufficiently strong and stable stairs and access ladders, gangways, etc, wherever necessary at his own cost. 11.1.7 The Contractor shall abide by the instructions and decisions of the Engineer at any stage of execution of the job unless he can convince that the same goes against the interest of satisfactory progress and completion of this work as per agreed schedule. 12. Shop Tests 12.1 Shop tests shall include all tests to be carried out at contractors works, works of his agents at manufacturers works and at works where raw materials supplied for manufacture of equipment. 12.2 The tests to be carried out shall include but not be limited to the tests mentioned below: i) Composition of all materials, castings, forgings, etc. ii) Hydraulic test for pressure vessels, tanks, pump castings etc. iii) Hydraulic tests for valves, specials etc. iv) Test to check faults in rubber lining (as per IS: 4682) or its equivalent and painting. v) Static and dynamic balancing test on all impellers. vi) Static balancing test on agitators, stirrers, paddles etc vii) Performance test (Head, Capacity, BHP) on pump and blowers. viii) Tests on motor as per IS: 4029. ix) Any other test that may be provided in I. S. Specification and as required by the Engineer. 12.3 All test certificates and reports shall be submitted to the superintending Engineer for approval. All tests are normally to be carried out in presence of the Engineer or his representative. However, waiver may be allowed in specific cases by the Employer at his discretion. 12.4 The employers representatives or his appointed agents shall be given full access to all tests. The contractor shall inform the Superintending Engineer/other assigned officer allowing adequate time so that the Engineer in charge or his appointed agents can witness the test, if it is so desired by the Engineer in Charge. 12.5 No component or equipment shall be dispatched unless accompanied by approved test certificates and reports. The approval shall be given provided the corresponding drawings /technical particulars are already approved an the Employers representatives or his appointed agents have witnessed the tests or a letter of inspection waiver is issued by the Engineer in Charge. 13. 13.1 Site Tests General
After erection at site, all components, equipment as Described below shall be tested to prove satisfactory performance and/or fulfillment of functional requirement without showing any sign of defect as individual equipment and as well as systems, The Contractor shall make all arrangements for testing and inform the Engineer for witnessing the tests. 346
i)
1.5 times the maximum attainable pressure in the system, to check against leak tightness. A higher factor shall have to be adopted in specific cases if so specified by the I.S./B.S. All manually operated valves / gates shall be operated throughout 100% of the travel and these should function without any trouble. All pumps shall be run with the specified fluid form shut off conditions to valve wide open condition. During the test the pumps and drive motors shall run without any undue vibration, leakage through gland, temperature rise in bearing parts, noise, flow pulsation etc. Visual check on all structural components, welding, riveting, rubber lining, FRP lining, painting etc. and if doubt arises will be tested again. All EOT and HOT hoists and its components shall be subjected to double the full working load during all motions without showing any sign of defect. Water leakage test of all liquid retaining structures as per IS specifications Load tests and integrity tests of piles. Load test of civil structures if desired by the Engineer. All test instruments and equipment shall be furnished by the Contractor to the satisfaction of the Engineer.
ii)
iii)
iv) v) vi). vii) viii) ix)
13.2 Mechanical Tests All the rotating / moving components like agitators, paddles etc. shall be run at the rated speed with water /chemicals upto the normal water /liquid level continuously for a period of twenty four (24) hours. During this period all the components shall function smoothly without any unbalance vibration, overheating at bearing parts, etc. 14. Erection Schedule
14.1 The Contractor shall prepare a time table for erection schedule of requirements of men and material and tools & tackles or erections and outlines of erection methods together with erection drawings and specifications and submit those for approval of the Engineer. Such schedules shall be submitted well in advance. Any revisions to such schedules shall only be effected after prior approval of the Engineer giving specific reasons for such revisions. 15. 15.1 16. Block Grouting All equipment after erection shall be properly grouted without charging extra. Setting Out and Foundations
16.1 Where setting out and preparation of foundations are carried out by others, the contractor shall approve the accuracy of the setting out before execution of foundation work. The Contractor shall be responsible also for the adequacy of such setting out an preparation of foundations.
347
17.
Protection of Plant
17.1 All plant shall be afforded adequate protection against corrosion, mechanical damage, deterioration etc. until the plant is taken over,. The Contractor shall submit his proposals for achieving this protection for the approval of the Engineer. 17.2 The Contractor shall make good to be satisfaction of the Engineer any deterioration of the protective coatings, paintwork, etc, which may occur during transportation, erection, commissioning etc. until the plant is taken over. 17.3 Finish painting of the plant at site, as specified shall be carried out before the plant is taken over. 17.4 Items of plant which are finished painted at the manufacturers works, such as switch boards, etc. shall be suitably encased in crate or their protection before dispatch. This plant may require to be returned to the works for making good of any deterioration of the paintwork etc. at the Contractors expense, which may have occurred during the period until the plant is taken over. 18. Tools and Tackles 18.1 All tools and tackles, measuring and testing equipment etc. required for the successful execution of all contract shall be provided by the Contractor as part of his responsibility with respect to erection and commissioning of the plant as per the terms of contract. 18.2 All tools and tackles supplied by him will be taken back by him after completion of works excepting special maintenance tools which shall be retained by the Employer till the plant is taken over by him. 19. Delivery and Erection Schedule 19.1 The tenderer shall quote his best schedules for delivery of equipment and plant, erection and commissioning, and shall indicate the expected delivery schedule required for components to suit the erection schedule of the plant. 20. Compliance with Statutes, Regulation etc. 20.1. The Contractor shall conform in all respect with the provision of any such state Ordinance or law as aforesaid and the regulations or Bye Laws of any local or other duly constituted authority which may be applicable to the work or to any temporary work and with such rules and regulations of public bodies and companies as aforesaid and shall keep the employer indemnified against all penalties and liability of every kind for breach of any such statute ordinance or law regulation or bye law. 21. Removal of Improper Work and Materials. 21.1 The Engineer shall during the progress of the work have power to order in writing from time to time. a) The removal form the place of work of site within such time or times as may be specified in the order of any materials which in the opinion of the Engineer are not in accordance with the contract. b) The substitution of in proper and the suitable materials, and c) The removal and proper re-execution (notwithstanding any previous test thereof or interim payment there for) of any work which in respect of materials or workmanship is not in accordance with the contract.
348
22
Packing
