Volume -2 (Part - 3) (R1) Specifications of Mechanical Works · Annexure-3 : Revised “...

Annexure-3 : Revised “ Volume-2(R1)”

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In continuation of Volume-2 (Part-2)

Volume -2 (Part - 3) (R1)

Specifications of Mechanical Works

February, 2020


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Specifications for Mechanical Works

Contents

Chapter

No.

Description Page

No.

1 Specifications for Mechanical Works 3-69


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13. SPECIFICATIONS FOR MECHANICAL WORKS

Specifications described here is in general for various works. However specifications

for only those Materials /Equipments/ Instruments shall be applicable which are

required or provided at site. If the specification of any items are not described here

then specifications as per the relevant IS code or prevalent as per the department

practice will be applicable as approved by Engineer-in-charge.

13.1. General Requirements for Mechanical Works

(a) Sufficient space shall be provided between items of Facilities or fixed structures to permit

safe and convenient access for operation and maintenance.

(b) Layout of the site structures/equipment shall be cognizant of code distances required

between non-hazardous and hazardous structures/plant/equipment, etc.

(c) An area adjacent to all mechanical equipment shall be provided as maintenance lay down

area.

(d) Electrically operated cranes, fixed runways, lifting eyes or other means shall be provided

to permit the removal of larger items of STP that may logically be required to be removed

during the course of its normal operational life for maintenance or replacement purposes.

(e) Areas where leakage of water is likely to occur, whether in normal use or during

maintenance, shall be provided with covered drainage channels which shall direct spillage

either to a suitable drain or to a sump from where it can be pumped to an appropriate

place for safe disposal.

(f) Where necessary, the equipment shall be provided with removable acoustic coverings to

limit the noise produced during normal operation to the limits detailed elsewhere.

(g) Wherever the electric motors, gear box are exposed to open atmosphere, a sunshade

shall be provided.

(h) Pipework shall be designed and installed to prevent blockages and to permit their

clearance without dismantling pipework or equipment.

(i) The Concessionaire shall take due regard to the potential of hazardous mixing of

chemicals, particularly as a result of leaks and spillages, and their drainage and

containment.

(j) Chemical pipework shall be secured to racks or trays, to walls of tanks and walls of

buildings as necessary. It shall be arranged to facilitate maintenance and removal of

individual runs without dismantling adjacent pipes.

(k) All chemical pipes shall be colour banded and suitably labelled to enable individual lines

to be identified throughout their run.

(l) Supply, Erection, Testing and Commissioning of all Items.

13.1.1. Relevant standards

The design, manufacture, supply, storage of all equipment’s shall comply with all Indian

Standards, (or in the absence of Indian Standards, the appropriate International

Standards),

Applicable Laws, including local statutes covering:

(a) Health and Safety

(b) Dangerous Goods

(c) Factories and Commercial Premises

(d) Buildings

(e) Electricity Regulations and Codes of Practice


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13.1.2. Pumping systems

(a) Provisions of pumping systems with isolation valves, non-return valves, and all

necessary pipework and fittings.

(b) Provision of pipe supports hangers and anchors to support and control movement of

pipes and valves all in accordance with recognized international piping standards.

(c) Unless otherwise specified, provision of all pumping systems with standby pump sets

of the same type and capacity as the duty pumps, providing a standby capacity of not

less than 50% of the total duty. All pumps shall operate at high efficiency throughout

their duty range and they shall be capable of continuous operation throughout their

required operational range. The minimum diameter of pipe for sludge transfer shall be

150mm.

(d) Lubrication arrangements shall be designed to avoid any contamination of pumped

fluid.

(e) Dry well mounted pumps shall provide effective means for collecting gland/seal

leakage water which shall be piped to a floor drain or sump.

13.1.3. Materials of construction

(a) All materials of construction for tanks, pipelines, pumps, valves, etc. shall be suitable

for long term contact with the liquid or chemical concerned and at the prevailing

concentrations. Equipment shall be coated and protected in accordance with painting

and protective coatings.

(b) All pipework employed shall comply with the schedule. It is the responsibility of the

Concessionaire to ensure compatibility of all pipelines with fluids or sludge carried

and with external and internal loadings and pressures.

13.2. Manual and Mechanical Screens

Scope of supply

The scope of supply shall provide complete Manual and automatic mechanical screen

systems with all accessories and appurtenances, including, but not limited to:

(a) Manual screen;

(b) Mechanically operated Step Type Fine screen;

(c) Mechanical Perforated Type screen

(d) Screenings collection, washing and disposal system;

(e) Automatic screen control system;

(f) Electrical & instrumentation for compliance of automatic system (electrical wiring

between all screen components, instruments, control devices and the local control

panels and the screen controls).

13.2.1. SPECIFICATION FOR MECHANICALLY OPERATED STEP TYPE FINE BAR

SCREENS FOR SEWAGE TREATMENT PLANTS

Mechanical fine Screens

Mechanically operated step screen completely made of Stainless Steel grade 304 having 6

mm average spacing between the bars shall be provided in inlet screen channel(s) for

screening out floating materials such as plastic pouches, bags, rags, floating debris, weeds,

paper wastes and other floating materials from the raw sewage coming from the pumping

station / gravity mains.

The screen shall include discharge chute as required to discharge the screenings on the belt

/ screw conveyor without employing any external mechanism / rake mechanism.


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The screen shall be factory assembled & movement tested at plant before dispatch to site &

shall be installed at the site in factory assembled condition only thereby avoiding chances of

misalignments.

SCOPE

Design, Supply, Installation, Testing & Commissioning of screening equipment consisting of following:

(a) Mechanized step screen having 6 mm average spacing between bars and suitable for installation at an inclination of 40 degrees in channel.

(b) Level sensing instrument for automatic operation of screen mechanism and allied accessories.

(c) Local control panel installed near screen. (d) Belt / screw conveyor to discharge the screened material to the waste bin.

Material of construction

The fixed as well as movable bars of 3 mm thickness, mechanism, support frame, fixings

discharge chute shall be manufactured from stainless steel grade 304 for long life in the

aggressive sewage environment. No component of the screen assembly shall be made of

carbon steel or any other material, which can get corroded in sewage environment.

Screen Construction

The step screen shall be a complete unit comprising of main frame with an integral

mechanism containing movable bars located in between fixed bars with out engagement of

external mechanism / rake mechanism for pulling out the screened material ensuring

minimum movement of the mechanism.

The mechanism comprising of movable bars located between fixed bars shall gradually move

the screened material upward in the form of a mat and deliver up to the discharge chute.

The fixed as well as movable bars shall contain a series of steps to prevent the screenings

from falling back into the main flow.

The mechanism shall be mechanically operated by Electro-motor or hydraulic system and

shall be suitable for automatic operation controlled by a level sensor.

The screen shall operate automatically when the upstream water level increases beyond a

pre-set limit and it shall stop when the upstream level decreases to a preset low level due to

upward travel of screened material.

The fine bar screen shall be capable of being tilted out of the sewage flow up to horizontal

position for the purpose of cleaning & maintenance.

The base of the screen shall be fitted with a specially profiled stainless steel plate with other

screened material thus reducing the possibility of building up of grit in front of the screen.

The installation and commissioning of screens have to be done in the presence of

manufacturer's representative(s) so as to avoid any possibility of misalignment and faulty

installation.

Packing of screens and allied accessories shall be transit worthy to avoid any possibility of

damage during the transportation to the site(s).


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Automatic screen clearing and screenings removal

The screen shall be provided with the necessary controls and sensors to anticipate blockage

of the screen, and automatically clear the screen and remove the accumulated screenings

from the screen surface. The screen shall operate automatically when the upstream water

level increases beyond a pre-set limit and it shall stop when the upstream level decreases to

pre-set low level.

Screenings conveyance

The screening system shall be supplied to convey the screenings to the automatic

screenings press and discharge system that discharges the screenings through a chute to

the screenings storage system.

Screenings discharge chute

The screenings discharge chute shall terminate 1.5 meters above ground level. A plastic

screenings bag shall be secured around the chute, thereby creating a totally enclosed

screenings collection system.

Screen covers

All screenings equipment shall be supplied with integral stainless steel covers that prevent

access to moving and wash water sprays. The covers need to be airtight to ensure that no

odours emanate from the screen.

Portable screenings container

Portable screenings containers made of galvanized steel duly epoxy painted shall be

provided to store the screenings until time of pick up. The container shall have capacity of

approximate 5 m3 and shall be of a convenient height to permit the discharge of screenings

directly into the container without having to transfer the screenings manually.

Electrical motor

The motor shall be TEFC type with IP 55 protection & Class F insulation and shall be suitable

for operation on 3 phase, 415V + 10% and frequency of 50Hz + 5%. Motors shall be squirrel

cage type conforming to IS 12615-2018 and of minimum IE2 class. The power rating of motor

shall be at least 125% of maximum power requirement.

Access

Safe access shall be provided to all screen equipment and instruments to allow for cleaning,

inspection and maintenance activities.

Corrosion resistance

All metal parts of the screen equipment that are in contact with the sewage shall be

constructed of a suitable grade of corrosion resistant stainless steel, aluminium or plastic.

Level Controller

The lever controller shall be Differential / Upstream type ultrasonic level switch/sensor.

Testing

The Manual & Mechanical fine screen shall be factory assembled & subjected to following

tests at the manufacturer’s promises – Dimension check, operational test and PMI Test for

material.


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Belt Conveyor

The conveyor shall be common to the mechanical and manual screens. The conveyor

system shall be a combination of a horizontal conveyor and upward inclined conveyor (if

required) and shall be capable to transfer the maximum screenings anticipated at the peak

flow. Belt conveyors shall conform to IS 11592:2000, IS 4776(PART1):1977, IS 8531:1986,

ISO 1536:1975, ISO 1537:1975, IS 8598:1987 & ISO 1537:1975.

Conveyor type : Horizontal

Capacity : To handle screening of peak flow

Speed : 15m/ minute (Maximum)

Type : Troughed Belt : 3ply Z duck, 3 mm top, 1.5 mm bottom, rubber cover CRM -24

Screw Conveyer

Screw conveyors move materials either horizontally, on an incline. the materials of screw conveyer shall be SS304.

In this assembly, the reducer output shaft, conveyor thrust bearing, end seal and trough end are combined into one complete screw conveyor drive unit. Four different mounting assemblies are available and variations on these are available to fit virtually all possible requirements. The reducer output shaft bearings, in this case, take the place of the conveyor thrust bearing. A shaft seal adequate for most dust applications between the conveyor and the reducer is also provided. Other types of drives available are:

1. Electric gear motor combination with roller chain drive.

2. Gear reducer connected through roller chain to the screw conveyor. couplings connect the reducer input shaft and the motor.

3. Hydraulic drives.

4. Variable pitch pulleys between motor and reducer in cluding the flange mount type pictured.

Conveyer Screw –

Compact,manufactured straight and accurate in helicoid, sectional, ribbon and special designs to meet your requirements.

Jig-Drilled Couplings:

Assures easy shaft alignment and assembly. Available with "Redi-Change" clamping key for quick disassembly of conveyor screw.

Tem-U-Lac Self-Locking Coupling Bolts:

Guards against system damage and costly down-time caused by coupling bolts or nuts working loose.

Hangers and Bearings:

Various styles and bearing materials selected to meet your needs.

Trough Ends:

Several bearing and seal styles are available to match your needs.

Troughs, Covers, Clamps and Shrouds:

Ruggedly constructed standard "U" and other styles of troughs including tubular. Covers, clamps and shrouds available for all applications.

Nu-Weld® Flange:

Continuously welded steel flange holds trough in alignment.


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Discharge Spouts:

All types available located where you need them...with hand, electric, hydraulic or pneumatic powered gates.

Supporting Feet and Saddles:

Align and fasten the trough to the floor or existing structure.

Materials

1. Screw flight, Discharge chute, support channel & trough end : SS304 2. Gear box type Helical gear 3. Transmission Reduction Gear + SS Chain Drive 4. Speed 1440rpm±10%

13.2.2. TECHNICAL SPECIFICATION FOR FILTER BAND / PERFORATED SCREEN Angle of Inclination for Filter band screen shall be in range of 45 Degrees.

Frame: The frame shall consist of two lateral stainless steel 304 plates connected by

means of cross braces.

Chain wheels: The machine shall work on the endless chain principle and incorporate

chain wheels at the top and bottom. The top wheels shall be keyed onto the main drive

shaft. The bottom wheels shall be carried on stub shafts incorporating a bush bearing of

suitable synthetic material.

Chain: The chain shall be constructed in stainless steel with the screen panels directly

attached.

Screen Panels: Minimum 3mm thick panels of stainless steel 304 construction shall

incorporate 6mm diameter perforations. These panels shall be carried on the chains.

The panels shall be specially formed to give a very rigid construction and shall create

steps to enable larger screenings to be removed.

Spray Nozzles shall be provided.

Screenings Discharge: Screenings shall be cleaned through water spray nozzles

mounted on screen in multiple quantity.

Enclosure: The entire assembly shall be enclosed above platform level in reinforced

fibre glass housing. An inspection hatch shall also be incorporated.

Drive Unit: The drive to the main shaft shall be TEFC weatherproof IP 66 motor fitted

with an anti- condensation heater. The motor shall be flanged to a shaft mounted gear

unit giving the final output speed. This shall produce a linear speed for the screen

panels of about 3 m/min. The drive shall be protected from mechanical overload by an

electrical current sensing device in the screen control panel. Overload prevention

switches shall be provided to annunciate screen jamming. Suitable conveyer

arrangement shall be provided to transfer the screenings to the nearest container/trailer.


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A spray system shall be provided to backwash the screen panels and to help in cleaning

the screenings. Water / treated sewage shall be used for back wash purpose.

Level Controller

The lever controller shall be Differential / Upstream type ultrasonic level switch/sensor.

13.2.3. Manual screen (For STP)

The manual screen shall be fabricated out of SS 304 of not less than Flat size (50 x 10)

mm. the manual screen shall be rectangular in shape and the clear opening for manual

screen shall be not more than 10 mm for screening out floating materials such as plastic

pouches, bags, rags, floating debris, weeds, paper wastes and other floating materials

from the Influent coming from the pumping station. The assembly of bar and frames

shall be fabricated by such a way that it can be installed and removed as and when

required. The screen inclination angle should be as per design of channel depth

dimensions.

13.2.4. Manual Fine Trash Screen

Manual fine mesh screen to be installed after the fine mechanical screen to prevent finer

floating wastes from entering into intake structure of pumping station.

The manual screen should comprise of equal spaced mesh of 5x5 mm within a sturdy

frame structure inserted in vertical guide channel. Structure provided should be with

perforated basket at its bottom. Guide channel extend upto to top of platform for guiding

upward movement. Material of construction should be in SS-304.

13.2.5. Manual and Mechanical Coarse Screen

13.2.5.1 Scope of supply

The scope of supply shall provide complete Manual and automatic mechanical screen

systems with all accessories and appurtenances, including, but not limited to:

(a) J Type Screen

(b) Manual screen;

(c) Mechanically operated Type Coarse screen;

(d) Screenings collection, washing and disposal system;

(e) Automatic screen control system;

(f) Electrical & instrumentation for compliance of automatic system (electrical wiring

between all screen components, instruments, control devices and the local control

panels and the screen controls)

13.2.5.2 J-type Coarse Trash Screen (FOR MPS) Manual Trash screen to be installed in front of coarse mechanical screen to prevent

large and medium sized floating wastes from entering into intake structure of pumping

station.

The manual screen should comprise of flat bars spaced apart in vertical and horizontal

direction forming mesh size of 80 x80 mm within a sturdy frame structure inserted in

vertical guide channel. Structure provided should be with perforated basket at its bottom

and guide roller on both sides for easy removal. Guide channel extend upto to top of

platform for guiding upward movement. The height of trash screen should be at level

with channel water depth. Material of construction should be in SS-304. Bar thickness

shall be 10 mm minimum.


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13.2.5.3 MANUAL BAR SCREEN (FOR MPS) The manual screen shall be fabricated out of SS 304 of not less than Flat size (50 x 10)

mm. the manual screen shall be rectangular in shape and the clear opening for manual

screen shall be not more than 20 mm for screening out floating materials such as plastic

pouches, bags, rags, floating debris, weeds, paper wastes and other floating materials

from the Influent coming from the pumping station. The assembly of bar and frames

shall be fabricated by such a way that it can be installed and removed as and when

required. The screen inclination angle should be as per the design of channel depth

dimensions.

13.2.5.4 Specification for Multirake Bar Coarse Screens (FOR MPS) Material of construction

All parts of screen including fixed bars, rakes, screen frame, guide rails, dead plate,

chains & sprockets and discharge chute shall be constructed from stainless steel

material grade Minimum SS 304 for long life in aggressive sewage environment.

Screen Construction

Screen bar in bottom side of screen

The screen shall be fabricated from flat (12x6x50) mm with trapezoidal in shape i.e. the

flat dimension of the screen would be not less than 12 mm front side of water flow,6 mm

rear side of water flow & 50 mm depth. Clear opening in between the flats for the screen

shall be 20 mm front and 26 mm rear side of water flow for scanning out floating

material.

Rakes

The rake shall be made of SS304 with minimum 12 mm thickness of plate.

The rakes shall be linked with the chain enclosed in SS guide and the rake on the

upstream side of the screen starts moving carrying the wastes upward. when the rake

reaches to the discharge point. The wiper wipes the waste from the rake and discharge

the waste to the collection bin or on to the conveyor installed across the screen.

The rakes shall be bolted to the side-plates of the drive-chain using special adaptor

links. The screens are to be supplied with heavy-duty chains of the roller type made

entirely from stainless steels and with a minimum breaking load of 112 KN. Chain

guides of stainless steel shall be securely fixed to sides of the screen within the

recesses of the supporting framework, with both chains and guides in an arrangement

that shall impose minimum hydraulic obstruction to the flow. Chain tension take-up

devices shall be provided at the top of the screen.

Screen frame

The steel of screen frame shall be minimum 6 mm thickness.

Dead Plate

The dead plate shall be minimum 4 mm thick in stainless steel and shall be suitably

braced to ensure rigidity and prevent caving / bending due to increased water flow in

monsoon.

The screen should have integrated scraper for discharging the screenings to discharge

chute. The scraper /wiper shall be cushioned during travel to the rest position by a shock

absorber.


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The scraper /wiper can be made from Poly ethylene.

Discharge chute

The screenings discharge chute shall terminate 1.5 meters above ground level. A plastic

screenings bag shall be secured around the chute, thereby creating a totally enclosed

screenings collection system.

After fabrication and assembly, the stainless steel parts and all welded joints are to be

further cleaned by acid pickling and after that they should be passivated to remove any

ferrous contamination that might have taken place during manufacturing /

handling/movement of raw and fabricated material.

The rake mechanism should be operated by a Geared motor and be suitable for

automatic operation controlled by a level sensor and electric control cabinet. Torque

switch should be provided to protect the screen from damages resulting from excessive

torque.

Electrical motor

The motor shall be of TEFC type with IP 55 protection & Class F insulation and be

suitable for operation on 3 phase, 415Vt 10 % and frequency of 50 Hz t 5%. Motors shall

be squirrel cage type conforming to IS 12615-2018 and of minimum IE2 class.

