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CONSTRUCTION OF THE UMGENI WATER

DARVILL WASTE WATER CONTRACT NO. 2013/136


TREATMENT WORKS UPGRADE C3: SCOPE OF WORK
C3.210

PS-13.14 Digester FOG Pump Station

PS-13.14.1 Introduction

PS-13.14.1.1 Employers Objective

1) The Employer wishes to procure and install a complete pumping system convey fats,
oil and grease from the primary settling tanks to the gravity sludge thickeners.

PS-13.14.1.2 Scope of Work

1) This specification defines the mechanical requirements for the performance, design,
supply, installation, testing and commissioning of the FOG Pump Station (FOGPS) for
installation and use at the Darvill WWTW.
2) The works shall include the following equipment, instrumentation and accessories:
a) A number of positive displacement pumps
b) Suction and delivery pipework, valves and specials.
c) Lifting Equipment

PS-13.14.1.3 Reference Drawings

INLAND/A08/P+ID/UI0665A/103 Process & Instrumentation Diagram – Primary Settlement Area


INLAND/A08/CIVIL/UI0665A/241 General Arrangement Drawing – Scum, Fats, Oils and Grease
Pump Station

PS-13.14.1.4 Specific Exclusions from this Scope of Work

1) Civil and Structural works

BSC Item 2013/136


CONSTRUCTION OF THE UMGENI WATER
DARVILL WASTE WATER CONTRACT NO. 2013/136
TREATMENT WORKS UPGRADE C3: SCOPE OF WORK
C3.211

PS-13.14.2 Civil Engineering Requirements

1) All civil engineering works are to be designed by the Employer and constructed by the
Contractor.
2) All works designed by the Employer and Constructed by the Contractor shall be
remunerated on a cost reimbursable bases based on the rates tendered in the
Schedule of Quantities.
3) It is intended that the equipment specified in this specification shall be installed within
proposed FOGPS.
4) The battery limits shall be as follows:
a) The mechanical installation for the FOG pumps shall be from the entrance of
the feed hopper box to the first flange outside the pump station and shall
include all pumps, valves, specials, instruments, gauges etc. All other piping
and pipework shall be considered as being a part of the civil engineering
infrastructure and shall be designed by the Employer, Constructed by the
Contractor and measured and paid in accordance with 1) and 2) above.
b) Lifting equipment
5) The Contractor shall provide the Employer with all necessary information to allow the
Employer to complete the necessary civil and structural engineering designs. The
information required by the Employer shall include the following:
a) A general arrangement drawing which clearly illustrates the location and
orientation of the equipment specified in this project specification such that
the Employer is capable of assessing the space available for operations and
maintenance.
b) A lifting plan that clearly illustrates how key components of the equipment are
to be dismantled, lifted and loaded onto a service vehicle. The Contractor
shall further provide the Employer with the detailed structural requirements at
the interface between lifting equipment and the supporting infrastructure.
c) All structural loadings that the Employer may need to execute the civil and
structural design of the infrastructure. This should include as a minimum the
weight of the equipment, thrust forces and vibration loadings.
6) In so far as the layout of the equipment is concerned, the Contractor shall ensure that
the following functional requirements have been met:
a) The Contractor shall provide the Employer with the centre line of the pumps
as well as the distance from this centre line to the floor level allowing
adequate working space under the pipework. In providing these levels the
Contractor shall ensure the following:
i) A minimum of 1 m working space shall be provided around and between
all equipment.

BSC Item 2013/136


CONSTRUCTION OF THE UMGENI WATER
DARVILL WASTE WATER CONTRACT NO. 2013/136
TREATMENT WORKS UPGRADE C3: SCOPE OF WORK
C3.212

PS-13.14.3 Performance Requirements

1) The medium being pumped is fats, oil and grease and may behave in a non-
newtonian manner.
2) The static suction head under normal operating conditions shall be between 20 and
23 m.
3) The pumping system shall be capable of conveying 15 L/sec of FOG from the hopper
feed box of the PSPS to the existing gravity thickeners.
4) The proposed philosophy shall be based on a duty – standby system. Drawing
number INLAND/A08/P+ID/UI0665A/241 indicates a 1 duty – 1 standby system
however the Tenderer may propose an alternative.