22.1 Materials used for packing of the equipment shall be of sound timber of dimensions proportional to the size the weight of contents. The seller shall not use second hand packing materials, All package shall be steel strapped with at least two (2) straps on each package to ensure a solid package and to prevent pilferage. Bundled materials shall be rigidly steel strapped. 22.2 Fragile materials shall be securely packed within the containers or otherwise apply protected and packed to prevent shifting or rattling. 22.3 The empty containers shall be fully covered by strong and durable water proof paper inside, before putting the material, in order to protect the contents from damage, dust and corrosion due to sea or rain water creeping into the cases and, in addition, they shall be properly lined to withstand the elements while in transit or stored without cover. 22.4 Machined parts shall be thoroughly greased and amply protected against rust forming and corrosive elements. 22.5 The Contractor shall not use open type crates or fiber board cartons, unless permission is received from the Employer. 22.6 The Contractor shall not forward any articles without packing as specified herein, without obtaining prior approval of Employer. 22.7 Spare parts shall be packaged separately; under no circumstances they shall be included in the containers with the related commodity. 23. Damage Risk and Insurance 23.1 The Contractor shall arrange the plant and equipment and each part thereof, to be insured against loss, damage or destruction to fire, lightening, earthquake theft and such other risks until it is handed over to the Employer after erection and trial run period as provided for in the contract and shall from time to time, when so required by the Engineer produce the policy and receipts for the premiums. All money received under any of such policies shall be applied in or towards the replacement and repair of the plant damaged or destroyed, but this provision shall not affect the Contractors liabilities under the contract. Separate insurance policies shall be obtained to cover i) ii) 24. Rail and / or road etc., transit of equipment to site; and Period of storage and erection and commissioning at site. Commissioning and Performance Tests
24.1 The Contractor shall undertake the complete responsibility for successful erection and commissioning of the plant and giving successful performance tests. 24.2 The commissioning of the plant shall involve the following steps of operations a) Testing of each unit on no load, to make complete check of its mechanical operations, alignment, clearance and rigidity and making necessary adjustments or alterations required to make such unit properly operatable mechanically. b) After the mechanical check has been made, as stated above, the equipment shall be energized and run progressively from no load to full load.
c) Thereafter, trial operations of the units under completion shall be taken at normal full load operating conditions for which the respective units are designed, further the units shall be rechecked for operation under normal overload conditions and 349
necessary adjustments and alterations of the units shall be carried out to prevent leakage, spillage, heating up, undue vibrations, etc. and ensure that the equipment as erected to fulfill the design requirement. For this purpose, continuous 72 hr. operation shall be demonstrated as a necessary prerequisition to commissioning vide 24.3 (d). 24.3 The initial performance tests shall involve the following steps of operations: a) Necessary pumps shall be started and flow established through all the streams, valves shall be adjusted so as to have rated distribution of flow through all streams. Various units of the plant shall be started simultaneously. Samples of water shall be drawn every hour in the presence of the Engineer or his authorized representative from the outlets of different units, fixtures and chlorinators and tested in the plant laboratory or in any other laboratory approved by the Engineer. The test results shall be compared against the required parameters. Similarly samples of raw water shall be collected in the presence of the Engineer or his authorized representative and tested in order to determine the efficiency of treatment at different stages of treatment. The initial performance tests shall be carried out at least for 72 hours continuous operation. e performance tests of the water treatment plant shall be deemed as a failure in case performance as specified is not met regarding quality and flow. All cost of the initial performance tests shall be borne by the Contractor. After the initial performance tests, the plant will be subjected to Trial Run.
b)
c)
d) e)
350
ANNEXURE-I ENVIRONMENTAL MANAGEMENT PLAN : PRE- CONSTRUCTION PHASE COMPREHENSIVE PLANNING OF WATER SUPPLY SERVICE IMPROVEMENTS IN ARMOOR
S.No. 1 2 Potential Negative Impacts Clearances Tree Cutting Mitigation Measures All clearance required for Environmental aspects during construction shall be ensured and made available before start of work. i) Try to save the trees by adjusting the plant layout or the alignment of reservoir structures, transmission mains, pumping stations, etc ii) Provide adequate protection to the trees to be retained with tree guards (e.g. Masonry tree guards, Low level RCC tree guards, Circular Iron Tree Guard with Bars) as required. ii) Identify the number of trees that will be affected with girth size & species type along the transmission mains, pumping station sites and water treatment plant site. The details to be indicated on map to scale and/or a strip map as may be appropriate. Prepare tree cutting schedule to facilitate clearance requirements. iii) Trees identified for cutting shall be removed from the construction sites before commencement of construction with prior permission from the Municipal Commissioner, Armoor Municipality (in Urban area)/MRO concerned (Rural area). iv) Undertake tree plantation (not less than two rows inside and along the boundary of Reservoir Headworks sites, and compensatory plantation as per the tree cutting clearances). v) Compensatory plantation by way of Re-plantation of at least twice the number of trees cut should be carried out in the project area. i) Identify the common utilities to be affected such as: telephone cables, electric cables, electric poles, water pipelines, public water taps, etc ii) Affected utilities shall be relocated with prior approval of the concerned agencies before construction starts. iii) Provide advance notice (not less than 10 working days) to affected parties. The advance notice shall be in the form of written notice and a grievance redressal cell shall be established for timely addressing of grievances Adequate measures shall be taken and checked to control the Baseline parameters of Air, Water and Noise pollution. Base line parameters shall be recorded and ensured conformance till the completion of the project. Time frame Before construction Pre-construction & construction phase Responsible agencies ULB / Concerned Departments & Contractor Contractor / ULB
Utility Relocation
Pre-construction & construction phase
Contractor / ULB/ Concerned departments
Baseline parameters
Pre-construction, construction and postconstruction phase
Contractor / ULB
351
S.No. 5
Potential Negative Impacts Planning of temporary Traffic arrangements
Mitigation Measures i) Temporary diversion will be provided with the approval of the Engineer-in-Charge. Detailed traffic control plans shall be prepared and submitted to the engineers for approval, at least two weeks prior to commencement of works. ii) The traffic control plans shall contain details of temporary diversion, details of arrangements for construction under traffic, details of traffic arrangement after cessation of work each day, SIGNAGES, safety measures for transport of hazardous materials and arrangement of flagmen. iii) Any accidents and/or risk of inconveniences caused to the community shall be borne by the contractor The contractor shall identify the site for temporary use of land for construction sites /storage of construction materials, etc. These sites shall be operated only after prior approval of the Engineer-in-Charge. i) Contractor shall follow all relevant provisions of the Building and the other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996 for construction and maintenance of labour camp. ii) The location, layout and basic facility provision of each labour camp will be submitted to Engineer-in-Charge prior to their construction. iii) The construction will commence only upon the written approval of the Engineer. The contractor shall maintain necessary living accommodation and ancillary facilities in functional and hygienic manner and as approved by the Engineer-in-Charge. iv) All temporary accommodation must be constructed and maintained in such a fashion that uncontaminated water is available for drinking, cooking and washing. The sewage system for the camp must be planned. Adequate health care is to be provided for the work force. The layout of the construction camp and details of the facilities provided should be prepared and shall be approved by the Engineer-in-Charge. The construction camp shall not be located within 1000m from the nearest water stream, residential areas and/or any sensitive land uses like schools, hospitals etc.