Level Sensor

The level sensor shall be of ultrasonic differential type.

Screenings conveyance

The screening system shall be supplied to convey the screenings to the automatic

screenings press and discharge system that discharges the screenings through a chute

to the screenings storage system.

Inspection and Testing

Multi rake mechanical screen shall be factory assembled & subjected to following tests

at the manufacturer’s promises – Dimension check, operational test and PMI (Positive

Material Identification) Test should be carried out with help of PMI machine and also

factory test certificates for material.

The installation and commissioning of screens have to be done in the presence of

manufacturer's representative(s) so as to avoid any possibility of misalignment and

faulty installation.

Packing of screens and allied accessories shall be transit worthy to avoid any possibility

of damage during the transportation to the site(s).

13.3. Grit Mechanical Detritor

13.3.1. Working Principle

A compact grit plant consists of a Square Grit Settlement Chamber with scrapers, screw

Type mechanical classifier and organic return screw pump, the grit chamber is designed

on the Principle of differential sedimentation.

The Organic return pump (screw pumps) returns the washed organic material from the

grit back to the grit chamber and the same is kept in suspension and passed on further

for treatment.


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13.3.2. Grit removing equipment

The grit chambers shall conform to the best industry practices. The material of

construction of all wetted parts shall be in SS 304.

The grit removal device shall be capable of removing the following at the specified

hydraulic peak flow rate, and no decrease in efficiency will be allowed at flows less than

this design rate.

13.3.3. Unit of Mechanical grit removable system

The Detritor mechanism for grit removal comprises of Detritor proper, classifier and.

organic return pumps. Detritor tank is fitted with reciprocating or screw classifier on

one side in an inclined position.

Detritor mechanism will comprise of central drive located over RCC /MSEP bridge along with

hand-rails and central drive shaft will be guided at the lower end in the guide bearing.

Scrapers will be connected to the lower end of the shaft and MS epoxy painted squeezes will

be provided on the scrapers in such a way so as to push the grit towards circumference and

subsequently to push through the opening to the bottom end of the classifier. Detritor drive

shall be of suitable rating and overload protection by way of shearing pin arrangement.

Turning vanes for flow control in Detritor shall be provided to obtain uniform velocity gradient.

Minimum three rake arms shall be provided.

The mechanism shall comprise but not limited to the following main components:

Bridge superstructure spanning half the tank diameter with central maintenance platform,

Drive assembly complete with drive head, chain & sprocket, geared motor etc., feed well,

centre cage, cone scraper, rake arms, tie rods for rake arms, squeegees, scum blade &

skimmer assembly, A-frame supports for the skimmer assembly, Scum trough and ramp with

support angle, scum baffle with supports and weir plate.

13.3.4. Organic return pump

Organic return pump will be located by the side of classifier so as to return organic back to

the Detritor. The organic mixer will have specifically designed impellers to create washing

action and suitable motor through worm gear drive will drive the mixer.

13.3.5. Materials for Constructions

Bridge

RCC/MS with Hot dip Galvanized (galvanizing minimum thickness shall be 80 micron) (welded/nut bolted/riveted truss in a consolidated single component and no site welding shall be allowed), grating/chequered plate 6 mm thick

Rake Arm

SS 304

Center Cage SS 304

Rake Blades SS 304

V-notch weir SS 304

Squeegees Neoprene rubber, 10 mm thick, adjustable type

Walkway RCC / MS with Hot dip Galvanized (galvanizing minimum thickness shall be 80 micron)

Handrail 40 NB SS 304


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Scum skimmer assembly

SS 304

Scum Box SS 304

Scum Baffle SS 304

Fasteners- Under water

SS 304

Fasteners- Above Water

Galvanised

13.4. Stainless Steel Decanter

a. The Decanter shall be motorized moving Weir Arm device with with top mounted Gear

Box, Electric Drive, Scum Guard, Down comers, Collection Pipe, Bearings.

b. The Decanter shall transport liquid from the weir trough via carrier pipes (down

comers) to a feeder discharge pipe (main shaft), which shall also serve as the center

of rotation.

c. The decanting mechanism shall be designed for a variable speed mode of operation. The rate of travel of the decanter shall be adjustable as per calculated rate of operation.

d. Weir loading for each decanter shall not exceed 125 m3/hr/m of the inlet weir. Maximum velocity in down comer shall not exceed 1.3 m/sec. at the designed decant flow. However, if required during certain circumstances the downcomers, feeder discharge pipes, motor and all other mechanisms shall be capable of operating for 15% additional discharge (i.e 143.75 m3/hr/min).

e. There should be maximum one decanting mechanism per basin.

f. Fill/Aeration, Settling and Decanting must take place sequentially and independently

without overlapping

g. Each Decanter mechanism shall be connected to main PLC. However, it shall have the provision for manual up down operation at installation site.

h. Upon reaching the designated BWL, the decanter shall return to its parked position. i. During non-decanting cycles, the decanter collection weir shall be parked above the

top water level of the basin during aeration and settling phases, thereby eliminating any possibility of solids carryover during these phases. Therefore weirs or entry ports of the Decanters shall not be submerged below the top water level of the basin during non-decant phase. Each decanter shall be fitted with a scum retention mechanism to prevent surface scums and floatables from exiting with the treated effluent.

j. Drive mechanism or actuator shall be equipped with variable frequency drive connected to PLC to facilitate its operation at varying flow rates to ensure controlled and seamless operation at varying flow rates.

k. Complete Drive Mechanism shall be mounted on the walkway to provide easy access for maintenance and service purposes.

l. The decanting mechanism shall of Stainless Steel (SS: 304)

m. Anchor Bolts: All anchor bolts, nuts, and washers shall be Type 316.

n. Fasteners: All bolts, nuts, washers, and other fasteners shall be Type 316.

o. The decanter seals and bearings shall be constructed of maintenance free, synthetic

materials for long service life. All seals and bearings shall be shipped factory

assembled.

p. Other related mechanisms of the bio-reactor i.e blowers, Automatic Valves,

Pumps/Mixers, switching mechanism shall be interlocked with the decanter controls

so that aeration/mixing is prevented in a basin which is settling or decanting.


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13.4.1. Testing

Positive Material Identification Test (PMI)

13.4.2. Diffuser

The aeration system may be provided to meet the aeration requirement as per the

process design requirement. Sufficient design calculations are to be provided along with

manufacturer standard having supplied diffuser during last five years to various waste

water treatment plants.

13.4.3. Fine bubble aeration system

The membrane diffuser shall be developed specifically for releases 1~3 mm fine bubble

in the wastewater treatment plant. All materials have been selected for their ability to

withstand the effects of the chemical, bio-chemical agents and 0~50°C used in

wastewater tank. The diffuser can be placed in an evenly distributed grid system over

the entire aeration tank bottom.

Diffuser grid shall be of fixed type. Diffuser shall be Tubular/Disc type with membrane

made of Polyurethane elastomer. It shall have uPVC diffusers holder with retainer

rings. Maximum air throughput from diffusers shall be restricted to 90 Nm3/hr/m2 of

membrane area. In case tubular type Diffusers are used, only top half surface area of

the Diffuser shall be considered for supply of air.

13.4.4. Aeration System

The aeration facility shall be installed for average flow.

Only Fine Bubble Type, PU Membrane Diffusers shall be acceptable with minimum

Membrane Diffusers to Floor Coverage Area of 5%. Combination of aeration

techniques using Aerators/Submersible Mixers etc. is not acceptable. Diffusers shall

be submerged, fine bubble / fine pore, high transfer efficiency, low maintenance and

non-buoyant type. Diffusers shall be panel / tubular type. In case tubular type

Diffusers are used, only top half surface area of the Diffuser shall be considered for

supply of air. Material of construction for entire under water system including

accessories shall be of non-corrosive. Complete Diffuser as a unit shall be

assembled at the manufacturing factory level. The grid supports shall of adjustable

type made of SS 304.

The Air Blower Arrangement shall be capable of handling Total Water Level and

Bottom Water Level operation conditions controlled by process sensors such as DO,

Temperature and Level.

Each set of Air Blowers shall have dedicated standby. The number of standby

blower shall be minimum 50% (fifty percent) of the number of working blowers

The Air Blowers shall be Turbo Blower type and head for Air Blowers shall be

decided on the basis of S.O.R. of Diffusers and maximum Liquid Depth in Basin duly

considering the losses governing point of delivery (Diffusers) and the Air Blowers. Air

Blowers shall be complete with Motor and accessories like Base Frame, Anti

Vibratory Pad, Reactive Silencer, Non Return Valve, Air Filter etc. as per

requirements. Further, Air Blowers shall have acoustic enclosure to ensure that the

noise level at 1.00 m from Air Blowers is below 85 db. The Air Blower House shall

have Rolling Shutter, Windows, Exhaust Fans, Safety Equipment with sufficient

Ventilation, Lighting and Working Space. It shall be equipped with sufficient capacity

Electrical Hoist with Travelling Trolley (Min. 3 Ton or 1.5 times the weight of Air


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Blower whichever is more) to facilitate removal of Air Blower / other Accessory for

repairs.

The operation of Aeration System shall include PLC based control. The operation and

speed of Air Blowers shall be automatically adjusted using parameters like Oxygen

Uptake Rate, Dissolved Oxygen and Temperature and Liquid Level in the Basin such

that the DO is supplied as per demand and power utilisation for operation of Air

Blowers is optimised.

The main Air Header/Ring Main shall be in MS as per relevant IS Code, painted with

corrosion resistant paint as per Manufacture’s recommendations. The Air Header/Ring

Main shall be supported on saddles at suitable intervals or shall be protected against

external corrosion in case laid below ground. The Sub-header shall have Auto Valves

to facilitate switch over of Aeration Cycle from one Basin to other by PLC. The Sub-

header shall supply air to Fixed Type Diffuser Grids at various locations through

vertical Air Supply Pipes. These Air Supply Pipes above water level shall be in MS,

painted with corrosion resistant paint and below water shall be in SS 304. All under

water Lateral Pipes shall be of UPVC. Junctions between horizontal Sub-header and

vertical Air Supply Pipes shall be suitably protected against corrosion due to dissimilar

materials.

All other accessories, whether specified or not, but required for completeness shall

form part of Contractors scope.

13.5. TURBO BLOWER SPECIFICATION

13.5.1. General Specifications

(i) Turbo Blower shall be Single Stage, Direct Drive, centrifugal type Turbo Blower

consisting of Bearings, Impeller, high-speed Motor, Inverter, Controller and Cooling

System. It shall be able to operate under varying pressure and flow conditions as

per process requirement. Minimum turndown ratio should be 50%.

(ii) It shall be composed of Casing, Suction Filter, Reducer, Acoustic Hood, Blow-Off

Valve, Inverter, Electrical Panel and Controller etc. Noise level should be less than

80 dBA at 1.00 m from Blower whereas Vibration level should be less than 1

mm/sec.

(iii) Casing shall be of high-quality Aluminium Alloy and able to resist thermal

expansion, vibration and air leakage.

(iv) Bearings shall be non-contact type with oil free lubrication, low noise and no

vibration. The wearing surfaces shall be made of Inconel. Bearings should be able

to withstand minimum of 20,000 On/Off in its life time.

(v) Impeller shall be of high strength Aluminium Alloy (A7075). It shall have high

compression efficiency, high surge stability and wide flow range. It shall be capable

to keep dynamic balance in high speed revolution and shall be suitable for

transmission of power and safety factor at critical speed. It shall be directly

connected with the motor shaft without any coupling. The inlet to the Impeller

Compartment shall be open without any restrictions like fins etc.

(vi) Inverter shall be high-speed Inverter equipped with Electrical Filter, AC Reactor and

LC Filter.

(vii) Control panel for Turbo blower shall be separate from blower assembly and be

placed in separate air-conditioned room.


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(viii) Motor shall be high-speed Permanent Magnet Synchronous Motor (PMSM). The

Shaft of the Motor shall be of Titanium and shall be directly connected to the

Impeller.

(ix) Motor, being high-speed, shall be provided with the best suited Cooling System to

ensure consistent motor output and longevity.

(x) Blower shall be equipped with Blow-Off Valve with Silencer.

(xi) Controller shall have 16-bit color touch screen with convenient user interface to

support various operation modes such as Auto Flow Mode, Auto power mode, Auto

RPM Mode, Auto Pressure Mode, Proportional Mode, DO-Link Mode and Failure,

Check and Reset Option. Following measurements and operating data are shown

on the Controller Screen:

(a) Operating State of the Turbo Blower: - Run - Stop - Error

(b) Measurement and Display Data: - Suction Filter Differential Pressure - Suction Temperature - Discharge Temperature - Discharge Pressure - Suction Flow Rate - Revolution - Power

(c) Warning and Error Message: - Filter differential Pressure Over - Motor overheating - Inverter Error

(xii) Material of construction of various parts of Blowers shall be as follows: Bearing : Inconel

Casing : Aluminium Alloy

Impeller : Aluminium Alloy (A7075)

Shaft : Titanium Alloy

Blower &

Control panel : SPHC

Enclosure

PLC Hardware : Conformal Coated

Blower details:-

Type : Turbo type

Capacity : As per design

Discharge Head : Suitable

No. of units : As per design requirement

(xiii) The operation of Aeration System shall include PLC based control. The operation and speed of Blowers shall be automatically adjusted using parameters like Oxygen Uptake Rate, Dissolved Oxygen and Temperature and Liquid Level in the


17

Basin such that the DO is supplied as per demand and power utilisation for operation of Blowers is optimised.

13.5.2. High Speed Turbo Motor

The high efficiency motor shall make it possible to have very high efficiency (95-98%)

over an entire operating range.

Motor shall be suitable for

(a) Input Power: 3Ø, 415V AC, 50 Hz (± 5%)

(b) Motor shall be PMSM grade.

13.5.3. Material of Construction

(a) Impeller : High Strength Aluminium Alloy.

(b) Shaft : Titanium alloy

(c) Permanent Magnet

Permanent Magnet to be used in the rotor, which has very good high temperature

characteristics. Even under very high temperature and high loading condition,

Permanent magnet shall not demagnetize and very stable.

(d) Bearing - Inconel

Oil free Teflon-S Air foil or Permanent Magnet bearings made from corrosion free

material like nickel, titanium alloy steel.

(e) Acoustic enclosure

Al-Zn coated steel, isolated with glass wool.

13.6. Roots Blower Specifications

(a) Blowers shall be designed to give clean, dry and oil free discharge. Each blower shall be

provided with a coupling guard and motor and the whole assembly shall be mounted on a

heavy duty rigid steel base-plate.

(b) Blower/motor and variable air delivery system shall be of the automated type designed to

save energy while matching air requirements in the aeration tanks at all times.

(c) Volumetric efficiency shall not fall to a level where it adversely affects air temperature rise

and overall blower efficiency.

(d) Operating pressure shall not be greater than 85% of blower maximum continuous

pressure Rating. Bearing design life should be 100,000 hours.

(e) For all blowers, standard atmospheric conditions of 20 oC and 1013 mbar will be used

with corrections for local ambient conditions for altitude, temperature and relative

humidity.

(f) The selection of the blowers shall include for losses for silencers, check valves and drive

system, which must be included in the total power figure staged and the blower speed

must be adjusted to take such losses into account.

(g) The electric motors shall be a high efficiency type suitable for minimum 415v/3ph/50Hz

and suitable for outdoor wet weather/wash down conditions, TEFC design and inverter

rated.

(h) The Blower noise level shall be within 85 db (A) at 1.86m distance from acoustic

enclosure and velocity of vibration should be less than 4.5 mm/s respectively.

(i) The Motor shall be compatible with VFD and selected automation system.

(j) The Blower shall be Tri lobe type.


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(k) Blowers shall have a variable flow output designed to run in concert with an automated

variable air flow control system, providing air as required in the aeration tanks based on

oxygen demand. The system shall include, as minimum.

(l) All blower sets shall be fitted with the following ancillaries:

i) Discharge pressure relief valve – set to 10% above system operating pressure and

capable of 100% blower discharge flow, with an accumulation not in excess of 10% of

set pressure;

ii) Discharge check valve;

iii) Pressure gauge;

iv) High discharge air temperature switch, to signal shut down of problem machine and

auto start standby unit.

v) Anti-vibration pads and inlet/discharge flexible connections of the expandable SS

corrugated/bellows type.

vi) Discharge silencer – reactive type – for all applications and sized to ensure minimal

pressure loss;

vii) Blower discharge piping shall be fitted with an after cooler designed to lower the

temperature of the blower discharge air to equal the approximate ambient

temperature of the wastewater in the aeration process.

viii) Inlet/Outlet isolation valves; and

(m) Electrical Motor

(i) The motor shall be TEFC type with IP 55 protection & Class F insulation and shall be

suitable for operation on 3 phase, 415V + 10% and frequency of 50Hz + 5%. Motors

shall be squirrel cage type conforming to IS 12615-2018 and of minimum IE2 class.

The power rating of motor shall be at least 125% of maximum power requirement.

(ii) Accessories with Each Blower

a. Fabricated steel base frame with CI slide rails.

b. Suction Filter

c. Discharge Silencer

d. Suction Silencer

e. Pressure Relief Valve

f. Non Return Valve with Companion Flange

g. Flexible SS -304 Bellow at Discharge

h. Belt Guard

i. Foundation Bolts

j. V Belt and Pulleys

k. Rubber Sleeve at Suction

l. Set of Anti Vibration Pads

m. Pressure Gauge with Isolation Valve

(iii) Material of Construction

a. Casing, End Covers : CAST IRON, GR. FG –260 AS PER IS –210

b. Rotor Lobe : ALLOY STEEL Gr. 23-45 OF IS 1030

c. Shaft : C40/EN-19 of BS-970

d. Timing Gears : Forged Alloy Steel 815M17/EN-353 of BS 970

e. Base Frame : M.S FABRICATED

f. Pulley & Gear Side Cover : CI confirming to IS 210 of FG 260


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g. Design & Manufacturing Code : BS 1571 PART- I

(n) After-Coolers

Compressed air plant shall incorporate after-cooling. Unless otherwise specified, a single

after- cooler with isolating and bypass arrangement shall be provided for all applications.

After-coolers shall either be of the air-cooled type with finned-tubes and electrically driven

cooling fan, or water-cooled shell-and-tube heat exchanger type. Materials in contact with

cooling water shall be resistant to corrosion. All heat exchange surfaces shall be accessible

for cleaning. Generally, the air outlet temperature shall approach the cooling medium

temperature to within 10 deg. C at maximum air throughput or as otherwise specified.

13.7. Sludge Thickener Mechanism

Gravity sludge thickener shall be circular (radial), fixed bridge, central turn table type or

central drive. Concessionaire may also provide alternatively the mechanical sludge thickener.

The sludge thickener mechanism shall be suitable for installation in a circular RCC tank and

shall include the following:

(a) Mechanism support beam spanning the diameter of the tank.

(b) Walkway and handrail from the edge to the centre of the tank.

(c) Drive mechanism with internal gear type.

