Scope and Specifications

91 Section VII. Work Requirements

Section VII. Work Requirements

Contents

Scope of Works ....................................................................................................... 92

Specification .......................................................................................................... 103

Drawings ................................................................................................................ 377 Supplimentary Information…………………………………………………………….....378


Scope of Work

Name of Work: Comprehensive Water Supply Service Im provements 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: Physical works to be completed

Period from the date of issue of

notice to proceed with the work

Milestone 1 Collection of all drawings from the Department

and submission of designs for ELSRs and WTP

for approval of PHED.

2 months

Milestone 2 Construction of approach roads (100%); Civil

construction works (50%) under Subhead-1 and

Sub-head-2; Supplying of 60% pipes and

specials under Sub-head-3 and laying of 60%

of pipelines supplied/procured.

9 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 :

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

and specials under Sub-head-3 and laying of

80% of pipelines under Sub-head-3 ,

18 months

Milestone 4 Completion of 100% civil work under Sub-head-

1, 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.

21 months

Milestone 5 Testing, Commissioning and Performance Trial

run for the whole Package.

24 months


Pumping Station

Q M3/ 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.

3. 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 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,


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


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


� 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

M3/ 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


House and Water Treatment Plant without any disruption or interruption during the 3 months period of Trial Run.



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 Materia l Internal diameter, in mm

Length, in M

DI/K-9 400 1025

DI/K-9 350 2515

DI/K-9 300 310

DI/K-9 200 1610

DI/K-9 150 2360

TOTAL 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


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 Zone No.1

Zone No.2

Zone No.3

Zone No.4

Total

97.4, HDPE 36158 22408 35073 39400 133039

124.0, HDPE 552 3779 1884 6944 13159

159.6, HDPE 320 1205 305 615 2445

200, DI/K-7 31 742 43 439 1255

250, DI/K-7 Nil 336 Nil 685 1021

300, DI/K-7 Nil 170 Nil 93 263

350, DI/K-7 Nil Nil Nil 217 217

Total 37061 28640 37305 48393 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)

Number

1 500 2

2 400 1

3 300 2

4 200 4

5 150 4

6 100 21

7 25 22

8 20 48

9 15 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.


� 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. No. Location

GL above

MSL(M)

Capacity in KL LWL

above MSL(M)

MWL above

MSL(M)

Stg. Ht.

Inlet Dia., mm

Outlet Dia., mm

Remarks 2026

1

Rajula Gutta (near

Housing Board)

384.61 450 KL, 400.61 405.41 16.00 150 200

Locations for new ELSRs

have been considered within the premises

under possession of the ULB.

2 Zirayath Nagar

376.74 450 KL, 392.74 397.54 16.00 150 300

3 Teachers Colony

379.43 450 KL, 395.43 400.23 16.00 150 200

Existing: GLSR

Sl. No. Location

GL above

MSL(M)

Capacity in KL LWL

above MSL(M)

MWL above

MSL(M)

Inlet Dia., mm

Outlet Dia., mm Remarks 2026

1 Siddala Gutta

1200 KL, 200 350

� 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:


Sl. No. Location

Type of existing utility to be

crossed Type of pipeline Method proposed Remarks

1 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 obtain permission from competent I&CA authority

2

Different locations on road from Sri Ram Sagar lake to NH 44

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.)


3

Near Journalist Colony, at two sites (Indira Nagar and near Balaji lodge)

Nizam Sagar Canal CW pumping main – 200 mm DI/K-9 line

By clamping with parapet/Railing along the existing bridge over the canal. Total involved length is about 16 m and 18.5 m, respectively


4 Near Rajula Gutta Nizam Sagar Canal

CW pumping main – 150 mm DI/K-9 line

By clamping with parapet/Railing along the existing bridge over the canal. Total involved length is about 16 m.


5 Different locations in the town

Small bridges and culverts over water ways

CW pumping main – DI/K-9 line and Different sizes of Distribution pipes

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/Muni-cipality

6 In different Wards

Different categories of existing Roads and alleys etc.

Different size of CW rising main (DI/K-9), distribution pipes at various places, 20 cases

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

ULB may obtain permission from concerned authorities of R&B department /Municipality

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.


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.



6. 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.

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 bidd er shall remain unchanged irrespective of the actual SBC / Foundation Strata and ground water tab le. No extra claim shall be entertained on account of variations in soil strata or Ground wate r 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.


SPECIFICATIONS

INDEX

Sl.No Section No. Specification

1 VII A General Specification of Workmanship and Materials for

Civil Work

Division 1 General Specifications

Division 2 Site work

Division 3 Earth work

Division 4 Masonry

Division 5 Plastering & Pointing

Division 6 Concrete

Division 7 Materials required for pipeline work

Division 8 Laying and Jointing of pipelines

Division 9 Ductile Iron Pipes for Water supply

Division 10 HDPE pipe lines

Division 11 House service connection Material

Division 12 Tree Plantation Strategy

2 VII B Technical Specifications for Civil Works

( ELSRs, CW sumps/GLSRs)

3 VII C Technical Specification for Equipment

4 VII D Technical Specification for Electro Mechanical Works

5 VII E Technical Specification for Electric Motors

6 VII F Technical Specification for Electric Motors, controls of WTP

7 VII G Specifications for transformers and feeder lines

8 VII H General conditions for Erection & Commissioning

Annexure-I 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

Appendix-II

List Of Tools / Electrical Equipment to be provided By

Contractor

Appendix-III List of Spare parts to be provided by the Contractor

Appendix-IV Water Quality Data

Appendix-V Soil Investigation Reports

Appendix-VI Salient Features of Labour Laws

Appendix-VII

Salient Features of some of the major laws that are applicable for protection of Environment


SECTION VII A

GENERAL SPECIFICATIONS OF WORKMANSHIP AND

MATERIALS FOR CIVIL WORK

1. GENERAL

1.1 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.


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


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;


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 Code No. Description

Building IS:1200 Method of measurement of A

Civil Engineering works.

Cement IS:269 Ordinary, Rapid Hardening

and Low Heat Portland Cement.

Sand IS:1242 Sand for Plaster

Aggregates IS:383 Aggregates-Coarse and fine,

from Natural source for Concrete.

IS:515 Aggregates for use in mass


General IS Code No. Description concrete, natural and

manufactured.

Concrete-Plain IS:456

Code of Practice for Plain and Reinforced Concrete for

General Building Construction

IS:3370 Code of Practice for

Concrete Structures for the Storage of Liquids

Brickwork IS:1077 Common Burnt Clay Building Bricks, Paving

IS:1235 Flooring Tiles, Cement Concrete, Floor Finish

IS:1443 Cement Concrete, Flooring Tiles Laying and finishing

Plaster and Painting IS:1661 Cement and Cement Lime

Plaster finishes on walls and ceilings

Steel (Revised) Iron Work

IS:800 Code of Practice for use of Structural Steel in General

Building Construction

2. Earth Work in Excavation & Fillings

2.1 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


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. Concrete

3.1 General

3.1.1 Applicable provisions of Conditions of Concrete shall govern work under this

section.


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 Contractor’s 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 Contractor’s 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 Contractor’s

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


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 : 20 mm

Plain Concrete : 20 mm.

Thin R. C. C. Members

Mat/Lean Concrete : 20/40 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 Reinforcement

3.4.1 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.


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 Contractor’s cost and expenses.

3.6 Concrete Proportioning

3.6.1 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.


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-in-

Charge.

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.


3.7 Workmanship

3.7.1 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 day’s

volume of concrete whichever is lower, a minimum of 3 (three) Cubes shall be cast for test

purpose, and tested at the Contractor’s 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.)


Grade of Concrete Cement Content (Kg.)

M 15 310

M 20 330

M 25 350

M 30 400

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


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 Engineer-

In-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.


3.9 Form Work

3.9.1 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


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


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-in-

Charge. 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 750C 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 Engineer-

in-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


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 1.1 to 1.15

Shore hardness 65 A to 75 A

Tensile Strength 250 to 300 Kg/Cm2

Maximum safe continuous

temperature

750C

Ultimate elongation Not less than 350%

Water Absorption Not more than 350% by weight in a 7 day test.

3.17 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 Unde r 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.


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 Cement : Sand

a) Ordinary brick work with Thickness 250 mm.

above for building superstructure 1 : 6

b) Brickwork in pillars and foundation 1 : 4

c) Half brick or brick-on-edge portion wall

with H.B. netting in every alternative 3rd

layer

1 :

4

d) Brickwork in water retaining structures 1 : 3

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.


5. Plastering, Painting and Surface Treatment

5.1 Cement Plaster

5.1.1 The plastering work shall be governed by IS: 1661. Unless otherwise specified

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-in-

Charge 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 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 White Washing

6.2.1 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 Snowcem or Similar Decorative Cement Finish

6.3.1 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


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 non-

absorbent 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-in-


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. Damp Proofing Work

7.1 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. Roof Water Proofing Treatment

8.1 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


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. Flooring

9.1 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


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. Iron Mongery

10.1 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.


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, de-

scaled 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. Structural Steel Work

11.1 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


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

x 600 x adequate thickness to withstand a load of 500 Kg/m2 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


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. Sanitary Installations

16.1 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


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. Plastic Fibre Reinforced Concrete Manhole Cover M.S. Ladder etc.

21.1 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


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 air-

terminals, 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.


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 contractor’s 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


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. Important Guidelines and Specifications

27.1 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,


27.6 All the exterior doors and windows shall be provided with R.C.C. chajja of approved

design.

27.7 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.


DIVISION – 1

GENERAL SPECIFICATIONS

The I.S. Codes shall be those indicated or subsequent amendments thereon

SL. No. Description I.S. No.

A) LIST OF INDIAN STANDARDS

I. CEMENT

1. Ordinary and Low Heat

Portland cement. 269/1976

2. Pozzolana Portland cement. 1489/1976

3. 43 Grade or 53 Grade Cement 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 2386/1963 (Part – I)

Part – II Estimation of deleterious

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


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. High Tensile Steel for PSC Pipes. 1784/1986 (Part-I)

4. Hand Drawn Wire 432/1953

5. Bending and Flexing of Bars for

Concrete Reinforcement. 2502/1963

6. Recommendations for detailing of

Reinforcement in reinforced concrete works. 5525/1969

V. CONCRETE

1. Plain and reinforced concrete,

Code of practice. 456/2000

2. Laying in Situ cement concrete flooring 2571/1970

3. Sampling and analysis of Concrete IRC: 15/2002

4. Code of practice for liquid retaining structures 3370/1967

5. Code of practice of concrete roads IRC: 15/2002.

VI. MASONRY

1. Brick Masonry 2212/1962

2. Construction of Stone Masonry 1597/1967

VII. PIPES AND FITTINGS

1. Asbestos cement pressure pipes. 1592/1980

2. Blue MDPE pipes. 4427/1996

3. Specifications for Centrifugally Cast (Spun)

D.I. Pipes for Water, Gas and Sewerage 8329/1980


4. D.I.Fittings for pipes for water, gas & sewerage:9523/1980

5. 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

10. Bolts&Nuts to be used in jointing C.I.D.F. Pipes 1363/1967

VIII. WATER SUPPLY FITTINGS

1. 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. Manhole covers and frames, cast-iron. 1726/1974

IX. LAYING OF PIPES

1. Laying of Asbestos Cement Pressures Pipes 6530/1972

2. Laying of MDPE Pipes 7634 (Pt. 2)/1975


3. Laying of Cast-Iron Pipes. 3114/1965

4. Laying of D.I. Pipes 3114/1965

X. MACHINERY

1. Batch type concrete mixer. 1791/1968

2. Sheep foot roller 4616/1968

XI. SAFETY

1. Safety code for excavation works. 3764/1966

2. Safety Code for scaffolds and ladders

Part – I – Scaffolds. 3696/1966 (Part – I)

Part – II – Ladders. 3696/1966 (Part – I)


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


a convenient place and deposited there temporarily, as directed by the Engineer-in-

Charge. 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.