Time frame Pre-construction & construction phase
Responsible agencies Contractor / ULB
Storage materials Construction labour camps
of
Pre-construction & construction phase During construction the
Contractor / ULB
of
Contractor
352
ANNEXURE-II ENVIRONMENTAL MANAGEMENT PLAN- CONSTRUCTION PHASE COMPREHENSIVE PLANNING OF WATER SUPPLY SERVICE IMPROVEMENTS IN ARMOOR
S.No. Activity BoQ Reference Anticipated Impact Duration of impacts During collection (i) Mitigation Measures Responsible for Mitigation Construction Contractor (CC) Monitoring Indicators of Mitigation Construction Contractor documentation Reference Document Contract document
Sourcing of Materials (Clause 1.1.2 of specificationsSection VII A)
105, 107, 109-112, 119120, 202-204, 206, 209, 210, 302-305, 308, 310, 311, 312, 313, 505, 505.2, 505.3, 516.3516.8, 521, 522, 601, 702-706, 711, 713, 805808, 811-814, 902-906, 908-909, 911-914, 916, 1002-1004, 1102-1106, 1110, 1215.3-1215.7, 1216.3-1216.7, 1218.2, 1218.3, 1219-1221, 1301-1303, 1404.81404.11, 1405.1, 1507, 1508, 1521.2-1521.7, 1522.2-1522.7, 15251527, 1602-1604, 1902, 1903, 1904, 1905, 1906, 2002, 2003, 2004, 2103, 2202- 2210, 2215, 22202225, 2230, 2302-2312, 2316-2317, 2321, 20422407, 2411-2416, 2421, 2422, 2424, 2052-2506, 2602, 2603,
Extraction of rocks and material may cause ground instability
Verify suitability of all material sources and obtain approval of Engineer-in-Charge; Use the approved quarries by the competent authorities. These include: Sand: Location- Janakampet Vaagu Distance- 7.5 Km from project area Coarse Aggregate: LocationJakranipalle, Distance- 8.5 Km Bricks - Locally Distance- 5 Km
(ii) All sites are environmentally safe (iii) DI pipes, HYSD steel, pumping machinery shall be obtained from the manufacturers.
353
S.No.
Activity
BoQ Reference
Anticipated Impact
Duration of impacts During construction activity
Mitigation Measures
Responsible for Mitigation Construction Contractor (CC)
Stock piling
103, 104, 504, 516.3, 520, 601, 714, 903, 1114, 1203, 1215.2, 1216.2, 1219, 1301-1303, 1404.7, 1507, 1508, 1521.2, 1522.2, 1225, 2208, 2310, 2411
(i) Dust emission (ii) Run-off from stockpiled materials during construction works can contaminate surface water quality at Intake well at SRSP.
Haulage / transportation
-do-
Fugitive Emissions from construction vehicles, equipment, and machinery used for excavation and disposal resulting in dust and smoke which increases the concentration of
During construction activity
i) Construction Contractor shall identify designated areas for stockpiling of sand, gravel, and other construction materials; ii) Construction material shall be covered or stored in such a manner so as to avoid being affected by wind direction. iii) Avoid stockpiling of earth fill especially during the monsoon season unless covered by tarpaulins or plastic sheets; iv) Conduct air quality monitoring at designated stock piling sites and sensitive receptors like. Pisa Mallana Temle (old) in ward no 5, Pisa Mallana Temple (new) in ward no 5 Shiva Temple in Raja Ramnagar Colony Masjid in Raja Ram Nagar Colony Mahalakshmi Temple near vijay public school Temple near Subhash Nagar Temple near Jhanda Colony Navanth Siddula on hills in ward 15 Temple near Industries Colony and major residential area of the working zones i) Unpaved haul roads near / passing through residential and commercial areas to be watered twice in a day. ii) Trucks carrying construction material to be adequately covered to avoid the dust pollution and to avoid the material spillage.
Monitoring Indicators of Mitigation Location of stockpiles
Reference Document The Environment (Protection) Act, 1986 The (Prevention Control Pollution) 1981 Air and of Act
CPCB standards of ambient air quality and vehicular and equipment emission
Construction Contractor (CC)
i) Complaints from sensitive receptors ii) heavy equipment and machinery fitted with air pollution
354
S.No.
Activity
BoQ Reference
Anticipated Impact
Duration of impacts
Mitigation Measures
Responsible for Mitigation
vehicle-related pollutants such as carbon monoxide, sulphur oxides, particulate matter, nitrous oxides, and hydrocarbons in the air.
Excavation [Clause 3.1 (Division 3) of specificationsSection VII A]
101, 102, 201, 301, 401, 501, 502, 505.1, 516.2, 601, 701, 801, 810, 901, 907, 910, 1001, 1101, 1201, 1202, 1215.1, 1216.1, 1218.1, 13011303, 1404.6, 1501-1503, 1521.1, 1522.1, 1601, 1801,1802, 1901, 2001, 2101, 2102, 2201, 2301, 2401, 2501
Fugitive Dust Pollution near settlements
i) All earth work will be protected in a manner acceptable to the engineer to minimize generation of dust. ii) Sprinkling of water on construction sites using water tanker when necessary during dry weather
Monitoring Indicators of Mitigation control devices iii) ambient air for respirable particulate matter (RPM) and suspended particulate matter (SPM); (iv) vehicular emissions such as sulphur dioxide (SO2), nitrous oxides (NOx), carbon monoxide (CO), and hydrocarbons i) Complaints from sensitive receptors / residents.
Reference Document
The Environment (Protection) Act, 1986 The (Prevention Control Pollution) 1981 Air and of Act
355
S.No.
Activity
BoQ Reference
Anticipated Impact
Duration of impacts During construction activity
Mitigation Measures
Responsible for Mitigation Construction Contractor (CC)
Shifting of common utilities [Clause 3.1 (Division-3) of specificationsSection VII A]
-do-
Disruption of services
i) Ensure community consensus and minimum impact to common utilities like telephone cable, electric cables, electric poles, water taps and etc., ii) Provide advance notice (not less than 10 working days) to affected parties. ii) Affected utilities shall be relocated with prior approval of the concerned agencies before construction starts.
Monitoring Indicators of Mitigation Complaints from sensitive receptors
Reference Document Contract document
6.
Dewatering (Clause 1.7 of specificationsSection VII A)
106, 503, 1506
Improper disposal can contaminate nearby water bodies.
Adequate care has to be taken by the contractor not to let out the dewatered water into the nearby water bodies falling under construction activity.
Analysis of water samples.
The Water (Prevention and Control of Pollution) Act 1974 The Environment (Protection) Act, 1986. The Water (Prevention and Control of Pollution) Act 1974
7.
Pollution from Fuel and Lubricants
Same as @ S. No.4
Leakage of Fuel and lubricants used in the machinery is the main source of water and soil pollution.
i) The contractor shall ensure that all construction vehicles parking location, fuel/lubricants storage sites, vehicle, machinery and equipment maintenance and refuelling sites shall be located away from rivers and irrigation canal/ponds. ii) Contractor shall ensure that all vehicle/machinery and equipment operation, maintenance and refuelling will be carried out in such a fashion that spillage of fuels and lubricants does not contaminate the ground. iii) Contractor shall arrange for collection, storing and disposal of oily wastes to the pre-identified disposal sites (list to be submitted to Engineer) and approved by the Engineer. All spills and collected petroleum products will be disposed off in accordance with MoEF and state PCB guidelines. iv) Engineer will certify that all arrangements comply with the
Analysis of water and soil samples.
356
S.No.
Activity
BoQ Reference
Anticipated Impact
Duration of impacts
Mitigation Measures
Monitoring Indicators of Mitigation
Reference Document
guidelines of PCB/ MoEF or any other relevant laws.
8.
Noise Levels (Vehicles, Plant & Equipment)
Same as @ S. No.4
Vehicular noise pollution at residential / sensitive receptors.
(i) Plan activities in consultation