(d) Reduction gear box.

(e) Chain and sprocket with guard.

(f) Central shaft with scrapper arm and picket fence.

(g) Skimmer scum baffle and scum trough.

(h) Overflow weir:

(i) Vertical pickets.

(j) Torque indicating device.

(k) Overload alarm protection.

(l) Auto lifting device.

The minimum thickness of all the underwater parts shall be minimum 6mm thick excluding

allowance for corrosion. All wetted parts shall be SS 304

13.7.1. Material of Construction

Tank : Reinforced Cement Concrete

Feed Well : SS 304

Bridge : MS with hot dip galvanized (galvanizing minimum thickness

shall be 80 micron)

Centre Cage : Mild Steel Galvanised

V-notch weir : SS 304 minimum 6 mm thick and

Squeegees : Neoprene

Handrail : 40 NB MS Pipe with Hot Dip Galvanised (radial up to centre)

Anchor Bolt & fasteners : Stainless Steel -316

Walk way : MS with Hot dip Galvanized (galvanizing minimum thickness shall be 80

micron), 6 mm thick chequered plate.

13.8. Centrifuge Decanter

Sludge dewatering shall be done by mechanical sludge dewatering units such as Solid Bowl

Centrifuge, Belt Filter Press. The material of construction shall be SS 304 L. The dewatering

units shall include but not limited to the following equipment’s:


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Powder or liquid polymer storage tanks/ Bach tanks with mixers, polymer metering pumps,

mixers and solution tanks, supply line & flush line, plant water supply pumps, sludge feeding

pumps, dewatering unit, cake hopper, control valves on sludge feeding line, and on chemical

feeding line, drain system.

The dewatering system should be so located that the dewatered sludge can be loaded into

trolleys/ drums/ bins directly – preferably the dewatering unit shall be so located that the

dewatered sludge falls into the containers/ bins without requirement of another material

handling unit.

The dewatered sludge should be truck-able & be suitable for disposal by open body truck and

should have a minimum solid concentration of 20% or more (measured as dry solids w/w

basis).

The dewatering unit should have a 90% solid recovery. Dewatering units shall be provided in

a separate sludge dewatering building. Feed pump station shall be provided at lower

level/floor and dewatering units shall be provided at upper level/ floor.

GENERAL

Solid consistency in inlet sludge 3 %

CONSTRUCTIONAL FEATURES

Type Solid bowl type

Power Transmission BELT & PULLEY ARRANGEMENT

Vibration absorption Anti-vibration pads

Lubrication GREASE

Gear Type Epicyclic, (Planetary two stage)

Noise level 85 dB at 1 m (dry run) & 75 dB at 5 Mtr

Painting Epoxy

CONVEYER ASSEMBLY

Conveyer Design Standard

Material AISI 304

MOTOR DETAILS

Motor type Squirrel Cage Induction Motor

Insulation Class F

Motor rating/rpm (Sync) 1470

Enclosure IP 55

Voltage / frequency/phase 415±10% / 50±5% /3

Ambient temperature 45 0C

PERFORMANCE


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Centrate solid concentration 0.1 – 0.2%

Solid recovery 90%

Outlet solid conc. 20%

MATERIAL OF CONSTRUCTION

Casing SS 304

Bowl SS 304

Screw SS 304

Base Frame MS Epoxy

Conveyer Flight SS 304

Solid Discharge Outlet Tungsten Carbide Weir liner

13.8.1. Centrifuge Feed Pump

These pumps shall be used for pumping sludge to centrifuge. The pumps shall be

designed to operate satisfactorily without detrimental surges, vibration, noise, or dynamic

imbalance.

All rotating parts shall be statically and dynamically balanced as per ISO standards.

A stationary coupling guard shall be provided for the coupling conforming to all relevant

safety codes and regulations. Guards shall be designed for easy installation and removal.

They shall be complete with necessary support accessories and fastener.

The power rating of the pump motor shall be the larger of following

(i) 115 % of power required by the pump at the duty point.

(ii) 110 % of maximum power required by the pump from zero discharge to the runoff point

total head.

Material of Construction

Type Screw

Rotor Alloy Steel / SS .316

Casing CI

Stator Synthetic Rubber

Shaft SS 410/420

Base plate CI/MS Epoxy painted

Fastener SS 304

Applicable code

Design IS 6595

Performance IS 9137

Testing

Material test certificate Casing, Impeller, Shaft

Hydrostatic test : 1.5 times shutoff head or twice the rated

Discharge head whichever is greater

Performance test : IS 5120 and IS 9137 at full speed

Mechanical balancing : As per ISO 1940, Gr 6.3 or better


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Visual inspection : Pump shall be offered for visual inspection before shipment.

:The pump components shall not be painted before inspection

Field Tests : Field performance tests required for satisfactory operation

13.8.2. Belt Filter Press

The Sludge Dewatering Device shall consist of combo units which includes Mechanical

Thickener and Belt Filter Press along with all appurtenances. It shall be designed to

adequately condition and dewater the sludge so that the dewatered sludge cake is produced

that easily discharges from the Belt Filter Press without blinding and that can be handled by

the pump or Conveying Equipment. Flocculator arrangement in SS 304 of suitable capacity

shall be provided at the inlet of each Belt Filter Press for mixing of sludge and Dewatering

Polyelectrolyte (DWPE). All other accessories, whether specified or not but required for

complete operation shall form part of contractor’s scope.

Number of Belt filter press : Min 2 Nos (1 W + 1 SB)

Operating Hour : 18 hours per day maximum Design

Inlet Sludge Consistency : 0.8-1. 0 %

Outlet sludge consistency : 20 %

Mixing arrangement of Polyelectrolyte and sludge : Online-mixing

Dewatering polyelectrolyte Dosing system is to be provided to dose Poly Electrolyte solution

to the incoming sludge at entrance to the belt filter press. The supernatant from Belt Filter

shall be taken by gravity to Wet Well of MPS/Inlet of STP. The pipes below Ground shall be

RCC NP-3, with HDPE lining, whereas the pipes above ground shall be of SS 304, Combo

unit including Mechanical Thickener and Belt filter press shall be capable of handling sludge

consisting of minimum 0 8 % solids by weight. The dewatered cake shall be based on

minimum consistency of 20 % by weight dry solids. MOC shall be SS - 304 General

Equipment furnished and installed under this section shall be fabricated assembled, erected

and placed in proper with the drawings, specifications. Engineering data, instructions, and

recommendations of the equipment manufacturer, unless the engineer notes exceptions in

workmanship and design. All components of the sludge dewatering equipment shall be

engineered for long, continuous, and uninterrupted service. The unit shall be “fully enclosed

multi-stage" type comprising with three belts. Gravity section shall be comprised with an

individual speed variable gear motor. All bearings, electrical and pneumatic components shall

be located on periphery of the frame allowing easy access for the operator for overhauls.

Sufficient number of removable inspection hatches shall be located on each side of the unit to

observe the factions of the unit. The sludge dewatering system shall consist of belt filter press

and all appurtenances. Each belt filter press shall be a fully enclosed having monologue

frame construction, complete prefabricated unit consisting of at least a sludge conditioning

system, a gravity drainage section, a pressure section, a belt alignment and tensioning

system and a belt washing system. Only units having an effective belt width of 1.0- 3.0 meter

shall be considered acceptable under this specification. The unit(s) shall be the "multi-stage"

Belt Filter Press type. Should equipment other than that specified be proposed, the contractor

shall be responsible for any redesign based on the requirements.

Multi-stage series sludge de waterer is a combination of a heavy duty belt thickener and a

filter press, and is designed for the most demanding, large capacity applications. The FP

multi-stage de waterer is easy to modify according to the characteristics of the sludge and

throughput and cake solid requirements.


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Multi-stage series sludge de-waterer is available with various configurations such as Filtrate

recycling systems, manual/automatic brush pipes, inline polymer injections, sludge level

probes, hydraulic type belt tracking and tensioning system and local PLC control panel

suitable for Audio/Manual operation with provision for interlocking with accessories.

13.9. Primary Clarifloculator

Rotating Half Bridge

The bridge in welded steel construction shall span half the tank diameter and further beyond

center in the direction of the walkway. The truss bridge is 1.2 M wide with walkway of MS

grating. The bridge is pivoted at the center on a slewing ring bearing and is attached to a

trolley with PU sleeved wheels resting on the peripheral wall of the clarifier or alternatively

steel wheels running on steel rails located along the periphery of the clariflocculator. A drive

assembly located on the trolley and coupled to the trolley drive wheel through chain &

sprocket arrangement rotates the bridge about the center of the clariflocculator.

Center Bearing Assembly

This shall essentially consist of a slewing ring bearing assembly that shall be located by an

MS platform and center tube. The platform shall be supported on the RCC center pier. Slip

Ring Assembly A slip ring unit with adequate no. of rings is provided at the center of the

clariflocculator above the center bearing assembly for supplying power to four (4) nos.

flocculator drives and one (1) no. bridge drive. Alternatively, a distribution board is provided

on board the clariflocculator bridge for distributing power to the five (5) drives from one

incomer.

Sufficient rings shall be included to cover the motor supply and any ancillary circuits with

common status of drive and flocculators units like ON, OFF, Trip, etc. (for remote monitoring

& alarm).

Drive Unit

This traction unit shall consist of a driving and idling wheel assembly.

Both the drive and idling unit shall be fitted with suitable diameter PU sleeved wheels / steel

wheels and shall be carried on the respective shafts supported on anti-friction bearings. The

wheels shall travel on the clariflocculator wall.

The mechanism shall be driven by adequate HP motor mounted on the periphery of the

bridge. The mechanism shall complete one revolution in 30 to 40 minutes.

Floor Scraper

Scraper shall be suspended from the bridge at various points across the bridge length

covering half the diameter of the tank. The scraper blades shall be manufactured from SS

fitted with renewable rubber squeegees and attached to steel arms suspended from the

bridge.

Flocculation Zone

The flocculation compartment shall be of RCC construction concentric to RCC

clariflocculator tank.

Four (4) nos flocculation paddles shall be suspended from the bridge, one on each side of

the center pier in the direction of bridge and one each in direction perpendicular to the

bridge.

The area of paddles shall be 10 – 15% of the cross sectional area of the flocculation zone.

These shall be supported from the rotating bridge. The material of construction and motor


24

HP shall be as per specification.

Overflow

The overflow from the clariflocculator shall be collected through V-notch 8 mm thick FRP

weir provided along the clariflocculator wall.

Local Distribution Board

A local distribution board shall be furnished along with the mechanism for distribution of

power to the peripheral drive motor and motors for flocculation paddles.

Painting

All MS parts shall be painted with coal tar epoxy paint to a total DFT of 250 microns.

There shall be one numbers of circular type RCC clariflocculator having central area for

coagulation and flocculation and outer area for clarification. The peak. flow shall be received

by each clariflocculator from the flash mixer by central inlet pipe.

The flocculation zone and sedimentation zone shall be separated by a circular RCC isolation

wall. In flocculation zone, chemical dosing shall be provided. The clarified effluent flow shall

be collected by peripheral weir with vertically adjustable V-notches

The formation of floc shall take place in the flocculation zone by gentle or slow mixing of

coagulated water received from flash mixer. While the removal of flocs as converted to

sludge will take place in the clarification zone.

The flocculation and clarifier zone shall be designed for the detention period of 30

minutes and 2.5 hrs respectively .The design parameter for surface loading and weir loading

have been taken as 30 cum/sqm/day and 12.5 cum/m/hr respectively for clarification and

effluent collection in outer launder.

The sludge from the unit shall be taken to the clarified sludge sump and pump house.

The Flocculator shall consist of SS flocculator paddles, fixed to a SS shaft with guide

bearings and guide brackets suitable for under water use. The paddle area shall be min 15%

of the sectional area of the flocculator zone.

Scrapers shall be suspended and arranged to give continuous and progressive scraping of

the entire floor of the clariflocculator and the swept area of the successive blades shall

overlap.

The Tertiary Treatment Plant shall conform to the specifications as mentioned below:

13.10. Disc filter assembly with Filter Cloth: Disc filter shall comprise multiple high strength and separable discs (proposed by

manufacturer). Each Disc shall be subdivided into smaller sections to constitute a prefab disc

frame (module) so as to ensure easy replacement and maintenance. Each disc consists of

total twenty-four (24) separable filter panels (12 filter panels on each side). In case of

replacement of fiber cloth, the left and right of the fiber cloth shall be replaced quickly without

disassembling of segments (Disc frames). Each disc shall be mounted on the center drum by

strap band (steel band) for the exact roundness and it shall not be fixed by Stud bolts. The

additional sealing material shall not be needed for assembling of filter cloth to segment and

the fiber cloth itself shall be acted as the sealing material. Filter cloth shall envelop some

parts of backside of filter frame and the several springs shall be used to fix the filter cloth.

The drum shall be round type and shall have the enough area in order to discharge the

treated water without trouble. The material of the filter cloth shall be polyester; the filter frame

that fixes the filter cloth, the disc frame and the segment cover shall be ABS resin. Central


25

drum shall be SS304. Maximum Filtration rate shall be 10 m3/m2/hr. Nominal pore size of

filter cloth shall be approx. 10 microns.

Filter shall be designed for average flow or decant flow whichever is higher. Suitable no. of

units shall be provided. Raw water shall flow into the respective Discfilter by gravity.

Maximum operating head loss across the filter shall not be more than 250 mm. The structure

shall ensure that Suspended Solids (SS) are filtered (treated) from outside to inside of the

filter cloth installed on both sides of the discfilter, and that filtered water is discharged

through the center drum to the treated waterway.

Sr No

TECHNICAL DATA OF FILTER

1. Type of Disc filter Fully submerged outside to inside type

2. Type of filter cloth Pile cloth with ABS frame

3. MOC of filter cloth Polyester

4. Nominal pore size, (microns) Approx. 10

5. Maximum Filtration rate (m3/m2/hr) 10

6. Total reject and backwash % < 3

7. Backwash System Automatic Backwash system based on time and level

8. Head loss across the disc filter unit (mm)

250

9. Thickness of drum 4 mm. (minimum)

10. MOC of Center drum SS 304

11. Filtration mode Continuous

Drive Assembly

Drive part of Discfilter shall be of Worm geared type with motor chain drive. The drive

comprises Drive Motor, Reduction Gears, Chain and Sprocket. Power shall be transmitted by

the SS 304 chain. The reduction gear shall be installed on the base for access f or the

tension adjustment. A protective cover made of SS304 shall be equipped for the drive motor,

reduction gear and the chain. The rpm of the disc filter drive shall be adjustable by the

inverter that is attached in the field control panel.

Sr No Drive Data

1 Motor Specifications Class F / IP 55

2 Gear Box Specifications Worm Gear, I = 1/450

3 Sprocket Drive Specifications Worm geared motor Chain drive type

4 Motor Protection IP 55

5 Material of Construction -

Reduction Gear Cast Iron FG 200

6 Material of Construction - Chain &

Sprocket

SS 304

7 Rotation speed of filter disc & < 1 rpm


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Backwash StStem

Cleaning device consists of Suction cleaning unit, which conducts the suction cleaning in

each side of disc, the automatic valve and the suction cleaning pump. Cleaning device

shall clean the contaminated filter cloth thoroughly by the suction unit on both side of

disc with automatic valve and suction cleaning pump which shall be activated by the

water level switch that contacts the water level raised with the increase of the loss of

head. Disc filter should be operated for filtration without the stop during backwash and

suction of sludge. Suction cleaning unit shall be made of or the even cleaning efficiency

without dead zone for all area of filter cloth.

Back wash Recovery system shall consist of flash mixer, Floculator, Lamella Clarifier,

Back wash sludge sump. Sludge generated shall be dewatered using centrifuge.

Overflow from Lamella Clarifier shall be sent to FDF.

Sr No Suction Cleaning Pump Details

1. Pump Type Horizontal single stage centrifugal vortex pump

2. Motor RPM ≤ 1450

3. Type of Sealing Mechanical Seal

4. Class / Protection Class F / IP 55

5. Power Supply 415V x 3￠× 50Hz

Material Of Construction Suction Cleaning Pump

Casing Cast iron FG 200

Impeller CF8M

Shaft SS304

Sleeve SS304

Control panel & Instruments

Control panel shall be SS304, double door (Inner & outer door), IP55, self- standing,

floor-mounted type in case if it is outdoor. Indoor control panels shall be CRCA, powder

coated and self- standing, floor-mounted type. Control panel shall contain PLC, HMI (6”,

colour, touch screen), circuit breaker, relay, terminal blocks, push button switch,

indication lamp, etc. on the door. Control panel shall accommodate an inverter/VFD to

control the rotation velocity of the disc drive. Automatic/Manual switch and indication

lamp shall be equipped in case of breakdown of the automatic interlocking device.

Control panel shall have a nameplate displaying the name of the equipment; operation

switch shall have a nameplate indicating its intended use.

Sr No Accessories

1. Control Panel Type

Self‐ standing type, Floor mounted Outdoor – Double door Indoor – Single door

center drum


27

Sr No Accessories

2. Control Panel MOC Outdoor – SS304 Indoor – CRCA, powder coated

3. Control Panel Protection Outdoor – IP55

4. Level Switch Quantity Min 1 per stream

5. Level Switch Type Conductivity Type (Electrode Bar Type)

6. Valve Quantity 1 Lot

13.11. Chlorination System including Chlorinators, Pumps and Tonners

Flow Maximum treated flow of STP

Number of units At least (1W + 1 SB)

Type Vacuum type

Chlorine dosing As per requirement

Chlorination system covering chlorine toners, chlorinator, piping, booster, pumps, ejector,

trunions lifting device with weighing scale, leak detentions and leak absorption system,

Eye wash system, safety equipment like canisters, gasmasks etc. & other ancillary shall

be provided in the chlorine house. It shall have sufficient ventilation as per the latest

norms for safety purpose with necessary lifting arrangements and EOT of minimum 3 T

capacity etc. complete. Immersion tank of sufficient capacity shall be provided at ground

level for emergent use. The system must have the provision for linking its operation to

PLC of STP so that quantity of chlorine usage can be varied automatically as per treated

water flow from Reactors.

Chlorination System (E&M for STP)

The list of equipment as well as, the detail of components, is indicative only, the contract shall be required

to provide complete chlorination system along with safety devices as approved by Engineer-in-Charge.

Sr. No.

Material Description

A. Tonners/ Trunnions

i. Empty Chlorine Toners

ii. Trunnions

B. Gas Piping

1. Auxiliary value with yoke

2. Copper tube

3. Manifold Valve

4. Gas Pressure Gauge

5. Isolating Valve for PG


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6. Gas filter

7. Wall manifold with dripleg, heater, built-in-filter, header valve

8. Mild steel piping for Gas under pressure with pipe and specials

C. Chlorinator capacity (as per requirement)

1. Vacuum Regulator

2. Automatic Vacuum Switchover unit

3. Floor Cabinet chlorinators with gas flow meter gate valve

4. Ejector

5. PVC vacuum manifold with 2 PVC ball valve.

6. 5/8” Vacuum tube 3/8 inch vent tube

D. Water Booster Pump Set

Water booster pump complete with electric drive motor of suitable capacity mounted on a common base plate with coupling.