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

Government’s (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:


(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.


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.


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


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.


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:

I.S. Sieve Designation Percentage passing by Mass

4.75 mm 100

2.36 mm 90 to 100

1.18 mm 70 to 100

600 Micron 40 to 100

300 Micron 5 to 70

150 Micron 0 to 15


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.


Permissible limit for Solids

Maximum permissible limit

1. Organic 200 mg/litre

2. Inorganic 3000 mg/litre

3. Sulphates (as SO4) 500 mg/litre

4. Chlorides (as CL) 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-in-

Charge 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.


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.


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 by weight passing

I.S., Sieve

I.S. SIEVE

Designation Class – A Class - B

4.75 MM 100 100

2.36 MM 90 to 100 90 to 100

1.18 mm 70 to 100 70 to 100

600 Microns 40 to 85 40 to 95

300 Microns 5 to 50 10 to 65

150 Microns 0 to 10 0 to 10

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.


(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 Mortar

5.2.1 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 Plastering with Cement Mortar Mix. Mm 7.5 Grade 20 Mm Thick

5.3.1 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


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


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 Grade s 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


DIVISION - 6

CONCRETE

6.1 Concrete Structures

6.1.1 Concrete in Structures

(a) Concrete in structures shall conform to the requirements of Paragraph 6.2

(b) 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 General Concrete Requirements

6.2.1 Composition

(a) 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.


(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:


Sl.No. Placing Condition Degree of

Workability Value of Workability

1. Concreting of lightly reinforced

sections without vibration or

heavily reinforced sections with

vibration

Medium 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 Qual ity 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-in-


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 Water: Shall conform to paragraph 4.1.5

6.2.5 Sand (Fine Aggregate)

a) 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-in-

Charge.

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


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


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 Engineer-

in-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.


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 bidder’s personnel and by the Engineer-in-

Charge 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 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


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 speci fied 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


Prevention of Repeated failure to meet tol erances

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


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-in-

Charge, reinforcement shall be placed within the following tolerances:

a) For effective depth 200 mm or less - + 10 mm

b) For effective depth more than 299 m - + 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.


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 Engineer’s

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


old work, particular attention being paid to corners and close spots, and work thereafter

shall proceed in the normal way.

6.2.12 Placing:

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 Engineer’s

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


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.


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 Engineer’s

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.


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


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. Repair of Concrete

a) 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.


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.


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 manufacturer’s 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

manufacturer’s 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 bidder’s 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.


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.


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


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.


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 - cast iron or ductile iron

Internal valve - 316 stainless steel

Relay valve - 316 stainless steel

Valve parts and fittings - 316 stainless steel

Trims, ported guide and seating - gunmetal to BS 1400 LG2C

Diaphragm, seating or plunger - reinforced synthetic rubber

Loading spring (if employed) - spring steel

Cylinder weights (if employed) - cast iron or ductile iron

Indicating rod - 316 stainless steel

Piston - 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


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.


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.


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: IS 12288/1987

HDPE Pipes: IS 4984/2000

8.4. 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 for the type of pipes used, as

mentioned below:


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


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.


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

IS: 8329: Specification for Centrifugally Cast (spun) Ductile Iron pressure pipes for water,

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-pressure-

Centrifugal 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

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


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 un-

machined 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


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) Indication of the source of manufacture.

(b) The nominal diameter

(c) The last two digits of the year of manufacture.

(d) PN rating of flanges when applicable, and

(e) Any other mark required by the purchaser.

Marking may be done on the barrel of castings or on the outside of the sockets. BIS Certification

marking.The fittings may also be marked with the Standard Mark.

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


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 Fittings

9.8.1 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

pressure for castings

Table 9.8-1 (Refer Table No. 2 IS 9523-2000)

Nominal Diameter DN (mm) Hydrostatic Test Pressure at

works, MPa

Up to and including 300 2.5

Over 300 and up to and including 600 1.6

Over 600 and up to and including

2000

1.0

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

External Diameter DE Wall Thickness mm

DN Nominal Tolerance K12 K14 Tolerance

(1) (2) (3) (4) (5) (6)

80 98 +1/-2.7 7.0 8.1 -2.38

100 118 +1/-2.8 7.2 8.4 -2.40

125 144 +1/-2.8 7.5 8.7 -2.42

150 170 +1/-2.9 7.8 9.1 -2.45

200 222 +1/-3.0 8.4 9.5 -2.50

250 274 +1/-3.1 9.0 10.5 -2.55

300 326 +1/-3.3 9.6 11.2 -2.60


350 378 +1/-3.4 10.2 11.9 -2.65

400 429 +1/-3.5 10.8 12.6 -2.70

450 480 +1/-3.6 11.4 13.3 -2.75

500 532 +1/-3.8 12.0 14.0 -2.80

600 635 +1/-4.0 13.2 15.4 -2.90

700 738 +1/-4.3 14.4 16.8 -3.00

750 790 +1/-4.4 15.0 17.5 -3.05

800 842 +1/-4.5 15.6 18.2 -3.10

900 945 +1/-4.8 16.8 19.6 -3.20

1000 1048 +1/-5.0 18.0 21.0 -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 Dimensions of flange Holes

Dia of

Holes

Bolt Size,

Metric

DN D (outer

dia)

b

(Thickness) No. Dia (d)

80 200 16 4 19 M16

100 220 16 8 19 M16

125 250 16 8 19 M16

150 285 16 8 23 M20

200 340 17 8 23 M20

250 395 19 12 23 M20

300 445 20.5 12 23 M20

350 505 20.5 16 23 M20

400 565 20.5 16 28 M24

450 615 21 20 28 M24

500 670 22.5 20 28 M24

600 780 25 20 31 M27

700 895 27.5 24 31 M27

750 960 29 24 31 M27

800 1015 30 24 34 M30

900 1115 32.5 28 34 M30

1000 1230 35 28 37 M33


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

Outer Diameter Holes Bolt Size, Metric

DN D No. Dia (d)

80 200 8 19 M16

100 220 8 19 M16

125 250 8 19 M16

150 285 8 23 M20

200 340 12 23 M20

250 400 12 28 M24

300 455 12 28 M24

350 520 16 28 M24

400 580 16 31 M27

450 640 20 31 M27

500 715 20 34 M30

600 840 20 37 M33

700 910 24 37 M33

750 970 24 37 M33

800 1025 24 40 M36

900 1125 28 40 M36

1000 1255 28 43 M39

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 nominal Diameter

DN mm

Deviation in L & H

mm

Flange socket,

Flanged Spigot,

Collars, tapers

80 to 1200 ±25

Tees 80 to 1200 ± 50/-25

Bends 90º (1/4) 80 to 2000 ± (15 + 0.03 DN)

Bends 45º (1/8) 80 to 2000 ± (10 + 0.025 DN)

Bends 20º (30) and

11º (15)

80 to 1200 ± (10 + 0.02 DN)


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


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.


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.


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.


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.


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


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 Engineer-

in-Charge.


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


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 IS: 8008

(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

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)


Nominal Dia

Pressure rating (kg/Sq.cm) 6 10 12.5 16 Min Max Min Max Min Max Min Max

50 2.9 3.4 4.6 5.3 5.6 6.4 6.9 7.8 63 3.6 4.2 5.8 6.6 7.0 7.9 8.7 9.8 75 4.3 4.9 6.9 7.8 8.4 9.4 10.4 11.6 90 5.1 5.8 8.2 9.3 10.0 11.2 12.5 13.9 110 6.3 7.1 10.0 11.2 12.3 13.8 15.2 16.9 125 7.1 8.0 11.4 12.8 13.9 15.5 17.3 19.2 140 8.0 9.0 12.8 14.3 15.6 17.4 19.4 21.5 160 9.1 10.2 14.6 16.3 17.8 19.8 22.1 24.5 180 10.2 11.5 16.4 18.3 20.0 22.2 24.9 27.6 200 11.4 12.7 18.2 20.3 22.3 24.7 27.6 30.6 225 12.8 14.3 20.5 22.8 25.0 27.7 31.1 34.4 250 14.2 15.8 22.8 25.3 27.8 30.8 39.5 38.2 280 15.9 17.7 25.5 28.3 31.2 34.5 38.7 42.7 315 17.9 20.0 28.7 31.8 35.0 38.7 43.5 48.0 355 20.1 22.3 32.3 35.8 39.5 43.6 49.0 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

Pressure rating (kg/Sq.cm) 10 12.5 16 Min Max Min Max Min Max

50 3.7 4.3 4.6 5.2 5.7 6.4 63 4.7 5.3 5.8 6.5 7.1 8.1 75 5.6 6.3 6.8 7.7 8.5 9.5 90 6.7 7.5 8.2 9.2 10.2 11.4 110 8.1 9.1 10.0 11.2 12.4 13.9 125 9.2 10.4 11.3 12.7 14.1 15.7 140 10.3 11.6 12.7 14.1 15.8 17.6 160 11.8 13.2 14.5 16.1 18.1 20.1 180 13.3 14.8 16.3 18.1 20.3 22.6 200 14.8 16.4 18.1 20.1 22.6 25.0 225 16.6 18.4 20.4 22.6 25.4 28.1 250 18.9 20.5 22.6 25.1 28.2 31.2 280 20.6 22.9 25.3 28.0 31.6 35.0 315 23.2 25.7 28.5 31.5 35.5 39.3 355 26.1 29.0 32.1 35.5 40.0 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 Test Temp C

Test Duration (min holding time)

Induced Stress (Mpa) P.E. 63 PE 80 PE 100

1 Type Test 80 165 3.5 4.6 5.5

2 Acceptance Test

80 48 3.8 4.9 5.7


The internal test pressure for the above test shall be calculated by adopting the formula

given below.

P = 2 x p x s (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) Reversion Test: Longitudinal reversion shall not be greater than 3% iv) 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 940.3–946.4 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


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

Sample number

Sample size

Cumulative Sample size

Acceptance number

Rejection Number.

1 2 3 4 5 6 Upto 150 First 13 13 0 2 Do Second 13 26 1 2 151-280 First 20 20 0 3 Do Second 20 40 3 4 281-500 First 32 32 1 4 Do Second 32 64 4 5 501-1200 First 50 50 2 5 Do Second 50 100 6 7 1201-3200 First 80 80 3 7 Do Second 80 160 8 9 3201-10,000 First 125 125 5 9 Do Second 125 250 12 13 10000-35000 First 200 200 7 11 Do Second 200 400 18 19

ii) 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.


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, app urtenances 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) PE particles can be abrasive if they enter eyes. ii) 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.


10.4 Earthwork and pipe support. a) Earth work shall be as per the specifications given for CI pipes except the following. b) 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

Out sidedia Of pipe (mm)

Width of Trench (mm)

Depth of Trench (mm)

Remarks

1 50 500 950

Provide 100mm thick bedding where soils are poor or rock is met with. Increase the depth of trench by 100mm in such cases.