with ULB which will result in least disturbance; (ii) Minimize utilization of horns; (iii) Maintain maximum sound levels not exceeding 80 decibels (dbA) when measured at a distance of 10 m or more from the vehicle/s and conduct noise level monitoring at sensitive receptorts and major residential areas. (iv) Servicing of all construction vehicles and machinery shall be done regularly and during routine servicing operations, the effectiveness of exhaust silencers will be checked and if found defective will be replaced. i) Try to save the trees and provide adequate protection to the trees with tree guards as required. ii) Compensatory plantation of at least twice the number trees felled should be done. iii) Require to plant 36 No. native trees for 12 No. removed ; iv) Prohibit workers from cutting of trees for firewood. i) Not to dispose any construction materials in Sri Ram Sagar Lake which may pollute the reservoir water
Construction Contractor
i) Complaints from sensitive receptors ii) Conduct noise level monitoring at sensitive receptors and major residential areas
Noise Pollution (Regulation and Control) Rules, 2000
9.
Tree cutting
3002-3004
Felling of the trees affect terrestrial ecological balance. No. of trees identified to be cut - 12 No.
Checking of conservation management plan for tree species and aquatic life
Forest (Conservation) Act, 1980, amended 1988 Andhra Pradesh Water, Land and Tree Act, 2002 Wildlife Protection Act Forest (Conservation) Act, 1980,
10
Aquatic fauna
106
(i) Impact on aquatic fauna affect water qualitytemporary
Checking of conservation management
357
S.No.
Activity
BoQ Reference
Anticipated Impact
Duration of impacts
Mitigation Measures
11
Disposal of Debris / spoil (Clause 1.8 of Genl. specificationsSection VII A and Cl. 2.2 & 2.4 of Division2 Section VII A)
518, 519, 1222, 1223, 1523, 1524
turbidity during construction (ii) Impact on Sri Ram Sagar Lake bed sediment- removal of part of sediment within intake structurelocal disturbance for aquatic life Solid wastes as well as excess construction materials impact aesthetic and land environment.
and aquatic fauna; ii) Quick removal of sediment and bonding materials to control turbidity at Intake well in SRSP.
Monitoring Indicators of Mitigation plan for tree species and aquatic life (ii) records of surface water quality inspection
Reference Document amended 1988 Andhra Pradesh Water, Land and Tree Act, 2002 Wildlife Protection Act
During construction period.
Manage solid waste according to the following preference hierarchy: reuse, recycling and disposal to designated areas as per ULB; Avoid stockpiling of excess excavated soils; Coordinate with Armoor Municipality for beneficial uses of excess excavated soils or immediately dispose to designated areas; The contractor shall not dispose excavated material near the cross drainage works viz., culverts, drains, streams so as not affect the natural regime of the water flow. It is estimated that the volume of Earth generation due to the project activity is 288990.30 cum. Excess earth quantities of 73009.98 cum is proposed to be carted out and disposed at the low lying pockets within
(i) Waste Management Plan; (ii) complaints from sensitive receptors (iii) ULB to report in writing that the necessary environmental restoration work has been adequately performed before acceptance of work.
The Municipal Solid Wastes (Management and Handling) Rules, 2000
358
S.No.
Activity
BoQ Reference
Anticipated Impact
Duration of impacts
Mitigation Measures
Reference Document
the ULB, near Arundhati Nagar near Molla Reddy cheruvu katta (for raising of embankment bunds) Housing Board open park Zirayath Nagar open park Nalla Temple area Pocham surrounding
Govt. School area in Ashok Nagar 12 Diversion of traffic during construction (Clause 2.1 of specificationsSectionVII A) 523, 1224, 1528 Traffic problems in rightof-way (ROW) during pipe laying During construc-tion activity i) Before taking up of construction activity, a Traffic Control Plan shall be devised and implemented to the satisfaction of the Engineer. ii) Construction shall be taken up in phase wise so that sections are available for traffic. iii) Temporary diversion will be provided with the approval of the engineer. iv) The traffic control plans shall be prepared and submitted to the engineers for approval one week prior to commencement of works. They shall contain details of temporary diversion, details of arrangements for construction under traffic, details of traffic arrangement after cessation of wok each day, SIGNAGES, safety measures for transport of hazardous materials and arrangement of flagmen. vi) The arrangement for the temporary Construction Contractor (i) Traffic Management Plan (ii) complaints from sensitive receptors (iii) number of sign boards placed at subproject sites. Contract document Appropriate Construction Techniques
359
S.No.
Activity
BoQ Reference
Anticipated Impact
Duration of impacts
Mitigation Measures
Reference Document
13
Stacking of pipes, valves & specials
506, 508, 510-512, 601, 709, 710, 802, 10071010, 1204, 1208-1211, 1304, 1401-1403, 1509, 1511, 1512, 1516-1518,
Improper stacking of pipes leads to traffic problems and accessibility to properties.
diversion of the road shall ensure to minimize the environmental impacts, like loss of vegetation, productive lands etc., prior to the finalization of diversion and detours. vii) Special consideration will be given to the preparation of the traffic control plan for safety of pedestrians and workers at night. viii) The contractor shall ensure that the diversion/detour is always maintained in running condition, particularly during the monsoon to avoid disruption to traffic flow. He shall inform local community of changes to traffic routes, conditions and pedestrians access arrangements. ix) This plan will be periodically reviewed with respect to site conditions. x) The temporary traffic detour will be kept free of dust by frequent application of water. xi) The construction site should be barricaded at all time in a day with adequate marking, flags, reflectors etc. for safety of general traffic movement and pedestrians. Through preliminary survey the following locations have been selected for setting up camp sites and storage of materials Pocham Padu 2 Km from SRS Lake Yanamgutta 5-6 acre nearby land near WTP Arundhati Nagar area within town Open park in Housing Board area
Location of stacking areas, complaints from sensitive receptors;
Contract document Appropriate Construction Techniques
360
S.No.
Activity
BoQ Reference
Anticipated Impact
Duration of impacts
Mitigation Measures
Reference Document
Open park in Zirayath Nagar area Nalla Pocham temple surrounding area Ashok Nagar Govt. school open area Construction Contractor (i) Complaints from sensitive receptors (ii) Number of walkways, sign boards, and metal sheets placed at subproject sites. Contract document Social impact assessment and compensation matrix
14
SocioEconomic Income.
508, 509, 1206, 1207, 1510, 1513, 1514, 1519, 1520
Impede the access of residents and customers to nearby shops during laying of DI pipe inlets to ELSRs and distribution pipelines in the town.
During pipe laying activity period
(i) Leave spaces for access between mounds of soil; (ii) Provide walkways and metal sheets where required to maintain access across trenches for people and vehicles; (iii) Increase workforce in front of critical areas such as institutions, place of worship, business establishment, hospitals, and schools; (v) Provide sign boards for pedestrians to inform nature and duration of construction works and contact numbers for concerns/ complaints. (i) Implement Health and Safety (H and S) measures including: (a) excluding public from the site; (b) ensuring all workers are provided with and use of Personal Protective Equipment like helmet, gloves and gumboots at concreting locations, nose musk at dust producing areas, safety belt during work at height; (c) H and S Training for all site personnel; (d) documented procedures to be followed for all site activities; and (e) documentation of work-related
15
Occupational Health and Safety (Clause 1.6 of specificationsSection VII A)
Applicable for implementing all BoQ items.
Occupational hazards which can arise from working in Project sites
Throughout the working period at project sites
(i) Health and Safety (H and S) measures; (ii) Equipped first-aid stations; (iii) Medical insurance coverage for workers; (iv) Number of accidents; (v) Supplies of
Environmental, Health, and Safety (EHS) GuidelinesWater and sanitation (2007) prepared by World Bank Group
361
S.No.
Activity
BoQ Reference
Anticipated Impact
Duration of impacts
Mitigation Measures