Pump Capacity (as per requirement)

Motor rating (as per requirement)

E. Water Side Piping

1. Gate Valve

2. Non Return Valve

3. Y-Strainer

4. Water pressure gauge with isolation cock.

5. Water piping including specials

F. Solution Side Piping

1. PP Ball valve

2. PP Non return valve

3. PVC diffuser

4. Rigid PVC pipe of suitable size with specials.

G. Chlorine Gas detector for one point (Toner shed)

1. Indicator Alarm Unit with digital readout

2. Gas Sensor

3. Audible Hooter

H. Safety Equipment

1. Self Contained air breathing apparatus c/w 30 minute duration air cylinder with full face mask, demand valve pressure regulator, carrying case.

2. Canister Gas Mask


29

3. Protective clothing comparison

PVC overall

Safety Goggle

Safety helmet

Pair of Gloves

4. Ammonia Torch

5. Emergency Repair kit for tonners

6. Emergency Shower & eye wash fountain

I. Material Handling Equipment

1. 3T Capacity lifting bar for toners

2. 3T Capacity crane type weigh scale

J. Electric Panel/Cable

1. Electric Panel for chlorination system

2. Electric Cables

K. Mandatory Spare Parts

1. Maintenance kit for vacuum regulator, chlorinator, ejector

2. Copper tube

3. Impeller, shaft bush for pump

4. Electrolyte solution for gas sensor

5. Lead Washers

L. Chlorine Gas Leak absorption Equipment

FRP Half Hoods

Caustic Solution tank in PP-FRP complete with solution inlet, gas inlet, overflow, drain manhole and PP diffuser,

Tank Capacity : 5 m3

Caustic Solution pump in Polypropylene c/w electric drive motor (415V/50 HZ/3 Ph/2900 RPM) mounted on a common base plate with coupling.

Air blower having impeller and inside casing in MS with FRP lined directly mounted on a electric motor shaft

(415V) 50HZ/3Ph. 2900 RPM)

PP/PVC air duct piping between hood, chlorination room and blower inlet.

PP/PVC air duct piping between discharge and to caustic tank.

PP piping for caustic solution comprise of

PP ball valve


30

PP NRV

PP V-strainer

Pressure gauge with PP ball valve for caustic solution 12M-PP piping.

Gas Sensors

13.12. Pump

(a) The pumps shall run smooth without undue noise and vibration.

(b) Pump should be vertical, centrifugal, single stage, non-clog type.

(c) It should be suitable for handling sewage containing stringy materials.

(d) Plate type strainer should be provided to prevent large size solids entering into pump

(e) The pump shaft journal bearings shall preferably be grease lubricated. No external water

will be made available for the lubrication of the bearings.

(f) Delivery piping with gun metal non-return valve should be supplied.

(g) Delivery pipe should be as per IS: 8329, K 9 and K 12 for specials.

(h) Pump should be operated automatically by providing float operated level switch.

(i) The base plate shall not be directly fixed to the floor. Channels should be grouted in the

floor and the base plate should be attached to the channel.

(j) Pumps provided should be energy efficient.

13.12.1 Materials of Construction (a) Impeller : Stainless Steel

(b) Casing : Cast Iron

(c) Shaft : Stainless Steel

(d) Cover plate : Steel

13.12.2 Definition For this Specification the following definitions shall apply: -

(a) Design duty: The total head to be developed and the quantity of fluid to be discharged

when the pump is running at rated speed.

(b) Static head: The difference between free water surface level on the suction side of the

pump and the delivery level.

(c) External friction head: The head required to overcome friction external to the Works

(Frictional loss in the transmission main) and the velocity head at the outlet of the

pumping main.

(d) Station losses: The friction losses in valves and pipes within pump room.

(e) Internal losses: The frictional losses in the pump suspension main and head bend up to

the delivery flange of vertical wet well pumps.

Total head: The sum of (.1), (.2), (.3) and (.4). Design duty head: The sum of (.2) and (.3).

NPSHa : Net positive suction head available at site.

NPSHr : Net positive suction head required by the pump.

LWL : Low Water Level at free water surface level on the suction side of the pump.

HWL : High Water Level at free water surface level on the suction side of the pump (during

flooding).


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13.13. Submersible pump

13.13.1 Design requirements

a. Submersible pumps shall be vertical shaped, centrifugal, non-clog type, suitable for

municipal sewage, design for continuous operation in submerged / partially submerged

condition and intermittent operation complete with motor control system, guide rail,

anchoring brackets, base elbow, power cable & pumping lifting cable/ SS chain with control

panel and level switches suitable for solid passage of 100mm diameter and above.

b. The efficiency of the pump shall be high at duty point and remain reasonably high during

the full duty range at the pumping system.

c. The pump shall be compatible with VFD and selected automation system.

d. The pump should be capable of developing the required total head at rated capacity.

Pumps should be suitable for single as well as parallel operation at any point.

e. The pump should deliver at least 125% of its rated capacity at 75% of the specified total

head. The H and Q curve should be continuously rising towards shut off head.

f. Operating range – system curve

g. The velocity of vibration should be less than 4.5mm/ sec. with noise level 85 dBA at

distance of1.85 meter.

h. The power rating of the pump motor should be the larger of the following:

i) The maximum power required by the pump from zero discharge to zero head.

ii) 115% of the power required at the duty point. Considering the combined efficiency

(motor & pump).

iii) System resistance curve shall be applicable within 5% of the duty point.

i. The motor efficiency shall not be less than 92 % and pump efficiency shall not be less than

65%. The highest efficient pump set shall be considered for selection.

j. Submission of pump data sheet shall be tagged as variable frequency drive/normal

operation.

k. The primary sludge pumps, dilution water pumps, treated effluent pumps, back wash

pumps, filter feed pump should have the efficiency of 60% and motor 85%. Only energy

efficient motor shall be accepted.

13.13.2 Material of Construction

Pumps

Pump casing : Cast iron

Discharge cover : Cast iron

Impeller : stainless steel SS316

Shaft : SS ASTM A276 Type 410/420

Bearing Bracket : Grey cast iron (CI IS: 210FG260/ Ductile iron)

Motor casing : Grey cast iron (CI IS: 210FG260/ Ductile iron)

Bolts, nuts : stainless steel SS316

Shaft protective sleeve : stainless steel SS316

Casing wear ring : Grey cast iron (CI IS: 210FG260/ Ductile iron)

O-ring : Nitrile rubber (NBR)

Efficiency : Min. 65%

Shaft seal

Type of seal : Double mechanical seal

Arrangement : Tandem


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Seal on medium side : With elastomer bellows

Mechanical seal, pump side : Silicon carbide

Mechanical seal, bearing side : Carbon/ silicon carbide

Monitoring

Thermal winding protection : Thermistors PT-100 in all three phase winding

Explosion proof protection :

Motor housing monitoring : By conductive moisture sensor electrode

Mechanical seal leakage detection : By float switch

Bearing temp monitoring : Thermistors PT 100 in upper bearing

Installation

Type of installation : wet well installation design for automatic connection

to a permanently installed discharge elbow with neoprene

seal to avoid metal to metal contact

Flange dimension to : EN 1092-2, PN 10

Claw : Bolted to the pump

Installation depth : As per data provided

Guide system : Stainless Steel

Lifting device : Stainless steel lifting chain

Length of lifting device : Suitable

Lifting loops : suitable

Installation accessories : Discharge elbow, fasteners, claw, bracket, lifting chain,

guide bars etc. complete

Motor

Min. motor efficiency : 92% and pump efficiency 65%

Degree of protection : IP 68

Insulation class : F

Coolant temp : </= 40 C

Starting mode : Direct

Rated voltage : 3ph, 415 V

Rated freq : 50 Hz

Nominal speed : Less than 1500- rpm (Synchronise)

Voltage tolerance : ±10%

Motor casing : Grey cast iron

Main cable : complete with cable length as per requirement

13.14. Horizontal centrifugal pump

13.14.1 Design requirements

a. The pump should be capable of developing the required total head at rated capacity.

Pumps should be suitable for single as well as parallel efficient operation at any point in

between the minimum and maximum system resistance indicated in the system resistance

curves.

b. The total head capacity curve should be continuously rising towards the shut off. The pump

should deliver at least 125% of its rated capacity at 75% of the specified total head.

c. The required NPSH at duty point should be at least 1.0 M less than the available NPSH.

d. Pumps shall run smooth without undue noise and vibration. The velocity of vibration should

be within 4.5 mm/sec. The noise level should be limited to 85 dBA at a distance of 1.85 M.


33

e. Operating range - -system curve shall be submitted along with that of motor and the

pump/s with VFD application with the data sheet tagged as VFD application.

f. The power rating of the pump motor should be the larger of the following:

i) The maximum power required by the pump from zero discharge to zero head.

ii) 115% of the power required at the duty point. Considering the combined efficiency of

pump and motor with zero negative tolerance.

g. The pump set should be suitable for starting with discharge valve open, as well as closed.

13.14.2 Features of construction

a. Pump should be suitable for applications in sewage handling or sludge handling as per

process requirement, with back pull out design. It shall have end suction and side discharge.

It should be of self-venting type.

b. Pumps should be identical for particular application and suitable for parallel operation with

equal load division. Components of identical pumps should be interchangeable.

c. Pump casing should be of robust construction. Liquid passages should be finished smooth

and designed so as to allow free passage of solids. The volute tongue should be straight

across and filed to a smooth rounded edge. Casing should be provided with hardened

renewable wearing ring.

d. Impeller should be suitable for application, enclosed type with smooth blunt edges and large

water ways so as to allow free passage of large size solids. It should be free from sharp

corners and projections likely to catch and hold rags and stringy materials. Impellers should

be provided with hardened wearing ring. Hardness of the Impeller ring should be at least 50

BHN more than that of casing ring.

e. The first critical speed of the rotor should be 30% above the operating speed. Complete rotor

should be statically and dynamically balanced.

f. Replaceable shaft sleeves should be provided to protect the shaft where it passes through

stuffing boxes. Surface hardness of shaft sleeve should be minimum 350 BHN.

g. Pumps should be provided with anti-friction bearings. Bearings should be easily accessible

for inspection and maintenance. Bearings should be grease lubricated.

h. Stuffing box should be of such design that they can be repacked without removing any part

other than gland and lantern ring. Stuffing box drain with pipe connection should be provided

at the lowest point so that no leakage accumulates in it.

i. Lantern ring should be of axially split type. Grease should be used for stuffing box sealing.

Water will not be available for this purpose. Gland should be of split type.

j. Pump should be furnished complete with flexible coupling.

k. Coupling guard bolted to the base plate should be furnished.

l. Base plate for pump and motor should be common. Suitable holes should be provided for

grouting. Foundation bolts should be complete with nuts and washers.

m. Tapping should be provided at suction and discharge nozzles for pressure gauge

connection.

n. Hand holes should be provided in the casing to allow easy access to the impeller as well as

to the casing throat. Casing drain connection with stainless steel collared plug should be

provided.


a. Casing : CI IS: 210 GR FG 260 with 1.5 to 2% Nickel.

b. Impeller : Stainless steel CF 8M STA STM A35/Gr.CF8M

c. Wearing rings : SS 316 STA STM A35/Gr.CF8M

d. Shaft : SS to AISI 431 STA STM A276 Type 410


34

e. Shaft sleeves : SS to AISI 410 STA STM A276 Type 410

f. Packing : Asbestos yarn coated with MoS2 (Molybdenum Di-Sulphide)

g. Packing : CI/MS fabricated.CI IS210 Gr F G260

h. Base plate : CI/MS fabricated IS 2062

i. Gland : Cast Iron CI IS 210 Gr F G260

j. Coupling : CI

Electrical motor

The motor shall be IP 55 protection with rain canopy or TEFC & Class F insulation and shall

be suitable for operation on 3 phase, 415V + 10% and frequency of 50Hz + 5%. Motors shall

be energy efficient and squirrel cage induction motor type conforming to IS 12615-2018 and

of minimum IE2 class.

13.14.3 Return Activated Sludge Pump & Surplus Activated Sludge Pump

Return sludge pumps shall pump the return sludge from the settling basin (main) to Selector.

Surplus Activated Sludge Pumps shall pump the sludge to sludge thickener if proposed by

bidder or to sump. Pumps shall be submersible type of non -clog design, the pumps shall

be fitted with a special tearing system on the suction side for tearing soft solid material. The

impeller shall be of a non-clog design with smooth passage. Maintenance-free antifriction

bearing, deep grooved permanently greased filled ball bearings shall be provided to take

care of all the axial and radial forces at any point of operation. The pump installation design

shall be such as to facilitate automatic installation and removal of the pumps without having

to enter into the sewage pit, the motor shall be squirrel cage type, suitable for three phase

supply continuous duty with class ‘F' insulation, Motor shall have integral cable parts and

the cable entries shall be sealed. The cables must be leak tight with respect to liquids and

firmly attached to the terminal block. The motor shall be designed for non- overloading

characteristics, there shall be thermal protection against overheating of the motor winding.

The pump design shall ensure that seal does not come directly in contact with the liquid

being pumped as well as cooling / lubrication by oil is provided. The moisture sensor of the

tripping unit shall be located inside the oil chamber.

The pump unit shall be supplied along with the special duck foot bend, flanged elbow, lifting

chain with shackles, enough guide pipe sufficient tough rubber sheeted water proof cable, as

well as stainless steel foundation bolts and nuts.

The velocity of vibration should be less than 4.5mm/ sec. with noise level 85 dBA.

The pump shall be compatible with VFD and selected automation system.

The motor efficiency shall not be less than 70 % and pump efficiency shall not be less

than 60%. The highest efficient pump set shall be considered for selection.

13.14.3.1 Pump Construction

(a) Pump casing

The pump casings shall be of Cast iron.

(b) Impellers

The material of impellers shall be as specified and they shall be of the single vane type.

They shall be dynamically balanced. The leading edge of vane s shall be rounded and cut

back to prevent rags, stringy materials etc. from impinging on the impeller vanes.


35

(c) Pump shaft

The pump shaft shall be stainless steel. The shaft shall be of one-piece construction.

(d) Pump Bearings

Pump bearings shall be of the antifriction type. The bearings shall be able to take normal

axial thrust loads due to unbalanced hydraulic loads on the impellers plus the weight of all

rotating parts of the pumps. Pump bearings shall be designed with a minimum life of

40,000 hours. The bearings shall be grease lubricated for life and shall be maintenance

free

(e) Guide Arrangement

The assembly may have C.I pedestal, bracket, delivery bend, SS 316 guide rail pipe, upper

guide rail holder, etc. complete. The pedestal and bracket may provide automatic coupling

between pump delivery and discharge bend.

(f) Mechanical Seals

A double mechanical seal of approved type shall be provided to prevent pumped liquid

entering into the motor winding. The seals shall be running in oil bath. The oil bath shall

have moisture sensors to sense water leakage. The sensors shall be used for tripping the

pump and also for alarm.

(g) Pump Balance:

All rotating parts shall be accurately machined and shall be in rotational balance.

Excessive vibration shall be sufficient cause for rejection of the equipment. The mass of

the unit and its distribution shall be such that resonance at normal operating speeds is

avoided. In any case the amplitude of vibration as measured at any point on the pumping

unit shall not exceed the limits set forth in the latest edition of Indian Standards. At the

operating speed, the ratio of relative speed to the critical speed of the unit or its

components shall be less than 0.8 or more than 1.3.

(h) Lifting chain

Each pump shall be provided with SS steel lifting chain of suitable capacity. One end of the

chain shall be attached to the pump and the other end fixed near the upper bracket for

Guide rail assembly, by means of SS D shackle. The chain shall have SS rings fixed at an

interval of about 1 meter for engaging the hook of the chain pulley block.

(i) Submersible Cable

Each pump shall be provided with submersible cables of equal length for power and control

so that the pump positions can be interchanged with each other. The cable shall be

terminated in common waterproof junction box.

(f) Moisture sensor

The moisture sensor shall be provided in the oil chamber to detect the failure of the

mechanical Seal.

(k) Motor

The motor shall be integral part of the pump. The enclosure for motor shall be IP-68. Each

phase of the motors shall be provided with thermistor. The motor winding shall be suitable

for star delta/soft starter. The motor shall be designed for minimum 10 starts/stops per hour,

irrespective of whether it is DOL start or otherwise.


36

13.14.3.2 Materials of construction:

Pump casing : Cast iron

Impeller : SS 316

Shaft : SS 410,420

Mechanical Seal fasteners : Silicon Carbide

Protective Coating : SS 316

13.14.4 Dewatering pump

a) Pump should be suitable for handling settled sewage containing grit and suspended

particles.

b) The pump motor should be suitable for working with or without submergence in sewage.

The motor rating should be more than the maximum power required by the pump.

c) The pump set should be portable with necessary hooks.

d) The pump should be suitable for dewatering from a pit 900mm x 900mm x 100mm deep.

e) The pump should be vertical, centrifugal, non-clog type.

f) The pump impeller should be mounted on the extended shaft of the motor.

g) The pump should be provided with mechanical seal.

h) The pump should be supplied with flexible hose pipe of 50mm, 50M length.

i) Suitable cable of 50 M length should be supplied with the pump.

13.14.4.1 Materials of Construction

a) Impeller : Stainless Steel

b) Casing : Cast Iron

c) Shaft : EN8 (as per IS: 970)

13.14.5 Progressive cavity pump

The progressive cavity pumps shall be self-priming and designed to handle abrasive, shear

sensitive and viscous materials, solids in suspension and liquid/solids mixtures.

Automatic Variable stroke frequency / stroke length arrangement shall be incorporated

wherever remote application with PLC/SCADA is envisaged and process demands these

changes through remote, Local Control Panel shall also be envisaged with each pump with

auto/manual selector switch and knob for these variations done manually.

The sludge will be a mixture of grit in the sludge that will be abrasive. The pump design shall

incorporate features that prevent ragging around pump connecting rod and rotor head and

include a shaft sleeve to protect the wear in these highly abrasive environments. These

conditions must be considered when selecting the pump. Pump should be screw type, slow

speed maximum 200 rpm having following construction features:

Casing : CI IS 210-FG 260

Rotor : SS316 Hard Chromed plated

Base Frame : ISMC Fabricated Epoxy coated

Bearing Housing : CI IS 210-FG 260

Shaft : SS 316

Foundation bolt : HTS GALVANIZED STEEL

Stator : Hypalon/Equivalent linning

Coupling : Flexible pin bush type

Coupling guard : MS Fabricated


37

The pumps must be sourced from a supplier that is ISO 9001:2000 certified to ensure that

the pump is manufactured to certified standards.

13.14.6 Chemical Dosing Pump

The dosing pumps shall be selected to achieve optimum dosing technology and control

safety with safety relieve valve. The pump shall have a resistant plastic enclosure that

can safely be used for the selected application and shall provide soft and low-pulsation

dosing.

The pump shall incorporate sensitive sensors that monitor the dosing flow and the

diaphragm and provide process stability. The pumps shall be designed to have separation

of hydraulics and electronics, to protected process from equipment failure.