2 63 500 950 3 75 500 950 4 90 600 1100 5 110 600 1100 6 125 600 1100 7 140 600 1100 8 160 600 1200 9 180 600 1200 10 200 500 900 11 225 500 900 12 250 500 900 13 280 500 900 14 315 500 1000 15 355 500 1000

10.5 PIPE LAYING. a) 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 40 x Dia 1. SDR = Ratio of outside diameter and wall thickness 42 33 30 x Dia 26 25 x Dia 2. Ambient temperature shall be 20 degree C or more <21 20 x Dia

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.


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 50-100mm layers up to 50-100mm above the top of pipe.

10.7 CONCRETE ENCASEMENT AND THRUST (OR ANCHOR) BLO CKS 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) It shall be done as specified for CI pipes except as provided herein. b) 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

Dia of pipe (mm)



Remarks

1 50 500 750

Provide mm thick bedding where soils are poor or rock is met with. Increase the depth of trench by 100mm in such cases.

2 63 500 800 3 75 500 800 4 90 500 850 5 110 500 950 6 125 500 1000 7 140 500 1000 8 160 500 1000 9 180 500 1000 10 200 600 1200


11 225 600 1200 12 250 600 1400 13 280 600 1400 14 315 600 1500 15 355 600 1500

Heavy Pipes laid under roads less than 3.0 wide / foot paths and no valves provided.

Sl No

Dia of pipe (mm)



Remarks

1 50 500 700

Provide mm thick bedding where soils are poor or rock is met with. Increase the depth of trench by 100mm in such cases.

2 63 500 700 3 75 500 700 4 90 500 700 5 110 500 750 6 125 500 750 7 140 500 750 8 160 500 750 9 180 500 900

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. Insert type joints.

2. Compression fittings.

3. Fusion welding.

4. Threaded Joints

5. Flanged joints, and

6. 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.


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.


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)

Initial bead Width(mm)

Soak time T2 (sec)

Max. t3 & t4 (Sec)

Min t5 (minutes)

Final bead with (mm)

Min t6 (Minutes)

SDR Min Mad 41 17 9

2 1 30 4 3 3 5 4 6 11 4 1 60 5 4 3 7 5 8 12 6 1 90 5 4 4 9 6 9 13 8 1 120 6 4 4 11 7 10 14 10 1 150 7 5 4 13 8 12 15 12 1 180 8 5 4 15 9 13 16

Note : 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. t2 time of contact between the plate and pipe ends after relieving the pressure p2 3. Excessive pressure will squeeze the melted PE out of the joint and weaken it. b) Butt fusion procedure. i. Clamp the pipes in the butt fusion machine. ii. 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.,


iv. Align the pipe ends and clamp in place v. Plane both ends until they are perfectly square. vi 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. Bring together the two pipe ends and ensure they are aligned. viii 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


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) Visual inspection of joints. i. 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


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.

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

Pipe Size (mm) Min number of samples.

>90 <110 2 >110 <180 4 >180 <315 6 >315 7


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


11.2 Technical Specification for House Service Connectio n 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 1555-

3 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


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.


5. The threaded outlet should be from sizes 1/2” – 2” BSP to suit the required outlet

connections.

6. The outlets should be reinforced with female threaded metal inserts to SS 304

7. 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. Body-Polypropylene

b. Nut / Cap – Polypropylene

c. Clip Ring-POM (Acetylic Resin)

d. Packing bush - Polypropylene

e. “O” Ring - NBR

f. Threaded metal inserts – SS 304 with BSP Threads

1. 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 - Leak tightness under internal pressure

Clause 8.2.2 - Resistance to pull out

Clause 8.2.3 - Leak tightness under Internal Vacuum

Clause 8.2.4 - Long term Pressure Test for Leak tightness of

Assembled joint

Clause 8.3.2.1 - MRS Valve as per ISO 9080

Clause 8.3.3.1 - Resistance to Internal Pressure


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. Odour & Flavour of water b. Appearance of Water c. Growth of Micro Organism d. Extraction of substance that may be of concern to Public Health (Cyto Toxicity) e. 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. Body and Handle - UPVC b. Seals - PTFE c. “O” Ring - NBR / EPDM d. 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.


The Ball Valves shall be tested as per ISO 4422. Following test methods will be

performed.

Clause 7.1 - Resistance of Valve Bodies to internal pressure

Clause 7.2 - Crushing Test

Clause 7.3 - Endurance Test

Clause 7.4.1 - Seat and Packing Test

Clause 7.4.2 - 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. Odour & Flavour of water

b. Appearance of Water

c. Growth of Micro Organism

d. Extraction of substance that may be of concern to Public Health

(Cyto Toxicity)

e. 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. Odour & Flavour of water

b. Appearance of Water

c. Growth of Micro Organism

d. Extraction of substance that may be of concern to Public Health

(Cyto Toxicity)

e. Extraction of Metals

3. Pressure Testing

The pressure rating of MDPE Blue PE 80 Pipes shall be confirming to Clause 4.1 of

ISO 4427/1996


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) PR rating

Wall Thickness

Minimum Maximum

20 PN 16 2.3 2.8

25 PN 12.5 2.3 2.8

32 PN 12.5 3.0 3.5

The dimension tolerance shall be as per ISO 4427 Clause 4.1.3


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 Melt Flow Rate 2 Density 3 Oxidation and Induction Test 4 Hydrostatic Test 5 Pigment Dispersion Test 6 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.


DIVISION – 12

TREE PLANTATION STRATEGY

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.

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:


• 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:

• 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.

6. 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.


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 Local name of specie(s)

Scientific name

Alternative plant species

Scientific name

1st Row

(Flowering

Plants)

Gulmohar Gulmohar Pink Cassias Cassia Grandis

1st Row

(Flowering

Plants)

Bengal Babul Acasia

auriculiformis 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


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:

• Its name

• The name of the supplier, unless otherwise agreed.

• The date of dispatch from the nursery.

6.2 Tree Planting

6.2.1 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


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.


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.


Figure -1: Ornamental Tree Guard with Welded Mesh


SECTION –VII B

TECHNICAL SPECIFICATIONS FOR CIVIL WORKS (ELSRs, CW Sumps/GLSRs)

1. Special Notes

All water retaining structures shall be built in RC C M 30. The water retaining

structures shall be hydraulically tested as per IS 3370 Part A, which shall be done in

the Engineer’s 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.


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 The system should be designed to provide a net output of 11.50 MLD.

1.9 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.


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) Detention period shall be 30 seconds.

b) Ratio of tank height to diameter shall be between 1:1 and 3:1

c) Ratio of impeller diameter to tank diameter shall be 0.2 to 0.4.

d) Shaft speed of the propeller shall be greater than 100 RPM.

e) Velocity induced in the water shall be about 2/3 of the peripheral

speed and not less than 3.0 M/Second.

f) Position of the impeller should be at the center of the liquid and 0.9 M below the water surface.

g) Head loss shall be 20 to 60 cm of water.

Necessary bye-pass arrangements should be made to direct feed the filter beds duly bye-

passing 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 Chemical House:

a) 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.


b) Alum Solution Tanks These should hold one day’s 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 As per hydraulic designs.

2. Flocculator Capacity As per hydraulic designs.

3. Clarifier capacity As per hydraulic designs

.

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.

(a) FLOCULATOR i) Detention period - 30 Minutes. ii) Depth - 2.4m to 3.60m

iii) Peripheral velocity (speed) - 2/5 peripheral velocity speeds of the paddles or 0.3 m/sec

iv) Revolution of the paddles - 1 to 5 RPM. v) Paddles Area - 10 to 15 % of the tank

Sectional area in the place of the shaft. vi) Head Loss - 150 mm.


(b) CLARIFIER

i) Detention period - 2.5 hours ii) Surface Loading - 30 to 40 m3/m2 (Clear

Clarifier area only) iii) Depth - 1.8 m Minimum. iv) Velocity through Intel ports - 15cms/sec to 25 cms/sec

v) Flow through velocity - 0.5 to 1.5 cm/sec. vi) Bottom slope - 1 in 12 to 18

The clarifier bridge, railing and assembling parts shall be provided with coats of

anticorrosive epoxy paint.

vii) Size of dispersion walls - 1/5 to 1/10 dia. viii) Outlet weir loading - 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 re ctangular type should be provided.

The area of each filter bed shall be based on the following criteria.

Rate of filtrations - 80 litres / minute / Sqm. Hours of working - 231/2 hours/day.

Shape of bed - 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/cm 2)

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) Ratio of the length to diameter of the lateral shall not exceed 60.

2) Size of perforation 5 to 12 mm dia.

3) Spacing of perforations along the material shall be 8 cms for 5 mm perforation and 20 cms

for 12 mm perforation.


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) Rate of washing not less than 60 cm. per minute for a period of 10 minutes.

8) 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) Filter head loss shall be not more than 2.0m.

b) Specification for Filter Sand: 1) 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) It should not create or increase difficulties in washing.

3) 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) The depth of filter sand should be 75 cm.

7) 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) Soluble fraction in Hydrochloric acid shall not exceed 5% cu/Metre.

9) 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) Wearing loss shall not exceed 3%.

c) 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:


5mm to 2mm 10 cm 12mm to 5mm 8 cm 20mm to 12mm 8 cm 40mm to 20mm 8 cm 60mm to 40mm 11 cm

Total 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) General Requirements 1. 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.


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. Description of the item Unit 1. 2. 3. 1.

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.


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

One Set One Set One Set One No.

3.

FLASH MIXER CHAMBER:

a) Mechanism for instantaneous mixing of Alum solution with raw water.

b) Gravity type desludge mechanism up to disposal point

One Set One Set

4.

CLARIFLOCULATOR:

a) Central Mechanism for Driving Bridge over rails motors and fabrication of walkways with hand rails

b) Mechanism for flocculation and raking in the flocculation compartment with driving motors

c) Mechanism for raking in clarifier compartment d) Central scrapper frame with brushes. e) 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.

One Set One Set One Set One Set One Set

5.

FILTRATION PLANT

a) Filter media of gravel and sand of suitable characteristics b) Filter under drainage system of suitable capacity c) Wash water and waste water gutters and appurtenances. d) The influent and effluent pipe gallery together with

valves, inlet and out let connections including all appurtenances.

e) Automatic rate of flow controller for each filter bed.

One Set One Set One Set One Set One Set

f) Flow gauge for each filter bed for inlet and out let. g) Loss of head gauge for each filter bed h) Air blower of suitable capacity along with air pipe system

complete for air scour. i) Back wash arrangements complete with water main. j) (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.

k) Surface wash system comprising of necessary pipe connections, controls etc., complete.

One set One set One No. One set One set. One set


l) 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.

One set

One set

One complete job

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

One No. One set One set One No.

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

g) Conductivity meter

h) Equipment and reagents required for analyzsing alum percentage in the ferric alum.

i) Test bench fully equipped with glass apparatus for sampling and testing of water before and after treatment

j) Equipment and reagents required for analyzing chlorine percentage in bleaching powder.

One No.

One Set

One No.

One No.

One No.

One No.

One No.

One Set

One set

One set

k) Necessary furniture: (i) Wooden Stools (ii) Wooden Almarah (Big Size)

One No. One No.


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.

One Unit One Unit

9. SPARES AND WORKING TOOLS: 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 loa d of 25% and Filter losses of 5% for 23.50 working hours per day over the stipulated capacity.

One Set


(I) CIVIL WORKS.