accidents; (ii) Ensure that qualified first-aid can be provided at all times ( at working sites and camp). First Aid box shall be easily accessible throughout the site; (iii) Provide medical insurance coverage for workers; (iv) Provide supplies of potable drinking water; (v) Provide clean eating areas where workers are not exposed to hazardous or noxious substances; (vi) Provide H and S orientation training to all new workers; (vii) Use fall protection equipment when working at heights (such as helmets, safety belts); (viii) Maintain work areas to minimize slipping and tripping hazards; (ix)For night work, provision of proper illumination for the work space, while controlling glare so as not to blind workers and passing motorists; (x) Ensure the visibility of workers through their use of high visibility vests when working in or walking through heavy equipment operating areas; (xi) Ensure moving equipment is outfitted with audible back-up alarms; and (xii) Disallow worker exposure to noise level greater than 80 dBA for a duration of more than 8 hours per day without hearing protection. The use of hearing protection shall be enforced
Monitoring Indicators of Mitigation potable drinking water; (vi) Clean eating areas where workers are not exposed to hazardous or noxious substances; (vii) record of H and S orientation trainings ; (viii) personal protective equipments; and (ix) % of moving equipment outfitted with audible back-up alarms;
Reference Document
362
S.No.
Activity
BoQ Reference
Anticipated Impact
Duration of impacts
Mitigation Measures
Reference Document
16
Asbestos Cement Pipes
1501-1503
Health risk
During pipe laying as per site condition
actively. (xiii) The contractor will make sure that during the construction work all relevant provisions of the Construction Workers (regulation of Employment and Conditions of Services) Act, 1996 are adhered to. i) No work is proposed on those parts of the existing system that contains AC pipes (carrier and disctribution mains), and these will be left in-site undisturbed, so there will be no deliberate excavation of AC pipes; and ii) The location of the new network has been planned to avoid all locations of existing AC pipes so these pipes will not be discovered accidentally
i) Records of trainings;
17
Work Camps (Clause 11.1.3 (J) of specificationsSection VII E)
Temporary air and noise pollution from machine operation, water pollution from storage and use of fuels, oils, solvents, and lubricants
Throughout the execution period
The contractor shall following:
guarantee the
i) The location, layout and basic facility provision of each labour camp will be submitted to Engineer prior to their construction. ii) The construction will commence only upon the written approval of the Engineer. iii) The Contractor shall construct and maintain all labour accommodation in such a fashion that uncontaminated water is available for drinking, cooking and washing. iv) Supply of sufficient quantity of potable water in every workplace/labour camp site at suitable
(i) Complaints from sensitive receptors (ii) water and sanitation facilities for employees; and (iii) ULB report in writing that the camp has been vacated and restored to pre-project conditions
Standard for handling asbestos prescribed by the Occupational health and Safety Administration (OHSA) amd the US Environmental Protection Agency (EPA) Contract document Environmental, Health, and Safety (EHS) GuidelinesWater and sanitation (2007) prepared by World Bank Group The Municipal Solid Wastes (Management
363
S.No.
Activity
BoQ Reference
Anticipated Impact
Duration of impacts
Mitigation Measures
Reference Document and Handling) Rules, 2000
and easily accessible places and regular maintenance of such facilities. v) The sewage system for the camp are designed, built and operated in such a fashion that no health hazards occurs and no pollution to the air, ground water or adjacent water courses take place. Ensure adequate water supply is to be provided in all toilets and urinals. Through preliminary survey the following locations have been selected for setting up camp sites and storage of materials: Sri Ram Sagar lake bank area Yanamgutta area adjacent to proposed WTP, in the town. Surrounding area of Siddala Gutta existing GLSR Open park near proposed ELSR in Zirayath Nagar Open park near proposed ELSR in Housing Board Vacant land within Ashok Nagar Govt. School. i) All fossils, coins, articles of value of antiquity, structures and other remains or things of geological or archaeological interest discovered on the site shall be the property of the Government and shall be dealt with as per provisions of the relevant legislation. ii) The contractor will take reasonable precautions to prevent his workmen or any other persons from removing and damaging any such article or thing. iii) He will, immediately upon discovery thereof and before removal
18
Chance Found Archaeological Property
Risk of archaeological chance finds
Throughout the execution period
(i)Records of chance finds
The Ancient Monuments and Archaeological Sites and Remains Act 1958
364
S.No.
Activity
BoQ Reference
Anticipated Impact
Duration of impacts
Mitigation Measures
Reference Document
19
Clearing of construction camps and restoration
Affect Land Aesthetics
After completion of the project
acquaint the Engineer of such discovery and carry out the SC's instructions for dealing with the same, waiting which all work shall be stopped. iv) The Engineer will seek direction from the Archaeological Survey of India (ASI) before instructing the Contractor to recommence the work in the site. i) Contractor to prepare site restoration plans, the plan is to be implemented by the contractor prior to demobilization. ii) On completion of the works, all temporary structures will be cleared away, all rubbish cleared, excreta or other disposal pits or trenches filled in and effectively sealed off and the site left clean and tidy, at the contractors expenses, to the entire satisfaction of the engineer.
Final clearance certificate from the Engineer in Charge.
Contract document
365
Appendix I List of Pump sets, Drawings etc, to be furnished by the successful Tenderer
1.00 1.02 1.03 1.04 1.05 1.06 1.07 1.08 1.09 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 Pump thrust bearing housing details. Pump non-reverse ratchet details. Pump sectional drawing with part no. Finally approved pump house layout with load data. Finally approved single line diagram of the electrical system and earthing. Cable schedule and termination chart. GA details of H.T. Board, L.T. Board, Control & instrumentation panel. Sectional drawing with part nos. for pump discharge valve, sluice valves, actuators. Schematic power wiring drawings (both H.T. & M.V.), panel wise. Schematic Control Wiring drawings panel wise. Purchase order references of individual equipment. List of authorized service centers of individual equipment. List of special tools & tackles required for effective installation & maintenance. Installation, operation, maintenance manuals for all equipment. Schematic wiring diagram for D.C. system & battery charge. Design calculation for earthing system. Completion drawings for all electrical circuit diagrams, layout Terms & Conditions. (The drawings etc. shall be furnished on transparency along with the copies mentioned). Details/type of bearings of pump & motor.
1.18
367
Appendix II List of Tools / Electrical Equipment to be provided By Contractor Sl No 1 2 3 Name of Tools/ Equipment Double Ended Spanner (6 mm to 25 mm) Screw Driver (6 mm to 25 mm) Sliding Pipe Wrench (a) 150 mm (b) 250 mm (c ) 300 mm (d) 350 mm 4 5 6 7 8 9 10 11 12 13 14 Hand Drill (6 mm to 19 mm) H.S. Drills (1.5 mm to 10 mm) Round Rough File- 350 mm Flat Rough File Steel Tale Hacksaw 300 mm Hammer with handle Cold Chisel Centre Punch Engineering Square Spirit Level Electrical Equipment 15 16 17 18 Multi Range Tong Tester Avo- Meter 500V Megger Multi Meter 1 no 1 no 1 no 1 no 3 sets 3 sets 3 sets 3 sets 3 sets 3 sets 3 sets 3 sets 3 sets 3 sets 3 sets 3 sets 3 sets 3 sets 3 sets Quantity 3 sets 3 sets
368
APPENDIX III List of Spare Parts to be provided by the Contractor. (Quantities shown may be changed, if required) Pump i) One set complete rotating assembly. ii) Driving and Non-driving end bearing for one pump. iii) Gland packing - 50 kgs. Motor Breaker i) Driving & Non-driving end Bearings for one motor - 1 set. i) Trip circuit mechanism with trip coil all complete - 6 Nos. ii) Closing coil - 2 nos. Control Panel i) TNC type switch - 4 nos. ii) Pilot lamps/Indication lamps 1 doz. iii) Push Button switch - 6 nos. iv) Selector switch - 4 nos. v) H.R.C. Fuse - 6 nos. PDV's i) Oil seals - 1 doz .ii) Oil - 1 sealed drum of desired grade iii) Push Button & indicating lamps - 1 doz .iv) Limit switch - 3 nos. v) Electrical Actuator limit & Torque switch - 1 no. vi) Capacitor Bank - 1 set of designed capacity Sluice Valves i) Gland packing - 25 kg. ii) AI-Bronze Nut - 4 nos. Relays Type MotPro. - 1 no. Type VAX 31 - 1 no. Type VAJH-13 - 1 no. Instruments Voltmeter Ammeter 2 nos. 2 nos.
369
APPENDIX - IV Quality Data of Raw water available for Armoor (HMWS&SB)