Diaphragm Valve, Gasket : PTTE

Liquid End : Stainless Steel 316

Foundation Bolt : Mild Steel Epoxy Paint

Wetted Part : SS 316

Base Frame : Carbon Steel, epoxy Painted.

Flanges : Carbon steel

Plunger : Carbon Steel

Accuracy : ±3%

Voltage : 415 ±10%

RPM : 1440

13.14.7 Polyelectrolyte Agitator

The equipment shall include drive motor, direct coupling, impeller assembly, and such other

fittings, devices or appurtenances necessary for a complete operating installation. The

Polyelectrolyte requirement has been estimated at 0.5 to 1.5 kg / T of dry solids. The drive

motor shall not exceed rpm of 1,500 and directly coupled with the gearbox. It shall be wired

for 415 volts, 50 cycles, and three-phase service and shall be totally enclosed, fan cooled,

rated for severe chemical duty with a minimum service factor of 1:1.5. The rotary speed of the

impeller shall not exceed 100 rpm.

Qty. : 2 No. (1W + 1S)

13.14.8 Polyelectrolyte Dosing Pumps

Dosing pumps shall be of the diaphragm type hydraulically operated. These shall permit

manual override and variable flow control at both sides of the chosen median duty point for

the duty already stated herein. These shall be able to handle a flow variation of plus 22 % of

the required flow. The construction shall be totally enclosed and corrosion proof.

13.14.8.1 Polyelectrolyte Dosing

Head PP

Check Valves PVC

Balls Glass

Diaphragm Teflon Faced Nitrile

Motor Details Explosion Proof Motor


38

13.14.9 Vacuum Pump

13.14.9.1 Overview

Pump is having impeller of high quality bronze material and motor withstand wide

voltage fluctuations. This pump with F class insulation and IP-55 protection. Typically

used in priming of large pumps, evacuation of air from suction pipes and chambers, and

specific applications such as twist drilling machine, removing water from pulp layer,

labelling, bottle filling de-odorising.

13.14.9.2 Features

Motor withstand wide voltage fluctuations

Impeller of high quality bronze material

Designed to prevent overloading and motor burning

Models with B class insulation and IP-44 protection

Dynamically balanced rotating parts ensure minimum vibrations

Sturdy casing, provided with foot, suction and delivery nozzles.

Rotor having outwardly bent multi blade design held on shaft by shaft sleeve nuts.

Deep stuffing boxes are provided to prevent entry of external air.

Long life - Due to replaceable wearing parts.

Dynamically balanced rotating parts ensure minimum vibrations.

Easy maintenance and spares availability

13.14.9.3 Application

Priming of large pumps

Evacuation of air from suction pips and chambers

Specific applications: Twist drilling machine, removing water from pulp layer, labeling, bottle filling de-odorising

General applications: Drying, evaporation, distillation, filtration, sterilisation, condensation, degasification sucking gases.

Extrusion machines

Printing machines

Confectionery machines

13.14.10 Agitator & Mixer

13.14.11 Submersible Type Mixer

Submersible mixers installed in open or closed topped tanks or chambers, should be

considered for the mixing of sewage, slurries and sludge where there is an absence of

rags and other large debris. The mixers shall be of robust construction, designed for

continuous operation under the most difficult operating conditions installed in basins. The

mixer shall be easily removable from the installed position and this shall be achieved by

means of a guide rail system which also allows depth adjustment of the unit.

The assembly shall be directly driven from a submersible motor through an oil casing and,

when the specified duty dictates, also via a reduction gearbox. The motor shaft shall

extend to form the drive shaft of the propeller.

The oil casing shall provide lubrication and cooling for the seals and create a barrier

between the motor and the media. Expansion of the oil within the sealed casing shall be

contained by an air volume. Moisture sensor shall be provided for detecting any seal

failures.

The propeller shall be designed to deter clogging and produce high efficiency, and the

shroud shall be fitted over the propeller to improve efficiency and direct the flow from the


39

mixer. The shroud shall be optional and the unit shall be capable of continuous operation

without it.

Motor cooling shall be achieved by the surrounding media.

Submersible banana blade mixers shall be easily removable from the installed position

and the blades shall be manufactured from lightweight glass reinforced plastic.

Shafts shall either be sealed from the media in which they are working or shall be

manufactured from grade 316 stainless steel. Coated shafts shall not be permitted.

Submersible mixer motors and equipment shall be certified for being capable of working

at liquid depth.

13.14.12 Bearings (Non-Static Mixers)

The axial thrust generated shall be taken by a thrust bearing arrangement or angular

contact bearings. Thrust bearing arrangements incorporated into the motor housing are

not permitted. The Contractor shall demonstrate that the bearings are suitably rated in his

submittals for approval. Setting of thrust bearings shall account for dynamic loading,

albeit setting is carried out with the machinery stationary.

Rolling element ball or roller bearings shall be sealed for life and shall be rated to give a

minimum life of 75,000 hours at maximum load without replacement. Bearings shall be

protected by water throwers and lip seals where appropriate. The bearing housing shall

be of the cartridge type to allow removal of the bearing without disturbing the units.

Plain/Bush Bearings where utilized, shall be in bronze or equal, split for easy

maintenance and positively locked to prevent rotation.

Bearing housings shall be of the cartridge type to allow removal of the bearing without

disturbing the units.

13.14.13 Sealing

Mechanical seals shall be employed in submersible or closed tank applications with

differential pressures greater than 17 Bar or where controlled leakage is not permitted.

The Contractor shall specify the type, size and material of the mechanical seal he intends

to supply. It shall be the responsibility of the mixer manufacturer to ensure that the

tolerances required by the seal manufacturer are not exceeded. Checks shall be carried

out on the mixer casing and shafting for:

(a) Shaft straightness

(b) Rotational Balance

(c) Shaft run-out

(d) Bearing clearance - lateral and radial movement

(e) Shaft tolerance and ovality

(f) Concentricity

(g) Seat squareness

(h) Coupling alignment

The Contractor shall ensure that the seat, face and component materials of the

mechanical seal are suitable for the media.

13.14.14 Balance

The whole of the rotating assembly, including locking key(s) and mixing element, shall be

dynamically balanced as an integral component. The mixing element shall also be

dynamically balanced separately and then assembled to the shaft, to form without further

adjustment, a dynamically balanced whole.


40

13.14.15 Rating Plate

Rating plates shall be fitted to all mixers, be manufactured and fixed by corrosion

resistant material (excluding brass), and include full details of the mixer including size,

type and serial number.

The weight of the mixer including motor/mounting brackets etc. shall be marked on the

data plate

13.14.16 Couplings

For large mixers, couplings shall be provided to permit the removal of drive shafts,

bearings, etc. without removing the mixer or motor. Couplings between the thrust bearing

and motor shall be accommodated within motor/support stools.

Couplings shall be of the pin and buffer type unless otherwise specified.

13.14.17 Guarding

All machine enclosures shall be safeguarded with guards fixed to the body or motor as

practical for the application.

Shaft guards shall extend the whole length of the shaft.

13.14.18 Submersible mixers in anoxic tank / sludge storage tank

The anoxic mixers shall be of robust construction, designed for continuous operation

under the most difficult operating conditions installed in aeration basins. The anoxic

mixers shall be energy efficient.

Submersible type mixer with motor housing in CI IS 210 Gr FG 250 and 3 blades

propeller in SS316 construction with suitable motor at 415 ± 10% V, 50 C/S. The

submersible mixer shall be complete with lifting device comprising of MS Hot galvanized

60mm tube, MS winch and steel rope and handle with all accessories.

13.14.19 Polyelectrolyte solution preparation and dosing system

Polyelectrolyte solution is needed to be prepared and dosed for aiding sludge thickening

and dewatering. The polyelectrolyte will be dosed online at the centrifuge inlet. Minimum

dosage of polyelectrolyte shall be worked out by the Concessionaire. There shall be two

poly-dosing tanks each suitable for minimum 8 hrs. of operation. Each-tank shall be

equipped with slow speed mixer (100 RPM) to prepare polyelectrolyte solution. The

solution will be fed using positive displacement metering type dosing pumps. There shall

be dedicated dosing pumps to each centrifuge with one common standby. The pumps

shall be interlocked with centrifuge so that it can only be running in auto when centrifuge

is on and should shut down when centrifuge stops. The dosing system shall be housed in

centrifuge house itself.

The polymer dosing required shall be as per design requirement. Polymer dosing pumps

hydraulically actuated diaphragm pumps simplex and duplex type with maximum injection

pressure of 5 kg/cm2 complete with PP head, PP / PVC fittings, strainer, inbuilt PRV

along with

415 V / 50 C / S suitable motor at 1000 RPM are required. The system will also have

storage bins, polymer batch tank and polymer batch tank mixers.

13.15 Chlorination System or Disinfection System

Chlorination if provided shall be as per IS: 10553(Part I) – 1983 and IS: 10553(Part 2) –

1983 and latest standards as applicable.


41

Chlorination system covering chlorine toners, chlorinator, piping, booster, pumps, ejector,

trunnions lifting device with weighing scale, leak detections and leak absorption system,

Eye wash, safety equipment’s like canisters, gasmasks etc. & other ancillary shall be

provided in the chlorine house. It shall have sufficient ventilation as per the latest norms

for safety purpose with necessary lifting arrangements and EOT of minimum 3T capacity

etc. complete. Immersion tank of sufficient capacity shall be provided at ground level for

emergent use.

13.16 Overhead Traveling (OT) Crane

13.16.1 Electrical Overhead Traveling (EOT) Crane

The capacities of various EOT’s shall be decided as per recommendations of IS: 875.

The crane shall be of single / double girder type designed from lowest sump level and up

to under size of the bridge.

Proper selection of reduction gears shall be done to run drive motors. Wherever required

the motor enclosure shall afford protection to IP: 55 of IS: 4691 and have cooling facility

to IC: 41 of IS: 6362. Each drive motor shall be fitted with an automatic electro-magnetic

brake to stop the crane on interruption of the power supply, whether intentional or

accidental power failure.

Suitable end stoppers/buffers shall be provided on the bridge girder and at each end of

crane rails. The crane and hoist shall conform to IS: 3177, IS: 3832 and IS: 3938, class 2,

medium duty and meet specified operational requirements.

EOT Operations and faults shall be interfaced with respective LCP about their operations.

Lifting speed

Low 0.9 meter/minute

High 3 meter/minute

L.T. speed 10 – 15 meter/minute

C.T. speed 10 meter/minute (Max.)

However, illumination lights to be operated by separate switch which will not be mounted

on pendant.

13.16.1.1 Other common specification:

Brakes All brakes are electro-hydraulic thrusters brake

Operation Through pendent push button

Gear box precise machine cut hardened material gear noiseless operation long

life

Cable All cables are insulated ISI Marked Power supply

All 415:440 4 phase 50 Hz. AC supply Control voltage

220/230 volts-50 Hz

The hoist shall comply Class II with the performance requirement IS 3177/80, IS: 3938/IS:

3832 Class 2.

The electric hoist shall be fitted with right and left handed spiral grooved cast iron drum

with a rope hoist arrangement with spring loaded rope band and guards to ensure

accurate rope guidance and location.

Hoist rope shall be extra flexible, improved plug plough steel rope with well lubricated

hemp core and having 6 strands 37 wires per strand with an ultimate tensile strength of

160/180 kg/sq.mm. The braking load for the hoist rope shall be as per IS: 2266.


42

Electromagnetic brake shall be provided to hold suspended load instantly, securely and

automatically in the event of the electric current being cut off whether intentionally,

accidentally or due to power failure.

The lifting hooks shall be single ‘C’ type complying with the requirement of IS: 15560

made from grade C30/C20 carbon steel. The hook shall have a safety latch to prevent

rope coming off the hook.

13.16.1.2 Electrical Hoists

The construction of the hoist, its components, the design, testing and commissioning shall

Conform to IS 3832. All lubrication points shall also be easily accessible without the need

for any dismantling of other equipment or accessories. The hoist must be equipped with

adequate safety devices. The hoist shall be designed, supplied, installed and tested in

conforming to the relevant Indian standards.

a) Frame

The frame is fabricated from steel sections and is of very robust construction. The

traveling trolley frame shall be made of rolled steel conforming to IS: 2062. The side

plates of trolley frame shall extend beyond wheel flanges, thus providing bumper

protection for wheels. The two side plates shall be connected by means of an equalising

pin.

b) Rope Drum

Rope drum is of fabricated mild steel plate or seamless pipe and machined & grooved at

working surface accurately to receive the wire rope in single layer. The Drum is supported

on anti-friction ball / roller bearings.

c) Rope Guide

A sturdy, specially designed rope guide is provided to guide wire rope in correct grooves

while fitting and lowering.

d) Gear box

Totally enclosed oil. Bath lubricated gearbox houses the gears machined out of steel and

teethed on precision hobbling machines.

e) Wire Rope

Extra. Flexible wire rope of best plough steel is used to provide a minimum FOS as per

ISS: 3938. The rated capacity of the rope should be 4-5 time the maximum load to be

lifted.

f) Cross Travel Trolley

The trolley wheel is provided by a separate motor and a separate totally enclosed

greased packed / Oil bath lubricated gearbox. The runner wheels are mounted on ball

bearings and are adjustable for various sizes of hoists.

g) Bottom Block

Rope Sheaves of forge / fabricated steel are provided. The bad hook that is of forged

steel and tested as per IS 3815, is supported on a Thrust bearing so that the load may

swivel freely.


43

h) Motors

Totally enclosed Fan cooled, three Phase Sq. cage inductors

Motor with high starting torque, specially designed and built as per IS: 322 and of reputed

makes. The motor is suitable for frequent reversals as well as braking and are provided

with class B/E insulation.

i) Brake

Instant action" FAST TO SAFE "Elector magnetic shoe brakes are used. The blade is

mounted externally, on the rear end of the motor so that the selling can be done easily

which reduces adjustment time.

j) Limit Switch

Snap action limit switches to prevent over hoisting or overweening are provided for

maximum safety. The amount of travel of the hook block can be governed by adjustment

of dust and vermin safety. The amount of travel of the Hook block can be governed by

adjustment of limit collars on a nod.

k) Controls

Control is by heavy duty, direct- on- reversing type air break contactors, which are

electrically interlinked for safety. The contractor, together with limit switches 0/L relays.

Fuses and LV transformers are goused in an easily removable fabricated steel panel box

which is dust and vermin proof. All control Components are of reputed make.

13.16.2 Hand-Operated Overhead Crane

Cranes shall be designed and manufactured in accordance with BS 2573 and shall

comply with the requirements of BS 466 Class 2 medium duty. The crane details and

ancillary equipment provided shall conform with applicable parts of the General

Requirements specified for electrically-operated overhead cranes, except that the crane

shall be manually-operated in all motions by conveniently-mounted endless chains,

arranged for operation by one man.The main features shall conform to the followings.

13.16.2.1 General Requirement:

The crane bridge shall consist of a single bridge girder carrying two wheels at each end of

the span. Steel used shall be of tested quality steel conforming to IS 2062. The girder

shall have enough strength to carry the test load without causing undue stress or

deflection.

The long travel bridge wheels shall be rim toughened, treated carbon steel or low alloy

steel or C.I. Tray shall be double flanged type. The wheels shall be machined on their

treads to match the runway rail section. The bridge shall have a geared shaft and pulley

connecting to opposite wheels of the span, to achieve the long travel motion of the bridge,

by means of a chain. The runway rails of adequate strength and rigidity, rail clamps and

other accessories for mounting the rails and suitable end stops for the bridge shall be

supplied by the contractor.

13.16.2.2 Trolley and Chain Pulley Block

The chain pulley block shall be operated on the lower flange of the bridge girder.


44

The load chain shall be made of alloy steel as per IS:3109. It shall be heat treated to give

ductility and toughness so that it will stretch before breaking. It shall be of welded

construction with a factor of safety not less than 5.

The hand chains for the hoisting and traverse mechanism shall hang well clear of the

hook and both the chains shall be on the same side. The hand chain wheel shall be made

from pressed sheet steel and shall be provided with roller type guard to prevent snagging

and fouling of the chain.

All the gearing shall be totally encased. Proper lubricating arrangements shall be provided

for bearings and pinions. Gears shall be cut from forged steel blanks. Pinions shall be of

heat treated alloy steel. Gears shall be as per BS 436/IS:4460.

The trolley track wheel shall be rim toughened, heat treated carbon steel or low alloy steel

or C.I. and shall be single flanged and shall have antifriction ball bearings. The wheels

shall be machined on their treads to match the flanges of the track joints.

The travelling trolley frame shall be made of rolled steel conforming to IS:2062. The side

plates of trolley frame shall extend beyond wheel flanges, thus providing bumper

protection for the wheels. The two side plates shall be connected by means of an

equalizing pin.

Axles and shafts shall be made of carbon steel and shall be accurately machined and

properly supported.

The lifting hooks shall be forged, heat treated alloy or carbon steel of rugged construction.

They shall be of single hook type provided with a standard depressed type safety latch.

They shall swivel and operate on antifriction bearings with hardened races. Locks to

prevent hooks from swivelling shall be provided. Hook shall be as per BS:2903/IS:3815.

The brake for the lifting gear shall be automatic and always in action. It shall be of screw

and friction disc type self-actuating load pressure brake. Brakes shall offer no resistance

during hoisting.

13.16.3 Jib Crane

Fixed Jib Cranes shall be provided in the lowering/removal of equipment/parts to/from the

required level and transferring the same to required area. The Jib Crane capacity shall be

1.25 times the maximum weight to be handled or 1.5 Tonnes whichever is maximum.

The lift and reach of the cranes shall be suitable to the equipment requirements. The

crane shall be capable of being swivelled by 360°.

All materials used in the construction shall be corrosion resistant. Mild steel used shall be

galvanised. Ropes, chains and pulleys shall be of stainless steel construction. Hardware

shall be of SS 316.

13.17 Painting

1) The painting work shall conform to the following requirements:

The surface preparation shall be carried out generally in accordance with IS: 1477

Part I and IS: 6005.

After surface preparation, two coats of primer-red oxide zinc chromate with modified

phenolic alkyd base conforming to IS: 2074 shall be applied. Dry film thickness of

each coat shall be 25 microns.


45

For finish painting, after application of primer as in (b) above, two coats of synthetic

enamel

Conforming to IS: 2932 shall be applied. Dry film thickness of each coat shall be 25

microns.

Colours shall be selected as per IS:5

2) The preparation, application and conditions for work shall comply with the recommendations

of BS 5493 and BS 6150 or if the protection is of a special nature, in accordance with the

manufacturer's directions.

3) Preparation for painting of Grit or Shot Blasted Parts: Grit or shot blasting shall be carried

outin accordance with B.S. 7079

4) Chromium Plated Parts: Where chromium plating is specified or offered by the manufacturer

it shall comply with the requirements of B.S. 1224.

5) Where hot-dip galvanizing is not practicable bolts and nuts shall be sherardized, which shall

conform to BS: 4921.

6) Painting System Failure - The painting system shall be deemed to have failed if: -

After painting, damage has been caused by handling, impact, abrasion or welding;

Any portion of the paint film separates from any other or the parent metal;

After painting the total dry-film thickness is less than that specified.