Sl. No Description of work Unit

1. 2. 3. 1. a) Construction of 10 m dia. (internal) RCC Intake well

– cum Pump House within Sri Ram Sagar lake,

about 1000 m inside

b) Construction of RCC Bridge, 800 m long from Intake

Well, towards bank, within Sri Ram Sagar lake

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

d) Costruction of Transformer yard and its switch

room, cable trenches and Barbed wire fencing with

gate etc.

One Unit

One Unit

One Unit

One Unit

One Unit


2.

3

a) Laying including supplying fitting fixing, with Specials

and Valves, Raw Water Pumping main (DI/K-9),

about 19000 m long

a) Construction of 11.5 MLD Conventional Water

Treatment Plant at Yanamgutta area of Armoor town

with usual components, as given in the BOQ

c) RCC Clear Water Reservoir, 1000 KL, with pipe

connections

d) RCC Clear Water Pump House, with pipe

connections

e) RCC NP3 S/S Sludge line, 200 mm dia.,110 m

f) Sludge sump – cum – Pump House and Distribution

box, with pipe connections

g) Sludge Pond (twin unit) with collection well etc.

h) Electrical Transformer yard, switch room, Cable

trenches, Barbed wire fencing etc.

i) Cascade Aerator Fountain with pipe connections

j) Administrative Building

k) Staff quarter building, having four flats

l) Internal roads (CC), Internal drains, Boundary wall etc.

One Unit

One Unit

One Unit One Unit One Unit One Unit One Unit One Unit One Unit One Unit One Unit Two Unit One Unit


4

5 6.

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

a) Laying including supplying fitting fixing, with Specials

and Valves, Clear Water Pumping main (DI/K-9), 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

a) Pumps and Motors, at Raw Water Pump House, and

Clear Water Pump House

Three Units One Unit Four Units Four Units Four Units Four Units One Unit

One Unit

One Unit

Two Units


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.

i. Necessary tube light points. ii. Necessary ordinary light points iii. Necessary plug points iv. Necessary sodium vapor lamps outside the Intake

HW, Filtration plant, Service Reservoir sites, for yard lighting.

v. Exhaust fans near Chlorination plant vi. Electrical fans 185 mm dia of good make vii. Lighting arrestor (Aluminium) viii. Main Busbar distribution system ix.

Two Units

7.

PLANT DRAWINGS: Supply 6 sets of complete drawings of the plant mounted on cloth

One Unit 8. 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

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 in-charge of work.


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 AN D 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.

• 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.

3.2 MATERIALS:

3.2.1. Cement : Shall conform to the requirements of Section 4.1.3.(Division-4)

3.2.2. Water : Shall conform to the requirements of Section 4.1.4.(Division-4)

3.2.3. Sand (Fine Aggregate) :Shall conform to the requirements of Section 6.2.5.(Div-6)

3.2.4. Coarse Aggregate :Shall conform to the requirements of Section 6.2.6.(Div-6)

3.2.5. Bricks :Shall conform to the requirements of Section 4.1.1.(Div-4)

3.2.6. Reinforcement : 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. 178-

1979 (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.


Specials, Manhole

Covers, Valves and

Jointing Material

3.2.8. Lightening Arrestor : Shall conform to the requirements of I.S. 3070-1794

3.2.9. Float operated Water : Shall conform the toe departmental requirements

level Indicator and gauge 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. CONCRETE:

3.5.1. 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.

3.5.2. Constructional Requirements : The construction of the structure shall conform to the requirements of I.S. 3330 Part, II and IV.

3.5.3. Leveling Course, : The concrete to be used shall be of M 10 Grade conforming to I.S. 456-1978.

3.5.4. Footings, Columns braces, R.C.C. ladders and staircase

: 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.

3.5.5. Other Members : 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.

3.6 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.


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 C.I. PIPE CONNECTIONS:

3.8.1 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 The jointing of pipes shall conform to the requirement in Division 8.

3.9 RCC VENTILATORS:

3.9.1 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.


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.


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 All labels must be affixed to apparatus before final acceptance tests are carried out.

2. 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. GENERAL REQUIREMENT, WORKMANSHIP & DESIGN OF PLA NT

3.1 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


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 re-alignment 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


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. Painting (Steel Structures)

9.1 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.


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 manufacturer’s 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 day’s 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 manufacturer’s 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.


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 Over coating Finishing

System A Red Lead Approved quality Approved quality

(to be followed Primer under coat (one Synthetic Enamel

unless otherwise (two coats) coat) (3 coats)

specified) 50 microns 25 microns 75 microns.

Total D.F.T. = 150

microns

Drying = 24 hours between coats.

Systems B Each Primer Zinc Chromate Approved quality

(after a (one coat) Primer Synthetic Enamel_

metallic coat (one coat) (two coat)

of zinc to a

thickness of 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).


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 Over coating

Each Primer Zinc

Chromate

(one coat) Primer

(one coat)

25 microns 25 microns

Total D. F. T. 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.


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) IS: 1537 C.I. Fittings (Socket & Flange medium class) IS: 1538

Mixed Steel Tubes \, Tubular and Other wrought steel fittings IS: 1239

Electrically welded steel Pipes IS: 3589

High Density Polyethylene Pipes (Series II) IS: 4984

Un-plasticized P.V.C. Pipes IS: 4985

Asbestos Cement Pressure Pipes (Class II) IS: 1592

13. Reflux Valves

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:


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 All pipes to pressure vessels etc shall have flanged connections.

16.5 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 Contractor’s 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.


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.


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, eye-rings, 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


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.


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.


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) Peak ambient temperature - 430 C b) Average ambient temperature - 350 C c) Peak relative humidity - 100% d) Wind Velocity - 44 m/sec e) Seismic Zone as per IS - Zone-II f) Climatic condition - Hot, Humid & Dusty

However, the maximum temperature and humidity shall not occur simultaneously.


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 Engineer’s approval of Manufacturer’s 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. Title

IS 210 - Grey Iron Casting

IS 318 - Leaded Tin Bronze Ingots and Castings

IS 807 - Code of Practice for design, manufacture, erection and testing (structural portion) of cranes and hoists

IS 1239 - Mild Steel tubes, tubular and other wrought steel fittings

IS 1367 - Technical Supply Conditions for Threaded Steel Fasteners

IS 1536 - Centrifugally cast (Spun) iron pressure pipes for water, gas and sewage

IS 1537 - Vertically cast iron pressure pipes for water, gas and sewage

IS 1538 - Cast iron fittings for pressure pipes for water, gas and sewage

IS 1710 - Specification for pumps – Vertical Turbine, Mixed and Axial flow, for Clean Cold Water


Standard No. Title

IS 2062 - Steel for general structural purposes – Specification

IS 2266 - Steel Wire Ropes for General Engineering purposes – Specification

IS 2312 - Propeller type ac ventilating fans

IS 2685 - Code of practice for selection, installation and maintenance of sluice valves

IS 2974 Part 3 & 4 - Code of practice for design and construction of machine foundations for rotary type machines

IS 3109 - Specification for Short link chain, Grade M(4)

IS 3177 - Code of practice for Electric Overhead Travelling Cranes and Gantry Cranes other than Steel Work Cranes

IS 3618 - Specification for Phosphate Treatment of Iron and Steel for Protection Against Corrosion

IS 3624 - Specification for Pressure and Vacuum gauges

IS 3815 - Specification for Point Hooks with Shank for General Engineering Purposes.

IS 3938 - Specification for Electric Wire Rope Hoists

IS 4460 (Parts 1 to 3) - Gears – Spur and Helical Gears – Calculation of Load Capacity

IS 4736 - Specification for Hot-dip Zinc Coatings on Mild Steel Tubes

IS 5120 - Technical requirements for roto dynamic special purpose pumps

IS 5312 (Part 1) - Specification for Swing Check Type Reflux (Non-Return) Valves for Water Works Purposes - Single Door Pattern

IS 5312 (Part 2) - Specification for Swing Check Type Reflux (Non-Return) Valves for Water Works Purposes – Multi Door Pattern

IS 5382 - Specification for Rubber Sealing Rings for Gas Mains, Water Mains and Sewers

IS 5600 - Specification for Sewage and Drainage Pumps

IS 6005 - Code of practice for phosphating of iron and steel

IS 6280 - Specification for Sewage Screens

IS 8329 - Centrifugally Cast (Spun) Ductile Iron Pressure Pipes for Water, Gas and Sewage – Specification

IS 9137 - Code for acceptance test for centrifugal, mixed flow and axial pumps – class C


Standard No. Title

IS 9523 - Specification for Ductile Iron Fittings for Pressure Pipes for Water, Gas and Sewage

IS 10981 - Class of acceptance test for centrifugal, mixed flow and axial pumps – class B

IS 11388 - Recommendations for Design of Trash Racks for Intakes

IS 11592 - Selection and Design of Belt conveyors – Code of Practice

IS 13095 - Butterfly valves for general purposes

IS 13349 - Specification for single faced cast iron thimble mounted sluice gates

IS 14845 - Resilient Seated Cast Iron Air Relief Valves for Water Works Purposes – Specification

IS 14846 - Sluice Valve for Water Work Purposes (50 – 1200 mm size) – Specification

IS 15310 - 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.


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.


1.4 Testing at Works

1.4.1 General

Tests of the equipment / item at the manufacturer’s works will be carried out in accordance with the specifications and Engineer’s approved QAP. All inspection, examination and testing shall be performed conforming to relevant Standards. Engineer’s 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. Manufacturer’s 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 manufacturer’s 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


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 stress-resisting 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


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 manufacturer’s 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 Engineer’s inspector may inspect such forgings and identify test pieces to check physical and chemical properties and witness such tests at manufacturer’s 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.


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 year’s 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 manufacturer’s 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.


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 manufacturer’s 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.

• The Operation and maintenance manual shall include the followings :

• Schedule of equipment supplied along with manufacturer’s 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.

1.12 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 manufacturer’s 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 manufacturer’s instructions.


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 manufacturer’s 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 manufacturer’s 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.


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 pi pe Velocity – Pipe size

50-150 mm m/sec.

Velocity – Pipe size

200 mm and above m/sec.

1 Pipelines at pump discharge & column pipe

1.5 – 2.0

1.8 – 2.5

2 Pipelines at pump suction / Bell Mouth

1.0 – 1.2 1.2 – 2.0 / 1.5

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


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.

c) Frictional losses in fittings shall be calculated as per Hydraulic Institute Standard.

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. Scour or drain valves of suitable size at suitable locations for adequate drainage of pipelines.

ii. Thrust blocks and expansion joints/loops at suitable locations. iii. Pipe supports / racks complete with all accessories iv. Any other accessories as required for safe and reliable operation of

respective pumping system.

The basic design philosophy of the pump houses (new construction) are as follows

v. 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.

vi. 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. vii. Other general layout criteria as specified in “Particular Specification” shall

also be adhered to while designing the pump house.

All piping having its scope upto client’s 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.


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. Manufacturer’s 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 manufacturer’s 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. STANDARD SPECIFICATION

2.1 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: Specification for pumps – vertical turbine mixed and axial flow

IS: 5120: 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 pump’s impeller shall preferably be of

non-overloading type.


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.


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.


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) 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.