Raw Water Quality of Sri Ram Sagar Lake
Parameters 03.12.2011 Color, Hazen Taste Turbidity (NTU) Odour pH at 28 C Electrical Conductivity at 0 28 C Tot. Dissolved Solids,mg/l Ph. Alkalinity, mg/l Tot. Alkalinity as CaCO3, mg//l Tot. Hardness as CaCO3, mg/l Chloride as Cl, mg/l Fluoride as F, mg/l Nitrate as NO3, mg/l Nitrite as NO2, mg/l Sulfate as SO4, mg/l Calcium as Ca, mg/l Magneseum as Mg, mg/l Phosphate, mg/l Iron as Fe, mg/l Lead, mg/l Arsenic, mg/l Zinc, as Zn, mg/l Copper as Cu, mg/l Dissolved Oxygen, mg/l COD, mg/l BOD5, mg/l Residual Chlorine,mg/l MPN of Bacteria/1000 ml Coliform 130 0.2 Not Detected 0.001 44 34 24.0 Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected 5.6 Not Detected Not Detected Nil 1620 5 128 0.2 Not Detected 0.001 42 33.6 23.5 Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected 5.8 Not Detected Not Detected Nil 1609 5 126 0.18 Not Detected 0.001 42 33.2 24.6 Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected 5.8 Not Detected Not Detected Nil 1620 4 124 0.18 Not Detected 0.001 40 32 25.0 Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected 6.0 Not Detected Not Detected Nil 1594 4 124 0.2 Not Detected 0.001 38 32 23.0 Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected 6.0 Not Detected Not Detected Nil 1594 5 122 0.2 Not Detected 0.001 38 32 22.0 Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected 6.0 Not Detected Not Detected Nil 1590 4 180 178 175 168 168 166
0
Water Quality Analysis Results 12.01.2012 <4.5 Agreeable 10.2 Unobjectionable 7.2 510 360 52 174 06.02.2012 <5 Agreeable 10.6 Unobjectionable 7.1 520 370 52 170 06.03.2012 <5 Agreeable 8.5 Unobjectionable 7.8 495 290 50 170 02.04.2012 <5 Agreeable 8.8 Unobjectionable 7.5 490 280 Not Detected 168 30.04.2012 <4 Agreeable 7.8 Unobjectionable 7.4 485 280 Not Detected 166
<5 Agreeable 12.0 Unobjectionable 7.3 520 380 54 180
MPN of E-Coli per 100 ml.
370
APPENDIX V SOIL INVESTIGATION DATA Soil investigations for the Project town were undertaken, which may be for guidance of the Bidders. The results are furnished below. However the Bidders will have to undertake soil investigation in order to assess SBC and groundwater status, at their own cost and arrangement before designing different structures. No payment will be made by the Employer for such exercises. Bore Hole Location Depth (m) From To 0.0 1.5 1.5 3.0 3.0 5.0 5.0 7.0 7.0 8.5 8.5 10.0 10.0 11.5 11.5 13.0 13.0 14.5 14.5 16.0 0.0 1.5 1.5 3.0 3.0 4.5 4.5 6.5 6.5 8.0 8.0 10.0 10.0 11.5 11.5 13.0 13.0 15.0 0.0 1.5 1.5 3.0 3.0 4.5 4.5 6.0 6.0 7.5 7.5 9.0 9.0 10.5 10.5 12.5 12.5 14.0 14.0 15.0 0.0 1.5 1.5 3.0 3.0 4.5 4.5 6.0 6.0 8.0 8.0 10.0 10.0 11.5 Sub Soil Profile Moorum Moorum Moorum Moorum Soft Disintegrated Rock Soft Disintegrated Rock Soft Disintegrated Rock Weathered Rock Soft Disintegrated Rock Soft Disintegrated Rock Moorum Moorum Soft Disintegrated Rock Soft Disintegrated Rock Soft Disintegrated Rock Weathered Rock Soft Disintegrated Rock Soft Disintegrated Rock Soft Disintegrated Rock Red Moorum Red Moorum Moorum Moorum Soft Disintegrated Rock Soft Disintegrated Rock Soft Disintegrated Rock Soft Disintegrated Rock Soft Disintegrated Rock Soft Disintegrated Rock Small Boulder Small Boulder Red Soil Red Soil Red Soil Red Soil Moorum IS Classification GP GP GP GP SDR SDR SDR Boulder SDR SDR GP GP SDR SDR SDR Boulder SDR SDR SDR GP GP GP GP SDR SDR SDR SDR SDR SDR Boulders Boulders GP GP GP GP GP
Arundhati Nagar, Bore Hole 1
Housing Board Bore Hole 2
Shastri Nagar Bore Hole 3
Teachers Colony Bore Hole 4
371
Bore Hole Location
Siddala Gutta Bore Hole 5
1300 Plots Bore Hole 6
Yanam Gutta Bore Hole 7
Jalalpur Bore Hole 8
Depth (m) From To 11.5 12.5 12.4 14.0 14.0 15.0 0.0 1.0 1.0 3.0 3.0 5.0 5.0 7.0 7.0 9.0 0.0 1.5 1.5 3.0 3.0 4.0 4.0 5.5 5.5 7.0 7.0 9.0 9.0 11.0 11.0. 13.0 13.0 15.0 0.0 1.5 1.5. 3.0 3.0 5.0 5.0 7.0 7.0 8.5 8.5 10.0 10.0 12.0 12.0 13.5 13.5 15.0 0.0 2.0 2.0 4.5 4.5 6.0 6.0 7.5 7.5 9.0 9.0 11.0 11.0 13.0 13.0 15.0
Sub Soil Profile Moorum Soft Disintegrated Rock Soft Disintegrated Rock Red Soil Red Moorum Weathered Rock Hard Disintegrated Rock Hard Disintegrated Rock Black Cotton Soil Black Cotton Soil Black Cotton Soil Moorum Moorum Soft Disintegrated Rock Soft Disintegrated Rock Weathered Rock Hard Disintegrated Rock Moorum Moorum Moorum Soft Disintegrated Rock Soft Disintegrated Rock Soft Disintegrated Rock Soft Disintegrated Rock Weathered Rock Hard Disintegrated Rock Moorum Moorum Soft Disintegrated Rock Soft Disintegrated Rock Weathered Rock Weathered Rock Hard Disintegrated Rock Hard Disintegrated Rock
IS Classification GP SDR SDR GP GP BOULDER HDR HDR BC BC BC GP GP SDR SDR BOULDER HDR GP GP GP SDR SDR SDR SDR BOULDER HDR GP GP SDR SDR BOULDER BOULDER HDR HDR
372
Appendix VI Salient Features of Labour Laws