PS-13.14.4 Mechanical Requirements

PS-13.14.4.1 Digester FOG Pump Installation

1) The proposed FOG Pump Station shall have a maximum of two (2) positive
displacement (PD) pump units installed in dry well conditions. Each pump unit shall
comply with the requirements of WIMES 1.04 (issue 4) (in the case of progressive
cavity pumps) or WIMES 1.11 (issue 2) (in the case of rotary lobe pumps) standard
specifications and data sheets T 2.2.35 and T2.2.36 respectively.
2) Each PD pump shall have a dedicated hopper feed box. The hopper feed box shall
comply with the following requirements:
3) Each hopper feed box shall be constructed from 316 stainless steel.
4) Each FOG pump unit shall discharge into a dedicated discharge main and then into a
single FOG rising main. The discharge pipework shall comply with the following
requirements:
a) The battery limits for the discharge pipework shall be the first flange outside
the FOG Pump Station.
b) The discharge piping shall be constructed from 316 stainless steel above
ground in accordance with the Umgeni Water Particular Specification for
Steel Pipe, Specials, Coatings and Linings, and class 16 uPVC if the pipe is
below ground.
c) The discharge piping shall be fitted with a bursting disk and an actuated
diaphragm valve as shown in P & ID INLAND/A08/P+ID/UI0665A/103. All
valves shall comply with the requirements of the Umgeni Water Particular
Specification Wedge Gate and Resilient Seal Gate Valves.
d) Either dismantling joints or flange adaptors or removable couplings shall be
provided to ensure that the bursting disk, the electrically actuated diaphragm
valve and the pump unit itself can be easily removed for maintenance
purposes.
e) The maximum allowable velocity in the discharge main shall be 1 m/sec.
5) General pipework, valve and special requirements:
a) All pipework, flanges, valves and specials shall be designed using a PN 10
rating.
b) All steel pipes shall be coated using system # 3 – three layer system and
lined with system 2 – solvent free epoxy.
c) All pipework shall be adequately supported by either hot dipped galvanised
mild steel pipe furniture (for all raised pipelines) or on reinforced concrete
plinths. (for pipelines at floor level)

BSC Item 2013/136


CONSTRUCTION OF THE UMGENI WATER
DARVILL WASTE WATER CONTRACT NO. 2013/136
TREATMENT WORKS UPGRADE C3: SCOPE OF WORK
C3.213

PS-13.14.5 Electrical Requirements

1) Refer to the Project Specification for Electrical Installations (PS-15)

PS-13.14.6 Control and Instrumentation Requirements

1) Refer to the Project Specification for Control and Instrumentation Installations (PS-14)

PS-13.14.7 Testing and Commissioning

PS-13.14.7.1 Factory Testing

1) All Electrical FAT Tests as specified in the Umgeni Water Particular Specification for
Electrical Installations and the Project Specification for Electrical Works below.

PS-13.14.7.2 Site Acceptance Testing

1) Dry Commissioning:
a) Illustrate compliance with the specification
2) Wet Commission:
a) Site Acceptance tests to complly with the following specifications
i) Umgeni Water Standard Specifications for Mechanical Installations
(section 2.6)
ii) WIMES 1.04 or WIMES 1.11
b) The Contractor shall further operate the equipment “ trouble-free” for a period
of 48 hrs..
c) The Employer reserves the right to instruct the Contractor, at his cost, to
proceed with detailed performance tests.

BSC Item 2013/136


CONSTRUCTION OF THE UMGENI WATER
DARVILL WASTE WATER CONTRACT NO. 2013/136
TREATMENT WORKS UPGRADE C3: SCOPE OF WORK
C3.214

PS-13.14.8 Scheduled Payment Items

1) Detailed Design . Sum


The sum tendered shall include for the mechanical design of the equipment, including
the provision of general arrangement drawings and design calculations illustrating that
the equipment offered is capable of complying with this specification
2) Fabricate, Supply, Deliver and Store (if required)
The sum tendered shall include for the complete fabrication, supply, delivery and
storage of the equipment in an approved store.
a) Pump Sets No.
b) Hopper feed box complete
Sum
c) Fixings, brackets and pump station furtniture as required Sum
3) Handle and Install
The sum tendered shall include for the recovery of the equipment from the approved
store and the final installation thereof.
a) Pump Sets No.
b) Hopper feed box complete
Sum
c) Fixings, brackets and pump station furtniture as required Sum
4) Factory Testing Sum
5) Dry Commissioning Sum
The sum tendered shall include for the dry commissioning / testing of the equipment
specified in this specification.
6) Wet Commissioning Sum
The sum tendered shall include for the wet commissioning of the equipment specified
in this specification.
7) Operations and Maintenance Manuals Sum
The sum tendered includes for the preparation and submission of three copies of the
Operations and Maintenance Manual. Payment is subject to review and approval by
the Engineer.

BSC Item 2013/136