Material of Construction (Subject to confirmation by the Pump Manufacturer considering

water quality)

Bowl : 2.5% Ni-Cast Iron, IS : 210, FG 260

Bowl Liner : Stainless steel, ASTM-A-276 Type 316 Ti

Diffuser Cone : 2.5% Ni-Cast Iron, IS : 210, FG 260

Column pipe : Mild steel, IS : 2062 (minimum 10 mm thick)

Galvanized as per IS : 4736

Discharge elbow : Mild steel, IS : 2062 ( minimum 10 mm thick)

Impeller : Duplex Stainless Steel, ASTM-A-351 Gr. CD4 MCu

Shaft sleeve : Stainless Steel, AISI :410

Shaft bearing : Cutless Rubber

Sole plate : Mild Steel, IS :2062

Line shaft : Stainless Steel, AISI :316

Impeller shaft : Stainless Steel, AISI : 316

Line shaft coupling : Stainless Steel, AISI : 316

Fastners : Stainless Steel, AISI : 316

Suction bell2.5% : Ni-Cast Iron, IS : 210, FG 260

Motor stool : Mild Steel, IS : 2062

Flow straightner : Mild steel, IS : 2062, Galvanized as per IS : 4736


Bush bearing : Bronze, BS : 1400, LTB 6

Painting

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 Manufacturer’s 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:

• Bowl and Suction bell

• Impeller and Bowl liner

• Shafts and shaft sleeves

• Couplings

• Bearings

• Column pipes

b) 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.


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) Bowl and Suction bell

ii) Column Pipe

iii) Discharge Head

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 client’s 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


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 manufacturer’s

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 manufacturer’s expert. The QH and Power

parameters can be measured with suitable measuring device to be arranged by contractor at no

extra cost.

2.2 Valves

2.2.1 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 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 : Stainless Steel, AISI410

Body Seat and Disc Seat : Bronze, IS:318 Gr. LT B2

Packing : Greasy jute packing

Fasteners : IS:1367, Class 4 / 4.6

Extended Spindle : Mild Steel, BS:970, EN8

Head Stock : Cast Iron,IS:210, FG 260

Hand wheel : Cast Iron, IS:210, FG 260

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.


Material of Construction

Body, Disc, Cover : Ductile Iron, IS:1865, Gr500/7

Trunion Shaft : Stainless steel, AISI 410

Body Seat : Gun Metal

Disc Seat : Natural Rubber

Fasteners : IS:1367, Class 4 / 4.6

2.2.3 Automatic Air Release Valve

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.


Body, Cover, Cowl : Ductile Iron, IS:1865, Gr500/7

Body seat, Disc Face, Stem Nut : Bronze, IS:318, Gr LTB2

Stem : Stainless steel, AISI 410

Fastener : IS: 1367, Class 4/4.6


The manufacturer will submit their QAP for Engineer’s approval including the following tests

and inspections which will be carried out at the manufacturer’s 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 Client’s 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.


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


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


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 full-

length 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 manufacturer’s 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.


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 manufacturer’s 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


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.


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 Woltman type Flow Meter

2.8.1 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 Appli cation)

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 lower half casing. 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: 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


and shall be suitable for parallel and continuous operation. The pump’s impeller shall

preferably be of non–overloading 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 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.

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.


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.


Material of Construction (Subject to confirmation b y the Pump Manufacturer

considering water quality)

Pump Casing : 2.5% Ni-Cast Iron, IS : 210, FG 260

Impeller : Duplex Stainless Steel, ASTM-A-351 Gr. CD4

MCu

Shaft sleeve : Stainless Steel, AISI: 410

Base Plate : Mild Steel, IS: 2062

Pump shaft : Stainless Steel, AISI: 316

Fastners : Stainless Steel, AISI: 316

Bush Bearing : Bronze, BS: 1400, LTB 6

Painting

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.


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:

• Pump Casing

• Impeller

• Shaft Sleeve

• Pump Shaft

• Bush Bearing

• Wearing Rings (Impeller & Casing)


b) Tests shall also include but shall not be limited to the following:

i) The entire surface of the impeller castings shall be subjected to Dye Penetration

Test as per ASTM–E– 165.

ii) Shaft shall be subjected to Dye Penetration and Ultrasonic Test.

iii) Witnessing of NDT / review of NDT reports.

iv) Static balancing test for impeller and Dynamic balancing test of complete

rotating assembly as per ISO/1940 or equivalent International Standard.

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 client’s 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 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 manufacturer’s

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 manufacturer’s 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


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 : Stainless Steel, AISI410

Body Seat and Disc Seat : Bronze, IS: 318 Gr. LT B2

Packing : Greasy jute packing

Fasteners : IS: 1367, Class 4 / 4.6

Extended Spindle : Mild Steel, BS: 970, EN8

Head Stock : Cast Iron, IS: 210, FG 260

Hand wheel : 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.


Body, Disc, Cover : Ductile Iron, IS: 1865, Gr 500/7

Trunion Shaft : Stainless steel, AISI 410

Body Seat : Gun Metal

Disc Seat : Natural Rubber

Fasteners : 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.


Body : Ductile Iron, IS: 1865, Gr 500/7

Disc : Ductile Iron, IS: 1865, Gr 500/7

Disc cover : Ductile Iron, IS: 1865, Gr 500/7

Body ring 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 : Nitrile rubber

Stub and Drive shaft : Stainless Steel, IS: 6603 Gr 12 Cr 12

Cover for NDE : Mild Steel, IS: 2062 Gr. Fe 410 WA

Spacer : Mild Steel, IS: 2062 Gr. Fe 410 WA

Gasket : CAF, IS: 2712 Gr. W/3

Split Thrust Ring : Aust – Iron, IS: 2749 Gr–ASG Ni 20 Cr 2

Flanged Bush : Bronze, IS: 318 LTB2

Packing for Bush : PTFE (Teflon)

Dowel pin : Stainless Steel, ASTM A276 Type 410


Spacer D.E : Mild Steel, IS: 2062 Gr. Fe 410 WA

U Cup Seal and ‘O’ Ring : Nitrile Rubber

U Seal Retaining Bush : Bronze, IS: 318 LTB2

Adaptor Plate : Mild Steel, IS: 2062, Gr.Fe 410 WA

U Seal Retaining Washer : Bronze, IS: 318 LTB2

Hardware in contact with water : Stainless Steel, ASTM A276 Type 304

Hardware not in contact with water : Carbon Steel, IS: 1367 Class 4/4.6


The manufacturer will submit their QAP for Engineer’s approval including the following

tests and inspections which will be carried out at the manufacturer’s 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 Client’s 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


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


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.


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.


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

manufacturer’s 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.


3. PUMPING SYSTEM

Armoor Water Supply System

Sri Ram Sagar Lake – Raw Water Pumping Station (Int ake)

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.


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 Sri Ram Sagar Lake – Raw Water Pumping Station

Liquid Data

Liquid Handled Raw Water

Temperature Ambient,Peak-50°C,Average - 40° C

Total Dissoleved Solids 250 mg / ltr

Total Suspended Solids 45 mg / ltr

pH Value 7.5 to 8.5


Sp.gr 1.00

Total BOD5 Nil Clear Water Pumping Station Yanamgutta WTP Clear Water Pumping Station

Liquid Data

Liquid Handled Clear Water

Temperature Ambient Peak-50°C Average - 40° C

Total Dissoleved Solids < 250 mg / ltr

Turbidity < 1.0 NTU

pH Value 7.5 to 8.5

Sp.gr 1.00

Total BOD5 Nil

Civil & Hydraulic Data

Pumping Station Designation Sri Ram Sagar Lake – Raw Water Pumping Station

Yanamgutta Village Clear Water Pumping Station

Civil Data

Existing Ground Level, m N.A (+) 374.00

Finished Ground Level, m N.A (+) 374.00

Plinth Level, m (+)334.00 (+) 374.60

Motor Floor Level, m (+)334.00 (+) 369.60

Pump Floor level, m (+)334.00 (+) 369.60

Sump Bottom Level, m (+) 316.00 (+) 369.60

Wet Well Diameter, m 10.00 N.A

Pump House Soffit Level, m (+) 341.50 (+) 380.60

Hydraulic Data

Maximum Water Level at Suction, m (+) 333.00 (+) 374.00

Minimum Water Level at Suction, m (+) 318.00 (+) 371.20

Discharge Level, m (+) 380.00 (+) 401.129*

*Highest in the Supply System 1. Vertical Raw Water Pump


Service Raw Water

Type Mixed Flow vertical


Designation RW Pump

Duty Continuous

Location Indoor

Design Capacity, m3 / hr 225

Numbers required 3 TDH at design capacity (Bowl), m 78.50

Speed, rpm < 1500

Minimum Bowl efficiency required at design capacity, % 80

Numbers of Pumps working 2

Numbers of Pumps standby 1

Numbers of Pumps working in parallel 2

Range of Operation Between 70% and 130 % of rated capacity Design & Constructional features As per "Standard Specification"

Materials of Construction As per "Standard Specification" Supply of Accessories & Services As required and as per "Standard Specification"

Tests and Inspection As per "Standard Specification"

Pumping Station Designation Yanamgutta WTP Clear Water Pumping Station

Service Clear Water

Type Horizontal Axially Split with Double Entry Impeller, Foot Mounted

Designation CW Pump

Duty Continuous

Location Indoor


Numbers required 3

TDH at design capacity, m 50.50

Speed, rpm < 1500

Minimum efficiency required at design capacity, % 80

Numbers of Pumps working 2 Numbers of Pumps standby

1

Numbers of Pumps working in parallel 2

Range of Operation Between 70% and 130 % of rated capacity


Design & Constructional Features As per "Standard Specification"



2. Valves


Yanamgutta WTP Clear Water Pumping Station

A. Sluice Valve Not Applicable

Type Rising Spindle Nominal Pressure, PN 10

Size, Dia, mm 250

Numbers required 3

A. Reflux Valve

Type Swinging Disc / Tilting Disc

Nominal Pressure, PN 16 10

Size, Dia, mm 200 200

Numbers required 3 3

B. Butterfly Valve

Type Double Eccentric

Nominal Pressure, PN 16 10

Size, Dia, mm 200 200

Numbers required 3 - Electrically Operated 3 - Manually Operated

3-Electrically-Operated 3-Manually-Operated

C. Butterfly Valve at CWR Not Applicable

Type Double Eccentric

Nominal Pressure PN 10

Size, Dia, mm 350 - Manually Operated

Numbers required 2

For All Valves


Materials of Construction As per "Standard Specification"

Supply of Accessories & Services As required and as per "Standard Specification"



3. Pipes & Fittings (Double Flanged)



Pressure Rating PN16 PN10

DN Approx. Length (mm)

Qty. No. DN

Approx. Length (mm)

Qty No.

1. Taper* 200/150 - 3 250/200 - 3 2. Taper* 200/150 - 3

3. Dismantling Joint 200 250 3 250 250 3

4. Dismantling Joint 200 250 3

5. Dismantling Joint 400 300 1

6. Tee 500/200 - 3 400/200 - 3

7. Tee 400/250 - 1

8. 90 deg. Bend 500 - 1 350 - 3

9. Bell Mouth 350 - 3

10. Straight Pipe (Between Tees) 500 750 2 400 1300 4

11. Straight Pipe (after 90 deg. Bend 500 1500 1 - - - 12. Straight Pipe (Between Cross) 400 1300 4

13. Straight Pipe 350

1000 3

2000 3

14. Straight Pipe 250 2000 3



17. Parddle Collar 250 1000 3

18. Blank Flange 500 - 1 400 - 3

19. Cross

400 / 350 / 250 -

2

Material of construction As per "Standard Specification" Tests and Inspection 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.


4. Gauges

Pumping Station Designation

Sri Ram Sagar Lake – Raw Water Pumping Station


Range, Kg / Cm2 Qty. No. Range, Kg /

Cm2 Qty. No.