SALIENT FEATURES OF SOME MAJOR LABOUR LAWS APPLICABLE TO ESTABLISHMENTS ENGAGED IN BUILDING AND OTHER CONSTRUCTION WORK (The law as current on the date of bid opening will apply) a. Workman Compensation Act 1923: The Act provides for compensation in case of Labour Laws 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 5 years service or more or on death the rate of 15 days wages for every completed year of service. The Act is applicable to all establishments employing 10 or more employees c. Employees P.F. and Miscellaneous Provision Act 1952 (since amended): The act Provides for monthly contribution by the employer plus workers @ 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. e. Maternity Benefit Act 1951: The Act provides for leave and some other benefits to women employees in case of confinement or miscarriage etc. 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 20 or more contract labour. Minimum Wage Act 1948: The Employer is supposed to pay not less than the Minimum Wages fixed by appropriate Government as per provisions of the Act if the employment is a schedule employment. Construction of Buildings, Roads, Runways are schedule employments. 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. 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. Payment of Bonus Act 1965: The Act is applicable to all establishments employing 20 or more employees. The Act provides for payments of annual bonus subject to a minimum of 8.33% of wages and maximum of 20% of wages to employees drawing Rs.3500/- per month or less. The bonus to be paid to employees getting Rs.2500/- per month or above upto Rs.3500/- per month shall be worked out by taking wages as Rs.2500/- per month only. The Act does not apply to certain establishments. The newly set-up establishments are exempted for five years in certain circumstances. Some of the State Governments have reduced the employment size from 20 to 10 for the purpose of applicability of this Section VII. Work Requirements
f.
g.
h.
i.
j.
373
Act. k. 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. l. Industrial Employment (Standing Order) Act 1946: It is applicable to all establishments employing 100 or more workmen (employment size reduced by some of the States and Central Government to 50). The Act provides for laying down rules governing the conditions of employment by the Employer on matters provided in the Act and get the same certified by the designated Authority. m. 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. n. 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 regulation of employment of children in all other occupations and processes. Employment of Child Labour is prohibited in Building and Construction Industry. o. Inter-State Migrant workmens (Regulation of Employment & Conditions of Service) Act 1979: The Act is applicable to an establishment which employs 5 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, traveling expenses from home upto the establishment and bank etc. p. The Building and Other Construction works (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 10 or more workers and 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. Factories Act 1948: the Act lays down the procedure for approval at 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 10 persons or more with aid of power or 20 or more persons without the aid of power engaged in manufacturing process
374
Appendix VII
SALIENT FEATURES OF SOME OF THE MAJOR LAWS THAT ARE APPLICABLE FOR PROTECTION OF ENVIRONMENT. Laws on protection of Environment Add the following as GC Clause 4.18: The contractor shall take all reasonable steps to protect the environment on and off the Site and to avoid damage or nuisance to persons or to property of the public or others resulting from pollution, noise or other causes arising as a consequence of his methods of operation. During continuance of the contract, the contractor and his sub-contractors shall abide at all times by all existing enactments on environmental protection and rules made there under, regulations, notifications and bye-laws of the State or Central Government, or local authorities and any other law, bye-law, regulations that may be passed or notification that may be issued in this respect in future by the State or Central Government or the local authority. Salient features of some of the major laws that are applicable are given below : 1. The Water (Prevention and Control of Pollution) Act, 1974, This provides for the prevention and control of water pollution and the maintaining and restoring of wholesomeness of water. Pollution means such contamination of water or such alteration of the physical, chemical or biological properties of water or such discharge of any sewage or trade effluent or of any other liquid, gaseous or solid substance into water(whether directly or indirectly) as may, or is likely to, create a nuisance or render such water harmful or injurious to public health or safety, or to domestic, commercial, industrial, agricultural or other legitimate uses, or to the life and health of animals or plants or of aquatic organisms. The Air (Prevention and Control of Pollution) Act, 1981, This provides for prevention, control and abatement of air pollution. Air Pollution means the presence in the atmosphere of any air pollutant, which means any solid, liquid or gaseous substance (including noise) present in the atmosphere in such concentration as may be or tend to be injurious to human beings or other living creatures or plants or property or environment. The Environment (Protection) Act, 1986, This provides for the protection and improvement of environment and for mattes connected therewith, and the prevention of hazards to human beings, other living creatures, plants and property. Environment includes water, air and land and the interrelationship which exists among and between water, air and land, and human beings, other living creatures, plants, micro-organism and property. The Public Liability Insurance Act, 1991, This provides for public liability insurance for the purpose of providing immediate relief to the persons affected by accident occurring while handling hazardous substances and for mattes connected herewith or incidental thereto. Hazardous substance means any substance or preparation which is defined as hazardous substance under the Environment (Protection) Act 1986, and exceeding such quantity as may be specified by notification by the Central Section VII. Work Requirements
2.
3.
4.
375
5.
6.
7.
Government. Forest (Conservation) Act, 1980 (amended in 1988) Forest (Conservation) Act, 1980 (amended in 1988) enacted by Government of India, restricts the de-reservation of forests for use of non-forest purposes. Forest (Conservation) Act, 1980 (amended in 1988) enacted by Government of India, restricts the de-reservation of forests for use of non-forest purposes. The Forest (Conservation) Rules, 2003 issued under this Act, provide specific procedures to be followed for conversion of forest land for non-forest purposes. Cutting of trees in non-forest land, irrespective of land ownership, also requires permission from the State Forest Department. Afforestation to the extent of two trees per each tree felled is mandatory. Andhra Pradesh Water, Land And Trees Act, 2002 The Act came into force on July 1, 2002 with an objective of promoting waste conservation and tree cover and regulating the exploitation and use of ground and surface water for protection and conservation of water sources, land and environment and matters connected therewith.'Preservation of trees' includes planting of new trees and transplanting trees to other sites including protection measures such as fence tree guards etc. 'To fell a tree' includes burning, cutting, debarking, girdling and release of harmful chemical and such other potations, which may damage any part of the tree guards etc. The Andhra Pradesh Infrastructure Development Enabling Act, 2001 (Act no. 36 of 2001) Under the Act, Polluter Charges means levy of Prescribed charges by the Infrastructure Authority on any Developer, if any Developer pollutes the environment or does not adhere to the specifications and measures for environment preservation & conservation agreed under the contract with the Government or the Government Agency or the Local Authority or fails to stop polluting the environment within 30 days of receipt of notice in writing from the Infrastructure Authority or the Government Agency or the Local Authority.
376