Failure shall not include: -

Loss of gloss;

Variation of shade, not affecting the anti-corrosive properties of the system.

13.18 Emergency equipment (General)

13.18.1 Fire extinguisher

There should be provision of dry powder type CO2 fire extinguishers (10 kg) for the

pumping station and switchyards at the following locations:

• Outdoor switchyard

• Indoor electrical room

• Pump rooms (maintenance bay)

• Control room

• GAS handling area

Besides above, ionisation smoke, optical smoke & heat detectors shall be provided in

control room with fire alarm panel having appropriate battery back-up. Fire alarm detectors

shall be provided both below & above false ceiling, if any Fire alarm system and public

address system shall be provided at the STP.

All the smoke and heat sensors shall be wired up to nearest Joint Breaker (JB) and

interfaced to respective PLC/DDC for alarm annunciations.

13.18.2 Spillage and leakage

Chemical preparing, dosing and transfer equipment shall be designed and arranged so that

any leakage and spilling can be controlled and cannot enter ducts, channels, etc. and have

a corrosive impact on pipes, cables or other equipment of the plant.


46

At all lubrication or greasing points grease trays or pans shall be provided to collect

excessive lubricant or spillage onto the equipment or into Sewage.

13.18.3 Installation work

Equipment shall be installed in a neat, workman like manner so that it is level, plumb,

square and properly aligned and oriented. Tolerance shall be as established in the

manufactures drawing.

Manufacturer’s drawings, instructions and recommendation shall be correctly followed in

handling, setting, testing and commissioning of equipment.

13.18.4 Levelling and grouting of machinery

The pumps, motors and other equipment shall be properly and accurately levelled and

aligned on the concrete plinth by means of tapered metal wedges and metal packing

pieces before any grout is poured. After correct alignment and levelling the foundation

bolts shall be nipped up to hold the machine firmly in position and it shall be the

Concessionaire's responsibility to check that the position is maintained after the grout has

been poured but before it sets. The grout, which will contain an approved expanding

agent, will be mixed and poured by the Concessionaire.

The horizontality of base plate top shall be within 0.05 mm/metre. The base plate top

surface and pump motor box are to be blue matched to get a contact area of at least

80%.

After the grouting mixture has set hard the foundation bolts shall be pulled up hard and

the alignment and level rechecked.

13.18.5 Name plate

Each main and auxiliary item to the pumping station shall have permanently attached to it,

in a conspicuous position, a name plate and rating plate, each of weather-resistance and

fire-resistance material. Upon these shall be engraved or stamped the manufacturer's

name, type and serial number of equipment, details of the loading and duty at which

designed to operate.

13.19 Pipe

For pipes refer specifications in the Civil Section.

13.20 Valves

13.20.1 Sluice valves

Sluice valves shall be generally conforming to IS: 14846:2000. Additionally, they should

meet the specific requirement given below. The valves shall be double flanged machined

and drilled to IS-1538 Part IV & VI.

Sluice valves shall comply with IS 14846:2000 or BS EN 1171:2002 and be of the solid

wedge gate type with non-rising stems. Where gate valves are used on the suction side of

pumps, they shall be of the rising stem type.

13.20.2 General

1. Sluice valve shall be conforming to IS: 14846: 2000 and with ISI marking.

Additionally, they should meet the specific requirement given here under.

2. Sluice valve must be from ISO-9001 certified company towards Quality

Management System.


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3. The valves shall be double flanged machined and drilled to IS- 1538 Part 4 & 6.

The back side of the drill holes to be spot faced for proper seating of bolts & nuts.

Reasonable clearance behind the rear face of the flange on body and bonnet to

be kept to provide free access to use spanners for assembling & dismantling. No

tap hole is acceptable.

4. 3 phase squirrel cage induction type with high torque low inertia characteristics.

13.20.2.1 Material of Construction

1. Body : Cast Iron to IS: 210 Gr. FG200

2. Wedge : Cast Iron to IS: 210 Gr. FG200

3. Spindle : St. Steel to IS: 6603 04Cr18Ni10

4. Seat Rings : SS to CF8

5. Spindle Nut : High Tensile Brass to IS – 320 HT2

6. Back Seat Bush : SS to CF8

7. Shoe & Channel Lining : SS to CF8

13.20.2.2 Shop Testing Witnessing

1. Seat Leakage Test (2 Minutes) : 10Kg/cm2

2. Body Leakage Test (5 Minutes) : 15Kg/cm2

3. Back Seat Leakage Test (2 Minutes) : 10Kg/cm2

13.20.3 Valve Actuators

All actuators shall be motorized type and local controls shall be protected by a lockable

cover. Each actuator shall be adequately sized to suit the application and be continuously

rated to suit the modulating control required. The gearbox shall be oil or grease filled,

and capable of installation in any position. All operating spindles, gears and head stocks

shall be provided with adequate points for lubrication.

The valve actuator shall be capable of producing not less than 11/2 times the required

valve torque considering valve spindle jamming and shall be suitable for at least 5

continuous operations.

The actuator starters shall be integrally housed with the actuator in robustly constructed

and totally enclosed weather proof housing. The motor starter shall be capable of starting

the motor under the most severe conditions the entire electrical system shall be

tropicalized.

The starter housing shall be fitted with contracts and terminals for power supply, remote

control and remote positional indication and shall also be fitted with internal heaters so as

to provide protection against damage due to condensation. Heaters shall be- suitable

for single phase operation. The heaters shall be switched ON when the starters are

OFF and shall be switched OFF when the starters are ON.

Each actuator shall be equipped as follows

(a) A/C electric motor with engage/disengage clutch mechanism of the dry type.

(b) Reduction gear unit (with thrust bearing if required)

(c) Torque switch mechanism

(d) Limit switch mechanism

(e) Geared hand wheel for manual operation of valve.

(f) Valve position indicator - open/closed

(g) Auto-Manual lever with suitable locking arrangement


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(h) Valve position transmitter

(i) Reversing contactor starter complete with overload relays of suitable

range and adequately rated control fuses

(j) Actuator with integral starter shall have selection between local/remote operations

(k) Local control switch/push buttons (l) 415 V/ 110 V AC control transformer

13.20.3.1 Special Features

(a) Two (2) nos. Interposing relays for matching the control voltage of remote

commands.

(b) The motor shall be specially designed for valve operation, combining 10\v inertia

with a high torque and with linear characteristics.

(c) AU motor actuators shall be provided with visible local valve position indicators

mounted on the actuator assembly itself

(d) The torque switch shall function to stop the motor on closing or opening of the

valve, on actuation by the torque when the valve disc is restricted in its attempt to

open or close. A minimum of two (2) torque switches, one for closing direction

and one for opening direction shall be provided

(e) The non-adjustable limit switches shall stop the motor and give indication when

the disc has attained the fully open or close position. Provision shall be made for

indication of stuck or jammed valve.

(f) All wiring connections from the various switches shall be brought out on to

separate terminal box mounted on the valve, having liberal space for wiring &

making connection.

13.20.3.2 Non-Return Valve or Check valve

1. Checking valve shall be conforming to IS: 5312. Additionally, they should meet the

specific requirement given below.

2. The valves shall be double flanged machined and drilled to IS- 1538 Part 4 & 6.

The backside of the drill holes to be spot faced for proper seating of bolts & nuts.

Reasonable clearance behind the rear face of the flange on body to be kept to

provide free access to use spanners for assembling & dismantling. No tap hole is

acceptable.

13.20.3.3 Material of construction

a. Body & Cover : Cast Iron IS: 210 Gr. FG 260

b. Door / disc : SS 304

c. Hinge Pin : St. Steel to AISI – 316

d. Seat Rings : Gunmetal with 2% Nickel / IS: 318 Gr. LT B2

e. Bearing Bush : Teflon

f. Fastener : carbon steel

13.20.3.4 Shop Testing Witnessing

1. Seat Leakage Test (2 Minutes) : 10Kg/cm2

2. Body Leakage Test (5 Minutes) : 15Kg/cm2


49

13.20.3.5 Kinetic air valve

General

1. Kinetic air valves shall be conforming to IS: 14845: 2000. Additionally, they should

meet the specific requirement given here under.

2. Kinetic air valves should be from ISO – 9001 certified company

3. The valves shall be flanged end machined and drilled to IS – 1538 Part 4 & 6


Body, Cover, Cowl : Grey Cast Iron. IS: 210 – 1993 Gr. – 260

Ball of small orifice : Seasoned timber ball covered with soft Vulcanite

Ball of large orifice : Seasoned timber ball covered with soft Vulcanite

Seat of large orifice : Neoprene Rubber

Nipple for small orifice: LTB. : IS 318 – 1980. LTB – 2. / AISI: 410

Isolating Gate valve : IS: 14846 (GM internals & AISI: 410 Spindle)

Bolt & Nut : M.S

Shop testing witnessing

Seat & body leakage test (2 Minutes): 10Kg/cm2

Painting & coating

Pre – inspection

1st Step Surface preparation

Blast cleaning to near white – SA 2 ½ Gr.

2nd step Application of primer coating after blast cleaning

One coat of two component epoxy based primer

Post – inspection, if applicable

3rd Step Application of finish coat

One coat of two component solvent free amine cured epoxy coating (shade)

13.20.3.6 Butterfly valves

Unless otherwise specified, valve body and disc shall be of close-grained gray cast iron.

Valves shall be mounted with shafts horizontal or vertical based on manufacturers design.

Valves shall be fitted with indicators to show the position of the disc, clearly marked with

‘open’ and ‘closed’ positions. Valves shall not contain any brasses containing more than

5% zinc. Gunmetal conforming to BS 1400 Grade LG2, aluminium bronze, or nickel

components may be used for internal components. Resilient-seated valves shall have

nitrile rubber seals.

For valves of 900mm and above, retaining rings shall be provided to enable the sealing

ring to be replaced without the need to remove the valve body from the pipe work. Metal

seated valves of 900mm and above, shall have seat clearances adjustable to obtain as

near a watertight condition as possible, without the need to remove the valve body from

the pipe work.

Percentage Opening - Flow Curve shall be submitted along with data sheet mentioning

area where such valves are subjected for any controlling of the fluid flow.

Component Material

1 Body Cast Iron : IS:210 Gr FG260

2 Inner lining Stainless steel : BS:970 Gr 304

3 Plate /DLSC Stainless steel : IS 3444 1987


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4 Stem Stainless steel : IS 6603:1972

5 Seat ring / Boss Stainless steel : IS 6603:1972

6 Gland housing Cast Iron : IS:210 Gr FG260

7 Gland packing Teflon Impregnated with asbestos+ Rubber

13.20.3.7 Pressure-Relief Valves (PRV)

Pressure-relief valves shall be designed to prevent the pressure in the pipeline upstream

of the valve rising above a pre-set level. The valve shall remain closed at lower

pressures. The pressure at which the valve opens shall be adjustable. A pressure gauge

shall be provided to indicate upstream pressure over the operating range of the valve.

Safety valves shall comply with BS 6759: Part 1.

They shall be designed to open at the specified pressure and re-close and prevent further

release of fluid after normal pressure has been restored. The pressure / temperature

rating shall be in accordance with relevant standards. Flanged ends shall be Class 900,

raised-face type complying with ANSI B16.25 or relevant standards.

Component material



3 Knife gate/ plate Stainless steel : BS:970 Gr 304

4 Stem Stainless steel : BS:970 Gr 304

5 Seat ring / Boss Stainless steel : BS:970 Gr 304



13.20.3.8 Ball valves

Ball valves shall conform where applicable to relevant standards. Multi-piece bodies shall

be used where work on the ball and seats when installed may be needed. If valves need

removal for servicing, one-piece bodies may be used. Seat materials shall be chosen for

long life, with erosion and corrosion resistance. Ball supports shall be of the floating ball

or trunnion type. If line pressure is too low to ensure a positive leak-free seal, built-in seat

loading devices, or specially shaped seating shall be used to ensure sealing.

Component material



3 Plate Stainless steel : BS:970 Gr 304

4 Stem Stainless steel : BS:970 Gr 304

5 Seat ring / Boss Stainless steel : BS:970 Gr 304



13.20.3.9 Knife gate valves

1. The valve shall meet standards C105/A21.5-10, C520-10, C706-10, C707-10, C713-

10 and D106-10 and testing requirements of MSS SP 81.

2. Outer body may preferably be provided with inner liner in corrosion resistant stainless

steel which shall extend into the gland. The body shall be devoid of any wedge/ dead

pockets to avoid setting of suspended particles and solids in the service fluid.


51

3. The gate / plate shall be precision buffed and the edge contoured to a knife edge. The

gate shall move along / be guided by the seat ring to ensure that it scraps any deposit

/ scale enabling smooth uninterrupted movement.

4. Seat shall be so designed that there is no recess / relieve groove to harbour deposition

that could build-up and swamp the valve. The design should also incorporate bosses

that guide the gate and avoid deflection ensuring positive shut-off. The stem shall

have double start threads cut in order to ensure smooth and speedy operation.

5. Gland packing shall offer minimal frictional resistance and precludes external

lubrication. As positive sealing elements, the packing shall also include a resilient

rubber ring. The knife edge and seat face in flow path shall be hard faced to a

hardness of 400 to 450 BHN to counter erosion. In such cases, provision shall also

be made to ensure the fluid contact with the seat ring is minimal.

Component Material

1 Body – Cast Iron : IS:210 Gr FG260

2 Knife gate/ plate – Stainless steel : BS:970 Gr 304

3 Stem – Stainless steel : BS:970 Gr 304

4 Seat ring / Boss – Stainless steel : BS:970 Gr 304

5 Gland housing – Cast Iron : IS:210 Gr FG260

6 Gland packing – Teflon Impregnated with asbestos + Rubber

13.20.3.10 CI flap valves (circular flap valves)

The flap valves with circular aperture, single door and double flanges, shall be provided.

The flap valves up to 600mm dia shall have sealing faces in angular section and secured

to the frame and door by a force fit. For sizes above 700 to 2000mm dia the sealing faces

are of rectangular section and are secured to the frame and door using countersunk taper

headed screws in the same material as the sealing face. The flap valve shall be suitable

for mounting on a vertical wall or flange for static seating heads up to 6 meters.

Material of specification:

Frame

Constructed in BS EN 1561 min. 250 cast iron designed for wall, thimble or pipe mounting

applications.

Door

Constructed in BS EN 1561 min. 250 cast iron designed to withstand static seating heads

up to 6 meters.

Sealing Faces

Copper alloy sealing faces to BS EN 1982: 1999 are supplied as the standard material for

ranges up to 600mm dia and for the ranges 700 to 2000mm dia phosphor bronze to BS

EN 12167: 1998. Sealing faces are set to 0.1mm feeler gauge non-acceptance to provide

an effective seal.

Hinge Links

Manufactured in Spheroidal Graphite cast iron

Fasteners

Standard fasteners are supplied in stainless steel to BS EN 10088: 1995 grade 1.4401

(316).


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Hinge Pins

Manufactured from stainless steel to BS EN 10088: 1995 grade 1.4401 (316).

Air Isolating Valves

Air isolating valves shall be generally of the cast iron gate type conforming to BS5150 or

butterfly type conforming to BS5155. Air isolating valves up to 50 mm N.B. may be in

copper alloy to BS5154 where compatible with the required temperature and pressure

rating. Isolating valves shall be tested in accordance with BS5146: Part 2.

Diaphragm Valves

Diaphragm valves shall be of the full-bore type to suit the maximum working pressure

ratings required. Body ends shall be flanged and drilled to BS EN 1092-1/ BS 4504.

Indicators shall be supplied where specified showing both OPEN and CLOSED positions

shall be supplied and provisions made for initiating the operation of remote indicator lights

in the fully OPEN and CLOSED positions.

Valves used for toxic or hazardous fluids shall be provided with an additional `O' ring seal

of nitrite rubber or other approved material.

Diaphragms shall be composed of moulded reinforced, flexible material attached by studs

to the compressor. Diaphragm materials shall, where required, be composed of corrosion

resistant material.

13.20.3.11 Specifications for Aluminum Open Channel Gates

General

The construction of Aluminum open channel gate shall be strictly in accordance with the

specifications mentioned hereunder. The open channel gate shall be capable of

performing the isolation duties in water / waste water treatment plant for those

applications where the height of water is at least 300 mm less than the height of opening /

shutter. They shall be so constructed that there is no undue wear or deterioration during

its operative life and so designed that the maintenance is kept to a minimum. The

contractor shall provide these gates manufactured by an ISO: 9001-2008 certified

company manufacturing the underspecified product for at least 10 years. The preferred

manufacturers shall be as stated in data sheet. The specification given hereunder shall

supersede other specification in case given elsewhere in tender document.

Design & Constructional Details

The open channel gate shall comprise of frame suitable for mounting in the parallel side

walls of the channel. The frame shall be self contained type with a yoke on top for

mounting of the operating arrangement. The shutter shall move within the frame guides

and shall be provided with suitable connecting arrangement to enable connect it to the

spindle. The frame guides will be made of UHMWPE material to prevent forced rubbing

movement between aluminum shutter and frame.

Water sealing on sides and bottom shall be affected by means of non corroding non

metallic seating faces secured in groves of frames and remaining in forced contact with

corresponding sealing arrangement mounted on shutter. Bottom sealing arrangement

shall be flush bottom type to ensure that invert level of channel on either side of gate

remains flush with the invert of the gate.


53

The spindle shall be rising type and provided with stop nut to avoid over closing of gate.

The rising spindle shall be provided with transparent scratch proof and UV resistant

polycarbonate cover tube to protect the threaded portion from the effect of dust, dirt and

rain. The operating arrangement shall be manual or electric as specified elsewhere in the

tender specifications. In case of manual operation operating mechanism should be such

that the effort required to open / close the gate does not exceed 18 kgs with diameter of

hand wheel / crank restricted to max. 750 mm.

Gate frame shall be manufactured of non corrosive marine grade 6061-T 6 high strength

extruded aluminum section weighing minimum of 5 kg/m. The shutter shall also be made

of same composition as the frame and sufficiently reinforced to restrict deflection to less

than 1/360 of span under the design head. All parts of shutter shall have minimum

thickness of 6 mm. All aluminum components of gate like Angles, Channels & Skin Plate

shall be made of marine grade 6061-T 6 aluminum only. Commercial grade aluminum

shall not be allowed in any case. To ensure this gate manufacturer will have to furnish Mill

Certificate of marine grade 6061-T 6 aluminum for review at the time of inspection.


The material of construction for various components shall be as under.

Gate frame, shutter/Door : Aluminum alloy 6061 T6 *

Side Guides : UHMWPE

Seating faces : UHMWPE

Rubber Seals : EPDM Rubber to ASTM D 2000

Rubber seal retainer bar : Stainless Steel ASTM A 240 type 304 **

Assembly bolts, nuts and

fasteners : Stainless Steel ASTM A 276 type 304

Stem & connecting pin : Stainless Steel ASTM A 276 type 304 **

Yoke : Mild Steel to IS : 2062 grade A, epoxy painted

Headstock : Plain Cast iron IS 210 FG 200

Spindle cover tube / pipe hood : Polycarbonate

* Mill Certificate required for review during the inspection.