Pressure Gauge at Delivery side 0 - 16 3 0 - 10 3

Compound Gauge at Suction side Not Applicable (-)1.0 - (+)1.0 3

5. Electrically Operated Overhead Travelling Gantry Crane & Hoist (EOT)

Pumping Station Designation

Sri Ram Sagar Lake – Raw Water Pumping Station


Type Double girder Electrically Operated Overhead Travelling

Double girder Electrically Operated Overhead Travelling


Capacity, Te 5 3

Span, mm (Approx) 5000 5000

Long Travel, mm (Approx) 10000 16500

Lift, mm (Approx) 22500 8500 Design & Constructional Features As per "Standard Specification"



6. Monorail Crane with Chain Pulley Block

Pumping Station Designation Yanamgutta WTP Clear Water Pumping Station

Capacity, Te 1.0

Long Travel, mm (Approx) 16500

Lift, mm (Approx) 8000

Numbers required 1



Supply of Accessories and Services As required and as per "Standard Specification"

Test and Inspection As per "Standard Specification"


7. Exhaust Fan



Type Axial Flow Axial Flow

Sweep, mm 300 300


Air to be removed, m3 / hr 6,600 9,800

8. Flow Meter



Type Ultrasonic Ultrasonic

Liquid Transmitted Raw Water Clear Water

Liquied Temperature °C Ambient 40 Ambient 40


Pipe Dia, mm 500 400

Duty Point Pressure, Kg / cm2 7.90 5.10

Flow Range m3 / hr 100 - 1000 100 - 1000

Velocity Range m / sec 0.14 - 1.41 0.22 - 2.21

Protection IP 67 IP 67





9. Sump (Dewatering) Pump

Pumping Station Designation Yanamgutta WTP Clear Wa ter Pumping Station

Service Seepage Water

Type Non-clog, Centrifugal

Duty Continuous

Location Indoor


Numbers required / P.S. 2


TDH at Design Capacity, m 10

Speed, rpm < 1450





10. Service Water Pump

Pumping Station Designation Yanamgutta WTP Clear Wa ter Pumping Station

Service Potable Water

Duty Continuous

Location Indoor

Numbers required 1


TDH at Design Capacity, m 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

Design and Constructional Features As per "Standard Specification"

Material of Construction As per "Standard Specification"




SECTION VII E TECHNICAL SPECIFICATION FOR ELECTRIC MOTORS

1 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 In case of any discrepancy, the driven equipment specification shall govern.

2 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.


5 Performance

5.1 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 Specific Requirements

6.1 Enclosure

6.1.1 All motor enclosures shall conform to the degree of protection IP 44 unless

specified.


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 in-

service 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 3600 in steps of 90

0 unless otherwise

approved.


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


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 720C over the maximum ambient room

temperature of 450C 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

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


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 Authority’s cable connections.


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 Lifting Provisions

8.3.1 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.


1.0 SERVICE CONDITIONS

Average Grade : Approx. 6.0M Relative Humidity

Design ambient Isoceraunic Level

Air : 500C Seismic Zone IV

Cooling Water : 360C

2.0 AUXILIARY POWER SUPPLY Supply Description Consumer

H.T. Supply 6000 V, 50 Hz Motors above 160 KW

non effectively earthed

L.T. Supply 415V, 3, 50 Hz Motors above 200W effectively earthed to 160 KW

230V, 1, 50Hz Motors below 200, W effectively earthed Lighting space heating A.C. control & protective devices D.C. Supply 110V DC unearthed D. C. alarm, control & Protective devices

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, 3-

phase, 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


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 72oC over the maximum

ambient room temperature of 45oC. 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 Manufacturer : 1.02 Rated output in Kw : 1.03 No. of Poles :

1.04 Speed : 1.04.01 -do- at present phase load condition : 1.04.02 -do at future phase load condition : 1.05 Nos. offered :

1.06 Type of duty & duly designation (as per IS 325)

1.,07 Whether the motor is capable for operation after one hot restart and/or 3 hourly restarts (equi-spaced).

1.08 Supply condition : 1.08.01 Rated Voltage (Volta) : 1.08.02 Allowable variation in voltage (%) : 1.08.03 Frequency (Hz) : 1.08.04 Allowance variation in frequency : 1.08.05 No. of Phases

1.08.06 Stator connection :

1.09 Currents :

1.09.01 Full load current :

1.09.02 No load current :

1.09.03 Starting current (%) of full load current : 1.10 Efficiency : 1.10.01 Full load efficiency : 1.10.02 Efficiency at present phase load condition : 1.11 Power factor :

1.11.01 Full load power factor : 1.11.02 Power factor at present phase load : 1.11.03 Power factor at future phase load : 1.11.04 No load power factor

1.12 Method of starting

1.13 Torque : 1.13.01 Starting torque (% of full load torque) : 1.13,02 Maximum torque (% of full load torque) : 1.14 Acceleration time (seconds) from dead stop :


1.14.01 With 100% terminal voltage : 1.14.02 With 85% terminal voltage :

1.15 Safe stall time - Cold/Hot : 1.16 Class of Insulation :

1.17 Ref. ambient (Temperature OC) : 1.18 Temperature rise in (CC) by resistance

method & class in which limited

1.19 Type of enclosure : 1.20 Degree of protection : 1.21 Installation :

1.22 Shaft orientation & mounting : 1.23 Space heaters : 1.23.01 Number :

1.23.02 Rating (Watts) : 1.23.03 Voltage, Phase, frequency : 1.23.04 Whether separate terminal bod provide for

1.24 Bearing : 1.24.01 Driving end : 1.24.02 Non driving end : 1.24.03 Anticipated life (hours)_ : 1.24.04 Recommended lubricant & Qty. : 1.24.05 Whether separate lubricant nipple provided

1.24.06 Interval of lubrication (Hours) : 1.25 Whether winding temperature detectors & bearing

temperature detector provided

1.26 Whether separate terminal box for BTDs RTD’s provided

1.27. Approx. weight of the motor (kgs) : 1.28 Dynamic load (kgs) : 1.28.01 Normal running condition : 1.28.02 Starting condition

1.28.03 Short circuit condition 1.29

GD2 value of load to motor shaft (kg.M2) :

1.30 Painting : 1.31 Earth terminal & lifting lug provided (Y/N) : 1.32 Technical leaflets/literatures provided or not


SECTION VII – F Technical Specifications for Electric Motors, Contr ols Etc of WTP.

1. General

1.1 This specification covers the design, manufacture, testing, supply, erection and

commissioning of the motor control center, electric motors and other electrical installations such

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. Motors

2.1 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.


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.


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

Engineer’s approval.

3. Starting Equipment (Motor Control Centre)

3.1 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 :


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.


Sl. No. Equipment/Unit Provision for Spare over ac tual number of motors 1. Flash Mixer 1 2. Alum Agitator 2 3. Clarification unit Scraper 2 4. Flocculator 2 5. Sludge pumping 1 6. Back wash water pumping 1 7. Recirculation of waste water 1 8. Air blower 1 9. Chlorination Booster 1 10. Alum solution make up water pumping 1 11. Rest of the motors 1 12. Lighting 2 3.7 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. Power and Control Cable 4.1 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.


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. Current Collector on Flocculation & Clarification Units

5.1 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. ILLUMINATION 6.1 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 co-

ordinated 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.


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. Ceiling and Exhaust Fans 7.1 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. Power Plug

8.1 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. Grounding / Earthing

9.1 The earthing system shall be as per IS 3043.

10. Control Switches in the Laboratory

10.1 All electrically operated instruments to be used in the laboratory shall be completely wired

with necessary control switches.

11. Electrical Testing Equipment

11.1 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. Inspection

12.1 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. Labels

13.1 All electric motors, Starters, Switchgears, Distribution boards, Isolating Switches, Switch

fuse units pillars and other similar items shall be labeled as to their function.


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.


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


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.

• Power frequency voltage dry test

• .Measurement of resistance of main circuit

• Tests to prove satisfactory operation.

• Dimension check

• Galvanisation test.

2.7 GUARANTEED TECHNICAL PARTICULARS:- The tenderer shall furnish the guaranteed technical particulars duly filled in the proforma after award of contract.


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. Number of Poles 3 2. No. of insulator per pole 2 nos.12 KV post - Insulators 3. Nominal system voltage 11 KV 4. Highest system voltage 12KV 5. Rated frequency 50 Hz 6. System Earthing Effectively earthed 7. Rated normal current 200 Amps 8. Altitude of installation Not exceeding 1000 M. 3.3 STANDARDS: The H.G. Fuse set shall conform to the following standards.

• IS-9385/1980 (for high voltage expulsion fuses and similar fuses)

• IS-2544-1973 (for porcelain post insulators or its latest amendments if any

• IS-2633-1979 (for Galvanisation of ferrous parts)

3.4 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


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 TESTING 4.1 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 11 KV Class Station Class Arrestor voltage rating 12 KV Rated frequency 50 Hz Continuous operating voltage, rms 9.6 KV

Leakage current through arrestor at operating voltage Less than 1 mA


Long duration discharge class Class 2 Nominal 8/20µs discharge current – peak 10 kA Maximum Lightning impulse residual voltage with 8/20µs discharge current peak

32KV(31KV*)

Maximum switching impulse residual voltage peak 28 KV (24 KV*) Maximum residual voltage with steep current peak 38 KV (34 KV*) High current impulse test value (4/10µs wave) 100 KA Insulator housing impulse withstand voltage, 1.250µs wave-peak

41.6 KV

Insulator housing power frequency voltage withstand capability for one minute (wet) – peak

29.68 KV

Minimum creepage distance of insulator 380 mm Minimum protected creepage distance 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. Maker’s 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) Maker’s 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 Voltage- To 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).


6. Impulse withstand voltage for positive and negative polarity ( 1.2/50) mircro second wave). - - a) Across the isolating distance 85 KV (peak) - b) To earth & between poles 75 KV (peak) - 7. One minute power frequency withstand voltage (a) Across the isolating distance 32 KV (RMS) - (b) To earth and between poles 28 KV (RMS) - 8. Rated normal current and rated frequency. 400 amps. 50 Hz 9. Rated short circuit making capacity 25 KA (peak). 10. Rated short time current. 16 KA (RMS) 11 Rated peak withstand current 40 KA (RMS) 12 Rated mainly active load breaking capacity 10 A 13 Rated Transformer off load 6.3 A( rms) breaking capacity 14. Rated line charging breaking capacity 2.5 A ( RMS) 15. Rated cable charging breaking capacity 10 A ( rms) 16. Minimum clearance between adjacent phases (a) Switch Closed. 760 mm ( centre to centre) (b) Switch opened. (centre/edge of blade) 380 mm 17. Temperature rise: (a) Temperature rise should not 65°C exceed to maximum limit as specified below at an ambient temperature not exceeding in 40°C

Copper contacts silver faced Terminal of switch intended to be connected to external conductor by bolts or screw at an ambient temperature at 40°C should not exceed 50°C .