Scope and Specifications

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Section VII.

Section VII. Work Requirements

specials under Sub-head-3 and laying of 60% of pipelines supplied/procured.

Section VII. Work Requirements

The Scope of Work

B MECHANICAL AND ELECTRICAL WORKS:

RAW WATER PUMP DETAILS:

Section VII. Work Requirements

Pump Speed R.P.M(Syn)

Raw Water Intake Pumping station (Sri Ram Sagar lake)

The Scope of Work for this contract under Sub-head-2 includes:

Section VII. Work Requirements

works of VRCC shall be in M 30 design mix).

Section VII. Work Requirements

Section VII. Work Requirements

B MECHANICAL AND ELECTRICAL WORKS:

Clear Water Pumping Station (WTP at Yanamgutta Village)

Lightening arrestors as per IS: 3070/1974 as per requirement. Note:

Section VII. Work Requirements

C Automation for flow measurements

The Scope of Work for this contract under Sub-head 3 includes:

Pipe Material DI/K-9 DI/K-9 DI/K-9 DI/K-9 DI/K-9

Internal diameter, in mm 400 350 300 200 150 TOTAL

Length, in M 1025 2515 310 1610 2360 7820

Section VII. Work Requirements

Zone No.1 36158 552 320 31 Nil Nil Nil 37061

Zone No.3 35073 1884 305 43 Nil Nil Nil 37305

Zone No.4 39400 6944 615 439 685 93 217 48393

Total 133039 13159 2445 1255 1021 263 217 151399

Size of meter (mm) 500 400 300 200 150 100 25 20 15

Section VII. Work Requirements

LWL MWL above above MSL(M) MSL(M)

Inlet Outlet Dia., Dia., mm mm

450 KL, 450 KL,

GL Sl. Location above No. MSL(M) 1 Siddala Gutta

Capacity in KL 2026 1200 KL,

Other components of Work

Section VII. Work Requirements

Type of existing utility to be crossed

Near WTP at Yanamgutta

Nizam Sagar Canal

500 mm (i.d.) DI/K-9 Raw Water Pumping main

By constructing one M.S. Structural bridge, 10 m span

ULB may permission competent authority

obtain from I&CA

Small bridges and culverts over water ways

500 mm (i.d.) DI/K-9 Raw Water Pumping main

ULB may permission competent authority

obtain from I&CA

Nizam Sagar Canal

CW pumping main 200 mm DI/K-9 line

ULB may permission competent authority

obtain from I&CA

Nizam Sagar Canal

CW pumping main 150 mm DI/K-9 line

ULB may permission competent authority

obtain from I&CA

Different locations the town

Small bridges and culverts over water ways

Different categories of existing Roads and alleys etc.

By open cut & fill method, 8 m to 15 m in length

Lightening arrestor as per IS: 3070/1974 - 1no each on ELSRs.

Section VII. Work Requirements