Positive material indentification (PMI) test required at manufacturer works during the

inspection.

Painting

Following painting procedure shall be adopted for the gates:

Surface Preparation : Blast clean to near white metal finish using shot blasting.

Priming : 1 coat of epoxy primer.

Finish Painting : Epoxy paint for gate assembly. Minimum DFT 200


54

microns inclusive of priming. Yoke & Headstock to be

provided with Epoxy primer and epoxy Grey paint having

minimum DFT 150 microns inclusive of priming

13.20.3.12 SPECIFICATIONS FOR WALL THIMBLE MOUNTED CAST IRON SLUICE GATES

General

The construction of cast iron sluice gates shall be in accordance with the specifications

mentioned hereunder. The Sluice gates shall be capable of performing the isolation duties

in water / waste water treatment plant & pumping stations and shall be so constructed

that there is no undue wear or deterioration during its operative life and so designed that

the maintenance is kept to a minimum.

Design & Conructional Details

The sluice gates shall be manufactured generally as per IS-13349-1992. The

constructional features and details of components of the required gates are to be as

under:

Gate Frame

The gate frame will be made from cast iron and shall be sufficiently rigid to withstand the

designated water head. The gate frame shall either be flat back type or flange back type

to suit the designed head and site condition. Both types of frames ease in mounting on

the flat flange of the wall thimble.

Back flange of the gate aperture frame to be precisely machined flat and drilled to engage

with the Cast iron wall thimble mounted on the wall. A rubber gasket will be provided

between the wall thimble and the gate for ease in future dismounting of the gate for

repairs / replacement and seal any leakage between the flange of frame and wall thimble.

The gate frame of these sluice gates shall either be self contained type or non self

contained type depending upon site requirement. In case of non self contained gates the

frames shall have short length extension guides and shall be without yoke at their top.

The length of extension guides in such cases shall be sufficient to engage atleast half the

overall vertical height of door when the gate is full open and shall be in accordance with

the relevant provisions of IS-13349. In case of self contained gates the frames shall have

full length extension guides and shall be provided with a yoke at their top. The length of

extension guides in such cases shall be sufficient to engage the overall vertical height of

door when the gate is full open position.

Wall Thimble

The Wall thimble will be made from cast iron for placement in the concrete wall. Its front

flange will be machined, drilled and tapped to match with the frame flange.

The cross section of the thimble shall be F shaped and the depth of thimble shall be

maximum 300 mm long or lesser in case wall thickness is less than 300mm. Gates

subjected to high unseating heads shall have thimble cross section shaped E.

To permit entrapped air to escape as the thimble is being encased in concrete, cast holes

of 40mm diameter shall be provided at the bottom of wall thimble in each entrapment

zone.


55

Gate Slide / Shutter / Door

The gate slide / shutter / door will be made from cast iron and shall be sufficiently ribbed

to withstand the designated water head.

The gate slide / shutter will be provided with integral pocket to house the thrust nut used

to connect the stem with the slide.

Seating/Sealing Faces

Materials: These should be of Stainless steel or Bronze or as specified.

Fitment : The facings shall be attached to flat / rectangular / dovetailed machined faces

of gate frame and door, depending upon the applicable water head, and be secured in

place using taper screws. The taper screws adopted for facings shall be of same material

as that of the seat facings.

The front faces of integral extension guides which can come in contact with the sealing

faces of door while opening, shall also be fitted with sealing faces of the same material as

that of the sealing faces on door. This is required to offer non corroding smooth sliding

surfaces to the sealing faces of door/shutter during its vertical travel for opening and

enhance the effective life of gate.

Finish: The mating seating/sealing faces on the gate frame and door shall be precisely

finished for proper contact. They should be so finished that the clearance or gap, if any,

between the mating sealing faces, in gate closed position, does not exceed 0.1mm.

Wedging Devices

The Sluice gates shall be provided with individually adjustable wedging devices to ensure

forced contact between frame and shutter seat facings, when the gate is in closed

position.

The gates meant for seating head shall be provided only with side wedging devices.

Gates meant for unseating head of sizes larger than 600 mm, shall be provided with side,

top and bottom wedging devices or with side and top wedging devices and flush bottom

closing arrangement as required.

The wedging devices comprise of wedge brackets fitted on gate aperture frame and door.

The wedge bracket on frame shall remain in fixed position and those on door shall be

adjustable or vice versa. A sort of slot and tennon arrangement shall be provided on

base of wedge brackets to prevent any tendency to shift. Provision shall be made to

clamp the adjustable brackets firmly in adjusted position.

The wedging devices shall be made of cast iron. If the wedges/wedge blocks of wedging

devices are of Cast Iron, then these are to be lined with contacting faces of the same

material as that of sealing faces attached to the gate frame and door.

Conventional or Flush Bottom Closing

The sluice gates shall be provided with conventional or flush bottom closure arrangement

as required.

The sluice gates provided with conventional bottom closing arrangement involve

corrosion resistant metallic contacting sealing faces at the bottom sill of gate. In such

cases, the invert of the gate is required to be kept above the floor of the channel /

chamber by at least 150mm to 250mm depending upon the size and type of gate. The


56

contractor should verify whether this clearance is available at the site of installation for

fitting a conventional bottom closure gate.

In case of conventional closing gate, if the invert of the gate is kept at the same level as

that of the channel/chamber floor, then there remains a slot or a groove at the invert of

the gate. Debris, dirt etc. which may settle in this slot and may not allow the gate to close

properly and this may give rise to heavy leakages while in operation. With a view to avoid

this, in situations where the invert of the gate is to remain at the same level as that of

the channel/floor, a Flush Bottom closing gate instead of Conventional Bottom Closing

gate should be provided.

Flush Bottom Closing shall involve a flexible rubber seal at the bottom of the gate,

mounted either on the shutter or on the frame, ensuring that the sealing face remains

flush with the floor. The cast iron bar fitted at the bottom of the frame is required to be

embedded in the channel / chamber floor and for this a cut out / recess of ample

dimensions is required to be provided beneath the waterway opening along the gate

invert, while constructing the floor. The dimensions of this cut out shall be provided

depending upon the feasibility to do so as per actual site conditions.

This cut out/recess is to be later on filled up with removable asphalt or loose concrete

mixed with sand dust or vermiculate after putting the gate in position so that it is possible

to break open this second stage grout for removal of the gate in future.

The rubber seal employed shall be made of EPDM or Neoprene rubber and the rubber

seal retainer bar as well as the fasteners for fitting the rubber seal and the retainer bar are

of stainless steel.

Gate Operating Headstock/Lift Mechanism

The operating headstocks shall be designed in such a manner as to permit the gate

operation by a single person under the specified maximum operating head with an effort

of less than 18kgs on the crank / handwheel.

The headstock may be ungeared or geared type and the geared headstock may be either

of single speed or of double speed, as might be necessary to make it convenient for one

person to open or close the gate as fast as practicable. Two speed headstocks shall be

supplied with gates requiring higher hoisting capacities. In this type of headstock the low

speed is meant for crack opening the gate when the effort required to open the gate is

maximum and the high speed is meant for further faster opening after the gate is crack

opened.

Geared headstock shall be supplied with easily removable crank handle or handwheel

with a radius not exceeding 375mm.

All the gears of geared headstock shall be kept completely encased in cast iron housing

to protect them from damage, dirt, dust, water etc. and other atmospheric effects and thus

ensure their smooth operation. Grease nipples shall be provided at proper places for

lubricating with grease.

Headstock meant for mounting on operating platform shall be supplied with a

pedestal/floor stand to provide a convenient operating height of approximately 900 mm.

The pedestal of the headstock shall be provided with a covered window opening to

enable cleaning and greasing of stem threads.


57

Lifting Spindle/Stem

The sluice gates shall be supplied with rising type lifting spindles/stems. The stem shall

be provided with acme / square threading, length of threaded portion being about 400mm

more than the height of waterway opening. This much extra length is required to allow for

a minor variation of approximately 100mm on either side of the specified height of

operating platform.

The design of stem will be done as per the provision in IS-13349.

Stem Block / Connecting Block / Thrust Nut

The rising type stem shall be connected to the door through a stem block/thrust nut

housed in a ribbed pocket cast integral with the door. The bottom end of stem shall thread

into the stem block and is locked in place by a set screw to prevent the stem from

unscrewing. The Stem block shall be cast bronze or Gunmetal.

Safety Stop Nut:

The stem shall be provided with a safety stop nut to prevent the chances of over closing

of gate which may otherwise damage either the stem or the lifting platform. The stop nut

shall be furnished with a set screw for setting it in a fixed position after the gate is

installed. Upon installation the safety stop nut should be set in such a way that its bottom

remains about 1 to 2 mm away from the top of headstock, in gate closed position.

In case of stainless steel stem, the stop nut shall also be of stainless steel material of the

same grade.

Stem/Spindle Couplings

For ease in transportation and handling, maximum length of one piece stem shall be

restricted within 5 meter length. Where the stem are required to be furnished in more than

one piece, threaded stem couplings shall be furnished to interconnect different sections

of the stem. The couplings shall have provision for pinning after inserting in the threaded

end of the stem.

In case of stainless steel stem, the couplings shall also be of stainless steel material of

the same grade.

Stem Guide Brackets

Longer stems shall be provided with sufficient number of stem guides to prevent buckling

of stem. The stem guide bracket to be provided shall be Adjustable Centre Type - wherein

a separate stem guide is bolted on to the wall bracket. The stem guide shall be adjustable

in the slots on wall bracket in a direction perpendicular to the face of wall. Wall bracket

should also offers minor adjustment in the direction parallel to the wall.

The stem guides shall have machine bored split journals to facilitate erection. The journal

shall be lined with brass/gunmetal bush.

IPE Hood for Stem

A Pipehood shall be provided on the top of headstock in case of rising spindle/stem gates

to cover the spindle threads for protection against damage, dirt, dust, water etc. It shall be

made of transparent fracture resistant polycarbonate material. The pipe hood shall have

vent holes to prevent condensation.


58

Gate Opening Indicating Arrangement

Gate opening indicating arrangement shall be provided to indicate the position of the

shutter. This shall comprise of scale mounted on the pipehood and an indicator nut

mounted on the rising spindle to show the extent of the opening and closing. The

minimum scale graduation shall be 25 mm.


The material of construction for various components shall be as under.

Gate frame, Shutter , Thimble, : Plain Cast iron IS 210 FG 200

Headstock, Wedges, Stem

Guides

: Plain Cast iron IS 210 FG 200

Seating faces, Wedge Lining : Stainless Steel ASTM A 240 type 304*

Rubber Seals (If applicable) : EPDM Rubber to ASTM D 2000

Rubber seal retainer bar

(If applicable)

: Stainless Steel ASTM A 240 type 304*

Assembly bolts, nuts and

fastener

: Stainless Steel ASTM A 276 type 304

Stem & Coupling : Stainless Steel ASTM A 276 type 304*

Yoke (If applicable), Stem

Guide

Bracket

: Mild Steel to IS : 2062 grade A, Epoxy Painted

Thrust nut and Lift nut : Gunmetal / Phosphor Bronze

Positive material indentification (PMI) test to be carried out for these components at

manufacturer works during the inspection.

PAINTING: Following painting procedure shall be adopted for the gates:

Surface Preparation : Blast clean to near white metal finish.

Priming : 1 coat of red oxide primer before and after shop

testing.

Finish Painting for gate assembly : Black bituminous paint. Minimum DFT 200 microns

inclusive of priming

Painting for yoke & Headstock : Epoxy red oxide primer and epoxy Grey paint

Minimum DFT 150 microns inclusive of priming.


59

Minimum Lab Equipment Furniture and Administrative Building Furniture at STP

Sr.

No. Items Quantity Unit

GLASSWARE FOR LABORATORY

1. Beakers 1000ml 6 Nos.



Laboratory Equipment:

4. Refrigerator with voltage stabilizer 320 ltr. Capacity 1 Nos.

5. Hot Air Oven 0-250o C 1 Nos.

6. Muffle furnace complete with Pyrometer 50 x 150 x 500 mm 1 Nos.

7. Water Distillation Apparatus 1 Nos.

8. Rectangular water bath 1 Nos.

9. Hot Air Oven Capacity 0-150o C 1 Nos.

FURNITURE :

10. Steel Almirah 6.5 ‘high 2 Nos.

11. Store well for chemicals ( Size = 2’6”) 2 Nos.

12. Office Tables (Steel) 5’ x 2’ x 2.5’With sun mica top & drawers both

side. 2 Nos.

13. Revolving stools with steel tops 6 Nos.

14. Office Tables (Steel) 3’ x 2.5’ x 2.5’ With sun mica top & drawers 2 Nos.

15. Executive chairs with Arms 10 Nos.

16. Wooden stools 2.5 ‘high 2 Nos.

MISCELLANEOUS ITEMS

17. Air Conditioner capacity 2 tonne (split type) 2 Nos.

18. Fire Extinguisher 4.5 kg Co2 10 Nos.

19. PVC/Rubber Mattings 6 Nos.

20. Wall Clock 3 Nos.

21. First Aid Box 3 Nos.


60

Sr.

No. Items Quantity Unit

22. Complete Crimping Tool with dies 2 Nos.

23.

Computer with specifications: 8th Generation Intel Core i7, 16

GB RAM, 1TB HDD, WIN 10 PRO, 3 years warranty, 24 LED

along with

HP LaserJet 1020 PLUS (CC418A) Laser Printer

Specification:

Printing Type: Black and White

Printing Technology: Laser

Print Resolution: 600x600 DPI

Print Speed Black: 14 PPM

Paper Size: A4, A5, A6, B5, C5, DL, Postcard

Network: LAN

Duty Cycle: 5000 Pages per month

Paper Tray: 150 Sheets

And with superior table and chair

1 Nos

24.

Laptop specifications: 8th Generation Intel® Core™ i3-8145U

Processor, Windows 10 Home Single Language, Intel® UHD

Graphics 620 with shared graphics memory, 4GB, 4GBx1, DDR4

2666MHz, 1TB 5400RPM 2.5" SATA Hard Drive, 39.6-cm. display,

Customize & Buy: Powered by 8th Generation Intel® Core i3-8145U

Processor, Windows 10 Home Single Language, 4GB RAM, 1TB

Hard Drive, FHD IPS Narrow Border Display & 1Yr Ltd Hardware

Warranty, In Home Service after Remote Diagnosis.

1 Nos

NOTE: The above items are indicative only. Bidder shall provide all other items, if required as

per site requirement.


61

LIST OF APPROVED MAKES FOR MAJOR ITEMS

PWSSB-19/D-2/10609-11 DATED 24.5.2019

S.

No. ITEM Makes

1 Actuators Auma India / Limitork/ Rotork / Marsh / L&T

2 Agitators / Mixers Asia LMI/Remi/Mixrite/Philgear/ Fibre & Fibre

3 Air Blowers KAY /SWAM/Everest/Aerzen/ USHA/ BETA/ Turbomax

Batliboi/Khosla/KPT

4 Air Circuit Breaker

L&T-U Power/ Siemens-3WL/ Schneider- Master pact NW/

ABB- E max/ Indo Asian Fuse gear/ Havells

Havells (Titania), C & S (Win Master), Schneider (Easy Pact

MVS) , L&T (U- Power), HPL (IntelliProtect), Indoasian (Opti

Break), Hager (H-3)

5 Aluminum Open

Channel Gate Jash / Yashwant / Upadhyay / BIC / Oriental Castings/ IVC

6

Analytical Online

Instruments (ORP/ DO/

Turbidity/ etc.)

Hach Company/SWAN/HF SCIENTIFIC/Endress+

Hauser/WTW/ABB/ Siemens

7 Ball Valve Fouress / BDK / Audco

8 Bituminous Paint Berger/ Asian /Dulux/ Shalimar

9 Bus Bars(Aluminium) Indal/ BALCO/ HINDALCO

10 Battery Exide /AMCO/HBL-NIFE

11 Battery Chargers Universal Instruments/Amararaja/Chabhi Electricals/HBL-

NIFE/Caldyne

12 Cable Termination Kits Mahindra Engg and Chemical/ REPL/Raychem

13

Cast Iron Pipes &

Fittings and

Detatchable Joints

The Indian Iron & SteelCompany/Jindal Saw/Electro-steel

Castings/Tata Iron & Steel/ ISI Marked

14 Cement ISI marked Ordinary Portland Cement grade 43 as per IS: 269-

2015 (latest edition with upto date amendments).

15

Chlorinator

Evaporator/ chlorinator

gas neutralization

system

Seven Trent services/Siemens/IEC Fabchem/Industrial devices

/Metito or Equivalent make Subject to Engg. Approval

16 Chlorine scale Force Flow/Concorde/Seven Trent services or Equivalent make

Subject to Engg. Approval

17 Crane Hercules Hoists/Batliboi/W.H. Brady

18 Cables


62

i

Copper Conductor

House wire cables ISI

marked

NICCO / Gloster / Unistar / Finolex /

Polycab/Cords/CCZ/Havells/ Universal/ Cable Corporation of

India / Indian Cables /KEI

Bonton. Polycab, HPL, Tamra, Gemscab, KEI, Grandlay,

Ultracab,RR Kabel,Anchor, Rallison, SCI, Vinay, Havells, L& T

ii Aluminium Conductor

LT cables ISI marked

Polycab, Gemscab, KEI, Grandlay, Ultracab,RR Kabel, Rallison,

SCI, Havells, Ecko, Alcon,Universals Unistar

iii Aluminium Conductor

HT cables ISI marked Polycab, Gemscab, KEI, Universals Unistar, Havells

19 48” (1200 mm sweep)

Five Star Ceiling fans Anchor , Polycab ,Havells, Orpic

20 Centrifuge Unit Humboldt/Alfa Laval/Pennwalt / Hiller

21 Chain Pulley Block Indef / Reva / W.H. Brady & Co

22 Chlorinators Toshcon Jesco/ Metito/ Pennwalt/ Capital Control/ Babu Bhai

Narotam Co. (Banaco) make/ Industrial devices

23 CI Sluice Gate

Jash/Oriental Castings/Indian Valves (IVC)/Bharat Industrial

Corporation (BIC)/ VAG

24 Computers HP / Compaq / Dell

25 Contactor L&T/Siemens/Schneider/ABB/Havells

26 Control Gear L & T / Siemens / Technic

27 DI Pipes ISI marked as per IS: 8329 (latest edition with upto date

amendments)

28 Diffusers

EDI/OTT/REHAU

29

Doors & Windows

a) Aluminum

Section Hindalco/ Jindal/Mahavir/Indian Aluminum

b) Glass Section Modi/ Saint Gobain

c) Hinges Earl Bihari or equivalent

d) Laminated Board Kit ply/ Nova pan

30 Dosing Pumps Asia LMI/Milton Roy/Positive Metering

31 Electric Hoist Indef / Reva / W.H. Brady & Co

32 Energy Meter/ CT and

PT unit

Secure or Other Approved make of Punjab State Power

Corporation Ltd.