18. Vertical Clearance from top of 254 mm (minimum) insulator cap to mounting channel 19. Type of contact 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


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


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. Operating voltage 11 KV - 3. Number of insulators - per phase 2 nos.12 KV Post Insulator per phase 4. Rated normal current and normal frequency. 200 Amps.50 Hz 5. Vertical clearance from top of insulator cap to Mounting Channel - 254 mm (minimum) 6. Height of the riser for carrying 150 mm from the horns - cap (top) of insulator. 5. Post Insulator. (a) Name of the manufacturer & country of origin - To be specified by the tenderer


(b) Type of cementing - To be quoted original cemented only (c) One minute power fre- 35 KV RMS.-frequency withstand voltage, Dry (d) One minute power frequency withstand voltage, Wet 35 KV RMS.-. (e) Visible discharge voltage 9 KV (RMS) (f) Dry Flashover Voltage- To be specified by the tenderer (g) Power frequency puncture 1.3 times of actual dry withstand volts, flash over voltage. (h) Creepage distance 230 mm minimum. (Actual creepage distance for which type test

have been conducted is to be specified by the tenderer) 8 Impulse withstand voltage (1.2/50 micro second wave positive & negative polarity. (a) Across the isolating distance - 85 KV (peak) (b) To earth & between poles - 75 KV (peak) 9. One minute power frequency withstand voltage (a) Across the isolating distance, 32 KV (RMS) - (b) 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.


Technical Specification For 11kv Feeder Lines, Mate rials Support Poles, Cross Arms And Bolts & Nuts

SCOPE OF WORKS The scope of works include execution with complete procurement, manufacturer’s 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. APPLICATION

5.1 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.


6. MATERIAL 6.1 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. 11 KV INSULATORS

8.1 PIN INSULATORS 8.2 DISC INSULATOR

Nominal Voltage 11 KV Minimum number of discs is string 1 Visible discharge voltage 9 KV rms. Wet power frequency one minute withstand voltage

35 KV rms.


Power frequency puncture voltage Impulse withstand voltage peak 75 KV Minimum creepage distance 320 mm Minimum protected creepage distance -- Minimum mechanical failing load for conductor sizes of 232 MM2 AAAC

120 KN

80 & 100 mm2 90

55 mm2 70

8.3 Tests

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 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

8.6 Routine tests The following routine tests shall be conducted on each set and results are to be furnished for consideration:

• Visual examination;


• Tensile load test;

• Power frequency voltage test;

9. 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 .

10. 11 KV LINE FITTINGS 10.1 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.

10.2 Measurements and Tests for Stay Wire Required Value (Grade 4) Nominal size of stay wire: 7/4.00 mm Nominal Diameter of Individual Wires : 4.00 mm Minimum Diameter of Individual Wires : 3.90 mm Maximum Diameter of Individual Wires: 4.10 mm Minimum ultimate tensile strength of individual wires 700 N Minimum percent elongation at rupture before stranding 5% Minimum percent elongation at rupture after stranding 4.25% Wrapping test for ductility :

Turns on and off its own diameter 8

Lay ratio of finished strand 19 to 21 Minimum weight of zinc coating before stranding 490 g / mm2 Minimum weight of zinc coating after stranding 475 g/ mm2 Chemical test : Sulphur and phosphorus content Less than or equal to

0.060 % each 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.


IEC/ISO/Other International

Standard IS Subject

IEC :1089 Round wire concentric lay overhead electrical standard conductors

IS 398 Alluminium Alloy Stranded Conductors

IS 9997 Alluminium Alloy redraw rods for electrical purposes

IEC 502 : 1994 Extruded solid dielectric insulated power cables for rated voltages 1.0 KV up to 30 KV

IEC 104

Alluminium Magnesium Silicon alloy wire for overhead line conductors

IS 1778 Reels and drums of bare conductor.

BS : 6485-1971 PVC covered conductors for overhead power lines.

2 H.T. Switch Gear

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.


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 45°C 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 c-

burden 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


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.


4 Cable

4.1 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-in-

Charge.

All jointing should be of dry type to be done with hydraulic crimping machine where


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


2.03 size and approx. length various point to point as per B O O & specification.

3.00 Control cable

3.01 Makes

3.02 Voltage grade & type.

3.03 Size and Approx length from various point to point as per B O O &specification.

4.00 Co axial shielded cable/signal cable.

4.01 Makes


4.03 Size and Approx length from various joint to point as per B O Q & specification.

5 Power Factor Improvement Capacitor and 0.2% React or

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


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


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 Limit the touch and step potential to tolerable values.

b potential through ground earth wires, cable sheath fences, pipe lines etc.

c 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


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 Arr angement

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.


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


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 Faciliti es

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


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. Employer Use of Equipment

10. 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 Contractor’s 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. Contractor’s 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.


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) Establish and maintain the area placed at his disposal for office/storage purposes.

b) Provide the necessary power and water connection from the supply mains and install and maintain the temporary distribution lines within the working area;

c) Erect and maintain necessary offices and storage space;

d) Provide temporary lighting at erection site required for erection;

e) Arrange for personnel accident insurance for his/their own personnel at site;

f) 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;

g) Gardening and landscaping and beautification of the site before commissioning;

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

i) 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.

j) 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.

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.


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 contractor’s works, works of his agents at manufacturer’s 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 employer’s 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 Employer’s representatives or his appointed agents have witnessed the tests or a letter of inspection waiver is issued by the Engineer in Charge.

13. Site Tests

13.1 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.


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.

ii) All manually operated valves / gates shall be operated throughout 100% of the travel and these should function without any trouble.

iii)

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.

iv) Visual check on all structural components, welding, riveting, rubber lining, FRP lining, painting etc. and if doubt arises will be tested again.

v) 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.

vi) . Water leakage test of all liquid retaining structures as per IS specifications

vii) Load tests and integrity tests of piles.

viii) Load test of civil structures if desired by the Engineer.

ix) All test instruments and equipment shall be furnished by the Contractor to the satisfaction of the Engineer.

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. Block Grouting

15.1 All equipment after erection shall be properly grouted without charging extra.

16. 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.


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 manufacturer’s 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 Contractor’s 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.


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 Contractor’s liabilities under the contract. Separate insurance policies shall be obtained to cover

i) Rail and / or road etc., transit of equipment to site; and

ii) Period of storage and erection and commissioning at site.

24. 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


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 pre-requisition to commissioning vide 24.3 (d).

24.3 The initial performance tests shall involve th e 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.

b) 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.

c) 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.

d) The initial performance tests shall be carried out at least for 72 hours continuous operation.

e) 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.


ANNEXURE-I

ENVIRONMENTAL MANAGEMENT PLAN : PRE- CONSTRUCTION P HASE

COMPREHENSIVE PLANNING OF WATER SUPPLY SERVICE IMPR OVEMENTS IN ARMOOR

S.No. Potential Negative

Impacts Mitigation Measures Time frame Responsible agencies

1 Clearances All clearance required for Environmental aspects during construction shall be ensured and made available before start of work.

Before construction ULB / Concerned Departments & Contractor

2 Tree Cutting 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.

Pre-construction & construction phase

Contractor / ULB

3 Utility Relocation 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


Contractor / ULB/ Concerned departments

4 Baseline parameters

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.

Pre-construction, construction and post-construction phase

Contractor / ULB


S.No. Potential Negative Impacts

Mitigation Measures Time frame Responsible agencies

5 Planning of temporary Traffic arrangements

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


Contractor / ULB

6 Storage of materials

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.


Contractor / ULB

7 Construction of labour camps

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.

During the construction

Contractor


ANNEXURE-II

ENVIRONMENTAL MANAGEMENT PLAN- CONSTRUCTION PHASE

COMPREHENSIVE PLANNING OF WATER SUPPLY SERVICE IMPR OVEMENTS IN ARMOOR

S.No. Activity BoQ Reference Anticipated Impact Duration of

impacts Mitigation Measures Responsible

for Mitigation Monitoring Indicators of Mitigation

Reference Document

1 Sourcing of Materials (Clause 1.1.2 of specifications- Section VII A)

105, 107, 109-112, 119-120, 202-204, 206, 209, 210, 302-305, 308, 310, 311, 312, 313, 505, 505.2, 505.3, 516.3- 516.8, 521, 522, 601, 702-706, 711, 713, 805-808, 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, 1404.8-1404.11, 1405.1, 1507, 1508, 1521.2-1521.7, 1522.2-1522.7, 1525-1527, 1602-1604, 1902, 1903, 1904, 1905, 1906, 2002, 2003, 2004, 2103, 2202- 2210, 2215, 2220-2225, 2230, 2302-2312, 2316-2317, 2321, 2042-2407, 2411-2416, 2421, 2422, 2424, 2052-2506, 2602, 2603,

Extraction of rocks and material may cause ground instability

During collection

(i) 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: Location- Jakranipalle, 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.

Construction Contractor (CC)

Construction Contractor documentation

Contract document


S.No. Activity BoQ Reference Anticipated Impact Duration of impacts

Mitigation Measures Responsible for Mitigation

Monitoring Indicators of Mitigation

Reference Document

2 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.

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


Location of stockpiles

The Environment (Protection) Act, 1986 The Air (Prevention and Control of Pollution) Act 1981 CPCB standards of ambient air quality and vehicular and equipment emission

3 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


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.


i) Complaints from sensitive receptors ii) heavy equipment and machinery fitted with air pollution





Reference Document

vehicle-related pollutants such as carbon monoxide, sulphur oxides, particulate matter, nitrous oxides, and hydrocarbons in the air.

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

4 Excavation [Clause 3.1 (Division 3) of specifications- Section 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, 1301-1303, 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


i) Complaints from sensitive receptors / residents.

The Environment (Protection) Act, 1986 The Air (Prevention and Control of Pollution) Act 1981





Reference Document

5 Shifting of common utilities [Clause 3.1 (Division-3) of specifications- Section VII A]

-do- Disruption of services During construction activity

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.


Complaints from sensitive receptors

Contract document

6. Dewatering (Clause 1.7 of specifications- Section 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

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.

The Environment (Protection) Act, 1986. The Water (Prevention and Control of Pollution) Act 1974





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.

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.


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.


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

10 Aquatic fauna 106 (i) Impact on aquatic fauna affect water quality- temporary


i) Not to dispose any construction materials in Sri Ram Sagar Lake which may pollute the reservoir water


Checking of conservation management

Forest (Conservation) Act, 1980,





Reference Document

turbidity during construction (ii) Impact on Sri Ram Sagar Lake bed sediment- removal of part of sediment within intake structure- local disturbance for aquatic life

and aquatic fauna; ii) Quick removal of sediment and bonding materials to control turbidity at Intake well in SRSP.

plan for tree species and aquatic life (ii) records of surface water quality inspection

amended 1988 Andhra Pradesh Water, Land and Tree Act, 2002 Wildlife Protection Act

11 Disposal of Debris / spoil (Clause 1.8 of Genl. specifications- Section VII A and Cl. 2.2 & 2.4 of Division-2 Section VII A)

518, 519, 1222, 1223, 1523, 1524

Solid wastes as well as excess construction materials impact aesthetic and land environment.

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





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 Pocham Temple surrounding area

� Govt. School area in Ashok Nagar

12 Diversion of traffic during construction (Clause 2.1 of specifications- SectionVII A)

523, 1224, 1528 Traffic problems in right-of-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


(i) Traffic Management Plan (ii) complaints from sensitive receptors (iii) number of sign boards placed at subproject sites.

Contract document Appropriate Construction Techniques





Reference Document

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.

13 Stacking of pipes, valves & specials

506, 508, 510-512, 601, 709, 710, 802, 1007-1010, 1204, 1208-1211, 1304, 1401-1403, 1509, 1511, 1512, 1516-1518,

Improper stacking of pipes leads to traffic problems and accessibility to properties.


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





Reference Document

• Open park in Zirayath Nagar area

• Nalla Pocham temple surrounding area

• Ashok Nagar Govt. school open area

14 Socio-Economic – 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) Complaints from sensitive receptors (ii) Number of walkways, sign boards, and metal sheets placed at sub-project sites.