33 Epoxy Paint Hindustan/Ciba Giegy/Fosroc/Naptha/Seiko Roffec/ Berger.


63

34 Exhaust Fan Bajaj / Crompton Greaves / GE / Khaitan

35 Fire extinguisher ABC/Minimax/Firex/Nitin fire

36 Flame arrestors Teltech Inst/ Combustion Research associates

37 Flaring system Teltech Inst /Combustion Research associates

38 Fabrication of

Aluminum Items Hindalco/ Jindal/ Mahavir/ Indian Aluminum

39 G. I. pipe Hindustan/ Jindal/ Tata/ Ravindra / Parkash

40 Glazed Tiles Somany/Kajaria/Orient

41 Gas flow meters Forbes Marshall/Rockwin/Flowmeter India / Combustion

Research associates

42 Gas Valve Audco/ Fouress

43 Gear Box Redicon/Elecon

44 Geared Motors Crompton/SEW/REMI

45 HDPE Pipes Reliance (Nocil)/Duraline/Hasti/Jain Irrigation

46 House wiring

Accessories

i

Flush Piano Type

switches and

Accessories

Anchor’s Penta Urea, SSK (Touch), Vinay (Catry), Fine (Top

Class)

ii Modular Type Switches

and Accessories

Wipro’s Northwest (Convex), C&S (Divino) , Anchor (Roma

Plus), Indoasian (Elvira), Havells Crabtree (Athena), Polycab

(Levana), SSK (Elegance), Schneider (Livia), L&T (Entice) ,

HPL (Smart) , Hager (insysta).

47 HV Vaccuum Circuit

breaker Seimens/ABB/ Crompton Greaves/BHEL

48 Indicating Lamps L&T / Esbee / Siemens

49 Indicating Meter AE/IMP/ UE/MI

50

INSTRUMENTATION

a) Level Indicating

Transmitter

EMERSON/ABB/Royce

Instruments/Siemens/Endress+Hauser/Kobold/Toshniwal

b) Air Flow Meter /

Flow transmitter/ EMERSON/ ABB/ Royce Instruments/ Siemens/ Pulsar/

Yokogawa/ Endress Hauser/Fitzer Instruments / George Fitcher

/ Toshniwal/Forbes Marshall c) Wastewater Flow

Meter

d) Pressure Gauge EMERSON/ABB/Wika/Kobold/Siemens/Krohne Marshall/ H.

Guru


64

51 Knife Gate Valves Indian Valve company/VAG/ Jash Engg/ Fouress/BDK/

Audco/Intervalve

52 Lab Equipments

HACH Co., USA/ DKK TOA Corporation,Japan/ Varian, USA/

Emerson / Forbes Marshall / Endress Hauser/ Shimadzu /

AMAR Equip/ Merck/ Weiber / DBK Instruments Mumbai /

Veetron / ELICO

53

LED Fixtures (Indoor

and Outdoor) (To fulfill

specifications

approved by Tech

Advisor to Hon’ble

Chief Minister, Punjab

vide memo no.

ATPB/20/GL dated

30.11.17)

Havells , C&S , Jaquar, Survey Twinkle , Trilux , Orient Electric ,

Eveready, Halonix, Keselec, Polycab , Lighting Technologies ,

Oreva, HPL , Cropmton , Bajaj , Panasonic, Wipro.

54 LPBS (Local Push

Button Switch) Hansu / Pustron / Elcon

55 Luminaries/LED Phillips/ABB/Crompton Greaves Limited/Wipro/Bajaj Electricals/

Havells/ Osram/ SSK/Anchor

56 Level/Float Switches EMERSON/ABB/Siemens/Royce

Instruments/Endress+Hauser/Kobold/ Krohne Marshall

57

LT Control Panels

(CPRI Approved /

Tested)

EMCO, ETE Electrogears, Power Associates Kalyani

Switchgear, Standard Control Panel, Bhandari

58 LT capacitor BHEL/ ABB/ CG power systems/ Universal Cables

59 Motor Control Center

LV Switchgears /MCC : Schneider Electric/ ABB/ Siemens/

GE/L&T/English electric/ Manufacturers with Central Power

Research Institute (CPRI) Test Certificate

HV Metal enclosed switchgears /MCC:

Siemens/ABB/Crompton Greaves Limited/BHEL/ Manufacturers

with Central Power Research Institute (CPRI) Test Certificate

60 Mechanical Bar

Screens Jash / Voltas / Triveni / Huber / Johnson

61 Mechanical Detritor Voltas / Triveni / HUBER / Shivpad- Asc

62 Motors Kirloskar/ABB/Siemens/Marathon/NGEF / Crompton / Bharat

Bijlee/Jyoti/Nord

63 Moulded Case Circuit

Breaker (MCCB)

L&T-D SHINE / Schneider-NS / Siemens-Sentron / ABB TMAX/

INDO ASIAN FUSE GEAR/Havells

Havells (Loadline), C&S (win break), Schneider (Easy Pac CVS

) , HPL (TAB) L&T (D-Sine), Indoasian (Optium), Hager (H-3)

64 MS Open Channel Gate Jash / Yashwant / Upadhyay / BIC / Oriental Castings


65

65 MS Pipes Tata Steel / Surya Roshni / Jindal

66 Metallic Bellows D Wren/ Flexatherm Expandllow/ Lonestar Industries/ Metallic

Bellows

67 Moisture trap Teltech Inst/ Combustion Research associates

68 Neutral earthing

resistors Bharatia Cutler Hammer/Crompton Greaves/Indcoil

69 Nuts & Bolts GKW

70 Needle Valve Fouress / BDK / Audco

71 Online Residual

Chlorine Analyzer

Hach Company/SWAN/HF SCIENTIFIC/Endress+ Hauser/

Krohne Marshall

72 OLTC & AVR UNIT Kirloskar/NGEF/MARATHON/CROMPTON/ VOLTAMP/

Jyoti/BHEL/NUCON

73

Other Paints (Synthetic

Enamel/ Cement based

etc)

Berger/Asian/ Nerolac/Dulux/Shalimar

74 Over Load Relay L&T / Siemens/Schneider/ABB

75

Outdoor Substation

Equipment

a) SF6 Circuit Breakers ABB/BHEL/Siemens/ Crompton Greaves

b) Isolators ABB/BHEL/Siemens/ Areva T&D/Crompton Greaves/S&S

Power Switchgears

c) Early Streamer

Emission Lighting

Arrester

Areva T&D/ABB/Crompton Greaves/ELPRO/OBLUM/Aditya

Birla/ Marathon

JMV , APS (LPI)

d) Insulators and Hard

wares Areva T&D/S&S Power Switchgears/W.S Insulators

e) Relay & Control

Panel ABB/BHEL/Siemens/Areva T&D/Crompton Greaves

76 Pipes

i

MS Conduit Pipe ISI

Marked GEC , RM-CON , Gupta Brothers (GB)

ii

Heavy Gauge PVC

Electrical Conduit Pipe

ISI Marked

Anchor , Polycab

iii

HDPE Electrical

Conduit Pipe (ISI

marked)

Himlayan Plato


66

iv

DWC HDPE Pipe (ISI

Marked )

TeleRex, Gemini

77 Pressure Indicator

Transmitter

EMERSON/ABB/Siemens/Endress+Hauser/ Kobold/ Krohne

Marshall

78 Primary/ Secondary

clarifier mechanism Triveni/Geo Miller/Voltas/Thermax

79 Progressive Cavity

Pump

Roto, Hydro-Prokav pumps India Limited, Flowrox, Netzsch,

Syno pumps

80 Protective Relays ABB/Schneider Electric/L&T/GE/ Siemens/ English

Electric/Easun Reyrolles

81 PLC / SCADA Siemens / Allan Bradley / Schneider / Rockwell Automation /

Tata Honeywell / Marathon

82 Receptacles Anchor / Kalinga / SSK / Crompton

83 Sanitary wares Hindware / Johnson / Parryware

84 Screw Pump ROTO / Tushaco / Ramo

85 Selector Switch L&T Salzer

86 Sewage

Pumps(Centrifugal)

Non Clog Horizontal Pumps : Mather & Platt/Kirloskar

/Beacon Weir /Flowmore/ WPIL / Jyoti / KSB

87

Silent Diesel

Generating set

Alternator

Kirloskar/Crompton/ BHEL/Jyoti/Stamford/Marathon

88

Silent Diesel

Generating set (5 KVA

to 2000 KVA)

Kirloskar/ Cummins/ Caterpillar/ Ruston now Greaves Power

Mahindra & Mahindra, Ashok Leyland, KOEL GREEN, Eicher

89 Single Phase Preventor L&T / Minilec

90

Sluice Valves/ NRV/

Reflux Valves/ Check

Valves/ Butterfly

Valves

Kirloskar Brothers Ltd./Indian Valve Company/Advance Valves

Ltd/VAG/ BDK / Intervalve/ Jash Engg/ Fouress

91

a) Starter for motors

above 10 HP and upto

50 HP

Kilburn / MEI / ASHOK / IMPEX/ Schneider / ABB / L&T /

Siemens/ GE

b) Soft Starter Marathon/ABB/Siemens/ Allen Bradley /Danfoss

c) Starter for motors

upto 10 HP L&T / Schneider / ABB / Siemens

d) Auto Transformer

Switch (ATS) starter Kilburn / MEI / ASHOK / IMPEX/Jyoti


67

more than 50 HP

92

a) Structural Steel

except reinforcement

steel

SAIL/TATA/Rashtriya Ispat Udyog

b) Reinforcement steel

Steel shall be ISI Marked, high strength deformed steel bars

(CTD bars) or TMT plant rolled bars grade FE_500 as per

IS:1786 latest edition with upto date amendments. The bidder

shall submit attested photocopies of license granted by BIS

authority for marking the steel with ISI certification mark. The

license should clearly indicate the validity and class covered in

it. The steel only procured from primary steel producers (who

produce steel using iron ore as basic raw material) and have

integrated plant such as SAIL, RINL, IISCO, TISCO /JINDAL

STEEL POWER LTDetc. shall be used on all works being

executed by Punjab Water Supply & Sewerage Board.

93

Submersible Sewage

Pumps/Sump Pumps

submersible pumping

set for w/s

Non Clog Submersible Pumps : Flyght/ KSB /ABS/ Grundfos/

Kishore/ Aqua / Kirloskar/Darling / SU Motors/ Mody Ind. FC /

CRI/JASCO

94 Switchgear L & T / Siemens / GE

95 Submersible Mixer Grundfos/ABS/Flyght/EMCO

96 Transformer

Power transformers :ABB/BHEL/Siemens/Kirloskar

Electric/Marathon/Crompton Greaves/As approved by

PSPCL/Voltamp/BHEL/Nucon Auxiliary

transformers: ABB/BHEL/Siemens/Kirloskar

Electric/Marathon/Crompton Greaves/Areva T&D/Bharat Bijlee/

Voltamp/ Nucon/ As approved by PSPCL

H.T & L.T Current Transformers: ABB/ CGL/BHEL/AE/English

Elecric/Voltamp/Nucon/As approved by PSPCL

Voltage and Current Transformers: ABB/ BHEL/Siemens/

Areva T&D/Crompton Greaves

/Kirloskar/Voltamp/Marathon/Nucon/As approved by PSPCL

97 Temperature Indicator

Transmitters

Kobold/Endress+Hauser/ABB/Siemens/ Hach

Company/Yokogawa/Lectrotec/ Masibus

98 Thickener mechanism Triveni/Geo Miller, Indo-fab Industries, Jash-Shivpad Industries,

Eimco-KCP

99 Vacuum Circuit

Breaker

Siemens/ABB/Crompton

Greaves/BHEL/KEC/Schneider/Marathon

100 Volt and Ampere Meter

with Selector Switch L&T / Rishabh /AE

101 Vacuum Pump Kirloskar, PPI Pumps, Busch, Finetech

102 VFD (Variable Danfoss/ABB/Siemens


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Frequency Device)

103 Water Proofing

Equipments

Fosroc / Sika

104

a) Water Tanks Sintex / Diplast

b) LDPE WATER

STORAGE TANK Sintex/Diplast/Frontier

105 Zero Velocity Valve Kirloskar /Indian Valve Company/VAG/Fouress

106 11 kV capacitor and

panel BHEL/ABB/CG Power Systems/Universal Cables

107 Submersible Cable Finolex, Polycab, RR Cable, Ecko

108 Submersible Pump Set KSB, CALAMA, WASP, WPIL, SU, SEEREX, LUBI, HIDUSTAN,

BS, AMRUT & CRI

109 Belt Press EMO, Dewa, Siemens, Andritz

110 Turbo Blowers Turbomax, DaeHa Engg, Korea Fluid Machinery

111 Fiber Disc Filter Yucheon, Siemens, Huber

Note: If agencies want to use items whose makes are not available in approved make list

of PWSSB then agencies shall take prior approval of the make of that item from the

Department.

13.21 INSPECTION AND TESTING REQUIREMENTS

13.21.1 INSPECTION, TESTING AND SETTING TO WORK — GENERAL

Each item of plant shall be subjected to the manufacturer’s own tests which shall be

certified. Each item of plant and its installation shall be subject to inspection and testing at

the place of manufacture. The Contractor shall be responsible for the provision of all

necessary test equipment. The Contractor shall demonstrate to the Employers

Representative, the correct operation of any item of plant and the Employers

Representative may witness any test. Tests which, in the opinion of the Employers

Representative, were failed or not performed correctly shall be repeated.

Before any test is made, the Contractor shall submit to the Employers Representative a full

list of test equipment to be used. Each item of test equipment shall have a standard of

accuracy better than that stated by the manufacturer of the item to be tested. The

Contractor shall provide evidence of the condition and performance of any item of test

equipment, in the form of test certificates issued by an appropriate authority independent of


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the Contractor and manufacturer, or as otherwise directed by the Employers

Representative. Test equipment shall be checked frequently during the period of the tests.

The Contractor’s staff responsible for supervising and carrying out tests shall be fully

conversant with the various items of equipment of other manufacturers and if necessary the

Contractor shall arrange for his personnel to attend suitable training courses on his own

expense. The contractor has to get approval from the client’s representative for the training

personnel to be employed by the contractor.

Any fault or shortcoming found during any inspection or test shall be rectified to the

satisfaction of the Employers Representative before proceeding with further inspection or

testing of that item. Any circuit previously tested, which may have been affected by the

rectification work, shall be re-tested.

13.22 PRELIMINARY INSPECTION AND TESTING AT THE PLACE OF MANUFACTURE

13.22.1 FIELD-MOUNTED INSTRUMENTS

After the successful completion of the manufacturer’s own inspection and testing of

instruments supplied under the Contract, similar tests shall be carried out in the presence

of the Employers Representative and the Contractor, if requested. Such tests shall include

a demonstration that an increase or decrease of the measured value at several points over

the full range of the instrument produces a corresponding increase or decrease in the

instrument output signal. These tests shall include checks on the specified accuracy of the

instrument at all points.

13.22.2 INSTRUMENT PANELS, ENCLOSURES AND MOUNTING BOARDS

The manufacturer shall not present instrument panels, enclosures and mounting boards

(assemblies) for inspection and testing until the manufacturer’s own tests and inspection

has been completed. A preliminary inspection and test of these assemblies may then be

witnessed by the Employers Representative. The Contractor shall give not less than 7

days’ notice in writing that he has completed his tests and inspection and is ready for the

witnessed tests and inspection. Where this notice period is different in the Conditions of

Contract, this shall take precedent.

The witnessed inspection and testing shall include the following:

a) A visual inspection of the panel assembly to show that the design, construction and

finish are satisfactory and in accordance with the Specification;

b) A check that equipment is securely mounted, accessible for removal or calibration

without damage to or undue disturbance of other components, wiring or piping;

c) That all engraving and labels are correctly positioned, fixed and designated in

accordance with the Specification;

d) Panel power-distribution circuits have the correct breaker/fuse rating coordination

and designation;

e) Power-isolation facilities meet the Specification;

f) The main incoming supply voltage, frequency and/or pneumatic supply pressure is

within the required limits, these being checked at the beginning and end of the test

and the results recorded on test certificates;

g) The output of all power supply units again at the beginning and end of the testing

with results being recorded;


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h) The power supply voltage or air pressure of all component instruments of the

assembly(s), these voltages/pressures being recorded on the test certificate;

i) The insulation resistance of all circuits except sensitive electronic equipment which

is liable to damage by application of the test voltage, such circuits being

disconnected before making the insulation resistance tests and these tests being

carried out in accordance with IEE Wiring Regulations;

j) That the clean earth bar is isolated from main frame of the panel. Internal lighting

and anti- condensation heaters and associated thermostats, isolators, limit switches

and wiring shall be checked for compliance with the Specification. Spare capacity

within the panel(s) shall be checked to see that it complies with the Specification.

This shall include future equipment space, spare terminals, space in wiring

trunkings and provision for additional cable entry.

13.23 FUNCTIONAL TESTING AT THE PLACE OF MANUFACTURE

General requirements

Once the preliminary inspection and testing is complete to the satisfaction of the

Employers Representative, functional testing shall commence. The purpose of the

functional tests is to demonstrate that instrument panels enclosures and mounting

boards (assemblies) conform to requirements of the Specification.

Not less than 30 days before the commencement of functional tests, the Contractor shall

submit to the Employers Representative, for approval, two copies of comprehensive test

procedural documents detailing each test to be carried out. The document shall include

results forms on which the results of each test will be entered. The forms shall include

spaces for numerical values, where necessary, and witness signatures. All applicable

drawings and data shall be provided at the place of inspection by the Contractor.

All tests as required, both at the factory i.e. Factory Acceptance Test (FAT) before

dispatch, and at site after installation i.e. Site Acceptance Tests (SAT), shall be carried

out. Detailed Test reports and certificates shall be submitted. Test reports and test

certificates for bought out components shall be submitted for approval. These

components shall also be included in the integrated FAT.

Factory Acceptance Test (FAT-Applicable For Inspection Category- A) (a) A Factory Acceptance Test, which shall be witnessed by Employer’s

Representative, is required for the system. No equipment shall be shipped

without written confirmation by the Employer’s Representative that the system

has successfully passed its factory acceptance test.

(b) The purpose of the FAT is to qualify the system as meeting all contractual

requirements. The test shall verify the performance and functional integrity of the

individual subsystems, including active interfaces between subsystems and shall

demonstrate the proper operation of equipment/systems.

(c) A complete set of system documentation, including design and maintenance

documents, user manuals and the test plan and procedures shall be available

during the FAT.

(d) The list of tests to be carried for both Factory Acceptance Test (FAT) along with

test instruments to be used shall be furnished for review by the Employer’s

Representative. Contractor shall indicate the place of inspection and the test

facilities available.


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(e) The testing of all the equipment and accessories shall be carried out as per latest

applicable Indian/International standards recommendations.

(f) Prior to testing, all relevant documentation and sufficient briefing about the tests

shall be given to Employer’s Representatives who would witness the testing.

(g) The FAT to be performed in the factory shall include but not be limited to

following:

Tests for guaranteed technical parameters

Integrated functional tests

Burn-in tests

Hydrostatic tests

Calibration tests

Power supply variation test

Alarm/Diagnostic check

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