Contract document Social impact assessment and compensation matrix

15 Occupational Health and Safety (Clause 1.6 of specifications- Section 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) 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


(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) Guidelines- Water and sanitation (2007) prepared by World Bank Group





Reference Document

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

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

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.

16 Asbestos Cement Pipes

1501-1503 Health risk During pipe laying – as per site condition

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;

Standard for handling asbestos prescribed by the Occupational health and Safety Administration (OHSA) amd the US Environmental Protection Agency (EPA)

17 Work Camps (Clause 11.1.3 (J) of specifications- Section 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 guarantee the following: 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

Contract document Environmental, Health, and Safety (EHS) Guidelines- Water and sanitation (2007) prepared by World Bank Group The Municipal Solid Wastes (Management





Reference Document

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.

and Handling) Rules, 2000

18 Chance Found Archaeological Property


Risk of archaeological chance finds

Throughout the execution period

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


(i)Records of chance finds

The Ancient Monuments and Archaeological Sites and Remains Act 1958





Reference Document

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.

19 Clearing of construction camps and restoration

Affect Land Aesthetics After completion of the project

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 contractor’s expenses, to the entire satisfaction of the engineer.


Final clearance certificate from the Engineer in Charge.

Contract document


Appendix – I

List of Pump sets, Drawings etc, to be furnished by the successful Tenderer

1.00 Pump thrust bearing housing details. 1.02 Pump non-reverse ratchet details. 1.03 Pump sectional drawing with part no. 1.04 Finally approved pump house layout with load data. 1.05 Finally approved single line diagram of the electrical system and earthing. 1.06 Cable schedule and termination chart. 1.07 GA details of H.T. Board, L.T. Board, Control & instrumentation panel. 1.08 Sectional drawing with part nos. for pump discharge valve, sluice valves, actuators. 1.09 Schematic power wiring drawings (both H.T. & M.V.), panel wise. 1.10 Schematic Control Wiring drawings panel wise. 1.11 Purchase order references of individual equipment. 1.12 List of authorized service centers of individual equipment. 1.13 List of special tools & tackles required for effective installation & maintenance. 1.14 Installation, operation, maintenance manuals for all equipment. 1.15 Schematic wiring diagram for D.C. system & battery charge. 1.16 Design calculation for earthing system. 1.17 Completion drawings for all electrical circuit diagrams, layout Terms & Conditions. (The drawings etc. shall be furnished on transparency along with the copies mentioned). 1.18 Details/type of bearings of pump & motor.


Appendix – II

List of Tools / Electrical Equipment to be provided By Contractor

Sl No

Name of Tools/ Equipment Quantity

1 Double Ended Spanner (6 mm to 25 mm) 3 sets

2 Screw Driver (6 mm to 25 mm) 3 sets

3 Sliding Pipe Wrench

(a) 150 mm 3 sets

(b) 250 mm 3 sets

(c ) 300 mm 3 sets

(d) 350 mm 3 sets

4 Hand Drill (6 mm to 19 mm) 3 sets

5 H.S. Drills (1.5 mm to 10 mm) 3 sets

6 Round Rough File- 350 mm 3 sets

7 Flat Rough File 3 sets

8 Steel Tale 3 sets

9 Hacksaw – 300 mm 3 sets

10 Hammer with handle 3 sets

11 Cold Chisel 3 sets

12 Centre Punch 3 sets

13 Engineering Square 3 sets

14 Spirit Level 3 sets

Electrical Equipment

15 Multi Range Tong Tester 1 no

16 Avo- Meter 1 no

17 500V Megger 1 no

18 Multi Meter 1 no


APPENDIX – III

List of Spare Parts to be provided by the Contracto r.

(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 i) Driving & Non-driving end Bearings for one motor - 1 set.

Breaker 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 - 2 nos. Ammeter - 2 nos.


APPENDIX - IV

Quality Data of Raw water available for Armoor (HMWS&SB)

Raw Water Quality of Sri Ram Sagar Lake Parameters Water Quality Analysis Results

03.12.2011 12.01.2012 06.02.2012 06.03.2012 02.04.2012 30.04.2012

Color, Hazen <5 <4.5 <5 <5 <5 <4

Taste Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable

Turbidity (NTU) 12.0 10.2 10.6 8.5 8.8 7.8

Odour Unobjection-able

Unobjection-able

Unobjection-able

Unobjection-able

Unobjection-able

Unobjection-able

pH at 280 C 7.3 7.2 7.1 7.8 7.5 7.4

Electrical Conductivity at 280 C

520 510 520 495 490 485

Tot. Dissolved Solids,mg/l 380 360 370 290 280 280

Ph. Alkalinity, mg/l 54 52 52 50 Not Detected

Not Detected

Tot. Alkalinity as CaCO3,

mg//l

180 174 170 170 168 166

Tot. Hardness as CaCO3,

mg/l

180 178 175 168 168 166

Chloride as Cl, mg/l 130 128 126 124 124 122

Fluoride as F, mg/l 0.2 0.2 0.18 0.18 0.2 0.2

Nitrate as NO3, mg/l Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected

Nitrite as NO2, mg/l 0.001 0.001 0.001 0.001 0.001 0.001

Sulfate as SO4, mg/l 44 42 42 40 38 38

Calcium as Ca, mg/l 34 33.6 33.2 32 32 32

Magneseum as Mg, mg/l 24.0 23.5 24.6 25.0 23.0 22.0

Phosphate, mg/l Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected

Iron as Fe, mg/l Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected

Lead, mg/l Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected

Arsenic, mg/l Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected

Zinc, as Zn, mg/l Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected

Copper as Cu, mg/l Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected

Dissolved Oxygen, mg/l 5.6 5.8 5.8 6.0 6.0 6.0

COD, mg/l Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected

BOD5, mg/l Not Detected Not Detected Not Detected Not Detected Not Detected Not Detected

Residual Chlorine,mg/l Nil Nil Nil Nil Nil Nil

MPN of Coliform Bacteria/1000 ml

1620 1609 1620 1594 1594 1590

MPN of E-Coli per 100 ml. 5 5 4 4 5 4


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) Sub Soil Profile IS Classification From To

Arundhati Nagar, Bore Hole 1

0.0 1.5 Moorum GP 1.5 3.0 Moorum GP 3.0 5.0 Moorum GP 5.0 7.0 Moorum GP 7.0 8.5 Soft Disintegrated Rock SDR 8.5 10.0 Soft Disintegrated Rock SDR

10.0 11.5 Soft Disintegrated Rock SDR 11.5 13.0 Weathered Rock Boulder 13.0 14.5 Soft Disintegrated Rock SDR 14.5 16.0 Soft Disintegrated Rock SDR

Housing Board – Bore Hole 2

0.0 1.5 Moorum GP 1.5 3.0 Moorum GP 3.0 4.5 Soft Disintegrated Rock SDR 4.5 6.5 Soft Disintegrated Rock SDR 6.5 8.0 Soft Disintegrated Rock SDR 8.0 10.0 Weathered Rock Boulder

10.0 11.5 Soft Disintegrated Rock SDR 11.5 13.0 Soft Disintegrated Rock SDR 13.0 15.0 Soft Disintegrated Rock SDR

Shastri Nagar – Bore Hole 3

0.0 1.5 Red Moorum GP 1.5 3.0 Red Moorum GP 3.0 4.5 Moorum GP 4.5 6.0 Moorum GP 6.0 7.5 Soft Disintegrated Rock SDR 7.5 9.0 Soft Disintegrated Rock SDR 9.0 10.5 Soft Disintegrated Rock SDR

10.5 12.5 Soft Disintegrated Rock SDR 12.5 14.0 Soft Disintegrated Rock SDR 14.0 15.0 Soft Disintegrated Rock SDR

Teachers Colony – Bore Hole 4

0.0 1.5 Small Boulder Boulders 1.5 3.0 Small Boulder Boulders 3.0 4.5 Red Soil GP 4.5 6.0 Red Soil GP 6.0 8.0 Red Soil GP 8.0 10.0 Red Soil GP

10.0 11.5 Moorum GP


Bore Hole Location

Depth (m) Sub Soil Profile IS Classification From To

11.5 12.5 Moorum GP 12.4 14.0 Soft Disintegrated Rock SDR 14.0 15.0 Soft Disintegrated Rock SDR

Siddala Gutta – Bore Hole 5

0.0 1.0 Red Soil GP 1.0 3.0 Red Moorum GP 3.0 5.0 Weathered Rock BOULDER 5.0 7.0 Hard Disintegrated Rock HDR 7.0 9.0 Hard Disintegrated Rock HDR

1300 Plots – Bore Hole 6

0.0 1.5 Black Cotton Soil BC 1.5 3.0 Black Cotton Soil BC 3.0 4.0 Black Cotton Soil BC 4.0 5.5 Moorum GP 5.5 7.0 Moorum GP 7.0 9.0 Soft Disintegrated Rock SDR 9.0 11.0 Soft Disintegrated Rock SDR

11.0. 13.0 Weathered Rock BOULDER 13.0 15.0 Hard Disintegrated Rock HDR

Yanam Gutta – Bore Hole 7

0.0 1.5 Moorum GP 1.5. 3.0 Moorum GP 3.0 5.0 Moorum GP 5.0 7.0 Soft Disintegrated Rock SDR

7.0 8.5 Soft Disintegrated Rock SDR 8.5 10.0 Soft Disintegrated Rock SDR 10.0 12.0 Soft Disintegrated Rock SDR 12.0 13.5 Weathered Rock BOULDER 13.5 15.0 Hard Disintegrated Rock HDR

Jalalpur – Bore Hole 8

0.0 2.0 Moorum GP 2.0 4.5 Moorum GP 4.5 6.0 Soft Disintegrated Rock SDR 6.0 7.5 Soft Disintegrated Rock SDR 7.5 9.0 Weathered Rock BOULDER 9.0 11.0 Weathered Rock BOULDER

11.0 13.0 Hard Disintegrated Rock HDR 13.0 15.0 Hard Disintegrated Rock HDR


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) Labour Laws a. Workman Compensation Act 1923: The Act provides for compensation in case of

injury by accident arising out of and during the course of employment. b. Payment of Gratuity Act 1972: gratuity is payable to an employee under the Act

on satisfaction of certain conditions on separation if an employee has completed 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. Maternity Benefit Act 1951: The Act provides for leave and some other benefits to women employees in case of confinement or miscarriage etc.

e. Contract Labour (Regulation & Abolition) Act 1970: The Act provides for certain welfare measures to be provided by the Contractor to contract labour and in case the Contractor fails to provide, the same are required to be provided, by the Principal Employer by Law. The Principal Employer is required to take Certificate of Registration and the Contractor is required to take license from the designated Officer. The Act is applicable to the establishments or Contractor of Principal Employer if they employ 20 or more contract labour.

f. 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.

g. Payment of Wages Act 1936: It lays down as to by what date the wages are to be paid, when it will be paid and what deductions can be made from the wages of the workers.

h. Equal Remuneration Act 1979: The Act provides for payment of equal wages for work of equal nature to Male and Female workers and for not making discrimination against Female employees in the matters of transfers, training and promotions etc.

i. Payment of Bonus Act 1965: The Act is applicable to all establishments employing 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

j. 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


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 workmen’s (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


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.

2. 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.

3. 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 inter-relationship which exists among and between water, air and land, and human beings, other living creatures, plants, micro-organism and property.

4. 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


Government. 5. 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.

6. 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.

7. 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.

Scope and Specifications

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